DIESEL GENERATOR MAINTENANCE AND OPERATION MANUAL

EN

THANK YOU

Dear KJ Power Generator User,

First of all, thank you for choosing KJ Power Generator.

This Operation and Maintenance Manual has been prepared to ensure the safe and efficient operation of
your generator set. It contains information and basic instructions for correct transport, assembly, operation
and maintenance.

Before using your generator set, it is necessary to read the manual carefully and follow the instructions
correctly in order to ensure your life and property safety.

KJ Power Generator sets are designed for electricity generation according to the environmental and
working conditions that specified or agreed in your contract. In case of any change in working
conditions and / or environmental conditions, you should contact with KJ Power Generator or the
institutions authorized by KJ Power Generator.

In order for you to use your generator set more efficiently, periodic maintenance of your generator should
be done at recommended intervals by experienced and competent people. For this, you can contact
with KJ Power Generator or the institutions authorized by KJ Power Generator about the periodic
maintenance contract.

Your generator is covered by the warranty for 1 (one) year or 500 (five hundred) working hours (whichever
period comes earlier) within the border of the country under the conditions specified in the warranty
document. In case of changes made on the generator without the approval of KJ Power Generator,
using non-original spare parts and faults caused by external factors, your generator will be out of warranty.

This manual has been prepared for a wide range of products. In case the specified instructions and
safety standards are updated, you can contact with After Sales Services Department of the KJ Power
Generator.

KJ Power Generator, who is continuing the continuous improvement and development activities
of its products, reserves the right to make changes in this operation and maintenance manual.
We hope you use your generator set on healthy and beautiful days with uninterrupted energy.

Manufacturer Company Information:

Title : KÜRKÇÜOĞLU JENERATÖR SANAYİ VE TİCARET A.Ș
Adress : Sanayi Mahallesi Uran Sokak No: 3/1 Pendik-İstanbul
Tel / Fax : +90 444 59 30 / 0216 378 97 06
Web : www.kj.com.tr
E-mail : info@kj.com.tr

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CONTENTS

INTRODUCTION 04
1.1. Definitions About The Generator 04
1.2. Basic Electrical Concepts And Units 04
1.3. Classification Of Generators According To Their Operation Time 06
1.4. About Kj Power Generator Set 07

SAFETY PRECAUTIONS 08
2.1. General 08
2.2. Lifting And Transport 09
2.3. Moving Parts 10
2.4. Hot Surfaces, Sharp Edges And Corners 10
2.5. Fire And Explosion 11
2.6. Toxic And Irritating Substances 12
2.7. Electric 13
2.8. Noise 13
2.9. First Aid In Electric Shock 14

GENERATOR SET AND PARTS 15

3.1. Diesel Engine 16
3.2. Alternator 16
3.3. Chassis And Fuel System 17
3.4. Lubrication System 18
3.5. Silencer And Exhaust System 19
3.6. Vibration Shocks 20
3.7. Battery 20
3.8. Battery Charge Rectifier 21
3.9. Engine Jacket Water Heater 21
3.10. Panels 22
3.10.1. Automatic Control Panel 22
3.10.2. Automatic Transfer Panel 23
3.10.3. Protection Switch Panel 24

SELECTION OF GENERATOR SITE AND INSTALLATION 25

4.1. Canopy Type Generator Layout 26
4.2. Open Type (Without Canopy) Generator Layout 27
4.3. Electrical Connections And Operation 30
4.3.1. Placement Of The Transfer Panel 32
4.3.2. Starting The Generator 32

FAULT DETECTION 34

MAINTENANCE OF GENERATOR 36
6.1. First Maintenance 36
6.2. 200 Hours / Annual Maintenance 37
6.3. Periodic Maintenance 37

WARRANTY 38
MAINTENANCE TRACKING CHART 40

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INTRODUCTION

1.1 DEFINITIONS ABOUT THE GENERATOR

Generators are complex electrical machines in which the chemical energy stored in fuels is first converted
into mechanical energy with internal combustion engines and then into electrical energy through
alternators.

Generators can be diesel, gasoline, natural gas or hybrid depending on their fuel consumption. Diesel
engines are widely preferred in generators used as utility backup.

The main components of diesel generators consist of the diesel engine, radiator (cooling group), alternator,
control panel, and chassis that containing the fuel tank up to a certain power.

Parts of the Generator

1.2 BASIC ELECTRICAL CONCEPTS AND UNITS

Voltage (U): It expresses the potential of electrical energy, unit is volt.
In low voltage systems in Turkey, phase-to-phase voltages is 400 volts, and the phase-to-neutral voltage
is 230 volts. Voltage values may differ according to the utility infrastructure of the countries. The output
voltage of diesel generators to be integrated into the system and the voltage of utility must be the same.

Voltage is similar to pressure in mechanical concepts.

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INTRODUCTION

Current (I): The amount of charge of an electric particle passing through a unit surface in 1 second, unit
is amphere. It varies according to the magnitude of the electrical charge. Current is similar to flow in
mechanical concepts.

Direct Current (DC): Its direction and intensity do not change depending on time.

Direct Current

Alternating Current (AC): Its direction and intensity are variable with respect to time; it has two components
as frequency and amplitude. Electric utilities and generator systems backing them up provide alternating current.

Alternation Current Wave

Frequency (Hz): The number of times an alternating current wave (sine curve) occurs in 1 second, unit is
hertz. Frequency may vary as 50 Hz / 60 Hz according to countries. In Turkey, the utility frequency is 50 Hz.

Electrical Power Units:

Apparent power (S): The power representing the capacity and physical size of generators, transformers,
and uninterruptible power supplies; its unit is kVA (kilovolt-ampere), which is the vector sum of active and
reactive power.

Active power (P): Refers to the effective active power. The unit is kilowatt (kilowatt). Electric motors
and other mechanical systems are referred to in kilowatts.

Reactive Power (Q): It is the inactive power component caused by the phase difference between current
and voltage in electrical circuits containing coils or capacitors; its unit is kVAr (kilovolt ampere reactive).

Power Triangle

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INTRODUCTION

1.3 CLASSIFICATION OF GENERATORS ACCORDING TO THEIR OPERATION TIME

Standby Power (ESP – Emergency Standby Power)

It is the situation where the generator is used as a backup energy source and operates intermittently under
variable loads; at the same time, It also refers to the maximum power that can be obtained from a gene-
rator. Generators cannot be loaded above standby power; they are limited to 200 hours of work per year.

In practice, the most common use of diesel generators is standby applications.

Limited Time Running Power (LTP) is the case when a standby generator is allowed to operate up to
500 hours per year as needed (eg hospital) as a utility backup. However, the expected maintenance period
should be decreased under such working situation.

Prime Power (PRP)

It is the situation in which the generator works continuously under variable loads; It can operate
continuously under variable loads for 365 days a year and 24 hours a day. It is recommended to choose
according to prime power in locations where there is no utility energy.

The generator may be allowed to be loaded 10% more than prime power for 1 hour at any time interval in
12 hours of period.

Prime Operation

Continuous Power (COP – Base Load)

It is the state of continuous operation of the generator under constant load; It can operate continuously
under 100% load for 365 days a year and 24 hours a day. In reality, it is not common practice for diesel
generators due to operating costs; It is mostly valid for units with natural gas engines or turbines.

Continuous power is the power selection criterion in applications that provide combined heat and power
generation in applications such as cogeneration and trigeneration; it is 20% lower than the main power.

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INTRODUCTION

1.4. ABOUT KJ POWER GENERATOR SET

As a result of the knowledge and experience gained since 1996, KJ Power Generator groups have been
designed with the aim of providing sustainable performance by keeping all kinds of life and property safety
at the forefront.

There is a “KJ Power generator set identification label” as shown in below picture on the chassis and / or
cabinet of your generator set. This label contains information about your generator’s manufacturing year,
voltage, current, power, frequency, power factor, weight, motor and alternator.

You can easily got your service, spare parts, technical support requests that you send to our factory or
authorized services, by using the reference information on the generator set identification label.

KJ Power Generator Set Identification Label

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SAFETY PRECAUTIONS

2.1 GENERAL
The generator set must be installed, operated and safety precautions must be followed in accordance with
the maintenance and user manual. The generator set will serve safely only in this way.

Safe operation responsibility of the generator set is belongs to the people who install, use and maintain the
generator set. When the safety precautions are followed, the risk of accidents will decrease.

The generator set should be used by people who have been trained or authorized in this area, and who
have read and understood the maintenance and user manual.

Failure to follow the rules, instructions, methods and safety precautions in this book may increase the
probability of malfunction, accident and injury; it may even result in death. Personal protective equipment
should be used during manual operation and periodic maintenance or controls of the generator.

When the generator is in automatic (AUTO) position, taking into account that the engine can start and
activate automatically at any time, unauthorized access to the generator site should be prevented.

Attention should be paid to the labels and warnings on the generator set. The generator set must be ins-
talled and operated in strict accordance with applicable standards, rules and regulations.

Before performing maintenance, repair or adjustment, the generator set should be turned OFF and preca-
utions should be taken against the intervention of others.

Do not operate the generator set unless it is safe. In unsafe situations, immediately attach a danger
warning sign on the generator set to prevent damage to other person / persons, disconnect the battery
terminals and disconnect all cable connections and disable the generator set

This book and its supplements should be considered as a whole. Safety precautions are provided in the
relevant chapters of this book.

Do not neglect to consult KJ Power Generator or authorized services for incomprehensible issues.

READ THE USER’S USE INSULATED GLOVES USE WORK GLASSES

MANUAL WHILE WORKING THE PANEL

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SAFETY PRECAUTIONS

2.2 LIFTING AND TRANSPORT

Use the lifting lugs on the chassis to lift the generator set. Do not lift from the lugs on the engine and
alternator.

Absolutely ensure the necessary checks for the lifting lugs or connection points before lifting, against wel-
ding cracks, ruptures, bending, cracks, rusted or lost quality parts, loose bolts and nuts.

Make sure that all lifting equipment and support materials are workable and will withstand a weight of at
least 10% more than the gross weight of the generator set. Make sure that the lifting hook or locks are
functional safety latches and are properly connected.

When the machine is lifted off the ground, use guide ropes or equivalent to prevent it from turning and
shaking. Do not try to lift the generator set under strong winds.

Generator Lifting and Transport

When the generator set is suspended, keep the operator of the lifting device always in place and ready.
Place the generator set on flat surfaces that allow more than 10% of its gross weight and have a bearing
capacity and are not at risk of slipping. Make sure that the personnel are out of the generator set before
closing and locking the doors.

Canopied type generators should be lifted from the chassis, not from the lugs on the cabin. In order to
prevent the generator from being damaged during lifting, the ropes should be tied to the eyebolt of the
crane with an apparatus (sling).

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SAFETY PRECAUTIONS

The generator chassis is not suitable for pushing or pulling directly with a forklift
when it is directly on the ground or when vibration shocks are mounted.

If the generator needs to be transported horizontally, suitable transport trolleys and

professional apparatus should be placed under the chassis, and the generator
should be moved with a forklift or crane support.
ATTENTION!
STAY AWAY FROM
OVER HEAD LOADS !
2.3 MOVING PARTS
Keep your body, especially hands, arms, hair and clothing away from propellers,
belts, pulleys and other moving and rotating part. Do not attempt to operate the
generator set while the fan and other guards are removed.

In case of working around the generator set or in front of moving parts, wear tight
clothes and collect your long hair.
ATTENTION!
MOVING PARTS

Keep the access doors closed except for checking, maintenance, repair, adjustment, service, and starting
or stopping the generator set.

Ensure that all personnel are at a certain safe distance from the generator set when it is started or out of
service.

In order to minimize the possibility of slipping and falling, keep your hands, feet, ground and walking areas
clean from fuel, oil, water, antifreeze or other liquids.

2.4 HOT SURFACES, SHARP EDGES AND CORNERS

ATTENTION! ATTENTION!
HOT SURFACE SHARP EDGE

Avoid body contact with hot oil, hot coolant, hot surfaces, sharp edges and corners.

Protect all parts of your body from hot exhaust pipes and gases.

When working inside, outside or around the generator set, wear protective clothing such as gloves,
boots and helmets.

Keep the first aid book handy. In case of injury, seek medical assistance immediately. Do not neglect
minor and cut injuries.

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SAFETY PRECAUTIONS

2.5 FIRE AND EXPLOSION

Refuel in accordance with the usage and norms from a fuel tank or service station designed for the
purpose of use.
If fuel, oil, battery electrolyte or coolant buildup accumulates on the ground, clean them with sawdust
or absorbent products.
Before adding fuel, checking the electrolyte level of the batteries or changing the oil, turn off the ge-
nerator set and allow it to cool down. Keep sparks, flames and other sources of ignition away from
the generator.

Do not smoke around the generator and do not allow smoking in the vicinity.

Do not allow the formation of fuel or oil film on the generator set, on the chassis or in the cabin if any.
Wipe dirty surfaces using a liquid industrial cleaner.

ATTENTION! ATTENTION! FORBIDDEN TO USE NO SMOKING

DANGEROUS EXPLOSIVE GASES OPEN FLAME
FLAMMABLE MATERIAL

Do not use flammable chemicals for cleaning.

Before connecting or disconnecting the battery, turn off or disconnect the connection to the battery charger.

Before starting repair or maintenance on the battery and its surroundings, disconnect the battery negative
(-) pole. Put a danger warning sign on the battery connector to prevent others from reconnecting in any
way.

Keep electrical cables, battery terminals and other terminals in good condition. If there is any cracked,
cut or corroded cable, insulation in bad condition, or worn, discolored or rusted terminal, replace it with
a new one.

Be sure to ground the bodies of conductive objects that exposed to draft, such as electrical materials and
terminals, in order to prevent them from creating an ignition source by arcing.

Do not attempt to weld or repair damaged fuel tanks or pipes, replace them with a new one. If any leakage
is detected in the fuel system, do not start the generator set and eliminate the leak.

Do not forget that the temperature of the exhaust gas, exhaust manifold and exhaust outlet is around
550 ° C, insulate the hot surfaces, do not approach these areas without making sure that the system is
cool down, and avoid the contact of flammable materials with these areas.

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SAFETY PRECAUTIONS

Before starting the welding process, remove heat-damaged or flammable materials from the environment.
Keep oily rags, chemical waste, leaves, garbage or other flammable materials away from the generator set.
Keep ABC class fire extinguishers close to the place where the generator set is located and check their
occupancy routinely (at least once a year).

Do not let leaves and branches come into contact with the hot exhaust system of the generator set used
in wooded and forested areas.

Do not attempt to install or operate generator sets in hazardous areas.

2.6 TOXIC AND IRRITATING SUBSTANCES

Inhaling engine exhaust gases is dangerous to humans. The exhaust gases of all generators in closed
spaces must be disposed of in unmanned areas by means of sealed pipes in accordance with the rele-
vant standards. Hot exhaust silencer and exhaust pipe should be kept away from flammable materials
and should be protected for the safety of personnel. Do not operate your generator in closed areas with
exhaust gas leakage.

Install and operate the generator set only in open or well-ventilated areas.

ATTENTION! ATTENTION!
TOXIC AND IRRITATING IRRITATING
SUBSTANCES SUBSTANCES

Inside the cabinet of cabin type generators and when open type generators are installed in a low ceilinged
room, it is recommended to make heat insulation with rock wool and aluminum embossing or heat insu-
lation jacket in order to prevent possible contact with the exhaust system.

Make sure that the exhaust gas outlets are not given to personnel areas and places where there is a
danger of going to these areas or near to air sunction ducts.

Fuels, oils, cooling fluids and battery electrolytes used in the generator set are industrial types; Necessary
precautions should be taken to prevent accidental ingestion or skin contact. If it penetrates into the body,
seek medical assistance immediately.

In case of contact with the skin, wash the contact area with water and soap.

While maintaining the batteries, wear an acid-proof apron and use a face protective mask or goggles. If
the electrolyte has spilled on the skin or clothing, clean it immediately with plenty of water.

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SAFETY PRECAUTIONS

2.7 ELECTRIC
The wiring of the generator set should be made only by trained and authorized
qualified electricians.

Make sure that the electrically powered parts of the generator set do not come
into direct contact with the body or any uninsulated conductive object.

Before making all cable connections, dismantling and operating the generator set,
ATTENTION!
ELECTRIC make sure that the grounding has been done in accordance with the applicable
HAZARD regulations.

While the generator sets are standing in water or on wet ground, do not attempt to start the generator; Do
not attempt to connect or disconnect the generator from the electricity

Before making or removing the electrical connections of the generator set, stop the engine, disconnect
the supply of the battery charger and the battery connection. Disconnect the ungrounded conductor
connections on the load side and leave them outside.

Prevent the direct contact of any part of your body with the moving parts of the electrical system on the
generator set or indirectly through any hand tool or other conductive object. In the adjustment and repair
of the electrical system of generator set, and stand on insulating surfaces with dry litter.

Re-install the generator set electrical connection terminal cover as soon as possible when the connections
are made or removed; otherwise, do not operate the generator set.

When the generator set is out of service, lock and close all access doors of the generator.

Keep the towing vehicle or equipment carriers at least 3 meters away from electric cables and buried
power cables connected to the generator set.

Perform repairs in clean, dry, well-lit and well-ventilated areas.

Connect the generator set only to receivers that comply with the electrical characteristics and are within
the specified power capacity limit. Make electrical connections with conductors within the current carrying
capacity limit in accordance with their norms.

2.8 NOISE
The sound intensity of diesel generators that are not equipped with a sound insulation
cabin is between 90 - 110 dBA at a distance of 1 meter. Prolonged exposure to sound
intensity of more than 85 dBA is dangerous to hearing.

For indoor generator sets, acoustic measurements should be made after installation and EARMUFFS
appropriate protective measures should be taken if necessary.

Earmuffs must be used while working at the generator site.

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SAFETY PRECAUTIONS

2.9 FIRST AID IN ELECTRIC SHOCK

First of all, turn off the electricity immediately, do not touch the casualty with bare hands until the energy is
cut off. If it is impossible, protect yourself with dry and non-conductive objects and completely remove
the casualty from the conductor. Then follow the steps below in order.

a) Call the nearest health facility and seek medical assistance.

b) Lay the patient face down, with his head facing to one side and his head on his hands.
c) Remove objects from the patient’s mouth such as dentures, tobacco, gum. Press firmly between the
shoulders of patient’s with the help of the palm of your hand. Make sure the tongue rests freely.
d) Kneel with one knee at the patient’s head and the other foot at the patient’s elbow.
e) Place the palm of your hands on the patient’s shoulder and shoulder blades.
f) Push forward with your arms in a vertical position. Pressure should be light and provided without
force (About 10-15 kg). Stay this way for 2.5 seconds.

g) Release the pressure with your hands by sliding it over the patient’s shoulders to the elbows
(approximately 1 second). Following this, gently lift the patient’s arms and shoulders by holding the
elbows, and simultaneously stretch them back for about 2-3 seconds (see figure-C). Lower the patient’s
arms (see figure-D) and bring your hands back to the patient’s shoulder blade.

h) Repeat the steps so that each complete breath takes seven seconds.
i) While the artificial respiration is maintained, another person should assist in loosening the patient’s clo-
thing and keeping the patient warm.
j) If the patient stops breathing, continue for artificial respiration. Four hours or more time may be needed

Do not give fluid until the patient regains consciousness.

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GENERATOR SET AND PARTS

KJ Power Generator branded generators are manufactured using internationally accepted diesel engines
and alternators with international standards. Diesel engine and alternator options are available in different
brands and models according to their power and operating conditions. Generally, the components that
make up the generator set are shown in the following image.

Jeneratör Seti ve Parçaları

1 Power Outlet / Switch Board 7 Crankcase Breathing 13 Oil Pan

2 Control Panel 8 Radiator 14 Oil Filter
3 Compensator 9 Lifting Eyes 15 Fuel Filter
4 Turbocharger 10 Aftercooler 16 Engine jacket water heater
5 Air Filter 11 Starter Motor 17 Charge Alternator
6 Cylinder Covers 12 Oil Cooler 18 Anti-Vibration Mounts

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GENERATOR SET AND PARTS

3.1 DIESEL ENGINE

KJ Power Generator uses heavy-duty diesel engines produced for generators that do not need to be mo-
dified in international standards.

Engines with the following characteristics are used in

the generator sets: precise speed regulation, low fuel
consumption, four-stroke, atmospheric or turbo-
charged depending on power, mechanical or electronic
governor according to power, water-cooled.

The electrical system of the diesel engines used is

12V or 24V direct current. 1 battery in generator
groups with 12V electrical system and 2 batteries
in groups with 24V, battery stand and connection
cables are provided with the generator. Diesel
engines are designed to operate safely and their
Diesel Engine filters are replaceable.

3.2 ALTERNATOR
Alternators used in KJ Power Generators have following standards: single bearing, self-cooling,
brushless, IP 21 and IP 23 protection standards. It is highly efficient, precisely regulated and self-warning
as standard. Optionally, different voltage and frequency levels, dehumidifying winding heaters and thermal
sensors can be provided.

General Structure of Alternator Internal Structure of Alternator

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GENERATOR SET AND PARTS

3.3 CHASSIS AND FUEL SYSTEM

The daily fuel tank of KJ Power Generators is in the chassis up to 1125 kVA standby power and is desig-
ned to operate for 6 - 8 hours at full load. The fuel suction and return connections of the generator are
made and there is a mechanical and electronic fuel level indicator in the tank. An opportunity is provided
for tank cleaning by using the fuel drain plug

Fuel temperature is an important factor for proper operation. High fuel temperature decreases the heat
content per volume and engine output power due to expansion.

Chassis

Prismatic or cylindrical external fuel tanks are used above 1125 kVA standby power. For long service
periods, main fuel tanks should be installed in addition to the daily fuel tank.

The connecting pipe from the main fuel tank to the daily fuel tank should be at least same size with daily
tank feed pipe section or more. Fuel pipes should be black pipes, galvanized pipes should not be used.

The fuel used must be clean, there should be no water and corrosive liquids in the fuel. Otherwise,
malfunctions may occur in the injector, fuel pump and actuator.

After filling the fuel tank and waiting for a while, it is recommended to drain the water and sediment that
collection pan until the fuel flows. Hazardous wastes such as engine oil, antifreeze and fuel should be sent
to authorized disposal companies.

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GENERATOR SET AND PARTS

3.4 LUBRICATION SYSTEM

The lubrication system of diesel engines is one of the most important parts of the engine. It ensures
smooth operation of all moving parts in the engine and cooling of the engine at the same time. Correct
engine maintenance (paying attention to oil change periods, filter change periods and the properties
of the oil used) extends the life of the engine and reduces the operating cost of the engine.

Engines are lubricated with oils that form a protective layer between moving parts, such as bearings
and piston rings / cylinder groups, by pumping oil to critical points of the engine by the oil pump. This
oil layer separates metal surfaces from each other and reduces friction. By pumping oil into the engine,
it is possible to maximize the power of the engine and reduce friction losses by reducing the friction
between moving parts of the engine

The word viscosity describes how easily an engine oil flows.

Engine Oil Types According to Climatic Conditions

The viscosity of an oil is defined as its resistance to flow. Two numbers are used to describe the oil
viscosity. The first number ends with the letter ‘W’ which means “Winter”. This value shows the fluidity
when the engine is first started and the oil is still cold. The second number is defined as the new fluidity of
the oil after the engine reaches its normal operating temperature.

The smaller the number, the higher the fluidity. In other words, a 5W-30 oil used in the first start-up
moments of the engine flows more easily than 10W-30 oil. At normal operating temperatures of the
engine, a 10W-30 oil flows more easily than a 10W-40 oil. This change is important because the engine
cools when stopped and the engine oil naturally thickens when it cools and becomes thinner with
temperature.

Thin or low viscosity oils flow more easily to protect engine parts at low temperatures.

Thick or high viscosity oils are better at maintaining the durability of the film to protect the engine at high
temperatures.

For engine oils to be used in extreme climatic conditions, the manufacturer onfirmation must be obtained.

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GENERATOR SET AND PARTS

3.5 SILENCER AND EXHAUST SYSTEM

The purpose of the engine exhaust system is to transport the
poisonous gases and exhaust fumes, which are burned in the
engine, out of the room without causing danger or discomfort,
and to reduce the noise.

To reduce the noise level of the engine, a suitable exhaust Exhaust Silencer
silencer must be installed in the exhaust outlet line.

- Exhaust pipes should be as short and straight as possible to reduce back pressure.

- A flexible connection (compensator) should be placed between the exhaust mani-

fold and the exhaust pipe system to prevent engine vibration from being transmitted
to the exhaust pipe system and the building.

Compensator

- Exhaust pipes should be supported by surrounding structures so that the exhaust pipes do not weigh on
the engine exhaust manifold and turbocharger outlet.

- The weight of the exhaust system should be given to the building. Steel construction or tension elements
can be used for this task to carry the load to the ceiling or floor.

- Flap-type counter-weighted rain covers can be used in various applications to prevent rain from entering
the open exhaust outlet.

- The exhaust outlets of more than one generator should not be combined using a single exhaust pipe.

- The turns in the exhaust installation should be made with circular radius patent elbows. It is not
appropriate to make an elbow by cutting and welding the two pipes by joining them with 90 °.

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GENERATOR SET AND PARTS

3.6 VIBRATION SHOCKS

Vibration shocks are used at the connection points of the engine-alternator set to the chassis and
between the chassis and the ground in order to prevent the vibration on the ground and the loosening of
the generator parts when the generator is running. Vibration shocks are selected according to the weight
of the machine in order to minimize the vibration and use it without problems for a long time.

Rubber Vibration Shock Steel Spring Vibration Shock

(Standard) (Optional)

3.7 BATTERY
Lead acid type batteries supplied with KJ Power Generator sets provide the electrical energy required
for the starter motor and the control panel to feed during the first start of the engine. Batteries should be
placed on battery stands as close to the generator as possible.

Battery

Batteries with low charge do not start well in cold weather. This is because more power is required to
activate the cold motor.

Over time, oxidation may occur at the battery terminals and connection points.

Oxidation will corrode the battery terminals and prevent charging. Therefore, the daily control and
maintenance of the battery is very important.

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GENERATOR SET AND PARTS

Battery Maintenance:

- Keep the top side and terminals of the battery clean.

- Top covers of battery terminals and terminal connections must be installed. If there are no covers, anti-
oxidizing oil should be applied.
- Terminals should be tightened with maximum 30 Nm at the correct torque. If over tightened, the
terminals may crack.
- The electrolyte level should always be 10 mm above the plates, please check regularly.
- Acid should not be added to batteries with low electrolyte level, pure water should be added till the ap-
propriate level.
- Make sure that the battery is not uncharged.

Pay attention to safety precautions while doing any work related to batteries. (See. 2.2.)

3.8 BATTERY CHARGE RECTIFIER

The charge levels of the batteries that store the electrical energy required
for the generator control system and starter motors at any time may dec-
rease while in standby. For this reason, “buffer battery charging rectifiers”
are used, which are supplied with utility energy and located in the control
panel.

The rectifiers can be of different values with 12 VDC or 24 VDC output

depending on the voltage value of the motor installation.

Buffer Battery Charger Rectifier

3.9 ENGINE JACKET WATER HEATER

It is important that the generator motor in standby state should be
warm during the initial start and load phase. In order to achieve
this, “motor jacket water heater” fed by utility energy is used.

These heaters heat the engine cooling water in a thermostatically

controlled manner, ensuring that the engine body is constantly at
the specified temperature. When the generator is running, the heater
is switched off.

Since the water capacity in high-power generator motors is high,

Engine Jacket Water Heater
water circulation pumps provide faster circulation of heated water
in the engine body in order to provide more effective heating.

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GENERATOR SET AND PARTS

3.10 PANELS
3.10.1 AUTOMATIC CONTROL PANEL

Electronic control modules are used to control and monitor the generator operation. Automatic or manual
selections are provided in standard control systems according to usage needs. The control panel mounted
on the generator chassis monitors the utility and enable monitors the start, stop, running status and output
value of the generator when necessary. In addition, it automatically stops the generator in case of low oil
pressure, high engine temperature and other malfunctions.

Before starting the generator, the user should be familiar with the operation of the control panel and the
duties of the elements on it. While the generator is running, the visuals on the panel should be observed
from time to time. Thus, the generator can be intervened before problems occur in extraordinary situations.

Automatic Control Panel

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GENERATOR SET AND PARTS

3.10.2 3.10.2 AUTOMATIC TRANSFER PANEL

In automatic generators, automatic transfer panels are used in order to transfer the load between the uti-
lity and the generator. Automatic transfer systems are integrated at the bottom of the control panel in KJ
Power Generators that standby powers are up to 75 kVA.

Transfer Panel

For the generators that powers are greater than 75 kVA, external (wall-mounted / free-standing) transfer
panels are used. Automatic transfer panels can be provided with 3 poles (3P) and 4 poles (4P) optionally.

For the installations with residual current relays, 4P transfer systems should be used to prevent faulty trips.

Transfer Panel

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GENERATOR SET AND PARTS

The working principle of the automatic transfer panel is shown in the diagrams below.

Utility Power Available; Generator Not Activated

Utility Power Not Available; Generator Activated

3.10.3 PROTECTION SWITCH PANEL

Thermal magnetic switches are used to protect the generator

operating under load against possible overload and short circuit.

Protection switches can be provided with 3 poles (3P) and 4 poles

(4P) as an option.

Protection Switch Panel

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SELECTION OF GENERATOR SITE AND INSTALLATION

The selection of the place where the generator set will be installed is very important for the high
performance and safe operation of the generator. There should be sufficient ventilation where the ge-
nerator set will operate. It must be protected against elements such as rain, snow, hail, flood water,
sunlight, freezing cold, extreme heat, sandstorm and snowstorm. It must be protected against harm-
ful airborne substances such as dust, oil fumes, steam that corrode or provide conductivity.

The generators are classified under two options according to their place for installation.

1) Open (without cabin) type

2) Canopied type

Canopied type units are generally operated outdoors. Rarely, as an alternative to room isolation, it is seen
that a cabinet type generator is placed in the generator room.

In the area where canopied groups will be placed;

- The place where it will be placed should be suitable for the wet weight, size, static and dynamic loads
of the generator.

- If the ground properties are not suitable, the base concrete must be made in the balance with the pro-
perties recommended by the manufacturer.

- There should be enough free space around it for opening the doors and for services.

- In the placement of more than one unit, cabin design should be made taking into account the hot air
exhaust fresh air intake interaction between machines, and the layout should be properly designed.

- The distance to residential area is important due to the effect of noise and smoke.

In the area where open type groups will be placed;

- The place where it will be placed should be suitable for the wet weight, size, static and dynamic loads
of the generator.

- If the ground properties are not suitable, the base concrete must be made in the balance with the pro-
perties recommended by the manufacturer.

- It is recommended to raise the generator set from the ground in places where water may accumulate
and in humid environments such as boiler rooms.

- In order to carry the generator into the room, there must be a suitable transportation route that the ge-
nerator can pass through.

- There should be enough free space around it for service.

-In order to supply fresh air at the required flow rate and speed to the generator room, there should be air
intake shutters with appropriate cross-section.

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SELECTION OF GENERATOR SITE AND INSTALLATION

- For the hot air to be thrown out of the room by the radiator fan, there should be flexible connection
hoods and air outlet shutters with appropriate cross-section.

- In order for the engine to work efficiently and not to overheat, it is necessary to ensure that enough fresh

air enters the environment where the generator set will operate and the hot air formed inside is discharged.

- In order to avoid pressure loss in the generator room, the fresh air intake cross section should be larger

than the hot air discharge cross section, and shutters should be made to provide the direction of air flow
towards the radiator from the back of the alternator.

- If the generator room is below ground level, the air inlet - air outlet louvers cannot be applied directly,

so ventilation ducts should be manufactured in appropriate sizes for fresh air intake and hot air discharge.

- Exhaust piping should be installed in order to discharge the diesel engine exhaust gases out of the

room, the height of the generator room should be at the recommended dimensions for the installation
of the silencer and the exhaust system.

- Cabling, busbar installation, channels that will be required for external fuel piping, if any, and mechanical

reserve spaces should be taken into consideration.

- The generator room must have infrastructure suitable for lighting and grounding techniques.

- In case the generator will be taken out completely for any reason in the future, there should be doors /
lids of suitable size.

- Current fire regulations should be considered in generator installations.

- Access of unauthorized persons to the generator site should be restricted.

4.1 CANOPIED TYPE GENERATOR LAYOUT

Canopied Type Generator Layout Example

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SELECTION OF GENERATOR SITE AND INSTALLATION

4.2 OPEN TYPE (WITHOUT CABIN) GENERATOR LAYOUT

Open Type Generator Layout Example

Proper Air Flow Improper Air Flow

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SELECTION OF GENERATOR SITE AND INSTALLATION

Notes:
- For distances longer than 50 meters, the voltage drop should be calculated and the recommended cable
sections should be confirmed.

- In case the generator energy output is projected with a busbar installation instead of a cable, the
alternator output should never be directly connected to the busbar line, the alternator output should be
connected to the busbar interconnection box with cable or flexible busbar.

Generator Room Ventilation at the Same Level (Elevation) with Outdoor Environment

Generator Room Ventilation in Basement

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SELECTION OF GENERATOR SITE AND INSTALLATION

4.3 ELECTRICAL CONNECTIONS AND OPERATION

The generator’s electrical connections should be performed by qualified and trained persons and ensure
that the safety precautions in section 2.7 are followed.

Power cables of the generator set should be calculated according to the load current, the operating
voltage and the voltage drop that may occur in the distance between the load and the generator. The
generator and transfer panel should be placed in a way that make cables as short as possible. In
3-phase systems, the phase sequence should be followed in the current utility connection, and after the
generator connections are made, the phase sequence should be checked before the generator power
is supplied to the load.

In order to provide generator - utility transfer, a 3-position changeover switch (1 -0-2) should be used in
manual models, and an automatic transfer panel should be used in automatic models.

The generator set and the transfer panel must be grounded before commissioning. The generator
should not be operated without grounding installation. Grounding is useful for protecting people against
electrical hazards and for the efficient operation of electronic control devices.

Grounding is done by burying the copper electrodes of appropriate size and amount in the ground, and
using copper conductors with appropriate cross-sections to connecting them to the designated place
in the body of the generator set.

Grounding resistance should be aimed to be at most 2Ω. Energy and grounding cable sections are
given in the cable selection table according to the generator power. There should be a terminal on the
generator and panel where the grounding cable will be connected. If there is no terminal and the cable
will be connected to the body, the paint of the place where the cable lug will contact should be scratched
for ground continuity.

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SELECTION OF GENERATOR SITE AND INSTALLATION

Table: Cable Selection Table

Notes: with a busbar installation instead of a cable, the

- For distances longer than 50 meters, the voltage alternator output should never be directly connected
drop should be calculated and the recommended to the busbar line, the alternator output should be
cable sections should be confirmed. connected to the busbar interconnection box with
cable or flexible busbar.
- In case the generator energy output is projected

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SELECTION OF GENERATOR SITE AND INSTALLATION

4.3.1 PLACEMENT OF THE TRANSFER PANEL

The points to be considered in the placement of the transfer panel are as follows:

- The transfer board should be clean, dry, well ventilated and away from excessive heat (cooled if neces-
sary). When the ambient temperature exceeds 40 ° C, the capacity of the fuses and switches may dec-
rease and they can open faster.

- There should be enough working space around the transfer panel.

- It is recommended to fix the transfer panel against seismic factors.

- The load to be connected to the generator should be distributed equally (symmetrically) to three phases
as much as possible.

- The value of the current to be drawn from one phase should never exceed the nominal current value.

- If the transfer panel is separate from the generator, it is recommended to place it as close to the main
distribution panel as possible. In this case, wiring costs can be saved.

- Energy cables of appropriate cross-section must be drawn from the generator and main distribution pa-
nel to the transfer panel. In addition, NYMHY (TTR) type control cable with a cross section of 7 x 2.5 mm²
should be drawn from the generator control panel to the transfer panel.

4.3.2 STARTING THE GENERATOR

Before starting the generator, make the final checks of the generator set by observing the necessary safety
precautions.

- Check engine oil, fuel and coolant levels and replenish if necessary.

- Switch the fuses in the panel and the load output switch, if any, to the open (O) position.

- Bleed the fuel system with the manual fuel automatic on the engine.

- Check the battery level and make battery connection, first connect the (+), then connect the (-) pole.

- Turn off the fuses in the panel, and if the emergency stop button is pressed, turn it on by turning to the

right.

- After the control panel is powered on, press the bulb test button to check the warning light.

- To run the generator in test mode without load, press the TEST button in automatic models and the
START button in manual models.

- While the generator is in test mode, check the voltage, frequency, oil pressure and coolant temperature
values.

- If the generator is required to be activated continuously, the control module will remain in the automatic
(AUTO) position.

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SELECTION OF GENERATOR SITE AND INSTALLATION

- The generator control panel continuously controls the utility phases. The phase-neutral lower limit of the
utility voltage is programmed as 180 volts and the upper limit as 250 volts. When the utility voltage goes
out of these values or when the utility power is cut off, the generator starts automatically and the contac-
tors / switches in the transfer panel change positions and take the load.

- When the utility energy returns to normal, the automatic control panel monitors the utility energy for a
while. If the utility energy is permanently at normal values, it first sends an opening command to the gene-
rator contactor / switch, then it transfers the load to the utility by closing the mains contactor / switch and
turns off automatically after cooling operation.

- Generator start delay, cranking time, number of consecutive starts and waiting time, transfer delay times
and cooling time are parameters that can be adjusted on the control module.

- There are status indicators and fault signals on the control panel. When one of the fault lamps turns on, it
is understood that there is a problem with the generator set. In this case, the generator automatically stops
and does not work. After the fault is resolved, reset the fault by pressing the OFF button on the control
panel. Start the generator set in TEST mode and switch it to automatic (AUTO) mode. The generator will
turn off automatically at the end of the set time.

Datacom Control Module

(Standard)

Deep Sea Control Module ComAp ControlModule

(Optional) (Optional)

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FAULT DETECTION

The engine is not giving enough power Oil pressure is too low

- Fuel pipe blocked - Oil viscosity is wrong

- Fuel filter dirty - There is a problem with the oil pump
- The air filter is dirty - Oil sensor malfunctioning
- Poor quality fuel
- Exhaust pipe is blocked
- Fuel control faulty Oil pressure is too high
- The governor faulty
- Oil viscosity is wrong
- Oil pressure indicator faulty
Diesel engine starts hard or
does not start
Engine temperature is too high
- Starter motor cannot spin diesel
- The fuel circuit has made air - Exhaust pipe is blocked
- Fuel control solenoid faulty
- The cooling fan is damaged
- The radiator cores are dirty or the inside
- The fuel filter is dirty
of the pipe is blocked
- The heater is not working
- Ventilation flow is insufficient
- Poor quality fuel - Water circulation pump is defective
- Fuel control faulty - Air filter or tube clogged
- Injector faulty or out of adjustment - Injectors defective or out of adjustment
- Battery charge level is low - Heating system malfunction
- Battery cables have poor contact
- Starter motor defective
- Starter relay faulty The engine does not stop

- Fuel return hose may be crushed or kinked.

Electronic panel does not work at all - The valve may have been (unnecessarily)
installed in the fuel return line and remained
- Measure the DC voltage from the terminals in the closed position.
voltage, turn off all the fuses in the board, - Selenoid malfunctioning
then open them all starting with the DC
supply fuse and retest.

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FAULT DETECTION

Alternator voltage high when loaded Engine runs erratically

- Voltage adjustment potentiometer not - Fuel pipe blocked

adjusted - Fuel governor faulty
- Automatic voltage regulator protection is - Fuel filter dirty
activated - Fuel pump malfunction
- Automatic voltage regulator faulty - The air filter is dirty
- Automatic voltage regulator cable - There is air in the fuel system
connection broken - Clamps of fuel hoses loose
- Diodes faulty
- Injectors faulty or not adjustment
- Valve adjustment is bad

Variable voltage

- Engine speed variable The generator operates even though

- Automatic voltage regulator cable the utility electricity is not interrupted
disconnected or continues to operate although the
- Automatic voltage regulator out of utility electricity is available
adjustment or faulty
- The generator must be grounded,
electronic systems may show instability in
systems that are not grounded. Check it
Black Smoke is Coming Out of Exhaust out.
- Air filter is dirty - Utility voltages may be exceeded
- Bad quality fuel programmed limits, measure the phase
- Exhaust is clogged voltages.
- Low engine temperature - Check that the device measures the utility
- Valf setting is wrong voltages correctly by pressing the MENU
- Injector settings are wrong or button.
malfunctioning - Utility lower and upper voltage limits may
- Overload be very narrow. Factory setting is 170/270
volts by switching to program mode.

Generator works but does not

generate electricity

- The fuse of the automatic voltage

regulator (AVR) may have blown
- Automatic voltage regulator faulty
- Alternator diodes blown
- Diode malfunctioning

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MAINTENANCE OF GENERATOR

Periodic maintenance extends the service life of the generator. Generally, the generator and its location
should always be kept clean. Materials such as water, fuel and oil should not be allowed to accumulate
on and around the generator. There is a service warning lamp on the control panel of the generator group.
When this lamp lights up, make sure the generator is serviced

General maintenance is required for the generator in the first 50 hours or once a year. Subsequent perio-
dic maintenance should be done every 200 operating hours or once a year. (Whichever of these periods
expires first is valid.)

- Check the oil, coolant, fuel and battery of the generator set once a week. While performing these checks,
definitely turn the generator to OFF position on the control panel.

- The coolant level in the radiator is checked and completed if necessary. While doing this, the radiator is
not filled completely, leaving space 2 cm below the upper chamber level for expansion.

- The amount of oil is checked by pulling the dipstick. The oil should be between the two lines on the stick.

- After making the checks, run your generator in TEST mode for 15 minutes. After 15 minutes of
operation, press the automatic (AUTO) button on the control panel. The generator will automatically stop
after 1 minute.

6.1 FIRST MAINTENANCE

Engine oil, oil filters and fuel filters are changed during 50 hours or first running-in maintenance; The air filter
is cleaned and replaced if necessary. The machine’s electrical connections and indicators are checked. It is
checked whether there is any oil, fuel and water leakage on the engine. Radiator and fuel system hoses and
clamps and straps are checked.

6.2 200 HOURS / ANNUAL MAINTENANCE

The operations performed in the first maintenance are repeated in the 200-hour maintenance. Battery
maintenance is done, the tension of the belts is checked, if necessary, its gap is removed by stretching.

In addition to these maintenance, the water and antifreeze in the cooling system are completely drained
and changed every 2 years.

Have your generator set maintained by authorized services and use original spare parts.
Otherwise, damages caused by incorrect maintenance and spare parts will be out of warranty.

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MAINTENANCE OF GENERATOR

6.3 PERIODIC MAINTENANCE

Periodic Maintenance Table

Note: Whichever of working hours and time periods expires first applies.

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