Emergency Diesel Generator

18.
EMERGENCY DIESEL GENERATOR

OPERATION & MAINTENANCE MANUAL
FOR
DIESEL GENERATOR SETS
Project SINHA 50MW IPP

Capacity BSDG 300kW
Model DH300DT
Edited Ver. 1 st Edition
Edited on November 22, 2010
Copied on : November 22, 2010

STD No. : DH-0612-1
OPERATION & MAINTENANCE
EDIT1st : Nov 22, 2010
MANUAL PAGE :2 / 29
Contents
IMPORTANT SAFETY INSTRUCTIONS
1. INTRODUCTION ------------------------------------------------------------------------------------------------------- 3
General
How to Obtain Service
2. OPERATION--------------------------------------------------------------------------------------------------------------7
General
Pre Operational Checks
Operation
3. TROUBLE SHOOTING-----------------------------------------------------------------------------------------------15
General
Trouble Shooting Guide
4. MAINTENANCE--------------------------------------------------------------------------------------------------------22
General
Periodic Maintenance Schedule
General Inspection
5. OPERATION RECOMMENDATION-------------------------------------------------------------------------------29
No-Load Operation
Exercise Period
Low Operation Temperature
DAEHUNG ELECTRIC MACHINERY CO., LTD.

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IMPORTANT SAFETY INSTRUCTIONS
SAVE THESE INSTRUCTIONS- This manual contains important instructions that should be followed
during installation and maintenance of the generating set & batteries.
Before operating the generator set(here in after called genset), read this manual & become familiar
With it & equipment. Safe & efficient operation can be achieved only if the equipment is properly
operated & maintained. Many accidents caused by failure to follow fundamental rules & precautions.
The following symbols, found throughout this manual alert you to potentially dangerous conditions to
the operator, service personnel, or the equipment.
Danger : This symbol warns of immediate hazards which will result in severe personal injury
or death.
Warning : This symbol refers to a hazard or unsafe practice which can result in severe
personal injury or death.
Caution : This symbol refers to a hazard or unsafe practice which can result in personal injury
of property damage.
FUEL AND FUMES ARE FLAMMABLE

Fire, explosion and personal injury or death can result form improper practices.
⊙ DO NOT fill fuel tanks while engine is running, unless tanks are outside the engine compartment.
Fuel contact with hot engine or exhaust is a potential fire hazard.
⊙ DO NOT permit any flame, cigarette, pilot light, spark, arcing equipment, or other ignition source
near genset or fuel tank.
⊙ Fuel lines must be adequately secured and free of leaks. Fuel connection at the engine should be
made with an approved flexible line. DO NOT use zinc coated or copper fuel lines with diesel fuel.
⊙ Be sure all fuel supplies have a positive shut off valve.
⊙ Be sure battery area has been well-ventilated prior to servicing near it. Lead-acid batteries emit a
highly explosive hydrogen gas that can be ignited by arcing, sparking, smoking etc.

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EXHAUST GASES ARE DEADLY
⊙ Provide an adequate exhaust system to properly expel discharged gases away from enclosed or
sheltered areas and areas where individuals are likely to congregate. Visually and audibly inspect
the exhaust daily for leaks per the maintenance schedule. Make sure that exhaust manifolds are
secured and not warped. Do not use exhaust gases to heat a compartment.
⊙ Be sure the unit is well ventilated.
⊙ Engine exhaust and some of its constituents are known to the government to cause cancer, birth
defects, and other reproductive harm.
MOVING PARTS CAN CAUSE SEVERE PERSONAL INJURY OR DEATH
⊙ Keep your hands, clothing, and jewel away from moving parts.
⊙ Before starting work on the genset, disconnect batteries negative(-) cable first.
This will prevent accidental starting.
⊙ Make sure that fasteners on the genset are secure. Tighten supports and clamps,
keep guards in position over fans, drive belts, etc.
⊙ Do not wear loose clothing or jewel in the vicinity of moving parts, or while working on electrical
equipment, Loose clothing and jewelry can become caught in moving parts.
⊙ If adjustment must be made while the unit is running, use extreme caution around
hot manifolds, moving parts, etc.
DO NOT OPERATE IN FLAMMABLE AND EXPLOSIVEE ENVIRONMENTS
Flammable vapor can cause an engine to over speed and become difficult to stop, resulting in
possible fire, explosion, severe personal injury and death. Do not operate a genset where a
flammable vapor environment can be created by fuel sill, leak, etc., unless the genset is equipped
with an automatic safety device to block the air intake and stop the engine. The owners and operators
of the genset are solely responsible for operating the genset safely. Contact your authorized
DEMCO. distributor for more information.
ELECTRICAL SHOCK CAN CAUSE SEVERE PERSONAL INJURY OR DEATH
⊙ Remove electrical power before removing protective shields or touching electrical equipment. Use
rubber isolative mats placed on dry wood platforms over floors that are metal or concrete when
around electrical equipment. Do not wear damp clothing (particularly wet shoes) or allows skin
surface to be damp when handling electrical equipment. Do not wear jewelry. Jewelry can short out
electrical contacts and cause shock or burning.
⊙ Use extreme caution when working on electrical components. High voltage can cause injury or
death. DO NOT tamper with interlocks.
⊙ Follow all applicable state and local electrical codes. Have all electrical installations performed

STD No. : DH-0612-1
MANUAL PAGE :5 / 29
by a qualified licensed electrician. Tag and lock open switches to avoid accidental closure.
⊙ DO NOT CONNECT THE GENSET DIRECTLY TO ANY BUILDING ELECTRICAL SYSTEM.

Hazardous voltages can flow from the genset into the utility line. This creates a potential for
electrocution or property damage. Connect only through an approved isolation switch or an approved
.paralleling device.
GENERAL SAFETY PRECAUTIONS
⊙ Coolants under pressure have a higher boiling point than water, DO NOT open a radiator or heat
exchanger pressure cap while the engine is running. Allow the genset to cool and bleed the system
pressure first.
⊙ used engine oils have been identified by some state or federal agencies as causing cancer or
reproductive toxicity. When checking or changing engine oil, take care not to ingest, breathe the
fumes, or contact used oil.
⊙ Keep multi-class ABC fro extinguishers handy. Class A fires involve ordinary combustible materials
such as wood and cloth; Class B fires, combustible and flammable liquid fuels; Class C fires live
electrical equipment.(ref, NEPA No. 10).
⊙ Make sure that rags are not left on or near the engine.
⊙ Make sure genset is mounted in a manner to prevent combustible materials from accumulating
under the unit.
⊙ Remove all necessary grease and oil from the unit. Accumulated grease and oil can overheating
and engine damage which present a potential Ire hazard,
⊙ Keep the genset and the surrounding are clean and free from obstructions. Remove any debris
from the set and keep the floor clean and dry.
⊙ Do not work on this equipment when mentally or physically fatigued, or after consuming any
alcohol or drug that makes the operation of equipment unsafe.
⊙ Substances in exhaust gases have been identified by some state or federal agencies as causing
cancer or reproductive toxicity. Take care not to breath or ingest or come into contact with exhaust
gases.
⊙ Do not store any flammable liquids, such as fuel, cleaners, oil, etc., near the genset. A fire or
explosion could result.
⊙ Wear hearing protection when going near an operating genset.
⊙ To prevent serious burns, avoid contact with hot metal parts such as radiator, turbo charger and
exhaust system .
KEEP THIS MANUAL NEAR THE GENSET FOR EASY REFERENCE

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1. INTRODUCTION
GENERAL
All operators should read carefully this manual before operating the genset for the first time. A
generating set(genset) must be operated and maintained properly if you are to expert safe, reliable
and quiet operation. The manual includes a troubleshooting guide and a maintenance schedule.
The engine manual is included with the set. Where there is conflicting information this manual takes
precedence over the engine manual.
Warning; Improper operation and maintenance can lead to severe personal injury or loss of life
and property by fire, electrocution, mechanical breakdown exhaust gas asphyxiation. Read
and follow the safety precautions carefully observe all instructions and precautions in this
manual.
HOW TO OBTAIN SERVICE
When the genset requires servicing contact your nearest DEMCO. distributor is ready to handle all
your service needs. If you are unable to contact a distributor send FAX or e-mail us using FAX No. or
address.
TEL : +82 51 266 5995

Fax : +82 51 263 7007
e-mail address : demkor@demkor.co.kr
When you ask servicings, always have to give Complete Model, Specification and Serial No. on the
genset nameplate.
Warning: Incorrect service or parts replacement can result in severe personal injury, death,
and / or equipment damage. Service personnel must be trained and experienced to perform
electrical and / or mechanical service.

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2. OPERATION
GENERAL
The following describes the function and operation of the DEMCO genset which designed specially
for Customer.
This section covers pre-start checks, starting and stopping and operating genset. Each operator
should read through this entire section before attempting to start the genset. It is essential that the
operator be completely familiar with the genset.
Refer to Section 6 for operating recommendations.
PRE OPERATIONAL CHECKS
Before starting be sure the following checks have been made and the genset is ready for operation .
1) Operation Area (Location)
Selecting a location for the genset can be most important part of genset operation.
Always locate the genset in an area that will provide adequate ventilation and physical protection for
the unit. For the purpose of simplifying maintenance and inspection requirements it will also be
important to place the genset in such a position so as to allow easy movement around the machine
without overcrowding.
The location should be clean, flat, not windy, dry, dust free and have good drainage capabilities.
The shading area is recommended. Another point to keep in mind is the ample space required to
undertake service operations. In some cases it may be necessary to remove major components.
The floor supporting the genset has to be resistant enough to support the weight of genset and
vibration energy Produced during operation. It will be a polished concrete floor, completely separated
from the buildings.
2) Exhaust System
Important note: Exhaust gas can cause death, severe nausea or fainting, hot exhaust components
may ignite nearby combustible materials.
It is imperious to canalize exhaust gas in a place that allows and facilitates their dilution in
atmosphere. Some constraints such as air pollution, radiance temperature, pressure drop, must be
taken in account for the exhaust gas system definition.
The exhaust system of this genset is equipped inside the sound enclosure so, it is not in need of
additional system
Some exhaust parts can reach very high temperature (400℃~ 600℃). All precautions must be taken
to prevent direct contacts and, infrared radiance. For direct contacts a heat insulated protection or
screen with a warning label is sufficient.
Check to make sure entire exhaust system is tight, that no combustible materials are near system,

STD No. : DH-0612-1
MANUAL PAGE :8 / 29
and gases are discharged away form the genset.
3) System Filling up
Lub. Oil Line

Generally speaking and except particular specification, The DEMCO gensets are fitted with Lub.
Oil ref. CALTEX APICG-4 15W40 or equivalent. If eventually the genset was empty without lub. Oil,
preferably fill up the diesel engine crankcase with lub. Oil ref. CALTEX APICG-4 15W40. If it is not
possible, use an equivalent lub. Oil
Check the presence of a label indicating the diesel engine tub. Oil reference.
Make sure that the lub. Oil level is not over the mark MAX on the dipstick. In another way a check of
the lub. Oil will have to be done after 5-6 minutes of the first starting the diesel engine.
< DEEPSTICK >
<LUB.OIL INLET>
Water Line

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Generally speaking, water fling up must be executed for the first time with pure water(without any
additive) to check. Cooling liquid normally used by DEMCO is anti-freezer. This cooling liquid,
ready for use and ensuring an anti-freezing protection up to -30 t is basic elaborated with
monoethylene glycol, without any nitrite and complies with the specification of standard.
This liquid containing Monoethylene Glycol is harmful swallowed.
Remove radiator cap indicated on the label and fill-up the water circuit slowly until the cooling liquid
flows out by the radiator cap. If it is not possible to fill up at the bottom,
fill-up by the radiator cap and execute this operation slowly to favor progressively the circuit
degassing.
Air pocket cancel out naturally during stopping periods. A check and eventual components will be
required during the commissioning phase.
<COOLANT INLET RADIATOR CAP>
Warning: Do not open a radiator cap or valve during engine is running. It may Cause explosion
or burns. Do after sufficient cooling of water for the safety.
Combustible(Fuel) Line
Diesel engine that equip gensets are, most of the time, high range diesel engines. This type of diesel
engines required consequently high-grade fuel. It is strongly advisable to use fuel according to ASTM
D975 No. 2D (the general automotive diesel engine purpose fuel oil) or equivalent which fully meet
requirement. Main characteristics are a feeble sulphur content (less than 0.5%) and perfect pureness
degree without any residue.
Make sure that day fuel tanks installed in the base frame have sufficient fuel and that fuel system is
primed.
For fill-up of fuel remove fuel cap of fuel inlet as indicated on the label and fill up the day tank until the
level gauge reaches and check there are no leaks and that all fittings in the line are tight.

STD No. : DH-0612-1
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< FUEL INLET(ONLY DESEL) and LEVEL GAGE >
4) Electrical System
Important note: installation and connection of electrical cables must comply with standard
specification
Starting Battery
Warning: For safe and proper use of the battery, please read the enclosed directions and
warning label on the battery cover.
Danger: The battery emits hydrogen gases. In particular, large amounts are emitted during the
latter phase of battery charging. Placing metal tools on the(+)/(-) terminals of the battery or
using the battery in highly flammable, wet and poorly ventilated areas can lead to explosion
and/or fire.
Danger: The battery fluid contains dilute sulfuric acid. Do not tiIt the battery or exert undue
necessary force. When checking the battery, always wear rubber gloves and protective eye
covering and be careful not to spill any of the battery fluid. Contact with the fluid can cause
blindness and burns. If the fluid comes into contact with the eyes, skin or clothes,
immediately rinse the affected area with large amounts of water. In particular, if the fluid gets
into the eyes, seek medical treatment by a physician or optometrist right away. If the fluid
enters the oral cavity or is swallowed, repeatedly gargle with water, drink large amounts of
water and then seek medical treatment right away.
Danger: The battery contains battery fluid and should be kept out of the reach of
persons(children) who are unfamiliar with the risks and dangers involved. The battery fluid
can cause blindness and severe burns.
Rubber gloves, Splash-proof safety goggles and long sleeves clothes are required when handling
batteries

STD No. : DH-0612-1
The supplied battery is RP Lead acid Battery installed inside the enclosure, which is no need to
Maintenance such as adding distilled water or Electrolyte throughout the life of the battery
Charge the battery in a well-ventilated area and prevent short-circuiting and/or the emission of sparks.
Keep batteries away from flammable areas/objects.
Keep batteries away from high temperature and high humidity and store away from rain, snow and
direct sunlight. A fresh water source is required in the vicinity of the place of work.
Do not tiIt the battery and do not exert force of any kind on the battery.
Some recommendations:
- Use only insulated tools
- Don't lie metallic articles on batteries.
- Remove wristwatch, rings, and any other jewelry that can touch battery terminals
- Charging battery emits flammable gas avoid any flame or spark in the vicinity.
- Don't disturb the battery charging connections.
- Never smoke near the battery.
- Discharge clothes static electricity before checking a battery
- Battery area must be sufficiently ventilated…
For safety the battery cables are disconnected when shipped from our factory. Put anti-corrosive
grease on terminals after connection and make sure that the top of the battery is clean and dry.
In spite of their great simpleness, bring into operation and maintenance are primary for MF Lead acid
Batteries good working and long life. Warranty application is subordinated to the application of the
following instructions.
The users only have to check the hydrometer mounted on the upper part of battery Indicating color on
the hydrometer, Battery is properly charged and ready.
“Green”: Battery is properly charged and ready for use.

At full charge the electrolyte specific gravity is 1.280
“Black”: Battery is discharged. Charge the battery until the hydrometer turns green.
While at 50% of charge considered the minimum serviceable condition.
“Clear”: Low battery fluid. Inspect the charging system and replace the battery.

STD No. : DH-0612-1
< HYDROMETER >
Some recommendations to ensure a long life for batteries

- Maintain elements and frame dry and clean.
- Check that batteries are well ventilated Have regard for instructions relative to charging current and
to quantity of electricity to charge.
- Execute correctly the commissioning.
- Check periodically the tightening of nuts of joining bars between elements.
After checking battery, Connect battery cable to the negative(-) terminal tightly and check hydrometer
on the battery as explained above.
<Ngative(-),Positive(+) connect terminal>
Supply AC 220V-50Hz AC source(commercial power) from Engine Alternator

STD No. : DH-0612-1
Power Cables
Important Note: In all cases whatever may be the use of the cables, the choice of ducts or cables tray
must be in accordance with the applicable rules and standards. Inspection of power connection :
Inspect that no metallic tools or pieces are left in the alternator terminal box as on the power circuit in
the control panel.
Check the fastening of power cables on all their length and especially at each end to make sure they
dont pull out on the terminals on which they are connected.
Check that the bending radius of power cables is correct at each change in direction and the tightness
of power cables connections at each end.
Warning: When tightening these cables on the terminals pads on the load switch(MCCB), an
excessive tightening can damage these terminals.
< LOAD CONNECTION >

STD No. : DH-0612-1
Grounding
Ground in accordance with any applicable National, Local or Federal Standards, Code or Regulation.
Regulations vary and advice should be sought from the local supply utility as to their requirements.
OPERATION
MANUAL MODE
1) Open MCCB for commercial(Main) power (place position)

2) Insert push button Manual mode and START for 3sec and then genset starts.
3) Check the voltage(380V) and if not the rated, adjust it by rotating VR and check the
frequency(50Hz).
4) Close Load switch(place position) and then Generating power is supplied to Load.
5) Check the current A.C Amperes meter.
PROTECTION DEVICES
1)Abnormal Conditions are occurred as below, protection device makes the genset stop and lamp lit.
- Lub Oil Pressure(OPL) :

- Coolant Temp.(WTL) :
- Overspeed :
2)Take stop position switch after clearing trouble(s) for restarting.

STD No. : DH-0612-1
3.TROUBLE SHOOTING
GENERAL
The genset control continuosly monitor engine sensors for abnormal conditions, such as low oil
pressure and high coolant temperature. If any of these conditions occur, the control will light a Engine
fault lamp.
In the event of an engine fault lamp, the control will stop the engine immediately; an alternator
shutdown fault,the engine will stop after cool-down timer has times out.
If the genset is stopped for this reason, the operator can restart the genset after making adjustments
or corrections.
Warning : Contracting high voltage components can cause electrocution, resulting in severe
personal injury or death. Keep the output box covers in place during trouble shooting
This document is intended to simplify the operator work ,when alarm appear by guiding him in the
investigations to take and find reason of failure and how to correct it.
Looking like a table, this guide comprises of several columns. The remedial action is explained in the
last column.
- Symptom : It’s the fault signal,when lighting the fault origin or a malfunctioning origin that could
appear without any signalization.
- Probable causes ; It’s cause(s) that can generate trouble.
- Detection means ; It’s the check and investigation to do determine accurate the fault origin.
- Remedial actions; It’s the action to be taken to remedy the fault origin.
The important Note ; The electrical drawing is necessary to carry out the remedial checks(refer to the
related drawing)
Warning : Take all the necessary precautions when checks are required inside the control
panel. Use only adapted and insulated tools for inspection of equipment under voltage. On
the other hand, It is essential to follow the procedure described hereinafter for the genset
isolation and energy dissipation before starting any work on it.
Genset isolation and Energy Dissipation Procedure
This procedure must be strictly applied before any remedial actions after alarms or maintenance
operations on the genset.
It is essential to respect the particular instructions mentioned in the following trouble shooting tables.
The completely application of the procedure and of these particular instructions will allow the operator
to work with an easy mind in the genset.
Caution : Disconnect battery charger from AC source before disconnecting battery cables.
Otherwise, disconnecting cables can result in voltage spikes damaging to DC control circuits
of the set.
Warning : Accidental stsrting of the genset can cause severe personal injury or death. Prevent
accidental staring by disconnecting the negative(-) cable form the battery terminal

STD No. : DH-0612-1
When troubleshooting a set that is shut down, make certain the genset cannot be accidentally
restarted as follows ;
1)Remove the negative (-) battery cable from the genset starting battery.
2)Make coming into the sight that the genset is isolated for maintenance works with a warning tag
hanged up on the enclosure of the genset.
At the end of the works, Inform all the affected services that the genset is again in service.
< Electric Governor Controller> - only 50Hz 100kw
Probable causes; Lack of residual, voltage regulator faulty ,inductors open,

Rotating diode faulty
Remedial actions: Execute a separate excitation
< Diodes Ass’y >
Probable cause; Malfuction of rotating diode

Detection means; Check the voltage value on the voltmeter or with a digital voltmeter

STD No. : DH-0612-1
Remedial actions; set again the voltage with the voltage adjustment potentiometer (VR)
On the voltage regulator.
Replace the rotating diode
Probable cause; Unknown

Detection means; a) The alternator is energized the voltage stays normal
b) The alternator is energized the voltage lower than normal
c) The alternator is energized the voltage disappears after removal of
separate excitation
Remedial actions: a) Allow the genset to run with load for several hours
b) Replace the voltage regulator and adjust it to the normal value
c) Check the inductors resistance and rotating diodes
Symptom : 2. Alternator Voitage Abnormally high
Probable causes: Wrong setting or disturbing of the voltage regulator

Detection means: Check the voltage value on the voltmeter or with a digital voltmeter
Remediai actions: Set again the voltage with the voltage adjustment potentiometer
(VR) on the control panel.
Replace VR
Probable causes; Genset speed excessive

Detection means: Check the speed (or the frequency) on the Hz meter
Remedial actions: Set again the speed with the injection pump on engine.
For 100kw, adjust governor speed controller on the control panel
Warning; this operation must be executed by a skilled operator
Symptom;3. 0verload
Probable causes; Short circuit on outgoing circuit

Detection means: Isolate the outgoing feeders, one by one and check their insulation Value.
Remedial actions: Repair the faulty circuit.
Symptom : 4. The frequency Abnormally low
Probable causes; Wrong setting or disturbing of the speed

Detection means: Check the frequency on the Hz meter
Remedial actions: Set again the speed with the injection pump on engine
For 100kw, adjust governor speed controller on the control panel
Probable causes; Genset speed excessive

Detection means: Check the speed (or the frequency) on the Hz meter
Remedial actions: Set again the speed with the injection pump on engine,
adjust governor speed controller on the control panel.
Probable causes; Fuel flter dirty

STD No. : DH-0612-1
Detection means: Abnormal exhaust smoke

Remedial actions: Remove and clean or change the fuel flter.
Probable causes; Water in the fuel circuit

Detection means: Abnormal exhaust smoke
Remedial actions: Purge the fuel circuit. Check for the water contamination and water in the fuel tank.
Probable causes; Air intake or throttling on the fuel suction pipe.

Detection means: Abnormal exhaust smoke or unstable speed
Remedial actions: Check the absence of air intake(good tightening of connections)
and the suction pipe appearance. Check the fuel level in the tank.
Probable causes; Air filter dirty

Detection means: Abnormal exhaust smoke and clogging indicator activated
Remedial actions: Remove and clean the air filter cartridge.
Probable causes; Injection pump faulty

Detection means: inspect the injection pump flow
Remedial actions: Remove and change the injection pump.
Probable causes; Too much load than the genset rated power
Detection means: Check Current A.C.AMPERES meter.
Remedial actions: Reduce the load
Symptom : 5. The frequency Abnormally high
Probable causes; Wrong setting or disturbing of the speed

Detection means: Check the frequency on the Hz meter
Remedial actions: Set again the speed with the injection pump on engine
For 100kw, adjust governor speed controller on the control panel.

Detection means: Inspect the injection pump flow
Symptom .6. Low tub. Oil pressure during running
Probable causes; Faulty tub. Oil level in the diesel engine sump
Detection means: Inspect tub. Oil level with dipstick
Remedial actions: Add tub. Oil up to the mark on the dipstick.
Probable causes; Leak in the tub, Oil circuit

Detection means: Inspect the pipe work for oil leaks.
Remedial actions: Repair leaks after locating. Clean carefully after repairing tub.

STD No. : DH-0612-1
Oil up to the mark on the dipstick.
Probable causes; Lub. Oil filter dirty

Detection means: The tub. Oil pressure is abnormal on the gauge even when the level is correct and
there is no leak.
Remedial actions: Remove and change the tub. Oil switch on the diesel engine.
Symptom : 7. High coolant temperature during working
Probable causes; Insufficient water level in the radiator

Detection means: Inspect water level by the radiator cap.
Remedial actions: add up if necessary.
Warning; wait until the water temperature fall to 40 "C before opening the radiator cap
Check fan belt and repair if necessary.
Probable causes; Leak in the coolant circuit

Detection means: Inspect water piping and radiator for water leaks .
Remedial actions: Repair leaks after locating. Clean carefully after repairing and Add up coolant
Mixture as required.
Warning; wait until the water temperature fall to 40'c before opening the radiator cap.
Probable causes; Radiator honeycomb dirty

Detection means: Check the radiator honeycomb cleanliness
Remedial actions: Clean the radiator honeycomb with a compressed air source.
Warning; use a low-pressure source with a detergent solution and eventually dry with
low-pressure compressed air source
Probable causes; Too much load for the maximum genset power
Detection means. Check the A.C.Ampere meter.
Remedial actions: Reduce a part of the load.
Probable causes; Air inlet blocked

Detection means: Abnormal exhaust smoke or fall of frequency
Remedial actions: Control and clean the air inlet
Probable causes; Hot air outlet blocked

Detection means: Rise of the temperature inside
Remedial actions: Inspect and clean the hot air outlet..
Probable causes; Slack fan belt

Detection means: Check the fan belt tension (refer to the engine manual)
Remedial actions: Adjust tension of belt.
Probable causes; Water temperature switch faulty

Detection means: Presence of alarm even when the water temperature is correct on the gauge,
Remedial actions: Remove and change the water temperature switch
Warning; it may necessary to drain partly the water circuit.
Therefore we must wait that the temperature falls below 40°C before beginning this operation.Clean
containers of coolant water,

STD No. : DH-0612-1
Fill water to correct level after change of the switch .
Symptom:8.Overspeed
Probable ; Wrong setting or disturbring of the speed

Detection means; Check the frequency on the Hz meter when starting
Remedial actions: Set again the speed with the injection pump when starting.
For 100kw , adjust governor speed controller on the control panel.
Warning: this operation must be exected by a skilled operator.

Detection means: Inspect the injection pump flow
Symptom: 9. Battery charging faulty
Probable causes; Starting battery faulty

Detection means: Inspect DC voltage on the DC voltmeter.
It is possible that the battery is discharged.
Remedial actions: Remove and change the starting battery.
Warning; before disconnecting battery cable,
STOP POSITION and place Load switch close position.
After replacement of battery refer to the
procedure as described on the “PREOPERATIONALCHECKS”
Symptom : 10. NO start
Probable causes; Poor battery connection :terminal or(and) terminal lugs rusted
Detection means: Visually inspect terminals and terminal lugs.
Remedial actions: Disconnect the battery to clean terminals and terminal lugs.
Warning; before disconnecting battery cable, Make stop position
Clean terminals and terminal lugs and cover them with conductive grease
before reconnection.
Warning: make sure that the polarities are reconnected correctly.
After replacement of battery refer to the procedure as described on the “PRE
OPERATIONAL CHECKS”
Probable causes; Discharged or defective battery

Remedial actions: Recharge or replace the battery.
Probable causes; Faulty battery charger

Remedial actions: Remove and change the battery charger
Probable causes; Air filter dirty

Remedial actions: Clean or change the air filter.

STD No. : DH-0612-1
Probable causes; Fuel filter dirty

Remedial actions: Remove and replace the fuel filter.
Probable causes; Air pocket in fuel line

Remedial actions: Remove by manual pumping of injection pump
(Refer to Doosan Operation & Maintenance Manual for leeding the
Fuel System)
Symptom :11 . Differential fault (Insulation fault)
Probable causes; Generator or power cable fault

Detection means: Check the insulation of the generator output cables with regard to the ground.
Warning: Make the STOP position and disconnect battery negative(-) terminal
before executing this operation.
Remedial actions: a) Correct insulation ? continue the check on outgoing cables from the generator.
b) Incorrect insulation: Open the load switch and check the output power cables
insulation with regard to the ground .
Probable causes; Fault on the outgoing circuit

Detection means: Isolate all the feeder equipments and check their insulation.
Remedial actions: Repair the faulty circuit.

STD No. : DH-0612-1
4. MAINTENANCE
General
Establish and adhere to a definite schedule for maintenance and service based on the application and
severity of the environment. The following table covers the recommended service intervals for a
genset on STANDBY service If the genset will be subjected to extreme operating conditions, the
service intervals should be reduced accordingly. Some of the factors that can affect the maintenance
schedule are the following:
㉧ Use for continuous duty (Prime power)
㉧ Extremes in ambient temperatures
㉧ Exposure to weather
㉧ Exposure to salt water
㉧ Exposure to dust, sand or other airborne contaminates
Consult your local DEMCO. distributor if the genset will be subjected to an extreme
operating conditions and determine a suitable schedule of maintenance.
Use the hour run meter to keep an accurate log of all service performed for warranty support. Perform
all service at the time period indicated, whichever comes first. Use the following table to determine the
maintenance required and then refer to the sections that follow for the correct service procedures.

STD No. : DH-0612-1
PERIODIC MAINTENANCE SCHEDULE

Service Time(Interval)
Maintenance Items Monthly/ 6month Yearly

Daily/ Weekly/
After s/ After or after
After 8hrs After
1000hrs 250hrs 500hrs
Lubricating System: Leaks ● ● ● ● ●
Oil level ● ● ● ●
Replace oil filter ● ●
Replace Lube. oil ● ●
Cooling System: Leaks ● ● ● ● ●
Radiator honeycomb ● ● ●
Coolant circuit ● ● ●
Check Oil level ● ● ● ●
Fan belt tension ● ● ●
Water pump, fan hub. ●
Cleaning cooling circuit ● ●
Suction System: Leaks ● ● ●
Restriction of air filter ● ● ● ●
Piping & connection ● ●
Cleaningfreplace air filter ● ●
Fuel System: Leaks ● ● ● ● ●
Fuel level ● ● ●
Injection pump link system ● ●
Piping & connection ● ●
Fuel filter ● ●
Exhaust System : Leaks ● ● ●
Back pressure ● ● ●
Condensate drain ● ● ●
Fittings/clamps/fasteners ●
Air outlet ● ● ●
Electric equip’t: Battery charging system ● ● ● ●
Charging voltage ● ● ●
Protection devices ● ●
Genset : Abnormal vibration ● ● ●
Fittings/clamoss/fasteners ●
Power distribution panel ● ●
Others: Load test ● ● ● ●
Tools & fixture arrangement ● ●
Generator insulation resistance ●
For engine system, Refer to Doosan engine Operation & Maintenance Manual for

STD No. : DH-0612-1
maintenance interval and/or procedure.

Check for oil. Fuel, cooling and exhaust system leaks. Check exhaust system audibly
and visually with set running repair any leaks immediately.
GENERAL INSPECTI0N
During operation, be alert for mechanical problems that could create unsable or
hazardous conditions. The following sections cover several areas that should be
requently inspected for continued safe operation.
Exhaust System
With the genset operating inspect the entire exhaust system visually and audibly
including exhaust manifold, muffler and exhaust pipes.
This genset includes all the exhaust system in the sound enclosure. Check for leaks at
connections, welds, gaskets and joints and also make sure that exhaust pipes are not
heating surrounding areas excessively. If any leaks are detected , shut down the
genset have leaks corrected immediately.
Warning; Inhalation of exhaust gases can result in severe personal injury or

death. Be sure deadly exhaust gas is piped outside and away from any windows,
doors, vents or other inlets to building and not allowed to accumulate in
inhabitable areas.
Fuel System
During genset operation, inspect the fuel supply lines, return lines, filters and fittings for
leaks. Check any flexible sections for cuts, cracks and abrasions and make sure they
are not rubbing against anything that could cause breakage. If any leaks are detected ,
have them corrected immediately.
Warning; lgnition of fuel can cause severe personal injury or death by fire or
explosion. Do not permit any flame, cigarette, arcing switch or equipment, pilot
light, or other igniter near the fuel system or in areas sharing ventilation.
AC Electric System
Check the followings while the genset is operating.
Frequency; The frequency should be stable and the reading should be same as rated.
AC Voltage; The line-to-line voltage at no load should be rated one.

AC Ammeter; At no load the current readings should be rated 0 With the load applied,
each line current should be the rated one.

STD No. : DH-0612-1
DC Electrical System
Check the terminals on the batteries for clean and tight connections. Loose or corroded
connections create resistance which can hinder starting. Refer to PREOPERATIONAL
CHECKS for cleaning and safety precautions
Engine
Monitor fluid levels and oil pressure and coolant temperatures frequently. Most engine
problems give an early warning. Look and listen for changes in engine performance,
sound, or appearance that can indicate service or repair is needed. Some engine
changes to look for are as follows;
㉧ Misfire
㉧ Vibration
㉧ Unusual Noise
㉧ Sudden changes in engine operating temperatures or pressure
㉧ Excessive exhaust smoke
㉧ Loss of power or if the genset has set idle for a period of time with no generator
㉧ An increase in oil consumption
㉧ An increase in fuel consumption
㉧ Fuel, oil, or coolant leaks
GENERATING SET MAINTENANCE
Battery disconnected
Warning; Ignition of explosive battery gases can cause severe personal injury or
death. Arcing at battery terminals, light switch or other equipment, flame,pilot
lights and sparks can ignite battery gas. Do not smoke, or switch trouble light
ON or OFF near battery. Discharge static electricity from body before touching
batteries by first touching a grounded metal surface.
Ventilate battery area before working on or near battery, Wear goggles for eye
protection, Stop the genset and disconnect battery cables, Disconnect negative
(-) cable first and reconnect first.
Caution; Disconnect battery charger from AC source before disconnecting

battery cables. Otherwise, disconnecting cables can result in voltage spikes
damaging to DC control circuit of the set.
Warning; Accidental starting of the genset can cause severe personal injury or
death. Prevent accidental starting by disconnecting the negative(-) cable from
the battery terminal before beginning maintenance procedures.
Mechanical Inspection
With the genset stopped, check for loose belts and fittings, leaking gaskets and

STD No. : DH-0612-1
hoses,or nay signs of mechanical damage. If any problems are found, repair them.
FUEL SYSTEM
Refer the Operation and Maintenance Manual for DOOSAN diesel engine for fuel
recommendations and fuel system maintenance, such as , draining of the fuel-water
separators and fuel filter replacement interval and procedure.
Fuel Handling Precautions
Warning; Ignition of fuel can cause serious personal injury or death by fire or
explosion. Do not permit any flame, cigarette, arc, spark, pilot light, or other
igniter near the fuel system.
To avoid condensation problems, keep fuel supply tanks as full as possible by filling up
each time the engine is used. In cold weather, warm fuel returning from the injectors
heats the fuel in the supply tank, If the fuel level is low, the upper portion of the tank
tends to form condensation. In warm weather, both the fuel and the tank will be warm
during the daytime. At night, cold air tends to lower the temperature of the tank more
rapidIy than the temperature of the fuel. If the fuel 1evel is low, the upper portion of the
tank will cool more rapidly and tend to form condensation.
Condensation(water) can cause clogging of the fuel liters with the sulfur in the fuel
forms acid which can corrode and damage engine parts.
LUBRICATI0N SYSTEM
Gensets are shipped filed with the correct type and quantity of oil. Be sure to check oil
level before initial start.
Oil API Classification and Oil Viscosity
Refer to the Operation and Maintenance Manual for DOOSAN diesel engine for
lubrication oil classification and recommendation .
Engine Oil Level
Check the engine oil level during engine shutdown periods at the intervals specified in
the maintenance table. The dipstick is stamped with high and low marks to indicate
level of oil in the crank case. For accurate readings shut off the engine and wait
approximately 15minutes before checking the oil level, This allows oil in the upper
portion of the engine to drain back into the crankcase.
Warning; Crankcase pressure can blow out hot oil and cause severe burns.
Do not check oil while the genset is running.
Keep the oil level as near a possible to the higher mark on the dipstick but never above
it. Remove the oil fill cap and add oil of the same API viscosity and brand when
necessary. Install the oil fill cap after adding oil.

STD No. : DH-0612-1
Oil and Filter Change
Caution; Do not operate the engine with the oil level below the low mark or above
the high mark, Overfilling can cause foaming or aeration of the oil while
operation below the low mark may cause loss of oil pressure.
Used oil and filters must be disposed of properly to avoid environmental damage and
clean-up liability. Check all federal, state and local regulations for disposal
requirements.
AIR CLEANER
Double air elements are applied on the genset. Refer to the Operation and
Maintenance Manual for DOOSAN diesel engine for air cleaner filter element
replacement interval and procedure.
BATTERIES
Warning; Ignition of explosive battery gases can cause severe personal injury
death. Arcing at battery terminals, light switch or other equipment, flame,
pilotlights and sparks can ignite battery gas. Do not smoke or switch trouble
light ON or OFF near battery. Discharge static electricity from body before
touching batteries by first touching a grounded metal surFace.
Ventilate battery area before working on or near battery, Wear goggle for Eye
protection, Stop the genset and disconnect charger Before disconnecting battery
cables, Disconnect negatives(-) cable first and reconnect
Caution; Disconnect battery charger from AC source before disconnecting

Battery cables. Otherwise, disconnecting cables can result in voltage Spikes
damaging to DC control circuits of the set.
Check the condition of the starting batteries at the interval specified in the maintenance
table. To prevent dangerous arcing, always disconnect the negative ground cable from
the battery before working on any part of the electrical system or the engine Disregard
the sections on checking specifc gravity and checking electrolyte level because we use
a maintenance-free battery.
Cleaning Batteries
Warning; Electrolyte is a dilute sulfuric acid that is harmful to the skin and eyes.
Do not get the substance in your eyes or contact with skin. Wear goggles and
protective, rubber gloves and apron when servicing batteries.
In case of contact, immediately wash skin with soap and water. In case of
minutes. IMMEDIATELY CALL PHYSICIAN.
Keep the batteries clean by wiping them with a damp cloth whenever dirt Appears

STD No. : DH-0612-1
excessive. If corrosion is present around the terminal connections, remove battery

cables and wash the terminals with a solution consisting of f/4 pound of baking sod
aadded to f quart of water.(This solution is also used for washing down spilled
electrolyte.)
Be sure the vent plugs are tight to prevent cleaning solution from entering the cells.
After cleaning, flush the outside of the battery and surrounding areas with clean water.
Keep the battery terminals clean and tight. After marking connections, coat the
terminals with a light application of petroleum jelly or non conductive grease to retard
corrosion.
Battery Replacement
Always replace the starting battery with the same number and type. Properly dispose of
battery in accordance with local environmental agency requirements.
Warning; Electrolyte or explosion of battery can cause severe personal injury or death.
Do not mutilate or burn the battery in a fire for disposal.
Damage to case will release electrolyte which is harmful to the skin and eyes and is
also toxic. Burning of battery may cause an explosion

STD No. : DH-0612-1
5. OPERATING RECOMMENDATIONS
NO-LOAD OPERATION
Periods of no load operation should be held to a minimum If it is necessary to keep the

engine running for long periods of time when no electric output is required, best engine
performance will be obtained by connecting a load bank of at least 30% of specified
rating ,
EXERCISE PERIOD
The cold starting of genset is can impose a severe burden on engine parts.
Regular exercising keeps engine parts lubricated, prevents oxidation of Electrical
contacts and in general helps provide reliable engine starting .Exercise the genset at
least once a month for a minimum of 30 minutes, under Not less than 30% of tale rated
output.
LOW OPERATING TEMPERATURE
Use a coolant heater if a separate source of power is available. The optional

heater available from DEMCO will help provide reliable starting under
adverse weather conditions. Be sure the voltage of the separate power source is
correct for the heater element rating.

Emergency Diesel Generator

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18.

EMERGENCY DIESEL GENERATOR

DIESEL GENERATOR SETS

Project SINHA 50MW IPP

Copied on : November 22, 2010

DAEHUNG ELECTRIC MACHINERY CO., LTD.

IMPORTANT SAFETY INSTRUCTIONS

FUEL AND FUMES ARE FLAMMABLE

⊙ Be sure all fuel supplies have a positive shut off valve.

DAEHUNG ELECTRIC MACHINERY CO., LTD.

EXHAUST GASES ARE DEADLY

⊙ Be sure the unit is well ventilated.

MOVING PARTS CAN CAUSE SEVERE PERSONAL INJURY OR DEATH

DO NOT OPERATE IN FLAMMABLE AND EXPLOSIVEE ENVIRONMENTS

ELECTRICAL SHOCK CAN CAUSE SEVERE PERSONAL INJURY OR DEATH

DAEHUNG ELECTRIC MACHINERY CO., LTD.

⊙ DO NOT CONNECT THE GENSET DIRECTLY TO ANY BUILDING ELECTRICAL SYSTEM.

GENERAL SAFETY PRECAUTIONS

⊙ Wear hearing protection when going near an operating genset.

KEEP THIS MANUAL NEAR THE GENSET FOR EASY REFERENCE

DAEHUNG ELECTRIC MACHINERY CO., LTD.

HOW TO OBTAIN SERVICE

TEL : +82 51 266 5995

DAEHUNG ELECTRIC MACHINERY CO., LTD.

PRE OPERATIONAL CHECKS

1) Operation Area (Location)

DAEHUNG ELECTRIC MACHINERY CO., LTD.

and gases are discharged away form the genset.

Lub. Oil Line

< DEEPSTICK >

DAEHUNG ELECTRIC MACHINERY CO., LTD.

This liquid containing Monoethylene Glycol is harmful swallowed.

<COOLANT INLET RADIATOR CAP>

DAEHUNG ELECTRIC MACHINERY CO., LTD.

< FUEL INLET(ONLY DESEL) and LEVEL GAGE >

DAEHUNG ELECTRIC MACHINERY CO., LTD.

Keep batteries away from flammable areas/objects.

“Green”: Battery is properly charged and ready for use.

DAEHUNG ELECTRIC MACHINERY CO., LTD.

< HYDROMETER >

Some recommendations to ensure a long life for batteries

<Ngative(-),Positive(+) connect terminal>

Supply AC 220V-50Hz AC source(commercial power) from Engine Alternator

DAEHUNG ELECTRIC MACHINERY CO., LTD.

< LOAD CONNECTION >

DAEHUNG ELECTRIC MACHINERY CO., LTD.

1) Open MCCB for commercial(Main) power (place position)

- Lub Oil Pressure(OPL) :

2)Take stop position switch after clearing trouble(s) for restarting.

DAEHUNG ELECTRIC MACHINERY CO., LTD.

Genset isolation and Energy Dissipation Procedure

DAEHUNG ELECTRIC MACHINERY CO., LTD.

< Electric Governor Controller> - only 50Hz 100kw

Probable causes; Lack of residual, voltage regulator faulty ,inductors open,

< Diodes Ass’y >

Probable cause; Malfuction of rotating diode

DAEHUNG ELECTRIC MACHINERY CO., LTD.

Probable cause; Unknown

Symptom : 2. Alternator Voitage Abnormally high

Probable causes: Wrong setting or disturbing of the voltage regulator

Probable causes; Genset speed excessive

Probable causes; Short circuit on outgoing circuit

Symptom : 4. The frequency Abnormally low