Operation and Maintenance Manual: For Natural Gas Generator Sets

OPERATION AND MAINTENANCE MANUAL
FOR NATURAL GAS GENERATOR SETS

Dear User
First of all, thank you for preferring our product and company.
TEKSAN Jeneratör, sustains all its activities at its modern facilities, according to its principle of providing
reliable products and services at high quality with CE norms and “ISO 9001:2000; Quality Management
System” certification. Your generator set is subjected to several test and quality controls at every stage
of production. There are several test and control procedures carried out on the time interval between the
very first “assembling” step and the very last “delivery” step. TEKSAN products are also manufactured
environment friendly at norms with “ISO 14001; 2004 Environment Management System” certification.
Our documents are being prepared carefully with the help of the academic education we have received
and also the knowledge and experience we have obtained from being in this business for the last 25
years. As a standard TEKSAN documentation, the “Operation and Maintenance Manuals” for your
“Natural Gas Engine”, “Alternator” and “Generator Set” must have been delivered to you together with
your generator set. Your duty as our customer, is to read, understand and remember all information
shared in these documents before using your generator set. This will help you avoid any possible
accidents that may be harmful for you, people around you or the generator set itself.
You may also sign for a “Periodical Maintenance Agreement” and get regular, complete and economical
maintenance and reparation services from TEKSAN, and receive non-problematic service for your
product.
We will be offering you an uninterrupted service, with our technical service team which is on duty for 7
days and 24 hours.
Please let us know about your wishes and suggestions in order to contribute to our product and service
quality…
TS ISO 8528-5 CERTIFICATE
ISO 9001 QUALITY MANAGEMENT SYSTEM CERTIFICATE
ISO 14001 ENVIRONMENT MANAGEMENT SYSTEM
CERTIFICATE OHSAS 18001 WORKERS’ HEALTH

AND SECURITY MANAGEMENT SYSTEM
GOST-R (RUSSIA) CERTIFICATE
CERTIFICATE OF CONFORMITY WITH EUROPEAN UNION DIRECTIVE
1
TABLE OF CONTENTS
PREFACE.................................................................................................................................................................... 1
1. SAFETY PRECAUTIONS ...................................................................................................................................... 3
1. GENERAL INSTRUCTIONS ............................................................................................................................. 3
2. LIFTING AND CARRYING ................................................................................................................................ 4
2.1. TOWING TRAILER TYPE GENERATOR SETS......................................................................................... 5
3. MOVING PARTS ............................................................................................................................................... 6
4. HOT SURFACES AND SHARP SIDES/CORNERS .......................................................................................... 6
5. FIRE AND EXPLOSION .................................................................................................................................... 7
6. HAZARDOUS AND CORROSIVE SUBSTANCES ............................................................................................ 8
7. ELECTRICAL COMPONENTS AND CONNECTIONS ..................................................................................... 9
7.1. FIRST AID IN POSSIBLE ELECTRICAL ACCIDENTS............................................................................. 10
2. GENERAL DEFINITIONS .................................................................................................................................... 11

1. NATURAL GAS GENERATOR SET ................................................................................................................ 11
2. NATURAL GAS ENGINE ................................................................................................................................ 12
3. ALTERNATOR ................................................................................................................................................. 13
4. BASE FRAME ................................................................................................................................................. 13
5. VIBRATION ISOLATORS ................................................................................................................................ 13
6. EXHAUST SYSTEM AND MUFFLER ............................................................................................................. 14
7. CONTROL SYSTEMS ..................................................................................................................................... 14
3. INSTALLATION .................................................................................................................................................... 15
1. SELECTION OF LOCATION ........................................................................................................................... 15
2. FLOOR AND PLATFORM................................................................................................................................ 16
3. VIBRATION...................................................................................................................................................... 16
4. COOLING AND VENTILATION........................................................................................................................ 17
5. EXHAUST SYSTEM......................................................................................................................................... 19
6. NATURAL GAS FUEL SYSTEM...................................................................................................................... 19
7. ELECTRICAL CONNECTIONS........................................................................................................................ 21
7.1. STARTER BATTERIES............................................................................................................................. 22
8. SOUND CONTROL.......................................................................................................................................... 23
9. FIRE PRECAUTIONS...................................................................................................................................... 24
10. GROUNDING................................................................................................................................................... 24
4. CONTROL SYSTEMS.......................................................................................................................................... 25
1. INTRODUCTION.............................................................................................................................................. 25
2. CONTROL PANEL........................................................................................................................................... 25
3. IGNITION AND FIRING SYSTEM ................................................................................................................... 28
4. BASIC PROCEDURES TO BE FOLLOWED BEFORE OPERATION............................................................. 28
5. BATTERY CHARGER DEVICES..................................................................................................................... 30
6. HEATER BLOCKS........................................................................................................................................... 30
7. TRANSFER (ATS) PANELS............................................................................................................................. 30
5. MAINTENANCE.................................................................................................................................................... 31
1. GENERAL INSTRUCTIONS................................................................................................................................. 31
2. MAINTENANCE OF NATURAL GAS ENGINE................................................................................................ 31
3. MAINTENANCE OF ALTERNATOR................................................................................................................. 32
4. ENGINE LUBRICATION OIL............................................................................................................................ 33
5. ENGINE COOLANTS………............................................................................................................................ 33
6. FUEL (NATURAL GAS).................................................................................................................................... 34
7. AIR FILTER...................................................................................................................................................... 35
8. SPARKING PLUGS.......................................................................................................................................... 35
9. BATTERIES...................................................................................................................................................... 36
10. RADIATOR....................................................................................................................................................... 37
11. GENERAL MAINTENANCE SCHEDULE........................................................................................................ 38
12. LOW LOAD OPERATION................................................................................................................................ 39
13. LONG TERM STORAGE................................................................................................................................. 40
6. TROUBLESHOOTING.......................................................................................................................................... 42
7. WARRANTY.......................................................................................................................................................... 45
2
READ AND UNDERSTAND
THE WHOLE OPERATING AND
1
MAINTENANCE MANUAL BEFORE
RUNNING THE GENERATOR SET
SAFETY PRECAUTIONS
1 General Instructions
Before installing or running the generator set, it is a responsibility for the user or operator to read the whole
documentation that is included within the generator set. (“Generator Set Operation and Maintenance Manual”,
“Natural Gas Engine Operation and Maintenance Manual” and “Alternator Operation and Maintenance
Manual”) All the safety instructions stated in these manuals must be provided in order for a safe operation.
The person who is in charge for installing, maintaining or using the generator set, is the only responsible for anything
that risks the safety of operation. For this reason, these people must follow and obey all the instructions stated in all
provided documentation, so that the risk of accident shall be minimized.
Because of this responsibility to take, the people who will install, maintain or use the generator set, must be trained
and authorized about the procedures for installation, usage and maintenance. Any disorder or disobeying about
these procedures, rules, instructions, methods or measures in manuals, will increase the probability of failure and
accidents that may end up with injuries or maybe death.
Pay attention to all labels and warnings on the generator set. Install and operate the generator set fully in conformity
with the related standards, rules and regulations. Furthermore, the local rules and regulations should be followed
too.
Make sure that the generator set is at OFF position before performing any maintenance, repair or setting activity. By
doing this, you will be isolating the generator set from any unauthorized access.
Do not start the generator set until you are definitely sure that it is absolutely safe to run it. Under any unsafe
condition, turn off the manual valve on the gas supply line immediately, so that the gas supply shall be blocked.
Attach a danger warning on the generator set in order to avoid people from staying around it or trying to run it. Also
disconnect all the battery connections from the battery pole heads and avoid any short circuit accidents.
Perform or get performed all the controls and tests periodically against any natural gas leakage possibility. Do not
start the generator set in any case of natural gas leakage probability.
This manual and the appendices are integral in total. All safety instructions are clearly stated in the relevant sections
of this manual. Also remember that you can always get in contact with TEKSAN Jeneratör and ask for advice about
any issue that is not understood clearly.
DANGER
Read this user and
maintenance manual carefully
before use. Any improper
usage of this generator set
may lead to serious and
dangerous accidents.
3
READ AND UNDERSTAND
1
SAFETY PRECAUTIONS
2 Lifting and Carrying

Use the lifting lugs located on the generator set, while you are trying to lift or move the generator set.
Before lifting the generator set, be sure that you have checked all the lifting lugs or any connection points for any
welding cracks, breakages, twists or rust that may cause any problem during the lifting process.
Make sure that all lifting equipment and supporting components are in a good condition, so that they can resist a
load 10% more than the gross weight of the generator set as a minimum. (Extra margin for any snow, ice, mud or
attached spare parts/equipment on set.)
Make sure that all the lifting hooks or locks have functional safety clips and all of them are connected correctly.
Be sure to use guide ropes or equivalents in order to prevent any rotation or swing action, when the machine is lifted
and there is no contact left between the machine and the ground.
Before lifting the generator set, disconnect all the connections of pipes, hoses, natural gas lines, cables, wires etc…
Check the ones that are left connected, be sure that they are all fixed firmly.
Again before lifting, make sure that all natural gas pipe connections are removed and drain the gas left in pipes,
hoses or any equipment on the gas line. Be sure that there is no gas left inside the fuel supply system.
Do not try to lift the generator set if there is a strong blowing wind around.
Once the generator set is lifted, be careful about the people around and keep them at a safe distance.
Once the generator set is lifted, also be sure that the operator of the lifting machine is always ready to handle any
case of emergency.
Always be sure that the generator set is placed on a flat surface. This surface to be selected, has to be able to resist
a weight 10% more than the gross weight of the generator set. Also be sure that there is not any risk of sliding, after
you put down the generator set.
Before closing and locking the doors of the generator set, be sure that there is nobody left inside the canopy or
container.
Lifting the Generator Set
4
READ AND UNDERSTAND
1
SAFETY PRECAUTIONS
2 1 Towing Trailer Type Generator Sets

Be sure that there is nothing wrong about the towing system including the towing bar, connection points, hooks,
pins, etc. Also check the chain, brake or electrical interconnections if there is available. Also check the moving
parts, connection or interlock points of the generator set. Be sure that they will not cause any problem during this
transportation process.
Before towing the generator set, remove all connections of pipes, hoses, natural gas lines, cables, wires etc. Be sure
that there is no connection left established on the generator set and the set is fully free to move around.
Beyond removing all natural gas pipe connections, be sure that all the gas left inside any equipment on the gas line
(pipe, regulator, etc…) has been drained completely.
Make sure that all tires on the trailer are in conformity with norms and standards and in good condition. Also be
sure that the air pressure inside these tires, is at a specified level depending on the gross weight of the trailer and
generator set. Do not change the size or type of tire without the confirmation of manufacturer. Furthermore, make
sure that all the bolts, nuts and parts are tightened with an appropriate torque.
If there are any available, make sure that all the headlights, signal lights, brake lights or the fog lights are running
properly and their covering lenses or glasses are clean and in good condition.
Do not let people to stand on the towing bar or travel on the generator set. Keep your hands and fingers away from
the tightening points. Do not attempt to pull the trailer by manpower.
If possible, choose a dry place for parking or placing the trailer. Also it is important to use wheel chocks for fixing all
the wheels.
Act in accordance with all laws and regulations that define the traffic rules. Especially be sure not to not exceed the
allowed speed limit while travelling with the trailer.
A Trailer Type Generator Set
5
READ AND UNDERSTAND
1
SAFETY PRECAUTIONS
3 Moving Parts
Keep your body (especially hands, arms and hair) and clothes away from gearwheels, pulleys, belts or other moving
and rotating parts.
Do not attempt to run the generator set, if any protection cover of fans or other moving parts is removed.
Be sure that your clothes completely fit on you, if you are working around a generator set that is running. Also tie
your hair if it is long.
Keep all the access doors closed, excluding the cases of starting up, control, maintenance, repair or service.

Before starting the generator set, be sure that everyone around is at a definite safety distance.
In order to minimize the risk of accidents due to sliding or falling, keep your hands, feet or the ground clean of fluids
like fuel, diesel, grease, anti-freeze or water.
DANGER
Moving parts can
crush and cut.
Keep guards
in place.
WARNING
Rotating parts!
Keep hands clear
while operating
4 Hot Surfaces and Sharp Sides/Corners

Avoid anyone from touching the hot grease, hot coolant, any hot surface, sharp edge and corners.
Keep your hands or any part of your body, at a safe distance to the hot exhaust pipes and gases.
While working inside, outside or around a generator set, wear protective clothes and accessories like gloves, boots
and helmets.
Keep a first aid kit close to you and seek for medical help urgently in case of any personal injury. Do not neglect any
small cuts or injuries.
CAUTION
Very hot water.

Do not open.
6
READ AND UNDERSTAND
1
SAFETY PRECAUTIONS
5 Fire and Explosion

Be sure that the natural gas mixture you will use is a Keep electrical any cables, battery terminals or other
well-designed combination of appropriate ingredients, electrical equipment in good condition. Replace any
according to its purpose of use. It also has to be at cracked, broken or defective cables, terminals, isolators
specified flow rate and pressure values or any further or any electrical equipment.
specifications.
Provide a proper grounding for the all the conductors
Do not use the natural gas generator sets in completely and electrical equipment that is directly exposed to
enclosed areas or indoor places. Be sure that you have electricity. This will prevent the accidents due to any arc
provided the necessary ventilation conditions. or spark occurrences caused by the electrical current
flowing through or around them.
Keep any spark, flame or other combustibles away from
the natural gas line and the generator set. Do not smoke Do not weld or repair defective pipes on the gas line,
and allow smoking around the generator set. just replace them in order for the safety of operation.
Be sure to install a gas leakage detector and a safety Do not make any welding or grinding activity around the
system around the generator set. generator set or gas supply line, when there is a natural
gas flow on the line. Before starting any welding or
Build a ventilation window at a highest possible place in grinding activity, keep any flammable material (fuel, gas,
the room. Always be sure to keep it open and unblocked. oil, etc…) away from the welding or grinding machine.
Check the gas supply system for any defections or Also block the gas supply and drain all the remaining
leakages periodically. Immediately close the valve natural gas inside the pipes or any equipment.
on gas line and block the gas supply if you detect a
leakage. Always remind that the temperature of the exhaust gas
at the manifold and the outlet is up to 550oC. Due to this
Keep the floor clean around the generator set. So that fact; provide the necessary insulation to all hot surfaces
you will not face any accidents due to slippery floor and keep yourself and any flammable material away
covered with grease, battery electrolyte or coolant. from these hot points.
Shut down the generator set long before any Before any maintenance or service activity, be sure
maintenance activity. So that the engine can get cooled that there is at least one full and well-maintained fire
before you do any maintenance on it. extinguisher around the generator set.
Do not let any formation of waste oil or fuel layer on the If there are trees around the generator set, keep the
generator set. Clean any filth on the engine, alternator, braches or leaves of these trees at a safe distance to
base frame or canopy with an industrial cleaner. Be sure the hot exhaust system and outlet of the generator set.
not to use combustive chemicals for cleaning purposes.
Before connecting or disconnecting the batteries, be Do not install or run the generator sets in places that
sure to remove charger connections on batteries. are not approved or prescribed as dangerous.
Remove the connections from negative (-) poles of the

batteries before any maintenance. Also place a warning
on the battery for preventing any short-circuit accidents.
7
READ AND UNDERSTAND
1
SAFETY PRECAUTIONS
6 Hazardous and Corrosive Substances

The generator set must be installed and operated in outdoor or well-ventilated areas.
Do not install or operate the generator set, unless there is a proper ventilation. Also be sure that the ventilation
windows stated in the previous sections of this manual are provided.
If the generator set will be operating at an indoor place, be sure to provide a proper exhaust outlet system so that
the exhaust gases can be released outdoor. Also provide a proper ventilation window for any natural gas leakage
emergency case.
Natural gas can give permanent damages to the health of any human being or living organism. It even can be deadly
for human beings or any living organism, in case of breathing deep and over-exposure.
A gas leakage detector and a safety system connected to it, must be installed around the generator set.
Be careful that the exhaust gas outlet is not redirected to indoor places, living areas, ventilation or fresh air suction
points of any machine.
Any material used for the engine (lubrication oil, grease, coolant, battery electrolyte, etc…) are industrial chemicals,
so any of them must be kept away from any part of your body. If there is any of these chemicals on any part of your
body by accident or somehow, you have to wash this exposed part/area using plenty of soap and water.
Wear a uniform that is resistant to acid and a glass for covering you face while maintaining the batteries. If any part
of your clothes or skin is exposed to the acidic electrolyte solution inside the batteries, then wash this exposed part
using plenty of soap and water.
Gas Intoxication:
If you see someone fainted or unconscious when you enter in a closed room, assume the case as an intoxication by
default, even if there is no smell of gas around.
Considering this assumption, do not switch on any electrical equipment, do not strike a lighter or match in order not
to cause any fire or explosion accident.
Determination of the particular symptoms on time, may be critical or even life-saving in odourless and colourless gas
intoxication cases.
Symptoms:
Headache, dizziness, ringing in the ears, loss of consciousness, nausea, vomiting, skin discoloration.
First aid:
• First of all, block the gas supply. Open doors/windows and provide ventilation.
• Sprinkle some water on patient’s face.
Stretch his/her arms for providing easier breathing.
• Call for ambulance and medical support immediately
• Provide artificial respiration or heart massage if necessary
• Take the patient to a hospital unconditionally.
8
READ AND UNDERSTAND
1
SAFETY PRECAUTIONS
7 Electrical Components and Connections

Cable classification and connections of a generator set should be installed and checked by only trained and qualified
electricians.
Do not touch the electrical hardware of the generator set directly with you bare hands or with the help of any
conducting material.
Before connecting or disconnecting power cables, or before starting the generator set, make sure that the generator
set is properly grounded in accordance with all related rules and regulations.
Do not run, connect or disconnect the generator set underwater or on a wet ground. Remind the conductivity of
water.
Before establishing any electrical connection to the generator set; first stop the engine, then remove the supply
connection from the charger input, then remove all battery connections and finally remove all non-grounded
conductor connections at the load side.
Avoid touching the electrical and moving parts of the generator set with bare hands or any tool. Also be sure that you
are standing on a dry and insulated ground if you have to touch them (electrical installation or equipment) for any
repair or maintenance purposes.
Be sure to keep the insulators at the alternator output on their places. Put them back to their places right after any
connection or disconnection activity. Do not run the generator set if these insulators are not mounted on their places.
Close and lock all the doors if the generator set is out of service, so nobody unauthorized can get in the generator set.
Keep the towing truck and equipment at least 3 meters away from the generator set and the power cables.
Perform any repair, maintenance or service activity in clean, dry, well illuminated and ventilated areas.
Be sure that the load connected is proper, according to the loading characteristic and capacity of the generator set.
Do not load the generator set more than its loading capacity. Also ensure that the power cables used between the
load side and generator set are at proper rating and specifications in accordance with related rules and regulations.
Never connect or disconnect electrical cables or equipment in case of gas leakage on supply line or the generator set.
9
READ AND UNDERSTAND
1
SAFETY PRECAUTIONS DANGER

High voltage
electric shock
risk.
7 1 First Aid in Possible Electrical Accidents

If you witness an electrical accident it is important to respond quickly but with caution at the same time. So do not
touch the victim until being sure that the electricity is switched off, otherwise you may receive an electric shock
too. If you are not able to switch off the electricity, you can try to rescue the victim by using some dry and dielectric
equipment as an alternative.
After taking the patient to a safe place far from the electrical installation;
Call for emergency service or any medical support.
Keep patient lying down at a prone position. (A) Put the head on arms and turn it to one side for allowing any
possible fluid drainage.
Remove all objects like denture, tobacco or chewing gum out from the patient’s mouth in order to provide an ease
on breathing or any possible fluid drainage. Using your palms, firmly press between the shoulders of patient. Be
sure that the patient’s tongue is released.
Kneel down in such a position that your knee is near the patients head and your other foot is close to his/her
shoulder. (B)
Put your hands on the patient’s shoulders and place your palms on his/her scapula.
Push your arms forward in a vertical position. Slightly apply pressure (10-15 kg.) on the patient’s scapula for 2,5
seconds.
A B
Release the pressure by sliding your hands over the patient’s shoulder to his/her elbows in around 1 second. Then
lift up the patient’s arms and shoulders slightly by holding from his/her elbows. Just after holding the arms and
shoulders for a short time, push them backwards for around 2,5 seconds for stretching (C). After all, release the
patient’s arms back (D) and put your hands back onto the patient’s scapula.
C D
Repeat all these steps in order to help the patient for breathing.
At the meantime someone is doing these movements for helping the patient to breathe, anyone else must;
a. Loose the clothes on the patient for making the patient breathe easier,
b. Keep the patient warm until the patient feels better.
If the patient stops breathing, apply artificial respiration and go on doing it until the patient breathes again. It may
take up to 4 hours.
DO NOT GIVE THE PATIENT ANY LIQUIDS UNTIL HE/SHE REGAINS CONSCIOUSNESS.
10
READ AND UNDERSTAND
2
GENERAL DEFINITIONS
1 Natural Gas Generator Set

TEKSAN Jeneratör designs and manufactures its products in accordance with ISO 8528 standards and provides continuous,
prime or standby power solutions for its customers depending on their needs.
According to the standard “ISO 8528”, there are 3 different operation modes defined for generator sets. The power capacity to
be supplied from any generator set, depends on this mode of operation. So the customer must be careful about this parameter
while selecting a new generator set. The 3 operation modes defined for generator sets is as follows;
Emergency Standby Power (ESP) Mode: The generator set is used as a back-up power source in case of any failure on the
mains network. The generator set runs for a limited time under varying load rates in this mode. It can run approximately up to
200 hours per year under an average of %70 loading rate. Overloading is not allowed on this mode.
Prime Power (PRP) Mode: The generator set is used as the only power source in this mode or application. There is not a
restriction of running time in this mode, it can run continuously under varying load rates. The average loading rate must be
around %70. Overloading up to %10 is allowed in accordance to the standards ISO3046, AS2789, DIN6271 and BS 5514.
Continuous Power (COP) Mode: The generator set is used as the only power source also in this mode, but the loading rate is
fixed this time. The average loading rate should be around %100 and overloading is not allowed in this mode of operation.
All our products have a nameplate on it and all the needed information (Model, serial, engine/alternator type, mode of operation,
date of manufacturing, output voltage/current/power/frequency/power factor values, etc.) is available on this nameplate. The
customer has to provide a picture of this nameplate in order for identification, on any after sales issue like warranty, service,
technical support, etc.
Generator sets are composed of several parts, but he main components of a generator set are shown in the figure below.
1 Base Frame 7 Lifting Lugs 13 Exhaust Line

2 Block Heater 8 Grounding Point 14 Natural Gas Engine
3 Starter Motor 9 Connection Box 15 Cooling Fan
4 Batteries 10 Control Panel 16 Radiator Cap
5 Alternator 11 Turbo Charger 17 Jacket Water Radiator
6 Vibration Insulators 12 Air Filter 18 Intercooler Radiator
11
READ AND UNDERSTAND
2
GENERAL DEFINITIONS
2 Natural Gas Engine

The natural gas engines used on TEKSAN Jeneratör sets are water cooled, 4 stroke, internal combustion engines
that are latest technology products and specially designed for heavy industrial applications.
It has all the hardware and specifications that are needed for a natural gas engine in order to operate efficiently and
safely.
The design of the fuel systems of natural gas engines are completely different compared to diesel engines which use
compression for fuel combustion in order to obtain kinetic energy. Thanks to arc sparking technology used on natural
gas engines, the engine can run with much lower compression pressure rates.
Natural gas is mixed with air at stoichiometric rates in a mixer. Then the mixture is transferred to the combustion
room. And here, the combustion is performed by the sparking plugs controlled by a microprocessor.
As a result of natural gas usage as fuel, higher performance and efficiency are achieved in natural gas engines with
lower emission rates in exhaust gas.
The electronic speed control system provides shorter response times, for the sudden changes in load.
There is no need for any fuel completion since the gas is supplied through a pipe line.
Natural gas engines are cheaper to operate, since the natural gas is much cheaper compared to other fuel types.
Their compliance with the environmental regulations and standards about emission and noise levels is another
advantage.
Water cooled turbocharger prevents any overheating problem on air suction inlet. Also the lifetime of the turbocharger
is extended since the turbocharger bearings are cooled effectively.
Natural gas engines used in TEKSAN, are in compliance with standards ISO3046, BS5514, DIN6271 in terms of
performance.
ATTENTION!
See the “Engine Operation and Maintenance Manual” that is supplied together with the generator set, for any
further information about the engine.
Alternators used on TEKSAN Jeneratör set are designed in compliance with the standards IEC600341, CEI23,
BS4999, BS5000, VDE0530, NF51100, NF51111, OVEM10 and NEMA MG 1.22.
12
READ AND UNDERSTAND
2
GENERAL DEFINITIONS
3 Alternator
Their insulation systems are in compliance with CE regulations and have UL certification.
They have brushless type self-excitation systems which do not require any maintenance action.
They provide a voltage regulation around %±0,5 under steady-state and linear loading conditions. It is recommended
to use PMG (Permanent Magnet Generator) under any unbalanced or non-linear loading condition.
The durability of the electrical equipment and installation is increased by applying high-quality resin with VPI (Vacuum
Pressure Impregnation) process, considering the corrosive environmental conditions. Thus the safety factor is kept
at a high level considering the worst operating conditions, so the more reliability for the alternator is achieved.
Protection class is “IP23” and insulation class is “H” as a default for alternators used on TEKSAN Jeneratör sets.
ATTENTION!
See the “Alternator Operation and Maintenance Manual” that is supplied together with the generator set, for any
further information about the alternator.
4 Base Frame
The base frame on which generator set is placed, has been manufactured using proper steel plate or special profiles
based on the necessary dynamic, static and vibration calculations in order for providing high resistance.
According to the standard DIN15018; in dynamic conditions, any material must resist up to 2,2 times more than it can
resist in static conditions. The base frames used on TEKSAN Jeneratör sets are designed to resist such conditions, in
case the lifting speed is not above 90 m/min. This fact also depends of the class of the crane used for lifting (H1-2-3-4).
5 Vibration Insulators
Vibration insulators are used in order to decrease the negative effects of vibrations caused by the rotational movement
of the engine and alternator. This insulators which also prevent the vibration to be transferred from base frame to the
ground, are placed between natural gas engine/alternator and base frame.
Depending on the static weight, proper insulators are selected for providing minimum equivalent deflection and
maximum (%70-%90) vibration protection. As a result of equivalent deflection levels, main parts of engine will have
a longer lifetime.
The insulators may be placed between the base frame and the floor in order to acquire higher level insulation, in
systems with higher power ratings.
13
READ AND UNDERSTAND
2
GENERAL DEFINITIONS
6 Exhaust System and Muffler

In general exhaust systems are designed to decrease the sound level and throw out the toxic exhaust gases (CO,
NOx) to the atmosphere, which both are the natural results of the fuel combustion process.
An exhaust system is designed for providing the optimum sound pressure level by considering engine back pressure
specifications at the same time.
The main components of an exhaust system are; flexible compensators (for compensating the vibration and thermal
expansion caused by the high levels of temperature.), exhaust (steel) pipes, elbows, silencers, mounting brackets,
chimney and catalytic convertor. You can see further details about them in “Installation” section.
7 Control Systems
Control systems are developed for protecting the whole system against any failure and controlling the switches for
load transfer. This way, they provide a more safe and efficient operation for the generator set. There are different
types of panels used on TEKSAN products, but all panels are manufactured from steel in order or more durability.
The panels are designed so that it is easy to access anywhere inside, but they also has a lock on them for more
safety.
Safety level is especially improved in natural gas applications, so there are extra sensors, connections or terminals in
natural gas generator set panels. Some of these are; low/high pressure protection for gas supply lines, valve leakage
detectors, gas leakage detectors in both the canopy and the room, ex-proof gas leakage detectors, emergency
stop buttons, earthquake detectors, fire alarms, multi block gas systems, special generator control units, ignition
interrupting systems, etc…
Any further detailed information or drawing can be found from “Control Systems” section of this manual.
14
READ AND UNDERSTAND
3
INSTALLATION
1 Selection of Location
The selection and preparation of the location that the generator set will be placed is the most important step of
installation. So please make sure that the generator set is installed at a place that is selected and prepared fully in
conformity with the instructions in this manual. Also remember that you can call us for any further information of
confirmation about this issue.
Natural gas generator sets must be placed at separate rooms or places that is specially prepared for them only.
Natural gas generator sets should not be placed together with hot water boilers, steam boilers, steam generators,
etc.
Natural gas generator sets cannot be placed at human or animal living areas.
There must not be any solid, liquid or gas fuel tanks in or close to the area/room that the generator set is placed.
The doors of the room that the generator set is installed in, must be fire proof and should open outwards.
If the generator will be placed on an upper floor not the basement or ground, the responsibility of static load distribution
belongs to customer. The customer should get an approval from an authority about this issue before installation.
Install generator set in such a place that it will not be directly exposed to harsh environmental conditions as rain,
snow, hail, flood, humidity, excessive sunlight, extremely low or high temperature, dust, soil, sand or wind.
The place that the generator set will be installed must be, clean, dry, well illuminated and ventilated, free of corrosive
or conductive pollutant substances like dust, lint, smoke, oil vapour, exhaust smoke, etc.
Be sure to leave enough blank space around the generator set, in order to ease future maintenance or repair
activities Remember that it can be necessary to disassemble the main parts like engine, alternator or the base frame
in some cases.
The base ground that the generator will be settled, must be clean dry and must have a well drainage system.
Put the generator set at such place that nobody unauthorized can access it, or at least take necessary precautions
about it.
Place generator sets at such places that they will not be effected by the operation of any other machines.
Do not install or run the generator set at any place that has any possibility of risk in terms of safety of operation. Also
provide the necessary precautions (canopy option) or protections against bad weather conditions if it will be placed
outside.
The doors of the room that the generator set will be placed in, must be at an enough size for the main parts (engine,
alternator, radiator, etc…) to pass through. Also ventilation windows can be built portable or mobile for this purpose.
15
READ AND UNDERSTAND
3
INSTALLATION
2 Floor and Platform

As stated before, the generator sets can be placed on upper floors or platforms, but the place to be settled on must
be able to withstand the total weight of the generator set.
It is recommended to build a concrete (strengthened with iron) platform for the generator set. Generally, the platform
is built at same horizontal sizes with the generator set and around 150-200 mm. thickness. A platform built at a
proper size depending on generator set size, will prevent the set from moving and reduce the negative effects of
vibration on engine.
If necessary, the platform can be constructed with such technical specifications that the floor is completely insulated
from the generator set against the negative effects of vibration.
If the generator set will be placed in such places that have the risk of flooding, then the thickness of the platform to
be built must be 300 mm. at least. This will ensure a dry and safe operation area for generator set and the people
working on it.
It is recommended to build standalone platforms for every single generator set. It also should be built separately from
any other building structures as other platforms, walls, etc…
3 Vibration
TEKSAN Jeneratör sets are designed for the minimum vibration transmission to the ground. For this purpose, rubber
vibration insulators are placed between the engine/alternator and the base frame. In applications with higher power
ratings, the insulators may be placed under the base frame for more efficiency in terms of vibration insulation.
If the generator set is placed on an upper floor, this vibration analysis of the generator and the base ground must be
done more carefully. In these types of applications, special insulation system designs may be needed, like spring type
insulators. The base ground has to withstand the total weight and the negative effects of the un-isolated vibration.
You should get a confirmation from an authority about this technical issue.
Get the generator set fixed tightly to the ground or platform with screws or similar items. This way, you will prevent
it from moving around and giving damage to the electrical installation, fuel line, exhaust system, or any equipment
around it.
16
READ AND UNDERSTAND
3
INSTALLATION
4 Cooling and Ventilation

Ventilation systems must be well-designed in order for The high operating temperature of the engine, may
cooling the engine and boosting its performance or cause a performance drop for the generator set or the
efficiency by increasing the quality of air that will be used staff around.
in combustion process. A ventilation system basically
releases the hot air to the atmosphere and makes the Ensure that the fan between the radiator and the engine
fresh air come in instead of this hot air. can easily push out the hot air caused by the engine,
alternator or the radiator. This way the room can be
Normally, the temperature of the ambient in which the ventilated and the generator set can be cooled efficiently.
generator set is running, must be around 25°C. If it is
higher than an upper limit (40°C), then the lifetime for The fresh air incoming, must be clean and cool as
the engine will decrease, as its performance and the possible. Thus the performance and the lifetime of the
efficiency goes down. engine will be increased. This fresh air can be supplied
directly from the installation area, but sometimes it may
The ventilation must not be indirect or supplied from an be necessary to build ventilation channels and bring
indoor place. Inlet and outlet connections of it, must be fresh air from outside.
directly made from/to outside.
At least two ventilation windows must be built for air
There must be a safety ventilation window inside the intake and outlet. The fresh air intake window should be
room, against any gas leakage probability. The location just before the alternator and the hot air outlet window
of this window must be far from the air entrance and exit should be just after the radiator.
windows. It also must be at a height maximum 40 cm. Be sure that hot air is discharged from the room.
under the ceiling. Sometimes it may be necessary to use a flexible air
channel between the radiator and window for this
Air entrance and exit channel connections should also purpose.
be made directly from/to atmosphere. Air resistance
will be higher in longer ventilation channels, so it may The dimensions of these air intake and outlet windows
necessary to widen the channel size or use forced must be calculated well in order for higher cooling
ventilation in such cases. performance. These windows must be sized at least the
same with the radiator area, or even %150 of it if possible.
In order for the protection of air channels, stationary or

mobile shutter systems can be built with these windows.
For an automatic generator set; a mobile shutter system
which is designed to open automatically when the engine
starts, is the best solution for this purpose. However,
manually opened mobile shutters can be acceptable in
some manual mode generator set applications.
The layout drawing on the left, is just showing a typical generator

set installation. It is for guidance purpose only. Every generator set
installation case or design must be studied carefully and individually.
17
READ AND UNDERSTAND
3
INSTALLATION
5 Exhaust System
The main target of designing an exhaust system is to exhaust lines, there should be an outlet for draining
compensate the back-pressure caused by the engine. water out from the line. Thus no water can reach to
High pressure values at the exhaust system may muffler or the engine.
cause the efficiency of the engine decrease and the
temperature of the engine increase. Placing the muffler at a closest possible location to
the engine, will help you decrease the sound level in
Exhaust pipes must be installed tightly so that there will exhaust pipes. There may be placed another muffler at
be no leakage on the exhaust line. Any material used on the end of the line, if the exhaust line is too long. Every
exhaust lines (pipes, silencer, sealant adhesives, etc…) engine must have its own, separate exhaust system.
must be heat-resistant. No multiple engines shall be connected to a single
exhaust line system. Because the exhaust gas, soot or
The exhaust pipes are recommended to be made of the condensation inside exhaust lines can be harmful for
stainless steel or enamelled Fe-37 / Fe-12 steel. The any engine when it is not running.
thickness of this enamelled steel sheet to be used for
exhaust pipes, must be 0,6 mm minimum. The exhaust line system should be integrated with the
exhaust outlet of the engine with a flexible connection.
The exhaust pipes cannot be made of galvanized iron, Breathing exhaust gases is harmful for human health,
asbestos, aluminium or plastic materials. it may even be deathful. Also exposure to the high level
noise caused by the engine, may cause permanent
The exhaust pipes should not be passing through any hearing losses. So the exhaust system of a generator
other life places other than the generator set settlement set must be designed and installed well. Also any
area. staff around the generator set, should wear ear plugs.
The generator set should never be operated with an
There should be a horizontally placed test point just after incomplete exhaust system.
the engine chimney on the exhaust line, for analysing
the exhaust gas. The exhaust outlet points must be selected carefully
in order for ensuring that the exhaust gas coming out
If any twist or curve is needed on the exhaust line, be from the engine, does not go back in through the fresh
sure that the radius of the elbow used on the turning air inlets. These outlets must not be put into any closed
point is more than the 150% of the inner radius of areas, passages, corridors, air channels, ventilation
exhaust pipes. or illumination spaces of buildings, open or closed
balconies, elevator hoist ways, any place in that the
The design of an exhaust system is mainly dependent flow of the exhaust gas may be blocked by the wind or
on the site, room or building in which the generator set anything else, any place that supplies fresh air for any
is settled. But be sure to use the shortest and minimum other machine, the yards between the buildings and
curved path for piping, in order for minimizing the back- especially the habitats of any living creatures.
pressure.
The chimneys at the end of the exhaust lines must be
Make sure that all piping is tightly fixed, supported at least 5 m away from the fresh air inlets of any other
and kept at a safe distance from places with too much machines. So that it can release the exhaust gas to an
vibration. Since the exhaust pipes will heat up to very open area where there is free air circulation.
high temperatures, put them at least 250 mm. away
from any flammable material. It is also recommended The height of the chimney exits should be at least 1
to cover or coat the exhaust pipes with high-thermal meter above the ground, not less. However, it has to
isolation materials. be 2-3 meters high in places where there is human
passage (pavement, sidewalk, etc…). This chimney or
At the end of vertical exhaust lines, there must be used a outlets must be protected from any external interference
rain protection hat, which can be easily opened with the by using corded cages made of stainless or galvanized
pressure of the exhaust outlet. steel. The distance between the chimney outlet and any
wooden or flammable surface above the chimney, must
At the very lowest point of any vertical or horizontal be more than 1,5 meters.
18
READ AND UNDERSTAND
3
INSTALLATION
5 Exhaust System
Catalytic Convertor
It is obligated by laws to use catalytic convertors on exhaust systems in many countries. In generator set applications, this
obligation is more about the operation mode of generator set. If the generator set will be used in a standby application then it is
not necessary to use a catalytic convertor on exhaust line, but if else (in prime and continuous applications) the manufacturer
has to use a catalytic convertor in the exhaust system. The type and the specifications of the catalytic convertor to be used,
is also dependent on the local regulations (about the emission Output Emmission
H 2 O Water
rates) in different countries. The lifetime of a catalytic convertor Stainless Steel Body Isolation Material CO2 Carbon Dioxide
N2 Nitrogen
is approximately 15.000 running hours under normal operating Temperature Isolation
conditions. But the difference in emission rate and temperature
values, still needs to be measured and observed in regular time Oksijen Sensor Plug
intervals.
In order for reducing the harmful contents (CO, NOx, etc…) of

the exhaust gas, it is recommended to use three-way catalytic
Active Catalyst Material
converters. For having an emission rate at a desired level, there
simply occurs three reactions inside a three-way catalytic convertor;
Exhaust Gas Emission
1. Combustion of CO (CO to CO2 conversion): HC Hydrocarbon The Main Reaction
CO+1/2O2 =CO2
CO Carbon Monoxide
2.CO + O2 2.CO2 NOx Nitrous Oxide H 4 C 2 +3O2 =2CO2 +2H 2 O
2. Reduction of the nitrogen oxides to nitrogen: CO+NOx=CO2 +N2
2.Nx.Oy X.O2+ Y.N2

3. Combustion of natural gas (Conversion of hydrocarbons to carbon
dioxide and water): 4.CxHy + (4X+Y).O2 4X.CO2 + 2Y.H2O
6 Natural Gas Fuel System

The natural gas that is used as fuel for generator sets, is a mixture of combustible gases formed of various hydrocarbon
compounds like Methane (CH4) and Ethane (C2H6). Other than methane and ethane, there are also small amounts of other
hydrocarbons like Propane (C3H8) and Butane (C4H10) in this mixture. This colourless and odourless gas mixture is lighter than
air. Also the emission rates of harmful contents of natural gas are extremely low compared to other fuel types.
Fuel is supplied from tanks in diesel generator set systems, however there must be a natural gas fuel line connection in order
to supply gas for natural gas generator sets. If there is no gas line available, then the natural gas must be supplied from a
CNG (Compressed Natural Gas) tank. The natural gas line for supplying fuel for the generator set must be designed so that,
it can supply clean gas to the engine uninterruptedly. Also the local regulations and specifications about all related subjects
must be taken into consideration while designing a fuel system. All sizes and technical specifications of fuel pipeline and other
instruments must be selected carefully, in order for supplying gas to the generator set at proper flow rate and pressure values
under different loading conditions.
The connection points on the whole gas line must be welded carefully. Also all the threaded screw connections between control,
measurement or adjustment instruments and the pipeline, must be made properly according to the standard TS61.
All the connections between pipes and instruments must be tested and checked for any gas leakage problems before
commissioning and running the generator set.
The connections must be made according to this rule; if the diameter is less than DN65, then the connections must be welded,
flanged or threaded. Otherwise (Diameter>DN65) the connections must be welded or flanged.
Any material used on the pipeline must be certificated and in compliance with the related specifications and regulations.
19
READ AND UNDERSTAND
3
INSTALLATION

If the pipeline will be installed underground, then it must be kept at a safe distance from sewerage, electrical cable or drainage
lines. It also must be placed at such a route that it can be found, checked or interfered easily in case of necessity.
The pipes should be protected against external effects and corrosion. Protective covering materials must be used on the pipeline,
especially if it is passing through walls or crooks.
The fuel (gas) line connections at dilation points of the building and the inlet of the generator set, must be flexible.
The electrical grounding of the fuel lines must be done properly and carefully.
A manual valve must be installed on the gas line at a closest place to the generator set, so the gas supply can be blocked easily
in case of any emergency.
The length and diameter of the pipeline will be effecting the flow rate, so these two parameters must be set properly in order for
supplying the necessary fuel at proper flow rate and pressure values for the engine at all loading conditions.
Other than a manual valve, there must be a solenoid valve on the gas supply line. This solenoid valve must be set for getting
activated by an ex-proof gas sensor/alarm system, which is placed at a higher position than the top ventilation point. The solenoid
valve must be placed at such a position that it can block the gas supply, when it receives any signal from the alarm/sensor device
in case of any emergency.
The high-pressure natural gas coming from the supply line, must be regulated before going into the natural gas engine. One or
more pressure regulators can be used on the gas supply line for this purpose. The pressure of the gas supplied for the engine
must be around 70 mbar in average.
Do not allow smoking or any existence of sparks/flames around the natural gas line and the engine.
For supplying cleaner gas for the engine, there can be used a gas filter on the fuel line. This will provide more safety and
efficiency in terms of engine operation.
While connecting the stationary gas line to a natural gas generator set, use a flexible connection in accordance with local
specifications and regulations.
Exhaust
Air Intake Outlet
Valve
Regulator Regulator Manual Gas
Pressure Gauge Filter Valve
Turbocharger Intake
Natural Gas
Carburetor
Intercooler
Firing Coil
Actuator
Solenoid
Valve
Actuator Controller
Unit Speed
Sensors
(MPU
Firing Controller
Unit
Natural Gas Fuel Supply Line drawing and Picture
20
READ AND UNDERSTAND
3
INSTALLATION

Stoichiometric Mixture: This “Stoichiometric” ratio is 16,1:1 in average for natural
The natural gas extracted from every different regions gas applications. The mixture is said to be “richer” or
of the world, does not always have the similar contents “leaner” depending on the contents of natural gas. This
or specifications. As a result of this, the performance of ratio is symbolized with (Lambda) and measured with
a natural gas engine can vary depending on the region a Lambda meter.
and gas quality.
AIR / GAS MIXTURE RATIO (AIR / FUEL RATIO)
Therefore, the rates of the air and gas in the mixture Methane Ethan Propane Other Stoichiometric
that will be used in combustion process of the natural (CH4) (C2H6) (C3H8) (CO2-N2) Air / Fuel Ratio
gas engine, must be re-calculated depending on the 100% 0% 0% 0% 17,2
quality of the natural gas that will be used. 90% 0% 10% 0% 16,8
85% 3% 10% 2% 16,4
80% 0% 15% 5% 15,8
7 Electrical Connections
Electrical connections must be designed, made and repaired possible overcurrent and overloading problems by use of
by qualified and trained technicians. fuses or circuit breakers.
All electrical connections and wiring must be done in
compliance with the diagrams or the drawings provided by It is important to load the generator set under balanced
TEKSAN. loading conditions. If the load connected to one phase
is much more or less than the other two phases, then this
All the connection, wiring and grounding processes must will cause overheating issues on the alternator or any other
be made fully in compliance with the related international, failures on 3-phase systems. Be sure that the current drawn
national and local specifications, standards, rules and from all phases do not exceed the projected and calculated
regulations. amount.
All the cables that will be used for wiring, must be selected If the generator set will be connected to an existing load
at proper ratings and specifications according to the current, installation, then it may be necessary to make some
voltage, temperature values and the wiring method. All the modifications on it. Power factor (cos Ø) of the load
electrical connections on the generator set must be made connected, must be well determined. If it is inductive and
by using flexible cables. This will protect the electrical lower than %80 (0,8) then it will cause overloading problems
equipment like conductors, alternator or circuit breakers from on the generator set. Capacitive power factor values, may
the negative effects of the vibration caused by the engine. cause overvoltage problems on alternator windings.
If it is not possible to use flexible cables directly, then use The power factor must be inductive and at least %80 (0,8) for
a terminal box close to the generator set and make flexible providing the optimum operating conditions for generator set.
connections to this terminal box. In order for having the power factor at a desired level, it may
be necessary to use additional compensation systems.
All connections must be checked very carefully before However, the compensation system must be well-designed
commissioning the generator set. Checking the connections, so that the power factor can stay in the desired limits. If the
conditions and phase orders of all cables, is very important power factor becomes too capacitive, it may cause voltage
for automatic and synchronous generator set applications. instabilities and over voltage problems.
Control panels are specially manufactured to be mounted
on the wall. The connections between the generator set and
the load distribution panel, must be protected against any
21
READ AND UNDERSTAND
3
INSTALLATION
7 1 Starter Batteries
The electrical resistance on the starting circuit, is a very important parameter for the operation of the natural gas
engine. Therefore, the batteries must be placed at a closest possible location to the generator set. This way the
battery connections will be shorter and the resistance of them will be lower. Also any loose connections must be
checked and fixed for this same purpose. (The batteries must be placed at a serviceable and accessible location.)
Batteries must always be maintained well and kept in a good condition, so that the generator set can be ready to
run at any time. Maintenance activities to be done on batteries are briefly explained in the relevant sections below.
Connecting and Disconnecting:

While connecting battery cables, first connect the positive (+)
terminal, then connect the negative (-) terminal.
While disconnecting battery cables, first remove the negative
(-) connection, then remove the positive (+) connection.
Cleaning:
Keep the batteries clean and dry. Any dirt or oxidation left
on the battery, terminals or connections will cause discharge
and voltage drop on batteries.
Remove and clean the pole heads while maintenance, use a
wire brush for cleaning the oxidation. Reconnect the cables
tightly back to the poles and use grease on these connections
to postpone the oxidation.
Adding Pure Water:

The level of the electrolyte in batteries, must be checked
periodically. If it is 5-10 mm lower than the top level, refill the
battery back by adding pure water and charge the battery for
30 minutes.
NOTE: Refer to the operating manuals for the special

maintenance methods of maintenance free or dry type
batteries!
ATTENTION!
The batteries must always be kept under a buffer charge.
The batteries on the generator sets that will be stored for a long time, must be removed and
kept charged. Otherwise, the battery plates will be corrupted and the batteries will be out of
service.
22
READ AND UNDERSTAND
3
INSTALLATION
8 Sound Control
Reducing the sound level is a key factor in today’s generator set technologies. TEKSAN Jeneratör sets are designed
and manufactured for providing an optimum sound level by regarding this fact.
Extra additional equipment may be installed to your system for minimizing the sound level. Some of the precautions
taken against high sound levels are, sound insulated canopies or rooms, exhaust silencers, acoustic shutter windows
or hoods.
The solutions and precautions against high sound levels are really dependent on varying environmental conditions.
So it is strictly recommended to get professional help when designing special sound reduction systems.
The sound level of a non-insulated diesel generator set is around 100-110 dB from 1 meters, however this rating
is 4-10 dB less in natural gas generator set applications. This lower sound level is like one of the most important
advantages of natural gas generator sets. The lowest possible sound level (also by regarding the economic facts) in
generator set applications, is around 65-75 dB. This can be provided by using additional equipment on natural gas
generator sets. Sound level reduction is a really important parameter for generator set applications used in hospitals,
schools, residential areas, offices etc…
Exposure to a sound level higher than 85 dB for a long time, may cause hearing problems. So it is recommended to
wear ear plugs around a running generator set.
Sound Level (1mt) dB(A)
Natural Gas
Diesel
Standard Diesel (7-13 lt)
Engine Speed (rpm)
23
READ AND UNDERSTAND
3
INSTALLATION
9 Fire Precautions
Take all the precautions stated in section “1.5” (Fire and Explosion) against any fire and explosion possibility.
There must be an emergency escape route and scenario in case of any fire and explosion possibility.
A fire alarm system and an extinguisher in accordance with the legal regulations and standards about fire and
explosion, must be provided around the generator set.
A gas leakage detector and alarm system must be installed around the generator set. This detector/alarm system
must also be connected to a solenoid valve on the gas supply line, which will block the gas supply in case of any
emergency.
A fire detector and alarm system must be installed around the generator set. This detector also must be connected
to a solenoid valve on the gas supply line, which will block the gas supply in case of any emergency.
Also a weight-driven gas supply blockage systems can be designed with melting wire equipment
for this same purpose.
The room in which the generator set installed, must be free of any flammable material or any
accumulated garbage by considering any fire possibility.
Do not allow smoking in the room that the generator set is installed in. Also keep any arc, spark
or flame away from here.
10 Grounding
In many electrical systems, the non-active parts and the parts connected to these non-active ones, must be attached
to the ground with the help of a conductor or an electrode. This principle is called is called earth grounding.
The parts and the equipment that are directly exposed to electrical voltage, must be well-insulated in order to ensure
the durability and safety of the electrical system and staff around it. However there can be some electrical failures
due to defection, corrosion, leaking points on these insulation systems. The natural gas pipelines must be grounded
with a connection to the building’s grounding systems.
Non-grounded conductors in an electrical system, may be a risk for both the system and the people around it. If all
the equipment is connected to each other and to the ground properly, then any leakage on system can flow to ground
through this connection and will not cause any problem.
The grounding must be done in accordance with the related international and local regulations. The
grounding resistance must not be more than 20 Ohms. The electricity may be harmful for human
beings if it is rated more than 15 mA and 50 V. The electrodes buried to the ground for grounding
purposes must be at least 20 meters away from another electrode.
All the generator set is at a same potential in terms of electricity, thanks to the grounding connections
between the base frames of the engine, alternator and the generator set.
24
READ AND UNDERSTAND
4
CONTROL SYSTEMS
1 Introduction
Programmable microprocessor based controller units are used in TEKSAN Jeneratör sets as a standard. These
controllers are capable of monitoring any electrical or mechanical changes or parameters on the generator set. They
also provide all necessary mechanical and electrical protections for the generator set.
The control systems in general, allow the user to run or stop the generator set. They also monitor and control the
measurement and protection circuits installed on the generator set. Since the controller unit is programmable, it also
provides flexibility in terms of usage under different conditions.
The control panels used on TEKSAN Jeneratör sets, are manufactured using A1 quality steel sheets and coated
with electrostatic powder paint in order for preventing corrosion.Manual (TJM), automatic (TJA) and synchronization
(TJPS) control panels are manufactured as a standard in TEKSAN. But it is also possible to design customized
control panels for different purposes or scenarios of usage.
Further details about the controller unit can be found in the additional manuals provided with the generator set.
2 Control Panel – TJ509T

It is designed for generator sets used as standby of the mains supply
and manual applications where mains supply is not available. Starts
and stops the generator set in requested situations.
Mains monitoring, protection and control operations are made by

TJ509-T generator control unit with programmable microprocessor.
The modes of operation are selected by pushing the front panel keys.
Changing the operation mode while the generator set is running will
result into behavior suitable for the new operating mode. For example,
If the RUN mode is selected, mains and genset contactor outputs can be controlled manually via the buttons on the
controller.
STOP: If this mode is selected the engine will be stopped immediately and mains contactor output
AUTO: It is used for generator set and mains automatic transfer. If at least one of the mains phase voltages is outside
the limits, the mains contactor will be deactivated. The diesel will be started for programmed times after the preheat
timer. When the engine runs, the crank relay will be immediately deactivated. The engine will run without load during
engine heating period. After this, if alternator phase voltages and frequency are within limits, then the unit will wait
for the generator contactor period and the generator contactor will be energized. When all the mains phase voltages
are within the limits, the engine will continue to run for the mains waiting period.
At the end of this period the generator contactor is deactivated and the mains contactor will be energized. If a cool
down period is given, the generator will continue to run during cool down period. At the end of the period, the fuel
solenoid will be de-energized and the diesel will stop. The unit will be ready for the next mains failure.
If the operation of the generator set is disabled by the weekly schedule, then the AUTO led will flash, and the
operation of the generator set will be as in the STOP mode.
25
READ AND UNDERSTAND
4
CONTROL SYSTEMS

TEST: It is used to test the generator when the mains are on, or keep the generator running in the emergency backup
mode. The operation of the generator is similar to the AUTO mode, but the mains contactor will not be deactivated
if the mains are not off. If the mains are off, mains contactor will be deactivated and the generator contactor will be
activated.
When the mains are on again, a changeover to the mains will be made, but the engine will be kept running unless
another mode is selected. To stop the engine, select AUTO or STOP mode.
RUN: It is used to run the generator set under load or without load. Once this mode is selected, the engine will run
and the load will be transferred to the generator set in case genset contactor is closed using genset button on the
controller interface. This mode also can be called as manual mode.
TJ509-T Controller Types
A-Type (TJ509-T/A)
- Improved firmware and software specifications and skills,
- Exact same dimensions with TJ507 or TJ509, (This way it can easily replace them directly.)
- AMF (Auto Mains Failure), ATS (Auto Transfer Switch), RS (Remote Start) and EC (Engine Controller) modes
of operation,
- 6 digital outputs (2x16A contact, 4x10A BAT+ control output,
- 8 digital inputs, (All programmable)
- 4 analogue inputs, (All programmable)
- J1939 CANBUS port,
- MPU (Magnetic Pickup Unit) input,
- USB port, (for establishing a PC connection.)
- RS232 port (for modem connection, 2400-115200 changeable baud rate)
- Digital input/output extension ports, (up to 4 modules x 8 terminals = 32 input/output)
- History log,
- Several language options,
- Operating Temperature: -20°C to 70°C (-4 to +158 °F),
- Storage Temperature: -40°C to 80°C (-40 to +176°F),
- IP54 protection at front side, IP30 protection at back side,
- Hi-temperature resistant ABS/PC (UL94-V0) case,
- Remote monitoring capability with use of a GPRS modem. (DKG090)
26
READ AND UNDERSTAND
4
CONTROL SYSTEMS

B-Type (TJ509-T/B)
In addition to Type-A;
- Not 6, but 8 digital outputs, (2x1A BAT- controlled relay outputs in addition.)
- Not 4, but 8 analogue inputs, (1 “Sender Ground” input and 3 spare inputs in addition.)
- RS485 port,
- Ethernet port, (10/100 Mb)
- USB host port (for USB storage devices or GPS)
- Remote monitoring capability by itself, (via its RS-485 port)
- Embedded Web Server, Modbus-TCP/IP, SNMP, Rainbow Plus and Rainbow Scada features via its ethernet port.
C-Type (TJ509-T/C)
In addition to Type-B;
- Synchronization and load sharing functionality, (up to 48 generator sets and 16 mains)
- Reverse power exporting (to grid) functionality with a single generator set,
- Synchronous transition on both sides and directions,
- Soft transfer capability, (from generator set to mains)
- Isolated AVR output,
- Governor control output,
- Isolated CANBUS communication port.

Accessories / Additional Equipment
External GSM-GPRS Modem (DKG-090)

- DIN rail mounted, (same size with 2 pcs. of fuses)
- Quad-band GSM/GPRS (850/900/1800/1900MHz)
- 12/24 V DC supply options,
- Resistance to possible high voltage shocks around the generator set,
- Supports E-Mail and SMS sending
- Connects all types of TJ5xx controllers to “Rainbow Scada” through GPRS, and allows the user to monitor,
control and set any parameter remotely through GPRS.
External GPS Device:

- Optional equipment for B and C type controllers,
- USB connection,
- 3 m cable length
Internal Battery:
- Optional equipment for all A/B/C type controllers,
- Up to 4-6 hours lifetime.
Rainbow Plus Software (Freeware)

- Connection to controllers via USB, RS485 or internet/web,
- Remote monitoring, controlling and programming capability,
- Capability of loading or changing the language and logo options of the controller.
27
READ AND UNDERSTAND
4
CONTROL SYSTEMS
3 Ignition and Firing System

Compared to diesel engines, natural gas engines need lower compression rates for fuel combustion.
An ignition system of a natural gas engine provides the timing with magnetic pickup units, firing with high voltage
ignition coils and combustion with sparking plugs.
Also a speed controller card is installed for controlling all these ignition equipment. This controller reads the speed
measurements from the MPU installed on the engine and controls the (Throttle Valve) actuator which mixes the gas/
air mixture to be used in combustion process. This way, it holds the engine at a desired fixed speed.

The ignition controller card coordinates the timing for the combustion processes in all cylinders by reading
measurements from the MPUs at every cylinder and controlling the ignition coils at every cylinders.
In short, this system controls the gas supply, the combustion process and the speed of the engine.
Manual Valve Manual Valve Pressure Pressure

GAS FLOW Regulator Gauge
Pressure
Speed Regulator
Controller Card Intercooler (Engine)
Ignition
Controller Card
(Throttle Valf)
Actuator Gas/Air
Ignition Coil
Mixer
Magnetic Pickup Air Filter

(Ignition Timing)
Turbocharger
Magnetic Pick Up (Timing)
LCD
Display Magnetic Pick Up (Reset)
Module
Exhaust Gas
Flow
A drawing that shows the principle of operation of the “Ignition System”
4 Basic Procedures to be Followed before Operation

All safety precautions stated in this manual, must be taken into account before running a generator set. Again before
running the generator set, re-check and ensure that all the electrical installation and wiring is done properly and in
accordance with the technical diagrams and drawings provided with the generator set.
The following procedures should be followed at every time before running a generator set. The staff that is responsible
for the operation of the generator set should be fully trained on these procedures.
1. Check the generator set manually and visually for a last time before starting it up. Do NOT start the generator set
if you see any leakage of liquids, cracked or broken parts, disconnected cables or parts, etc…
2. The generator set must be placed on a smooth and proper surface. It should also be protected against any
external effects like rain, dust etc.
3. Check the fresh air inlet and hot air discharge windows or ducts. Be sure that they are not closed or blocked.
28
READ AND UNDERSTAND
4
CONTROL SYSTEMS
4 Basic Procedures to be Followed before Operation

4. Check the exhaust outlet and be sure that it is not closed or blocked.
5. Check the gas supply line for any leakage. Do NOT start the generator set if there is any leakage.
6. Check the gas pressure at the gas supply line and be sure that it is at an appropriate level.
7. Check the quality and level of the engine lubrication oil. Change or fill it if necessary.
8. Check the coolant level and antifreeze ratio. Change or refill it if necessary. Remember that the antifreeze ratio
changes depending on the lowest ambient temperature. Be sure that the amount of added antifreeze and water
is at a proper ratio.
9. There are two types of batteries used on generator set systems; lead-acid and dry (maintenance free) types. If it
is a lead acid type battery, check the electrolyte level and charge if necessary. If it is a dry type battery, then just
clean and charge it.
10. Check the air filter and be sure that it is not too dirty or blocked. Change it if necessary.
11. Any unprotected object around the generator set may prevent the operation of the generator set or cause injuries
during operation. Check if there is any unprotected object around the generator set and put it away to a safer
distance.
12. Switch the generator set circuit breaker to OFF position.
13. Switch all the fuses inside the control panel to OFF position.
14. Make the battery pole connections.
15. Switch all the fuses inside the control panel back to ON position.
16. Check all the emergency stop buttons and be sure that they are all at ON position.
17. Run the generator set manually from the control unit.
18. Check if there is any abnormal noise or vibrations on the generator set.
19. Check if there is any leakage of liquids like water, oil, fuel, etc…
20. Observe the temperature and pressure values from the controller screen or the gauges. Be sure that they are in
allowed limits.
21. Observe the voltage, current or frequency values from the controller screen. Be sure that they are in allowed
limits.
22. The composition and technical specifications of the natural gas supplied may differ in different regions. Since
every single generator set leaving TEKSAN factory is set to average values in terms of gas supplied, the voltage
and frequency levels may not be at a desired level during first operation. In this case, you may need to change
“Air/Gas Ratio” by using a lambda meter.
23. Check the phase sequence of the generator set. If they are not same with the mains sequence, then change
cable connections.
24. If all the results of all these checks are normal, you can finally run your generator set on load. Also be sure that
you are not exceeding the capacity of your generator set in terms of loading capacity.
ATTENTION!
• Be sure that all precautions stated in this manual are taken into account before starting the generator set.
• Be sure that all the installation and electrical wiring is done and checked properly.
• The generator set will not start if any emergency stop button is pushed, switch all ON by pulling clockwise.
• The fuel, lubrication oil and the coolant quality level has to be in limits prescribed by the manufacturer.
• Ensure a proper grounding for the generator set. It may be important in terms of any possible electrical problems.
• Do NOT start or stop the generator set when it is still under load (when the load breaker is at ON position).
• The generator set must be maintained periodically (daily, annual, etc…) in order for the efficiency and safety of
operation.
29
READ AND UNDERSTAND
4
CONTROL SYSTEMS
5 Battery Charger Devices

Battery charging devices are used for keeping the batteries charged at all times, even when the generator set has
not been running for a long time. A charger is a standard equipment in control panels and supplied by a mains
connection. The speed of charge depends on the capacity of the batteries (Ampere x Hours) and the remaining
charge in batteries.
Initial charge current will be high but it will decrease with time during the charge process. Protect the battery charger
device against any heavy weather conditions like rain or snow. Be sure that the electrical wiring and connections and
the grounding of the equipment are done properly.
Turn off the battery charger device before removing any battery connection, for avoiding any arc or spark possibility.
Battery charger devices should be used according to related instructions. They must not overcharge the batteries. If
the temperature of batteries rise above 52°C, then it may cause damage on the batteries. This fact must be taken into
consideration especially in tropical countries, the charger and the batteries must be located at a cool and shaded place.
Other than this charger devices, there can be used a charger alternator on the engine for charging the batteries.
Check the pulley and belts installed on the charger alternator. Change them with new ones if they are defected.
6 Heater Blocks
There can be used water heater blocks on the engine’s cooling water circuit, in order to ease starting up and taking
load actions for the engine. This heaters are used as standard in automatic generator set applications, but it can also
be installed on manual systems optionally. There are thermostats available installed on these heaters and they are
set approximately up to 40°C.
Nominal power ratings of heaters may differ depending on the size of engine. Single or multiple 1000 W heaters are
used for engines rated below 800 kVA, while 3000 W water pumped heaters are used for engines rated above 800 kV.
All these block heaters are programmed to switch off automatically when engine starts.
7 Transfer (ATS) Panels

Transfer panels are used for controlling and transferring the output power safely. So the equipment in these panels
(circuit breaker, contactor, fuses, etc…) must be at proper ratings depending on the output power of generator set.
The switching equipment must be controlled by the generator set controller in automatic mode applications.
The transfer panel must be designed so that the generator set cannot be started or stopped under load, otherwise
there may be seen various problems on both the generator set or the alternator.
Under voltage release coils must be used for motorized circuit breakers applications. Also changeover relays can be
used in manual mode applications with thermal magnetic circuit breakers.
30
READ AND UNDERSTAND
5
MAINTENANCE
1 General Instructions
Maintaining the generator set properly and periodically is a key factor in terms of efficiency, durability and safety of
operation. It also necessary for being sure that the generator set is always ready for operation and minimizing any
risk of failure on the generator set.
The parts to be controlled or to be replaced during a maintenance activity, have been declared in the “Generator
Set Maintenance Schedule”. Any further details about this issue can also be looked up from the manuals supplied
with both the engine and alternator. Be sure to perform all maintenance activities according to the recommended
schedule.
All the documentation including service registration forms, model and serial number nameplates, drawings or
diagrams, spare part lists, maintenance schedules and the manuals supplied with the generator set, must be kept
in a good condition. Remind that all these documentation may be needed during any service or repairing activity.
The staff who will perform any maintenance or repair activity on the generator set, must be trained and authorized.
ATTENTION!
• Be sure that there is nobody left around or inside the generator set before running it or performing any
maintenance or repair activity on it. Keep all the doors locked after finishing any repair or maintenance activity.
• Be sure that the engine is stopped and the gas supply is blocked before performing any maintenance activities
like lubrication oil fill-up, coolant fill-up or changing battery electrolytes.
• Also remove the AC supply connection of the charger device and the battery (-) connection from the battery pole
before starting to work on the engine. This will prevent the engine from starting without your control. Also place
a warning around the connections you have removed, so nobody around touches or re-connects them.
• Always be sure to make the necessary changes on the generator set when it is stopped. Stop it for making
changes, make the necessary changes and run it again. Do not forget that only some qualified technicians which
have a deep expertise on related issues, can make changes on a running generator set.
2 Maintenance of Natural Gas Engine

Please see the detailed instructions in “Operation and Maintenance Manual” supplied with the natural gas engine.
31
READ AND UNDERSTAND
5
MAINTENANCE
3 Maintenance of Alternator
Any maintenance or repair activity to be performed on alternator, must be carried on by trained and qualified
technicians. Also be sure that the alternator is not running and all necessary precautions are taken before taking
action.
The maintenance intervals are specified depending on the alternator, operation mode and environmental conditions.
In general the alternator must be checked for any vibration, detonation, abnormal sound before commissioning and
one (1) year (or after 500 running hours) after it. Also the tightness of all electrical or mechanical connections and any
defections on the alternator body or the cooler fan must be checked during these maintenance activities.
Alternator bearings can be used up to 20.000 running hours under normal conditions, but some factors like improper
lubrication, very high ambient temperature or high levels of vibration will be decreasing this lifetime period.
The recommended check and change period for the lubricant (grease) is 4.000 hours. Some recommended lubricant
(grease) types are as follows; Mobilux 3 (MOBIL OIL), Alvania 3 (SHELL), GR MW 3 (AGIP), Beacon 3 (ESSO).
The temperature at the alternator bearings level must not exceed 60°C. In case of any doubt about corrosion on
bearings, the operating temperature must be measured and checked. Check the coupling, if the temperature is rising
up to 80°C during operation. If it is normal but the bearings change colour to blue, then the bearings must be replaced
with a new one. Any dismantled bearing must be replaced with a new and equivalent one, it is not recommended to
re-install and use any dismantled bearing. Heating the bearing up to 80°C will ease the assembling process.
Check the mechanical connection and the centring between the coupling of alternator and the flywheel of engine.
Make sure that all bolts on this connection are properly tightened. Sealants like “Loctite - Type 242” can be used on
this connection for providing extra strength.
Generally, alternators are manufactured with a single bearing. For this manner, the user must be very careful while
lifting or carrying it. Because the rotor can drop down if the alternator is lifted, so the rotor must be fixed before lifting.
It is strongly recommended to perform an insulation test on stator windings, if the alternator has not running for a long
time. Be sure to remove all the terminal connections on AVR before this insulation test. If the measured resistance
between the stator winding and the ground is lower than 5 Ohms, then the alternator must be cleaned, dried and
maintained properly. Related industrial cleaners (like ELEKTRO SOL) can be used for this cleaning purpose. Wait
for some time after applying cleaner on windings, then blow compressed air to remove this volatile substance on it.
ATTENTION!
Always keep in mind that the alternators are dangerous machines in case of interference with their rotational parts
or exposure to high amounts of electricity.
32
READ AND UNDERSTAND
5
MAINTENANCE
4 Engine Lubrication Oil

The lubrication oil must be changed periodically in
specified intervals for obtaining the best performance
and lifetime for engine. The lubricant and this changing
period is specified by the engine manufacturer, so be
sure to comply with these standards, specifications
and instructions about lubrication, otherwise the
engine may be damaged.
Use a reputable brand of lubricant in accordance

with API standards, be sure its quality level is “CF” or
higher. The sulphur content of the lubrication oil must
be less than 0.5%. The quality and specifications of the
oil to be used may vary depending on environmental
conditions, so be sure to use a proper lubricant. In Standards for lubricants to be used under
some cases, if the temperature is lower than a minimum different environmental conditions.
level, the engine may lose its cold start capability but
it does not get damaged. However it is not advised to run the engine for a long time in such conditions. Any further
details about the lubrication system, lubricant specifications and intervals for changing the lubricant, can be found
on the “User and Maintenance Manual” supplied with engine.
5 Engine Coolants
Coolants are mixtures of water, antifreeze and any other chemicals for several purposes. The main purpose of using
this mixture is cooling the engine. But with addition of antifreeze and other chemicals, this mixture prevents the
cooling water from freezing and protects the cooling system against corrosion.
Use 50 % antifreeze (glycol) and 50% pure water as coolant mixture if there is any risk of freezing. By using this
mixture throughout the whole year, the engine will be protected at temperatures down to -40°C.
Any further details about the cooling system, coolant specifications and intervals for changing the coolant, can be
found on the “User and Maintenance Manual” supplied with engine.
ATTENTION!
• Drinking this coolant mixture of water, antifreeze and some other chemicals, is dangerous.
• The antifreeze ratio must be at least 40% in order for an effective protection against corrosion, on the other hand
it also must not be more than 50% since this will decrease the engine’s cooling performance.
• In order for more precise ratios, the mixture should be mixed in a separate vessel before filling into cooling system.
33
READ AND UNDERSTAND
5
MAINTENANCE
6 Fuel (Natural Gas)

Natural gas is a combustible gas mixture, composed of
CONTENT OF NATURAL GAS MIXTURE
several hydrocarbons like Methane (CH4), Ethane (C2H6),
etc… Methane Ethane Propane Other
(CH4) (C2H6) (C3H8) (CO2-N2)
Natural gas is a colourless and odourless gas mixture and Natural Gas (NG) 80-100% 0-15% 0-5% 0-5%
it is also lighter than air in terms of density. However, it
Compressed
is generally odorized at gas supply or depressurization Natural Gas (CNG)
80-100% 0-15% 0-5% 0-5%
stations for an easier detection in case of any gas leakage. Liquefied
93-98% 2-7% - -
Natural Gas (LNG)
The content of natural gas may differ depending on the
region of the world it is extracted from, so the air/gas ratio of the mixture to be used in combustion process must be
adjusted in accordance with the quality and specifications of the natural gas and the environmental conditions.
Normally, natural gas is not a toxic gas but an asphyxiant gas which means it reduces or displaces the normal oxygen
concentration in breathing air. Breathing this oxygen-depleted air, can lead to death by asphyxiation (suffocation).
Combustion range of natural gas is wide, which means its lower explosive limit (LEL) is much lower and its upper
explosive limit (UEL) is higher compared to other fuel types.
Since natural gas is lighter than air, it tends to accumulate at the top of any enclosed area in case of any leakage.
Since natural gas can be liquidised by pressurizing for storage and transportation purposes, it is the best fuel type
compared to others. Therefore it has the highest demand in market.
Lower heating value (LHV) of natural gas is 8250 kcal/m3. (The amount of energy released by combusting 1 m3 of it.)
Natural gas is much more environment friendly compared to other fuel types, it is a non-toxic, ash and smoke free
fuel type. No pollutants like carbon monoxide or sulphur oxides are produced after the combustion of natural gas.
The only last products of a complete natural gas combustion process are CO2 and H2O.
Natural gas does not freeze easily, it can be liquidised at -162°C under normal atmosphere pressure.
Natural gas can be compressed and stored in (CNG) tanks for using at places with no supply line connections.
It is an economic fuel type in terms of operating and maintenance costs. There is no need for preparation before use.
The natural gas at main distribution points are at 70 bar pressure. Main lines in cities are at 20 Bar, lower lines
between buildings are at 4 Bar. The pressure of the natural gas to be used in industrial applications can be up to 1
bar, however it is between 300 mbar and 21 mbar for residential usage purposes.
COMPARISON OF FUEL CHARACTERISTICS
There are two main criteria to be ensured about the
Natural Gas Diesel Gasoline
supplied gas for natural gas generator sets; The natural Molecular Formula CH4 C12H26 C8H17
gas supplied for the engine, must be at around 70 mbar Max. Caloric Value (kcal/kg) 13384 10685 11362
pressure. Min. Caloric Value (kcal/kg) 12107 10135 10563
Max. Stoic A/F Rate (kg/kg) 17,2 14,6 14,7
The maximum flow rate required for the natural gas engine Combusting Limit (Lambda ) 0,7-2,1 0,48-1,35 0,4-1,4
Inst. combusting Temp. (°C) 650 250 350
to run under different loading conditions, must be satisfied. Octane Rating 120-130 ~ 87-90
Combustion energy (MJ/m3) 3,4 3,78 3,76
34
READ AND UNDERSTAND
5
MAINTENANCE
7 Air Filter
Air filters are placed on the air inlets of engines and provides clean and fresh air for the engine. Besides this air
cleaning role, they prevent high levels of noise like silencers and also acts like a flame arrester.
Any possible dirt and dust particles included within the air supplied for combustion, may cause serious damage on
cylinder surfaces and piston segments of the engine. This damage on cylinders and pistons may lead to higher oil
consumption rates and shorter the lifetime for the engine.
Blocked or dirty air filters may cause richer gas/air mixture for combustion, and higher fuel consumption rates. For
this reason, they must be cleaned, maintained and replaced periodically at regular intervals.
The cleaning, maintenance and replacing intervals for air filters may be shorter in dirty, dusty or similar environments.
8 Sparking Plugs
Sparking plugs should be changed and replaced in accordance with the intervals given in maintenance schedule.
Sparking plugs to be used, must be selected in accordance with the “Engine Operation and Maintenance Manual”.
The sparking gap of the plug must not be higher than a specified value. (A= 0,39~0,40mm). The sparking plug must
be replaced, if this gap is more is not proper. Do not ever use a repaired (electrode bent) sparking plug.
When a sparking plug will be removed for any purpose, pay attention to the cylinder it is removed from and check
the ceramic outer surface of sparking plug. Checking the colour change and waste quantity here, will be useful for
troubleshooting many problems.
If the waste on this ceramic surface is shiny and brown, this means that more oil than required is consumed inside
the related cylinder.
If the waste on this ceramic surface is sooty and black, this means that more fuel
than required is consumed inside the related cylinder.
If there is not any or very few waste on this ceramic surface, this means that the gas/
air mixture is very lean inside the related cylinder.
The best colour of waste to be observed on this ceramic surface is light bronze or
light brown, which shows that the gas/air mixture is at an optimum level and the
operating conditions for the engine are all normal.
Lean gas/air mixture will have negative effects on the engine in terms of performance
and lifetime. It should be corrected immediately. Rich gas/air mixture will result in a
black smoke at exhaust outlet.
Tighten the sparking plugs with proper torque values (2,5 – 3 kg.m), not more.
Also replace any broken or cracked sparking plugs, do not ever use them.
35
READ AND UNDERSTAND
5
MAINTENANCE WARNING
Acid included
this enclosure.
9 Batteries
Different types of batteries can be used in generator sets. Maintenance free batteries are used in TEKSAN products.
They are completely enclosed and does not require any pure water addition.
Discharge duration is long for batteries on TEKSAN products, because their internal resistance is very low (5 milliohm).
Since the batteries are completely based on oxygen recombination principle, no waste gas is formed and there is no
gas release on these batteries. They are also equipped with special low-pressure safety valves for this same reason.
Operating temperature range for these batteries is very wide (approximately between -20°C and 60°C).
Chemical energy is converted to electric energy in batteries, so there are several chemical reactions in battery cells.
Since these chemical reactions are reversible, the batteries can be charged and discharged many times.
These batteries can be used (charged/discharged) up to approximately 4 years, they must be replaced after then.
Another widely used battery type is lead acid type, which is formed of positive and negative electrodes immersed
into the electrolyte (sulphuric acid) inside cells between sheet plates.
Check the density of battery liquid with a hydrometer. The proper readings should be around 1,27 under nominal
conditions and temperature (15°C).
Pure or distilled water is used in electrolyte solution, so the water to be added into the battery must also be so.
Keep the batteries clean for a better performance.
Clean the top cover of the battery before lifting it for any purpose. Add pure or distilled water up to a height 5-10 mm
above plates, close and tighten the top cover. Dry the top cover and keep it clean and dry.
Check the operation range of batteries before installation, especially in terms of temperature (between -5°C and
50°C). Inappropriate selections will affect the operation, performance and lifetime of battery due to freezing or boiling
issues.
ATTENTION!
• Do not smoke or have any spark/flame around the batteries, they may be releasing flammable gases.
• Handle batteries with care and wash your hands after touching them for protection against acid burns.
• Wear protective clothes before changing or maintaining the batteries.
• Keep anyone unauthorized, away from the batteries and its charging system.
• Do not forget to check the charging system together with the batteries.
• Batteries should always be kept under a buffer charge. Batteries that are not charged for a long time, may break down.
36
READ AND UNDERSTAND
5
MAINTENANCE DA N G E R
Very hot
surface!
Do not open.
10 Radiator
The radiator installed on your generator set is designed and manufactured for functioning properly for long years, if
the necessary and recommended maintenance activities are performed properly and periodically.
Here are some recommendations about the operation and maintenance of your radiator;
• The coolant liquid inside the radiator is at high pressure and temperature, so be careful when opening the cap or
any draining points.
• Do not perform any repair or maintenance activity on the radiator until it is cooled down to a safe temperature.
• Do not perform any repair or maintenance activity on the radiator while the cooler fan is running or the any
protective covers on it are removed.
• Corrosion is the very first reason for many problems seen on radiators, be sure to check it in case of any failure.
• Be sure that there is no leakage on the radiator, any inlet/return line or any hose connections.
• Radiators should be filled and kept completely full. This will prevent any failures due to corrosion. Partially filling
radiators may cause corrosion inside the radiator. For this same reason, all the liquid must be drained if the
radiator will not be running or will be stored for a long time.
• The water to be used in a radiator, must be pure, distilled or soft for preventing corrosion. Also additive chemicals
can be used in the coolant mixture for preventing corrosion.
• If the radiator is running at a dirty and dusty ambient, then its cells may be blocked with dust, dirt, steam or different
particles. This will affect the operation, performance and the lifetime of the radiator and cause overheating issues.
• The radiator must be cleaned properly and periodically for the reason above. Low pressure steam should be
used for this cleaning purpose. The radiator can be immersed into an alkaline solution in case of any stronger
sediments. The radiator must be washed with hot water after waiting at least 20 minutes inside this alkaline
solution.
37
5
FIRST COMMISIONING
MAINTENANCE
FIRST MAINTENANCE
WORKING HOURS PERIODICAL
(50 hour/6 months)
Every 2 years
Every 1 year
2000 hours
1000 hours
400 hours
200 hours
11 General Maintenance Schedule
DAILY
ENGINE LUBRICATION SYSTEM
Check the Oil Level
Change Oil
Change Oil Filters
Check for any Oil Leakage
ENGINE COOLING SYSTEM
Check the water heater blocks
Check for any Coolant Leakage
Check the Coolant Level
Check the Antifreeze / Water Ratio
Check the Cleanliness of Radiator
Change Coolant
AIR INLET AND EXHAUST SYSTEM
Check the Air System for any Leakage (hoses, clamps, etc.)
Check the Turbocharger
Clean or Change Air Filters
Check the Exhaust System for any Leakage (pipes, spiral, etc.)
Check the Color of Exhaust Smoke
Check the Emission Rate of Catalytic Converter
NATURAL GAS FUEL SYSTEM
Check the Gas Supply Line and Equipment
Check the Filters on Gas Supply Line
Check the Gas Supply Line and Pipes for any Leakage
Check the Air / Gas Mixer
Check the Actuator (Throttle Valve)
Check the Gas Pressure Regulator
Check Speed Controller Unit and its Connections
ELECTRICAL SYSTEM
Check and Clean the Batteries
Check the Ignition and Firing System
Check Ignition Coils and their Cable Connections
Check the Battery Charger and Charging Alternator
Check or Change Sparking Plugs
Check the Settings of AVR Card and Governor Card
Check the Power Cables, Transfer Panel and its Connections
Check the Control Panel and Generator Set Controller Unit
OTHERS
Check the Tensions of V-belts
Check any Screws or Bolts used for Assembling Purposes
Check the Compression Pressure (if necessary)
Check the settings of Valve Gaps
Check the Vibration Insulators
Perform a General Cleaning on the Generator Set
• This is table shows basic maintenance activities, please check the engine and alternator maintenance manuals for more details.
• Test your generator set on load for a 15 minutes duration, at least once in every week.
• You must definitely get the first maintenance (at 50 hour/6 months) done, in order for the continuity of your warranty coverage.
• The maintenance periods may change due to reasons about ambient, lubricant or fuel quality or operating category.
38
READ AND UNDERSTAND
5
MAINTENANCE
12 Low Load Operation

Besides overloading, running a generator set under too light loading conditions can also be harmful for the generator
set. Running the generator set below a specified loading rate may cause damage on engine and reduce its reliability.
This fact must be taken into consideration, especially in higher capacity generator set applications.
Any generator set to be used in a standby application must be loaded not less than 30% of its full capacity.
Any generator set must not be running under no-load or low-load conditions for a long time. If you really have to run
it in such conditions, then the duration shall be minimized. For example; if the weekly test will be performed without
load, then it should not take more than 10 minutes.
Any engine which has operated under a 30% or less loading condition for 1 hour, must be operated with a 60% load
for 30 minutes in order for the engine to re-gain its performance.
For burning and cleaning any remaining carbon compounds inside the engine and exhaust system, any generator set
must be operated with a 75% load and for a 4 hours duration every year. The load level must be increased gradually.
If the sufficient loading rate cannot be provided for the generator set, then a dummy load can be connected to it.
Maintenance intervals must be more frequent for the generator sets running under low loading conditions. For
example the air filter must be replaced every year, the oil filters must be changed every 6 months if a generator set
is running in standby mode and under low loading conditions.
Here are some problems that may occur in case of running the generator set under low loading conditions;
Oil Leakage in Exhaust and Air Inlet Systems
Since the temperature in cylinders will be lower than normal, the gas delivered to cylinders cannot be combusted
properly. This will increase the oil condensation on exhaust system. Also the turbocharger oil seals cannot function
properly due to this lower temperature, so the oil will be leaking with air to the air inlet and exhaust systems.
Due to these two reasons above, oil leakage problems can be seen on air inlet and exhaust manifolds and so the oil
consumption of the engine will be higher than normal.
Carbon Accumulation on Cylinder Covers and Exhausts Manifolds

The combustion process performed under low temperature, is not at a required quality. The resulting oil steam and
the soot will contaminate the exhaust holes on cylinder covers, valves, pistons, exhaust manifold and sparking plugs.
This all will lead up to a lower engine performance and possibly a serious damage on the engine later.
Corrosive Damage
If the temperature of the engine body is not at a proper value, then it will cause more corrosion on moving components.
Black Smoke
If the gas is not combusted in cylinders properly, then it can be thrown out from the exhaust line as a black smoke.
39
READ AND UNDERSTAND
5
MAINTENANCE
13 Long Term Storage

If the generator set will not be used or will be stored for a long time, some protective precautions must be taken since
this non-operating or storage duration will have negative effects on engine, alternator and other equipment. Running
the generator set directly without any controls after this long duration, may cause damage on all these main parts.
There must be taken some additional precautions if the generator set will be stored for a duration more than 3
months. However if the storage duration is 3 months or less, then it will be enough to cover the generator set with
a protective packing material and store it in a dry and clean place. It also should be operated at least once in every
15 days.
In order not to face any problems on re-commissioning after this storage duration, the generator set must be operated
for a while (until it reaches to its nominal operating temperature; 75°C) and checked for any failures before storage.
The procedures to be followed (by an authorized technician) before any long storage duration are as follows;
Storage between 3-6 months

• Change the engine oil and oil filters,
• Check the coolant level and rating in cooling system, re-fill or re-rate if necessary,
• Test the generator set for a final time and stop it after the test is finished,
• Turn off the manual valve on the natural gas supply line and be sure that it will not be turned on out of your control,
• Remove all battery connections, clean and remove the batteries. Be sure to keep the batteries under charge,
• Clean generator set completely with a damp cloth. Do not use pressurized water for cleaning purposes,
• Check all the electrical connections and apply moisture repellent spray on all electrical system and equipment,
• Apply protective oil on the air intake line,
• Loosen the V-belts,
• Close/block the air intake and exhaust outlet channels,
• Pack the generator set properly and place a warning label on it.
• Keep the packed generator set at a dry, clean place and ensure that it will not be directly exposed to harmful
environmental conditions like dust, wind, sun, rain, snow and sudden temperature changes.
Storage for more than 6 months (up to 2 years)

• Test the generator set for a final time and stop it after the test is finished,
• Turn off the manual valve on the natural gas supply line and be sure that it will not be turned on out of your control,
• Drain out all the lubrication oil from the engine and fill it back with engine protection oil up to its maximum level,
• Drain out all the coolant from the radiator and the engine block,
• Apply protective oil on the air intake line and the turbocharger (especially compressor side of it.)
• Remove the cylinder rocker covers, apply protective oil to valves, valve springs, valve guides and cylinder heads
inside and close back the cylinder rocker covers.
• Close/block the air intake and exhaust outlet channels,
• Loosen the V-belts,
• Remove all battery connections, clean and remove the batteries. Be sure to keep the batteries under charge,
• Clean generator set completely with a damp cloth. Do not use pressurized water for cleaning purposes,
• Check all the electrical connections and apply moisture repellent spray on all electrical system and equipment,
• Pack the generator set properly and place a warning label on it.
• Keep the packed generator set at a dry, clean place and ensure that it will not be directly exposed to harmful
environmental conditions like dust, wind, sun, rain, snow and sudden temperature changes.
40
READ AND UNDERSTAND
5
MAINTENANCE
13 Long Term Storage

Re-Commissioning after Storage
• Remove the covering package on the generator set,
• Remove the sealing covers on the air intake and exhaust outlet lines,
• Check the generator set manually and visually,
• Be sure that the generator set is installed properly in accordance with related rules and regulations,
• Be sure that all the pre-commissioning preparations are completed,
• Check the engine lubrication oil and filters, re-fill or replace them if necessary,
• Check the air filters and clean or replace them if necessary,
• Check the V-belts and tighten or replace them if necessary,
• Dismantle the turbocharger lubricating pipe, clean and lubricate the bearings inside the turbocharger. Also check
the rotor of turbocharger manually and visually,
• Check if the valve gaps are proper, clean and adjust them if necessary, (especially for storage longer than 6
months)
• Remove the cylinder rocker covers, lubricate all the valves, valve springs, valve guides and cylinder heads inside
and close back the cylinder rocker covers,
• Check all hoses, pipes, bracelets and screws on them, tighten all if necessary,
• Check all screws, bolts and plugs used for assembling purposes, tighten any loose or dismantled ones,
• Check the coolant level and rating in cooling system, re-fill or re-rate if necessary,
• If you notice humidity in the storage place, you should apply an insulation test to the stator windings before running
the generator set. Do not forget to remove all AVR connections before this insulation test. If the measured value
is lower than 5 ohms, then clean and dry the alternator windings and make the same measurement again,
• Rotate the engine rotor for 2-3 rounds manually before cranking,
• Be sure that the batteries are at a good condition and fully charged,
• Make all the necessary battery connections,
• Check all natural gas supply line and equipment used on it,
• Check the flow rate and pressure level of the natural gas supplied, then turn on the manual valve and supply gas,
• Rotate the starter motor manually for a while before cranking,
• Be sure to run the generator set under no-load conditions until the engine is heated up to an appropriate level,
• Check the generator set for any noise, gas/liquid (gas, oil, water, etc…) leakage and excessive vibration issues,
• Run the generator set under load for a while, and check it again for any disorder,
• If you have faced a problem during these controls and you cannot resolve it on your own, do not hesitate to call
and ask for help form TEKSAN or its authorized dealers.
41
READ AND UNDERSTAND
6
TROUBLESHOOTING
• The following inspections and corrective actions should be performed by a well-trained and authorized staff, by using
appropriate equipment.
• Do not change any settings or replace any part without a full-knowledge on related issues.
• You can find any further details in the troubleshooting sections of “Operation and Maintenance Manuals” supplied with the
engine, alternator and any other equipment used on generator set.
• If you cannot get a solution by using the table below, feel free to contact TEKSAN or its authorized dealers any time.
PROBLEM POSSIBLE CAUSES SOLUTION

Batteries may be discharged. Check / Repair / Replace
Starter motor may be faulty. Check / Repair / Replace
Starting relay may be defective. Check / Repair / Replace
Control unit may be defective. Check / Repair / Replace
Emergency stop button may be pressed. Check / Turn OFF
Generator set may be in OFF mode. Check / Turn ON
The quality or specifications of fuel may not be proper. Check / Change
Checkthe fuel supplied.
No or insufficient fuel supply pressure or flow rate.
Checkfor any leakage.
The manual valve on fuel supply line may be closed. Check / Open
Check supply connections.
The solenoid valves on fuel supply line may be closed. Check control signals.
Repair / Replace
Engine is not running Fuel supply line may be blocked. Check / Repair
Fuel filter may be dirty or blocked. Check / Repair / Replace
The connection between the mixer and regulator may not
Check / Repair
be established properly.
The pressure regulators on fuel supply line may be faulty. Check / Repair / Replace
The carburetor (mixer) on fuel supply line may be faulty. Check / Repair / Replace
The air/gas ratio supplied for engine may not be proper. Check / Adjust
Ignition/firing system may be faulty. Check / Repair
The air intake system of the engine may be blocked. Check / Repair
Air filters may be blocked. Check / Repair / Replace
The compression pressure may not be proper. Check / Adjust
There may be a mechanical failure on engine (pistons etc) Check / Adjust / Repair
The ambient temperature may be very low Check / Change
There may be an electrical connection or wiring problem. Check / Repair
Batteries may be discharged. Check / Repair / Replace
Starter motor may be faulty. Check / Repair / Replace
The lubrication oil may not be proper in terms of quality. Check / Change
The compression pressure may not be proper. Check / Adjust
There may be a mechanical failure on engine (pistons etc) Check / Adjust / Repair
Control unit may be defective. Check / Repair / Replace
There may be a connection/wiring problem in control panel. Check / Repair
There may be an electrical connection or wiring problem. Check / Repair
Engine is revolving slowly, The connection between the mixer and regulator may not
Check / Repair
be established properly.
but it is not running
The air/gas ratio supplied for engine may not be proper. Check /Adjust / Replace
No or insufficient fuel supply pressure or flow rate. Check / Change
The solenoid valves on fuel supply line may be faulty. Check / Repair / Replace
Fuel supply line may be blocked. Check / Repair
The ignition timing may be adjusted wrong. Check / Adjust
The actuator (throttle) may not be functioning properly. Check / Repair / Replace
42
READ AND UNDERSTAND
6
TROUBLESHOOTING
PROBLEM POSSIBLE REASONS SOLUTION

There may be a problem about mains supply line. Check / Adjust
The protective fuses may be defective or switched off. Check / Repair / Replace
Generator set Control unit may be defective. Check / Repair / Replace
cannot be stopped There may be a problem on the fuel supply line. Check / Repair
The solenoid valves on fuel supply line may be faulty. Check / Repair / Replace
The generator set may be cooling down the engine. Check / Adjust
The sparking plugs may be faulty. Check / Repair / Replace
The sparking plugs may not be selected or installed properly. Check / Repair / Replace
Fresh air supplied for combustion may be insufficient. Check / Adjust
Hot air ventilation around the engine may be insufficient. Check / Adjust
The shutter or the hoods may not be selected properly. Check / Adjust
The radiator may be dirty or blocked. Check / Repair
Intercooler may be blocked. Check / Repair
The coolant inside the radiator may not be at a proper level. Check / Adjust
The engine is overheating. Cooling fan may not be functioning properly. Check / Repair / Replace
The V-belts may be loose or faulty. Check / Adjust / Replace
The lubrication oil level may be more than required. Check / Adjust
Water hoses on the cooling line may be blocked or defected. Check / Repair / Replace
Water pump on the cooling line may be faulty. Check / Repair / Replace
The thermostat of the engine may be faulty. Check / Repair / Replace
There may be a (air/coolant) leakage on cooling system. Check / Repair
The generator set may be overloaded. Check / Change
The back pressure of the exhaust outlet may be too high. Check / Repair
The speed settings of the engine may be adjusted wrong. Check / Adjust
The connection between the mixer and regulator may not be
The generator set is running established properly.
Check / Repair
unstable. There may be a leakage on the fuel supply line. Check / Repair
There may be a mechanical failure on engine (pistons, etc). Check / Adjust / Repair
The pressure of the lubrication
Oil pressure sensor may be faulty. Check / Repair / Replace
oil is very high. Oil pressure indicators may be faulty. Check / Repair / Replace
The lubrication oil level may be more than required. Check / Adjust
Blue colored smoke at the
The oil consumption may be more than required. Check / Adjust / Repair
exhaust outlet. The compression pressure may not be proper. Check / Adjust
There may be a mechanical failure on engine (pistons, etc…). Check / Adjust / Repair
The generator set may be overloaded. Check / Change
The air/gas mixture may be richer than required. Check / Adjust
Black colored smoke at the The sparking plugs may be faulty. Check / Repair / Replace
exhaust outlet.
Fresh air supplied for combustion may be insufficient. Check / Adjust
The air through the turbocharger may not be cooled enough. Check / Adjust / Repair
Thelubrication oil level may be more than required. Check / Adjust
The lubrication oil may not be proper. (Low viscosity) Check / Change
There may be a leakage on the oil lubrication system. Check / Repair
Oil consumption is too high. The generator set may be running under low-load or no-load. Check / Change
There may be a mechanical failure on engine (pistons, etc…). Check / Adjust / Repair
The oil cooler may be defective. Check / Repair / Replace
The cylinder covers may be defective. Check / Repair / Replace
43
READ AND UNDERSTAND
6
TROUBLESHOOTING
PROBLEM POSSIBLE PROBLEMS SOLUTIONS

Fuel consumption is too high. The ignition timing may be adjusted wrong. Check / Adjust
The lubrication oil may not be proper. (High viscosity) Check / Change
The quality or specifications of fuel may not be proper. Check / Change
There may be a problem on the fuel gas supply line. Check / Repair
The ambient temperature may be very low. Check / Change
No or insufficient fuel supply pressure or flow rate. Check / Repair
Fresh air supplied for combustion may be insufficient. Check / Change
Hot air ventilation around the engine may be insufficient. Check / Change
Manual fuel lift pump may be faulty. Check / Repair / Replace
Fuel injection pump may be faulty. Check / Repair / Replace
The fuel injectors may be faulty. Check / Repair / Replace
The generator set may be overloaded. Check / Adjust
The power at the output of the
The turbocharger may be faulty. Check / Repair / Replace
engine, is less than required.
The air through the turbocharger may not be cooled enough. Check / Adjust / Repair
The compression pressure may not be proper. Check / Adjust / Repair
The connection between the mixer and regulator may not be
Check / Repair
established properly.
The pressure regulators on fuel supply line may be frozen. Check / Repair
The air/gas ratio supplied for engine may not be proper. Check / Adjust / Repair
Fuel supply line may be blocked. Check / Repair
The ignition timing may be adjusted wrong. Check / Adjust / Repair
The back pressure of the exhaust outlet may be too high. Check / Repair
Electrical connections may be faulty or loose. Check / Repair
Alternator does not produce
voltage properly. Rotating diodes or the suppressor may be faulty. Check / Repair / Replace
(The voltage is less than 10% There may be an open or short circuit on ignition circuit. Check / Repair
of nominal value under no load.) Residual voltage may be lower than required. Apply external excitation
Alternator does not produce The fuse on AVR card may be faulty or broken. Check / Replace
voltage properly.
AVR card may be faulty or broken. Check / Adjust / Replace
(Voltage is less than 20-30%
of nominal value under no load The ignition stator may not be connected properly. Check / Repair
and it does not respond to the
turning of AVR potentiometer.) The ignition stator may not be installed properly. Check / Repair
The speed settings may be adjusted lower than required. Adjust the speed potentiometer
Alternator does not produce
The voltage potentiometer may not be set properly. Adjust the voltage potentiometer
voltage properly.
The fuse on AVR card may be faulty or broken. Check / Replace
(Voltage is less than 50-70% of
AVR card may be faulty or broken. Check / Adjust / Replace
nominal value under no load.)
Over excitation limit may be adjusted lower than required. Adjust the AMP potentiometer
The voltage potentiometer may not be set properly. Adjust the voltage potentiometer
The voltage at the output The load may be more capacitive than a specified level. Remove any unneeded capacitive load
is too high. AVR card may be faulty or broken. Check / Adjust / Replace
Engine speed may be varying in time. Adjust the speed of engine
The voltage at the output The stability potentiometer may not be set properly. Adjust the STAB potentiometer
is unstable. AVR card may be faulty or broken. Check / Adjust / Replace
44
READ AND UNDERSTAND
7
WARRANTY
Duration
This warranty applies to new TEKSAN Jeneratör Sets to be free from defects in material and workmanship in
production for 12 months or 1000 hours from the date of delivery to first user (which occurs first). Warranty period is
limited by 18 months from the date of shipment ex-works Teksan.
TEKSAN Responsibilities
If a defect in material or workmanship is found during the warranty period (provided that Buyer/Owner has fulfilled its
due contractual obligations), TEKSAN Jeneratör will, during normal working hours and through a place of business
of a Teksan Dealer or other source approved by Teksan:
• Replace or repair the defective parts, at Teksan’s discretion
• Provide for reasonable repair costs to correct the defect as agreed with Teksan
• Provide for the cost of oil and filters which are made unusable by the defect
Teksan either will dispatch parts to the Buyer/Owner free or to repair at the factory or on site. If the repair is decided
to perform at the factory by Teksan, the Buyer/Owner is responsible to disconnect the product from and reconnect
the product to its attached equipment, mounting and supporting systems as well as transporting the product from the
site to the factory and from factory to the site.
If the repair is decided to perform at site, travel expenses are not covered by Teksan.
Parts of complete products replaced will become the property of Teksan and they shall be forwarded to Teksan (if
requested), carriage-paid by Buyer/Owner.
Any parts repaired or replaced shall be under warranty, until the original warranty period for the diesel generator set
expires.
45
READ AND UNDERSTAND
7
WARRANTY
Buyer/Owner Responsibilities
• Buyer/Owner should install, operate and maintain the generator set in accordance with the maintenance and
operation, diesel engine and alternator handbooks supplied with the genset. If these books are lost, Buyer/Owner is
responsible to provide those books. In case of failures occurred due to not respecting to these books, the warranty
will be invalid.
• Commissioning approval and start-up process should be made by Teksan dealers or its authorized representatives.
• Giving timely notice of a warrantable failure and making the equipment available for repair as the defect has become
apparent.
• Accepting the Teksan’s sole judgment as to whether the faulty is under warranty coverage or not.
• Any costs of investigations, unless a defect is accepted by Teksan as a warranty claim.
• Any costs in excess of the purchase price of the genset.
• Other miscellaneous costs such as courier, travel, mileage, lodging, taxes, telephone calls, overtime, etc.
• Buyer/Owner has the right of searching and asking for the ID card from the staff appointed for technical service.
• Disconnecting/Reconnecting the product from/to its attached equipment, mounting and support systems as well as
to transport the product from the site to the factory and from factory to the site.
• Sufficient amount of lubricating oil, coolant or additives with specifications specified in the Maintenance and
Operation Handbook should be used. In case of using lubricating oil and coolant that lost property or dirty or with
different specifications and standards, warranty will be invalid.
• After Teksan’s transportation responsibility (as stated in contract) is finished, transportation, loading and unloading
is under Buyer/Owner’s responsibility. The possible damages during these processes are not under the warranty
coverage.
• The storage of the generator set during the time between the delivery or commissioning date and the first start-
up date of the generator set. If this duration is longer than 3 months, then storage must be done with respect to
storage principals as indicated in the Maintenance and Operation Handbook.
• Generator set control unit should be programmed, set or changed under Teksan approval.
• Run and stop the generator set stated as in the maintenance and operation handbook. Do not run or stop the
generator set under load. This may damage engine valves and its components, alternator exciter windings, rotating
diodes, suppressor and voltage regulator card.
• Commissioning approval is only valid for installation location. If the position of the generator set is desired to be
changed, Teksan dealer or authorized representatives should be informed.
• Original spare parts and consumable items (oil, fuel, filter, belt etc.) approved by Teksan should be used.
• Completing any outstanding payments for the purchase of equipment, parts or services relating to the equipment
under warranty.
46
READ AND UNDERSTAND
7
WARRANTY
Limitations
The warranty does not cover;
• Periodical maintenance, controls and settings should be made strictly according to maintenance and operation
handbooks.
• Any interference to generator set by people not confirmed by Teksan.
• Any failures resulting from abuse, neglect and/or improper repair.
• Any failures resulting from Buyer/Owner’s delay making the product available after being notified of a potential
product problem.
• Normal wear, the spare parts that should be changed and consumable items such as lubricating oil, filters, coolant,
V-belt, injector nozzles etc.
• Any failures in batteries or failures resulted from batteries.
• Any failures resulted from using biodiesel, jet fuels (JP), sub-kerosene fuel, fuel-oil, benzene, etc. and additionally
dirty, water mixed, with chemical additives. Diesel fuel, specified in the handbooks should be used for the diesel
generator sets.
• Any failures resulted from modifications and additions on Control panel systems - manual, automatic,
synchronization panels, transfer panels or any other equipment etc. - These are should be made by Teksan or
authorized representatives.
• Any failures of switching devices resulted from high current, low or high voltage due to the fact that generator
transfer panel is made suitable to generator output rating - contactor, motor circuit breaker - etc.
• Any failures resulted from erasing, removing or changing of the labels belonging to Generator Set.
• Any failures resulted from under no-load or low load as indicated in Maintenance and Operation handbook.
• Any failures resulted from operating the generator set in different operation mode, loads greater than rated power
as stated on its label (Standby) and unbalanced load.
• Any failures emerged after warranty period expiration date will not be considered under warranty coverage.
• Any failures resulted from act of god, earthquake, snowstorm, avalanche, fire, flood or mains electricity are not
under warranty coverage.
* In no event will Teksan be liable for loss of use, loss of profits, loss of or damage to other property, inconvenience,
commercial loss or other special, incidental or consequential damages whatsoever.
* Any warranty of fitness for purpose shall not be effective unless explicitly confirmed by Teksan in writing. In case
of an express confirmation of fitness for purpose, the provisions above shall apply accordingly.
47
READ AND UNDERSTAND
7
WARRANTY
Claim Submissions
Warranty service requests should be claimed to Teksan dealer or authorized representative who made commissioning
process.
Buyer/Owner has to report failure without delay by “Warranty Claim Form” given in the documentation with the
delivery of generator set. This form has to be filled in right way completely. Especially, genset model, serial numbers,
engine running hours, description of the faulty, comments about the failure and defective parts information should
be supplied.
Additionally, sufficient pictures of the failure should be sent.
Any required operations in purpose of correcting the failure should be done after the approval of Teksan in writing.
Warranty claims must be done in 5 working days from date of failure.
If requested, Buyer/Owner is responsible to present all kind of documents to prove the validity of the warranty period.
48
TEKSAN JENERATÖR
Yenidoğan Mah. Edebali Cad. No:12
Sancaktepe 34791 İSTANBUL / TÜRKİYE
Tel: +90 (216) 312 05 50 Pbx
Fax: +90 (216) 312 69 09
e-Mail: info@teksanjenerator.com.tr
www.teksanjenerator.com.tr

Operation and Maintenance Manual: For Natural Gas Generator Sets

Uploaded by

Document Information

Original Description:

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Operation and Maintenance Manual: For Natural Gas Generator Sets

Uploaded by

Copyright:

Available Formats

OPERATION AND MAINTENANCE MANUAL

FOR NATURAL GAS GENERATOR SETS

TS ISO 8528-5 CERTIFICATE

ISO 9001 QUALITY MANAGEMENT SYSTEM CERTIFICATE

ISO 14001 ENVIRONMENT MANAGEMENT SYSTEM

CERTIFICATE OHSAS 18001 WORKERS’ HEALTH

GOST-R (RUSSIA) CERTIFICATE

CERTIFICATE OF CONFORMITY WITH EUROPEAN UNION DIRECTIVE

2. GENERAL DEFINITIONS .................................................................................................................................... 11

2 Lifting and Carrying

Lifting the Generator Set

2 1 Towing Trailer Type Generator Sets

A Trailer Type Generator Set

4 Hot Surfaces and Sharp Sides/Corners

Very hot water.

5 Fire and Explosion

Remove the connections from negative (-) poles of the

6 Hazardous and Corrosive Substances

7 Electrical Components and Connections

SAFETY PRECAUTIONS DANGER

7 1 First Aid in Possible Electrical Accidents

1 Natural Gas Generator Set

1 Base Frame 7 Lifting Lugs 13 Exhaust Line

2 Natural Gas Engine

6 Exhaust System and Muffler

2 Floor and Platform

4 Cooling and Ventilation

In order for the protection of air channels, stationary or

The layout drawing on the left, is just showing a typical generator

In order for reducing the harmful contents (CO, NOx, etc…) of

2. Reduction of the nitrogen oxides to nitrogen: CO+NOx=CO2 +N2

2.Nx.Oy X.O2+ Y.N2

6 Natural Gas Fuel System

6 Natural Gas Fuel System

Natural Gas Fuel Supply Line drawing and Picture

6 Natural Gas Fuel System

Connecting and Disconnecting:

Adding Pure Water:

NOTE: Refer to the operating manuals for the special

Engine Speed (rpm)

2 Control Panel – TJ509T

Mains monitoring, protection and control operations are made by

2 Control Panel – TJ509T

TJ509-T Controller Types

2 Control Panel – TJ509T

External GSM-GPRS Modem (DKG-090)

External GPS Device:

Rainbow Plus Software (Freeware)

3 Ignition and Firing System

Manual Valve Manual Valve Pressure Pressure

Magnetic Pickup Air Filter

A drawing that shows the principle of operation of the “Ignition System”

4 Basic Procedures to be Followed before Operation

4 Basic Procedures to be Followed before Operation

5 Battery Charger Devices

7 Transfer (ATS) Panels

2 Maintenance of Natural Gas Engine

4 Engine Lubrication Oil

Use a reputable brand of lubricant in accordance

6 Fuel (Natural Gas)

Keep the batteries clean for a better performance.

(50 hour/6 months)