MALCOMSON GENERATOR

GENERAL MAINTENANCE &

OPERATION MANUAL
Dear User,

We would like to thank you for choosing our company and our product.

Malcomson Generator operates in its modern facilities, providing safe and

high quality products and services under ISO 9001 Quality Management System and CE
standards. Your generator set is subject to quality control and testing in each
phase of manufacturing-through assembly to delivery; and is manufactured environmental
and people friendly in accordance with ISO 14001 and OHSAS 18001 Quality
Systems.

Our documents are meticulously prepared with extensive academic background and 20 years
of experience. General Maintenance & User Manual, Diesel Engine Maintenance and User
Manual and Alternator Maintenance and User Manual including the danger, warning and
safety measures have been delivered to you with your generator set. Before using your
generator, we kindly request from you to read, understand and keep all documents carefully
for your and others safety of life and property.

You can use your product economically while rendering a hassle free service by having the
control and maintenance completely performed at regular intervals through
signing Support Service Agreement.

We will continue to provide an uninterrupted service to you with our technical service teams that
are ready at work for 7days - 24hours.

Please inform us about your requests and suggestions for you contribution to our product
and service quality (info@malcomson-power.co.uk)
Manual and Alternator Maintenance and Operation Manual and safety precautions

generator set, disconnect the battery terminals and disconnect all cable

relevant sections of the book. Please refer to the Malcomson for incomprhensive
 Lifting
Point

Wh en t h e g en e ra to r s e t i s s u s p en d ed , al ways keep the lifting d evice o p erato r in

during the maneuvers and do not restrict the maneuvers of the towing vehicle.
Do not Remove the Guards Protect your body
and your clothes
Make sure that the exhaust gas outlets are not directed to the areas where the personnel are
located, to the areas with danger of diffusing or next to the air intake ducts.

Generator sets involve a group of components that may pose a risk to the environment. The
main ones of these are lubricating oil, diesel fuel, gasoline, exhaust gas, battery and etc.

Do not dispose of batteries that are new or ended their life cycle, and deliver them to the
Bring the patient to prone position so that his head faced to one side and the forehead rested
on his hands.

and applied without force. ( 10-15 kg is enough). Keep this position approximately for 2.5 seconds.

Release the pressure by sliding from the shoulders to the elbows of the patient with your
hands (approximately 1 sec). Following this, by holding the elbows, lift the patient’s arms and
shoulders slightly, at the same time stretch the patient backwards (about 2.5 secs). (See C)
Lower the patient’s arms (see D) and take your hands back again so that your hands will be
over the patient’s shoulder bones.
 Malcomson

11 12 13 14 15 16 17 18

3 4 5 6 7 8 9 10

Junction-Box
engine is provided with all the equipment that is necessary to ensure the safe operation.

Alternators; manufactured in accordance with IEC 60034-1; CEI 2-3; BS 4999-5000, VDE 0530;
NF 51 -100.111; OVE M-10; NEMA MG1.22 standards and CE norms; state-of-the-art technology
product; high-efficient; with maintenance-free bearing system; has brushless self-excited voltage
regulation system provides precise setting and regulation of voltage; passed the test stages;
designed to ensure trouble-free operation, ease of maintenance and long service life are used.

You can find all the technical details of the engine and alternator in the original DIESEL ENGINE
MAINTENANCE AND OPERATION MANUAL, and ALTERNATOR MAINTENANCE AND OPERATION
MANUAL that are provided with GENERAL MAINTENANCE AND OPERATION MANUAL.
Generator uses daily fuel tank inside the chassis for the generator sets up to
800kVA. Legged type external fuel tank is provided for greater power sets.

A primary fuel filter or a water separator filter to be mounted over the fuel supply line between
the tank and diesel engine is recommended.
Malcomson generator makes its own chassis production based on international standards
for all generator sets. The chassis are designed and manufactured from plate sheet or profile
content so as to provide high strength against vibration and stress.

Malcomson
Various systems have been developed for performing a safe and reliable service, to protect the
system against failures and for the transfer of load.
that are not exposed to contaminants, corrosive or conductive dust carried with wind, lint, smoke,

Place generator sets to areas where effects of motor vehicles or heavy machinery can not interfere.

Do not install and use the generator set in an environment likely to be pose a danger in anyway.

(Protective cabinets may be used upon request)

Generator set can be placed on floors such as platform, dirt surface, building and steel construction.

If desired, the platform can be constructed so as the remaining part of the floor can be isolated

Secure generator sets to the floors and platforms with joint bolts or equivalent and prevent them
In order to protect air openings, louvers must be installed for the windows. They may be fixed or
Caution!

The principle of the fuel system

1. Fuel Tank
2. Filter
3. Fuel Filter Cartridge
4. Fuel Filter Housing
4a. Water drain tap
4b. Bleeder screw
5. Fuel pipe fitting
6. Fuel injection pump
7. Injector
8. Fuel pressure relief valve
9. Fuel return line
10. Fuel feed pump
 lmproper use
maycause
fire and injury

6.1. Diesel Fuel Storage

The most preferred method for supplying the fuel is the storage of the fuel. The fuel tank сап Ье
placed above or under the ground.

А vent hole should Ье available іп order to the bleed the air pressure formed іп the main tank
caused Ьу filling of the tank and to prevent vacuum іп the tank due to the fuel consumption.
А drain valve should Ье attached іп order to drain the water accumulated at the bottom of the
tank as а result of condensation.

Embedding the tank below the frost Ііпе allows the prevention of seasonal effects.

Another point to Ье taken into consideration іп the placement of the main tank is the difference
of height between the main tank and the auxiliary tank (daily tank). Vertical lifting capacity of
the standard electrical pump is 5 m. Оо not рІасе the fuel tank to the heights exceeding the pump
lifting capacity. Іп addition, do not neglect the possibilities of pressure falls induced Ьу the extreme
horizontal distances and elbows. The fuel distribution Ііпе supplying fuel to the engine and the fuel
return Ііпе delivering more fuel back to the tank must not Ье smaller than the inlets over the engine.
Іп order to provide adequate flow for long-term operation or low ambient temperatures, the
dimensions of these lines must Ье increased.

Fuel lines сап Ье made of steel tubes or апу material proper to оіІ. Оо not use galvanized pipes.
Тапі< bleeding pipes should Ье made of same material at the same size.

The fuel return Ііпе must return back to the tank from its top side and must not contain апу shut-off
valve. This Ііпе should Ье designed with the minimum number of elbows and slope іп order to avoid air
entrainment іп the system. Fuel should not Ье supplied from а point 50 mm lower
according to the bottom of the tank.

Іп order to prevent the damage to Ье occured Ьу vibration of the generator, flexible tubing should Ье
used at access points of the generator set.

22
7. ELECTRICAL CONNECTIONS
ОпІу trained and qualified electricians should Ье authorised to carry out the connection of
electrical installation or repair work.

АІІ electrical connections must Ье made according to the schemes provided Ьу Malcomson
Generator.

Іп order to operate the generator set, аІІ connections should Ье fully compatible with аррІісаЬІе
international, national and ІосаІ standards, rules, regulations, and with the requirements including
earthing and earthing failures.

[ables that are used must Ье proper to the voltage rate. The cables shold selected according to the
table values, ambient temperature and the method of drawing іп order to identify the current to Ье
passed through.

The electrical connections to the generator set must Ье made with flexible саЬІе, іп orde r
not t o damage vibration conductors, alternator o r circuit breaker elements.

lf using flexible саЬІе completely is not suitable, а junction Ьох сап Ье placed close to g enerator Ьу
means of а flexible connection.

АІІ connections must Ье checked very carefully. The direction of phase return path must Ье checked
whether it is appropriate for the installation or not. This has а vital significance for the automatic
transfer рапеІ or if generators will Ье operated as parallel.

The control рапеІ сап Ье mounted onto the wall.

The cables connecting the generator set to the electrical load distribution board must Ье protected
with circuit breaker, fuse, or other means to disengage the generator set against апу overload or
short-circuit.

During the distribution system planning, ensuring the connection of а balanced electrical load to the
generator set is important. An excessive load over а phase compared to other two phases will result іп
overheating of the alternator windings, the imbalance between the phases and а possible damage
over the precise three-phase installation that is connected to the system. Make sure that the
calculated current rate drawn Ьу the generator does not exceed апу drawn phase current. Іf а generator
set will Ье connected to ап existing installation, а re-arrangement for the electrical system may Ье
required. The connected load's power factor (cos phi) should Ье identified. Power factors under О.В
lead to extreme loading over the generator. The generator set will work safely with power factor value
of О.В. Іп order to regulate the power factor for appropriate values, automatic power factor correction
equipment сап Ье established. However, it must Ье considered that the system should not exceed the
capacitive value. Otherwise, this situation will cause the generator output voltage instabilities and
the occurance of hazardous excessive voltage.

23
 7.1. Starter Batteries

The electrical resistance over the starter circuit has а significant impact оп the operation of the
diesel engine. Therefore, the batteries сап Ье placed as close as to the generator set, it should Ье
ensured that the connections are correct and not loose
(Batteries must Ье accessible for ease of service).

The maintenance procedures should Ье carried out delicately due to the necessity of being іп
excellent condition of the batteries to run the generator set at апу moment. Battery charging
system and battery maintenance are described іп the relevant sections.

Connection and removal

First connect the battery (+) lead. Then connect the
battery (-) terminal. Begin the disengaging process from the
battery (-) terminal. Then disconnect the (+) роІе connection.

Cleaning
І<еер the batteries сІеап and dry. Dirt and oxidation
formed over the battery or the terminals cause the
battery voltage to drop and discharge the battery.

Remove and сІеап the terminals during maintenance.

Use а wire brush for oxidation. After connecting
and tightening the cables again аррІу Grease onto
the terminals to retard oxidation.

Adding distilled water

The electrolyte level of the batteries that requires
maintenance should Ье checked from time to time. Іf
the fluid level is decreased Ьу 5-10 mm, fill up with distilled
water. Then, charge the battery approximately for 30 minutes.

NOTE: See the user manuals for special maintenance methods of maintenance-free or dry-type batteries.

24
8.SDUND CDNTRDL

Malcomson generator has proven itself with its quality and ехрегіепсе оп generator sets
sound insulation that has а great importance for reducing noise pollution today.

Vour generator set сап Ье fitted with equipment that reduces the sound propagations. 5ome
of them are; sound isolation cabins, room isolation, super exhaust silencers, acoustic louver
windows and hoods. Every environment has variable requirements, so that we recomend you
to contact with us for precise installations.

5ound propagations of diesel generator sets (without sound insulation) are between
100 dB and 110 dB from 1m distance. The lowest attainable sound pressure level is between
65 dB and 75 dB from 1m distance. The sound insulation has much more importance for
hospitals, schools, residential areas, offices and etc. Being іп environments with more than
85 dB sound pressure level for а long time сап cause hearing problems. Use earplugs at areas
where the generator set is running.

25
 9. MEASURES ТО ВЕ TAKEN AGAINST FIRE

The following points should Ье taken into account for the installation of а generator set;

* Іп case of апу fire outbreak іп а room, there must Ье а convenient escape route for the
company staff.
* А fire extinguisher or fire extinguishing system must Ье provided іп accordance with
the Fire Code and standards and according to the рІасе or building where the generator is located.
□
* гор weight fire valves that activate via fusible links mounted оп the motor must Ье placed
onto the fuel lines. The room should Ье kept сІеап and free from masses of waste that cause
to start fire.

10.GROUNDIN(i

Equalizing the inactive sections and their connected parts іп electrical installations with the
ground Ьу means of ап electrode is called grounding. For electrical system's persistency and to
protect human life, the contact surfaces are isolated. However, for various reasons, failure or
defects іп the form of distortion against the ground are always unavoidable for these parts.

ln this case, the surfaces that the conductor contacts are exposed to electric leakage potential.
Potential voltage formed against the ground eliminates the risk of current flow from human to
the ground іп case of contact Ьу connecting of аІІ conductive parts with опе another and with
ап effective earthing.

Perform the grounding іп accordance with the current national and ІосаІ standards, rules,
regulations or other directives. Grounding resistance should Ье less than 20 ohms. Contact
voltage rates above S0V and 15mA are dangerous for human health. Іп the event of embedding
more than опе grounding plates or rods for different purposes, the distance between them
should Ье а minimum of 20 meters. The total mass of the generator set has ап equivalent
potential Ьу connecting the alternator body to the generator chassis.

liroundin11
Point

26
4 CONTROL SVSTEMS
1. INTRODUCTION

Malcomson Generator sets use generator control units with standard programmable micro-
processor that are сараЬІе of monitoring of аІІ measured values and alarm messages and
provide protection.

Control systems unsure the running and swicthing off the generator set and monitoring and
maintaining а variety of values. They provide а convenient use through programmable
parameters according to changing conditions. Control panels аге made of А1 quality type steel
plate that is protected against corrosion with surface treatment and electrostatic powder paint.
Along with, (Auto) and (Synchronization) standard control panels, different sets аге also
manufactured іп accordance with the customers' requests and business operations іп terms of
various operating scenario the (Manual) "Manual" and "Automatic" control panels will Ье
discussed. You сап contact us to obtain necessary information about our different applications.

2. MANUAL CONTROL PANEL

lt is designed for use when the power goes off ог for the cases іп which the generator set is
activated ог deactivated Ьу the user.

The control and protection procedures are performed Ьу the programmable device. Operating
modes аге selected Ьу pressing the desired key оп the front рапеІ.

OFF: Іп this position, the engine shuts off immediately.

AUTO: lt is used for automatic operation of the generator. As the RЕМОТЕ START signal comes оп,
the engine is started according to programmed times. А waiting time is elapsed between each
cranking. As the generator starts to run, cranking is cut off immediately. As L1-L2-LЗ-phase
voltages reach the limits, first the engine warm-up time and then the generator contactor time аге
waited to elapse and the generator contactor is energized.

Опе of the auxiliary геІау outputs сап Ье assigned as Generator Contactor signal.

As RЕМОТЕ START signal goes off, engine runs as long as the mains waiting time. Then the
generator releases the contactor. lf а cooling time is given, the generator runs as Іопg as the
duration of cooling time. At the end of time, CONTA[T output is de-energized and the diesel stops.
The device stays ready to activate the generator with а new REMOTE START signal.

Іf the weekly operating schedule interrupts the operation of the generator, AUTO led will flash and
the generator does not run. TEST: lt is used for starting the generator ог holding the generator іп
emergency backup position as long as there is по REMOTE START signal. Everything works just like
іп AUTO position. However, unless there is REMOTE START signal, generator does not draw the
contactor, as the REMOTE START signal comes оп, generator draws the contactor (if the emergency
backup is selected). As REMOTE START signal goes off, the generator releases the contactor but the
engine continues to run. То stop the generator, switching to AUTO or OFF mode is required.

27
 З. AUTOMATICCONTROL PANE

lt is designed for automatic activation or de activation of generator sets to Ье used as а stand Ьу

for mains power.

Electric network monitoring, control and protection procedures are performed Ьу the programmable
generator control unit. Operating modes are selected Ьу pressing the desired key оп the front рапеІ.

OFF: Іп this mode if the mains phase s are within the programme d limits, the mains draws the
contactor. lf the generator is running, it is shut-off immediately.

AUTO: lt is used for automatic transfer of the generator and the mains. Іп case of опе of the
mains phases exceed the limits, the mains release the contactor. At the end of waiting time the
engine is cranked according to programmed times. А waiting time is elapsed between each cranking.
As the generator starts to run, cranking is cut off immediately. As аІІ of L 1-L2-L3-phase voltages
reach the limits, first the engine warm-up time and then the generator contactor time are waited
to elapse and the generator contactor is energized.

As аІІ of the mains phases are entered into the limits, it is waited until the mains waiting time is
elapsed. Then the generator releases the contactor and the mains draw the contactor. lf а cooling
time is given, the generator runs more as long as the duration of cooling time. At the end of time
CONTACT output is de-energized and the diesel stops. The device stays ready to activate the
generator at а new electric grid blackout.

lf the weekly operating schedule interrupts the operation of the generator, AUTO led will flash and
ап equivalent operation to OFF position is performed.

TEST: lt is used for trying the generator or holding the generator іп emergency backup position
when there is electric network. Everything works just like іп AUTO position. However, as long as
the electric network exists, generator does not draw the contactor, if there is electricity cut off, the
mains releases the contactor and the generator draws the contactor (if the emergency backup is
selected). As the power comes back оп, the load is tranferred to the mains again but the generator
continues to run. То stop the generator, switching to AUTO or OFF mode is required.

LOAD TEST: lt is used to test the generator at load. As this position is selected, the generator runs
and increases the load.

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4. SVNCHRONIZATION PANELS

Malcomson generator provides alternative solutions for energy projects via using
synchronization systems designed Ьу its own. This system formed Ьу combining more than опе
generator together for your high kVA requests; provides considerable advantages іп comparison to
а single generator with same power. These advantages are; low cost, low initial investment
budget, flexibility, ease of maintenance and service, ease of delivery and supply of spare part and
being а secure system.

Special synchronization control panels are designed for these solutions. The designed panels are
mainly used for the following applications:
* Synchronous operation of more than опе generator sets with each other.

* Synchronous operation of а single generator set with electric network

* Synchronous operation of more than опе generator sets with electric network

* Synchronous operation of more than опе generator sets with multiple electric network

29
 5. BASIC PRDCEDURES BEFDRE START-UP

Observe safety precautions described іп the General Maintenance & Operation Manual before
operating the generator. Make sure that the installation is made completely and precisely.

Make sure that the electrical connections are performed іп accordance with the technical
instructions and schemes.

The following procedure should Ье used іп every operation of the generator set. РеорІе, who will
use the generator set, must Ье trained for this issue.

1. lnspect the generator set (engine and alternator ) manually and visually іп general.
Оо not operate it if there are апу leaks, broken parts, cracks and etc.
2. The generator set should Ье оп ап ideal and level surface. lt should Ье protected against
conditions such as precipitation, dust and etc.
З. lnspect fresh air intake and hot air outlet windows or ducts are not closed or clogged.
4. Check that the exhaust outlet is closed or clogged.
5. [heck the engine оіІ level and, if necessary, add оіІ.
Б. Check the coolant level and anti-freeze level and, if necessary fill up. Anti-freeze level must Ье
adjusted according to the coldest conditions of the region.
7. [heck the fuel tank and fuel level and if necessary add fuel.
8. The batteries сап Ье maintenance-free or lead-acid type batteries. Check the electrolyte level
if it is lead-acid type battery and charge it. СІеап and charge, if it is maintenance-free type.
9. [heck the air filter against excessive contamination or clogging and if necessary replace it.
10. Апу object or апуопе around the generator may obstruct the operation of the generator set or
cause injury. Please check and warn them.
11. Make sure that the power output is switched to CLOSE (OFF) position.
12. Ensure that the fuses are swithed to CLOSE (OFF) position.
13. Make саЬІе connections to the battery terminals.
14. Bleed the air from fuel system and fuel filter completely Ьу using а fuel priming pump. For
details, refer to the DIESEL ENGINE SERVl[E-MAINTENANCE ВООК.
15. Switch the fuses to OPEN (ON) position.
16. [heck the Emergency Stop Button is at ореп position.
17. Run the generator manually via the control unit.

30
18. Check abnormal noise and vibration.
19. Check апу water, оіІ, fuel and etc. leakage.
20. Look оп the temperature and оіІ pressure gauges.
21. Check the voltage and frequency values.
22. Check direction of generator and electric grid phase return paths. Stop the generator, if return
paths are not іп the same direction with the electric grid and change the generator phases direction.
23. Іf аІІ values are normal, you сап run the generator at electrical load. Оо not use the generator set
other than capacity specified оп the ІаЬеІ.

CAUTION !

* Observe safety precautions described іп the General Maintenance & Operation Manual before
operating the generator.
* Make sure that the installation is made completely and precisely.
* Proper grounding of both stationary and mobile generator sets prevents the possibility of death
or personal injury іп the event of power failure.
* Since the battery system has negative grounding, first (-) terminal should Ье removed and for
reconnection, the negative (-) terminal should Ье connected at last.
* While the safety stop button is pressed, generator does not run іп automatic or manual position.
* Switch оп the emergency stop button Ьу turning it clockwise.
* Never start-up or stop your generator set while power output switch is at OPEN (ON) position.
* The generator set's maintenance and controls according to daily, weekly, annual and working
hours schedule should Ье carefully followed.

31
 6. ВАПЕRУ CHARGER

Battery charger is designed to keep starter batteries always charged even the generator is not
operated for а long time. Generator is supplied from the power grid at stand Ьу position. Battery
charger is available іп automatic control panels as standard.

Charging speed depends оп the state of the battery ampere-hour- Ah (size) and the current state
of the charge.

The initial charging current will Ье reduced as the battery is charged.

Оо not operate the battery charger іп the environments that are not protected against rain or snow.
Ensure that the power grid supply connection is correct and perform the right grounding.

Before removing the battery turn off the battery charger, and avoid апу spark or flame. Surrounding
dense smoke сап cause the battery to explode.

Ву following the instructions, battery charger must Ье used properly, should not Ье overcharged and
batteries should not Ье damaged. lf а lead-acid type battery temperature rises to 52 °С, the battery
will Ье damaged. Care must Ье taken to charge the batteries especially іп tropical countries; the
charging environment should Ье сооІ and shady.

There is а battery charging generator to charge the batteries of diesel engine with battery chargers
that run with mains power.

Check the pulleys and V-belts rotating the charging alternator. Replace lf they are defected replace
and adjust belt tension if loosen.

Check that the warning light and power supply саЬІе connections of the charging alternator are
correct and firm.

7. BLOCK WATER HEATERS

Heaters сап Ье placed over the engine water system to ensure convenient operation and quick
drawing of the load of the diesel engine. Heaters are available іп automatic control systems as
standard. They сап Ье used іп manual control systems upon request.

Heaters are used with thermostat adjusted approximately to 40 °С. Heaters' rated powers (kW)
vary according to the engine capacity. Heaters of 0.8-2kW are placed into the generators under
800kVA. Heaters of 3-12kW with water pump сап Ье used for large-sizes (800 kVA and above) and
іп cold climates. АІІ of these heaters are automatically de-activated as the engine starts-up.

8. TRANSFER BOARDS

Transfer boards are used to control and for safe transfer of the generator set output power. For this
reason, the generator set should have sufficient capacity to meet the standards of the output power.
Contactor, motor circuit breaker and etc, are used оп boards of auto-activated generator sets. The
control of switching components іп automatic control systems must Ье performed Ьу the generator
control unit. For manual generator sets that are activated Ьу hand, inverter switches сап Ье used
together with thermal-magnetic circuit breaker located at power output.

Standard wiring diagrams of transfer board are given іп the "Attached Booklet".

32
5 MAINTENANCE
1. IN GENERAL

lmplementing а good maintenance program is the most important factor for the long-term
operation and useful economic life of your generator set. At the same time, your generator set will
Ье ready to give service at апу moment and failure risks will Ье minimized. Carry out and have
your maintenance made based оп these programs.

АІІ the maintenance and controls to Ье performed are specified іп General Maintenance Schedule
and they аге also available іп the original ENGINE MANUAL and ALTERNATOR MANUAL іп detail.

А сору of аІІ generator service registration forms, model and serial numbers tag, drawings and
connection schemes, spare parts lists, service and maintenance schedule and this manual should
Ье maintained. These records will serve as reference for the service and will Ье helpful for the
diagnosis of а further problem.

Maintenance and repairs should опІу Ье performed Ьу authorized and trained personnel.

CAUTION !

Іf the generator set is large enough to take а person inside, before making adjustments and
maintenance, inform other staff members and secure аІІ the access doors against closing or locking
up Ьу others. Stop the engine before changing or adding of fuel, оіІ, and coolant and battery electrolyte.

Before starting the repairs and adjustments іп order to prevent the generator to run, cut off the
battery charger supply and disconnect battery negative (-) terminal. Іп order to prevent апу
re-connection Ьу others put а warning sign оп the battery connection.

Make the adjustments опІу when the generator set is switched off. Make the adjustments if
needed, and then re-run the generator to control adjustments. Adjustments during operation should
опІу Ье performed Ьу specialized technical service personnel.

2. DIESEL ENGINE MAINTENANCE

See DIESEL ENCilNE MAINTENANCE AND OPERATION MANUAL.

33
CAUTION!
 7. ВАТТЕRV MAINТENANCE

Batteries used generator sets аге іп different types. Іп Malcomson generators maintenance-free
type batteries аге used. They аге completely closed, and do not require апу addition of distilled
water.

Since its internal resistance is vегу low, discharge time is too long. lt has а wide ope rating
te mpe rature гаtе {approximate ly from -20 °С to БО 0 С)

The еІесtгіс роwег used is obtained from chemical reactions realized inside the cells. This
reaction is гесусІеd and the battery сап Ье charged and discharged оvег and оvег again.

Batteries remain permanently charged approximately 4 уеагs. After this регіоd they аге герІасеd.

Another type of commonly used batteries аге lead acid type batteries іп which they аге а
combination of cells ог plates with а group of positive and negative electrodes dipped into
electrolyte (sulphuric acid).

Check the battery fluid's density with а battery hydrome te r. The re ading іп each сеІІ should Ье
approximately 1.27 at nominal temperature гаtе (15 °С).

The most ргорег water to Ье used fог the ргерагаtіоп of the electrolyte is distilled wate r. This
also applies to the water to Ье added daily to the battery.

Іп огdег to avoid contamination, сІеап the top of the battery and remove the caps. Add distilled
□
water about 5-10 mm above the plates. Reinstall and tighten the caps. гу the uррег рагt of the
battery. Check the operating temperature values of the battery that you use (approximately
between -5 °С and 50 °С). The battery fluid may freeze ог ЬоіІ under suboptimal temperatures.
Fог this reason, it becomes inoperative.

CAUTION !

* Batteries геІеаsе flammable gases. Оо not smoke, avoid sparks ог ореп flames around the
batteries.
* Always hold the batteries carefully and to prevent possible acidic burns wash уоuг hands after
contacting.
* Wеаг suitable protective clothing
* Оо not allow unauthorized personnel around battery charging агеа
* Checl< the charging systems together with batteries.

36
8. RADIATDR MAINTENANCE

The radiator, provided together with the engine radiator, are designed and manufactured to
operate smoothly under industrial conditions for years, as long as the maintenance is performed.
General information about the methods of radiator maintenance will Ье given.

* Radiator coolant normally works under pressure and it is extremely hot.

* Оо not work оп the radiator or remove the radiator hoses until it cools down.
* Оо not work оп the radiator and remove the guard when the fan is operating.
* Corrosion over the radiator is the primary cause of failures. Always make sure that whether there
is а leak or not іп the radiator hose connections.

The radiator must Ье filled up full. Partial filling of the radiator will lead to rapid spread of
corrosion. For а non-operative generator, drain the radiator completely or make sure that the
radiator is protected. Radiator сап опІу Ье filled with distilled water or soft natural water or а certain
amount of proper corrosion inhibitors must Ье added to the water. Radiator іп dusty and dirty
environments may not fulfill its duty due to clogging Ьу dirt, engine fumes, humidity, various
particles and etc.; this contamination degrades the performance of the radiator.

* Low pressure steam must Ье used for cleaning the deposit formations regularly. For tougher
residues, radiator сап Ье dipped into alkaline solutions up to 20 min and then washed with hot
water.

9. LOW-LOAD OPERATION

Using the generator set over the category (ESP/PRP/COP) and capacity specified іп the ІаЬеІ
values is as disadventegous as using it at low-load.

This condition should Ье considered further іп particular for the use of high-capacity generators.

The minimum allowable load for generator sets under ESP and PRP category is 30% of the full
power. This is 25% for СОР.

Operating the generator sets at no-load or low-load should Ье avoided or this period should Ье
decreased to the minimum level.

lf weekly-test run should have to Ье performed at no-load, the test must Ье limited to 10 minutes.
lt is recommended to run the engine, operating at 30% or at no-load for 1 hour; at load of 60% or
more for 30 minutes or longer.

lt is recomended to run the generator set at 75% load and for 30 minutes or longer every year for
4 hours.

lt should Ье monitored at regular intervals whether there is оіІ leakage or not, the exhaust manifold
and muffler should Ье removed, and checked and cleaned against carbon accumulation.

37
The turbocharger bearings running at extreme high-speed are primarily influenced by abrasion that
may cause oil leakage and damage. There will be more oil consumption than the normal value as a
result of such running.
 PROBLEM POSSIBLE CAUSES SOLUTION

Engine turns slowly,

but not running

Engine is not running

Use appropriate oil

Repair
 Repair
Generator does not
stop

PROBLEM POSSIBLE CAUSES SOLUTION

Add
Repair

pressure is too high

Load over 30%

output

White exhaust gas

output
 Replace

Replace

Replace

PROBLEM POSSIBLE CAUSES SOLUTION

Fuel over-

Replace

Replace

Motor output power

loss
Alternator does not
produce voltage (no-load
voltage is lower 10% than Exciter circuit short-circuit or disconnected
nominal voltage) Apply external warning

Alternator does not

produce voltage (no-load Exciter stator link is broken
voltage is lower 20-30%
than nominal voltage. Exciter stator is connected incorrectly Control
Speed is lowerthan nominal Control Engine Speed
Set
Fuse is blown
Voltage is at 50-70% of
nominal value

Voltage pot. Is not set Adjust Voltage (V) pot

Output voltage is too high

Engine speed is variable Adjust Engine speed
Stability pot is not adjusted Adjust STAB pot
Instable output voltage
Malcomson Generator products are covered under the scope of guarantee in accordance with the
terms and instructions specified in the guarantee procedure. In order to receive guarantee
service and not to be excluded from the guarantee coverage of your generator set within the
warranty period, act in accordance with this procedure.

Keep invoices, warranty certificate, dispatch note and service registration forms of your generator
set. These documents must be presented when requested.
Obligations of Malcomson Generator

* The warranty period is 1 (one) year or 1.000 hours of operation - whichever comes first- from the
date of invoice.

* The complete part of the product, including all components is covered by our company’s warranty
against manufacturing and product defects.

* Malfunction of product within the warranty period due to defects both in terms of material and
workmanship and as well as assembly; will be repaired without requesting any charge under labor
costs, under the cost of replaced parts or under any other name.

* Malcomson is obliged to deliver the maintenance and operation manuals together with the
product.
Obligations of the Customer

* The issues included in General Maintenance and Operation Manual, Diesel Engine Manual and
Alternator Manual provided with the generator set should be observed. The damages due to failure
to comply the issues included in these manuals are excluded from the scope of guarantee. In case
of losing any of these books, the customer is obliged to obtain the book as soon as possible.
* Installation approval and commissioning process of the generator set should be performed by
Malcomson or an authorized service technician. On the contrary case, the guarantee shall be invalid.
* The intervention of third parties, other than the technical services of Malcomson, should not be
allowed under any circumstances. Otherwise, the guarantee shall be invalid.
* The placement and installation of generator set should be performed in accordance with
installation principles specified by Malcomson. Failures due to improper installation shall not be
covered under the scope of guarantee.
* The periodic maintenance, inspection and adjustments specified in General Maintenance and
Operation Manuals should be carried out exactly. In case of failure to perform any of them, the
guarantee shall be invalid.
* Spare parts and consumables (engine oil, filters, antifreeze, belts, injector nozzle, etc.)that are
naturally weared or needed to be replaced depending on the generator set’s operating hours or the
period of being in use, are excluded from warranty coverage, and the replacements are charged.
* Specific and suf f i cient amounts of lubricating oil, antifreeze or additives specified in General
Maintenance and Operation Manual must be used. In the event of the use of oil and anti-freeze
with dif f erent characteristics and Standard that are dirty and lost their characteristic features, the
warranty shall be invalid. In case of not using anti-freeze, the warranty shall be invalid.
* Diesel (diesel fuel) specifications that are mentioned as fuel in manuals must be used for diesel
generator sets. The guarantee shall be invalid in case of using biodiesel, JP4, JP8, kerosene-based
fuels, fuel oil, gasoline and etc., and also fuels that are dirty, aqueous and including chemical
additives.
* Batteries must be stored under protection and should not be discharged. Batteries that are
deformed, broken, and lost their features due to being discharged and overcharged are excluded
from the guarantee covarege.
* Attachments and modifications over the generator set’s control system-manual, automatic,
synchronization panels, transfer boards, equipment and etc. - must be carried out by Malcomson.
On the contrary case, the warranty shall be invalid.
* Generator control unit programs must be set up or changed by Malcomson technical of f i cer. On
the contrary case, the warranty shall be invalid.
* Operate and stop the generator sets as described in the general maintenance and operation
manuals. Do not operate and stop under load. This may lead the engine valves and components,
alternator excitation windings, rotating exciter diodes, suppressor and voltage regulator card to be
damaged. The damages occurred due to this condition are excluded from the coverage.
* Original spare parts and consumable materials (oil, fuel, filters, belts, etc.)approved by
Malcomson should be used during the warranty period. The guarantee is terminated in case of
using spare parts and supplies that are not approved.
* The guarantee shall be invalid in case of deleting, removal or changing the labels of the
generator set.
* Generator set should be used according to the category (Standby) and declared value indicated
on its label. Faults due to imbalanced loads exceeding the declared value at dif f erent operating
category, are excluded from the guarantee coverage.
* The generator set should not be used under 30% load for a long time. Faults caused by operating
under no-load or low-load specified in the general maintenance and operation manual are out of
warranty.
* Natural disasters, earthquakes, snowstorm, landslides, fire, flood, inundation or damages
resulting from the power grid are excluded from the scope of the guarantee.
 Manufacturer Company
Malcomson
Building 2, Guildford Business Park Rd, Guildford GU2 8XG, United Kingdom
info@malcomson-power.co.uk
+441483928117 +441483928117
malcomson-power.co.uk

Product Details
Type: Genset Brand: Malcomson
Genset model: Genset serial no:
Engine model: Engine serial no:
Alternator model: Alternator serial no:

Dealer Company’s
Title:
Address:
Phone: Fax:
Invoice Date and No: Dealer Authorized Person Name & Signature:
Delivery Date:

Buyer Company’s
Title/ Name Surname:
Address:
Phone: Fax:
E-mail: Buyer Authorized Person Name & Signature: