Jakson & Company JakPower Kirloskar Koel Green 2R1040 G1 Installation, Comissioning & Operator Manual Download

Page: 21 / 36

JAKSON & CO.

Choked fuel injector holes

Contact to KOEL Service Dealer

Dirty/Choked fuel filter

Contact to KOEL Service Dealer

Fuel level setting wrong

Contact to KOEL Service Dealer

Faulty fuel Pump

Contact to KOEL Service Dealer

Water mixed with fuel

Check the reason and sort out or Contact to
manufacturer/ KOEL service dealer

Radiator fins choked

Clean the radiator fins

Loose V-Belt

Contact to KOEL Service Dealer

No coolant or level low in radiator

Top up with K Cool super plus

Wrongly adjusted valve clearance

Contact to KOEL Service Dealer

Blown cylinder head gasket

Contact to KOEL Service Dealer

Valve leakage

Contact to KOEL Service Dealer

Broken/worn out piston rings

Contact to KOEL Service Dealer

Worn out cylinder liner & piston

Contact to KOEL Service Dealer

In correct valve & fuel timing

Contact to KOEL Service Dealer

Injector needs adjustment

Contact to KOEL Service Dealer

Faulty governor setting

Contact to manufacturer or KOEL Service Dealer

Engine needs overhauling

Contact to KOEL Service Dealer

Choked fuel line

Clean and clear fuel line

Poor quality of fuel

Change the fuel and use good quality fuel

Choked fuel injector holes

Contact to KOEL Service Dealer

Damage or dribbling nozzle

Contact to KOEL Service Dealer

Dirt / choked fuel filter

Contact to KOEL Service Dealer

Faulty fuel Pump

Contact to KOEL Service Dealer

Injector needs adjustment

Contact to KOEL Service Dealer

Faulty governor setting

Contact to manufacturer or KOEL Service Dealer

Load at the time of starting

Start generator at no load

Choked fuel line

Clean and clear fuel line

Dirt / choked fuel filter

Contact to KOEL Service Dealer

Control lever setting wrong

Contact to KOEL Service Dealer

Engine overloading

Ensure Load as per rating or manufacturer
recommendation

Dirt/clogged air cleaner

Clean air cleaner

Damage or dribbling nozzle

Contact to KOEL Service Dealer

Faulty fuel Pump

Contact to KOEL Service Dealer

Engine used after a long time

Contact to KOEL Service Dealer

Wrongly adjusted valve clearance

Contact to KOEL Service Dealer

Blown cylinder head gasket

Contact to KOEL Service Dealer

Valve leakages

Contact to KOEL Service Dealer

Broken/worn out piston rings

Contact to KOEL Service Dealer

Worn out cylinder liner & piston

Contact to KOEL Service Dealer

Incorrect bearing clearances

Contact to KOEL Service Dealer

Damaged main & connecting rod bearings Contact to KOEL Service Dealer
Incorrect valve & fuel timing

Contact to KOEL Service Dealer

Injector needs adjustment

Contact to KOEL Service Dealer

Faulty governor setting

Contact to manufacturer or KOEL Service Dealer

One or more cylinder not working

Contact to KOEL Service Dealer

Engine needs overhauling

Contact to KOEL Service Dealer

Engin dos not reach
governed speed

Engine speed does
not remain constant

Excessive smoke at
no load or low load

Summary of Contents for JakPower Kirloskar Koel Green 2R1040 G1

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Page 3: ...int to Jakson care No 8800447864 General Note 1 Please always sign the report made by our Service Engineer 2 Warranty is applicable for two years for engine alternator only subject to use of Kirloskar K Oil Premium Kirloskar genuine filters K cool super plus and services sourced through KOEL authorized Service Dealer Revalidation If Generator set kept without commissioning not in F operation after...

Page 4: ... SUMP CAPACITY NEPAL 11 11 ROUTINE MAINTAINANCE OF SDG SET 12 12 PRE COMMISSIONING CHECK 13 13 ROUTINE CHECK POINTS 14 14 DO S DON T S 15 15 TROUBLE SHOOTING ENGINE 16 20 16 TROUBLE SHOOTING ALTERNATOR 21 22 TROUBLE SHOOTING GUIDE FOR 23 MANUAL PANEL TROUBLE SHOOTING GUIDE FOR 24 25 AMF PANEL INDEX JAKSON CO 17 18 19 SAMPLE WARRANTY CERTIFICATE NEPAL 26 20 SAMPLE WARRANTY CERTIFICATE DOMESTIC 27 2...

Page 5: ...be minimum 1 5 meters Ø A low height shelter for the Silent DG Set should be avoided It should not obstruct the hot air outlet shelter height minimum 1 5 meter or equal to height of genset Ø It is preferable to install the DG set in an open area No shade roof is required over it However if the AMF Panel is outside the Acoustic Enclosure then a shelter is recommended for the AMF Panel Ø For Roof To...

Page 6: ...to support 1 5times of the total wet weight of the single generator and 2 times of the total weight for the multiple generators Ø Please refer to the dimension of DG set for deciding the foundation length width and depth Note Please ensure that the foundation should not be made over any basement water tank or Sewer Line B Roof top Installation Ø A rooftop installation requires proper planning and ...

Page 7: ...GR CONSULTANT TABLE FOR BAR S SIZE RATING OF SLENT DG SET UP TO 82 5 KVA 100 KVA TO 200 KVA 250 KVA TO 750KVA SIZE OF BAR 10MM DIA 12MM DIA 16MM DIA FFL THERMOCOL SAND SOLD SERVICED TITLE PART NAME DRAWN BY CHECKED BY APPROVED BY FOUNDATION DRAWING OF SOUND PROOF GEN SET C 266 267 IND AREA PHASE 2 MAYAPURI NEW DELHI 64 FOUNDATION DRAWING DRG NO RF 7 06 DATE 7 02 06 KIRLOSKAR ENGINE 200 450 PCC 50 ...

Page 8: ...meters Ø An earth pit cover should be provided Ø A watering pipe of 25mm with a funnel should be provided for each pit wherever depth of the earthing pit is not at water level Ø Earthing system should be checked with megger and resistance between earth pits and terminal should be less then 1 B W 2 earth pits Ω Ø The earthing plate pipe and strip size should be above 100 mega Ω when Genset is not c...

Page 9: ...as possible and load of the extended exhaust pipe silencer should not be on the engine manifold 1 If the extension of exhaust pipe is more than 5 meters above Genset increase pipe diameter by 13mm for every 3 meters 2 If no of bends are more than 4 increase the diameter of exhaust pipe and bend by 13mm for addition of each bend 3 Joining of Exhaust pipe for the both bank is not recommended In case...

Page 10: ...er Ø Size of the fuel piping should be 12mm upto 250 KVA DG set Ø B C Class M S pipe 19 mm 25mm I D is recommended For fuel piping above 250 KVA DG sets Ø MS pipe should be used with proper welded joints Ø Stop valve and flange should be used in supply line to engine near fuel tank for Fuel Tank mounted outside PRECAUTIONS TO BE TAKEN FOR FUEL PIPING AND FUEL SYSTEM Ø Never use GI pipes in fuel pi...

Page 11: ...l be provided by customer Note a Correct size cable glands should always be used for holding the cable b Control wiring should always be done with 2 5 sq mm copper cable For 3 Phase KVA 10 35 40 125 Al Cable Size 3 5 core sq mm 10 35 150 Copper cable size 3 5 core sq mm 4 16 70 KVA 140 320 500 600 625 750 1010 Al Cable Size 3 5 core sq mm 185 2x300 or 3x150 or 4x95 3x300 or 4x185 or 5x120 4x240 or...

Page 12: ...tery charger which is connected with 230V AC supply Ø The Battery charger is provided with an AMF Panel Auto Mains Failure Panel under the standard scope of supply 230V AC supply is essential for battery charger operation Note Battery charger is not supplied with a std manual Panel So it is suggested that the DG set must run once a day for 15 20 minutes so that battery get charged by engine dynamo...

Page 13: ...m date of commissioning whichever is earlier G1 Check Ø G2 Check within 550 hours or 13 months from date of commissioning whichever is earlier Ø G3 Check within 1050 hours or 19 months from date of commissioning whichever is earlier Ø After first service Oil change period is 500 hours or 12 months whichever is earlier Remark Labour will be free and Consumable oil filter will be in customer scope E...

Page 14: ...tery condition Charged Discharged 9 Battery Terminal Leans Proper damaged replaced 10 Electrolyte level High Medium Low 11 Fuel Filter water separator Proper to be replaced 12 V Belt for charging alternator Proper Tightened not Proper 13 V Belt tension Proper adjusted 14 Coolant level in the Radiator High Medium Low filled 15 Check coolant temp safety OK not OK 16 Wiring Engine Panel OK not OK 17 ...

Page 15: ...eck G2 Check after 250 hours or 3 months whichever is earlier Ø After first service Oil change period is 500 hours or 6 months whichever Ø is earlier If Service carried out after completion of 500 hours or 6 months then it Ø shall be chargeable If SDG Set kept idle Not in operation for 6 months from date of invoicing Ø without preservation then revalidation must be carried out SUMP CAPACITY LITERS...

Page 16: ... Lube oil filter cartridge Every 500 Hrs Battery and lead connections Every 50 Hrs V Belt condition and tension adjust replace if required Radiator fins depends on site condition externally Radiator tubes internally Replace fuel filter cartridge after every 500 Hrs Injector Fuel strainer Button filter Thermostat element change if necessary Valve clearance adjust if necessary Starter Alternator Fas...

Page 17: ...laying fitting and connection jobs are completed with proper glanding Ø If panel is out side canopy Power Cable Control cable laying fitting connection jobs have been completed Ø Most important Battery is charged Ø If the DG set is with AMF Panel then 230 V AC mains or 415 V AC mains R Y B N supply is provided at the AMF Panel to check its operation and for Battery Charger Ø Diesel is available in...

Page 18: ... for any leakage Ø Check for any loose connections Ø Check Battery condition Ø Check Lube oil level and quality lube oil should not be very thick with visible carbon and metal particles Ø Check electrolyte level in battery Ø Check electrical wires for any loose connection if found tighten it ROUTINE CHECK POINTS 14 JAKSON CO ...

Page 19: ...genset as per recommended schedules in the user manual Call on the authorised service dealer for servicing maintenance work Please refer maintenace maual before doing any maintenance work Cable entry hole if not in use should be properly closed DON Ts Do not Repair Service any part when set is running Never operate the genset with any parts or ducting removed If any fault is traced Do not attempt ...

Page 20: ...ing Check wiring it should be as per drawing andTightened Dirty clogged air cleaner Check Vaccum indicator if red ribbon is visible then Clean air cleaner refer manual for cleaning No fuel or Low fuel in tank Fill Fuel in tank Poor quality of fuel Change the fuel and use good quality fuel Air in Fuel line Vent air from fuel line Choked fuel injector holes Contact to KOEL Service Dealer Dirty or ch...

Page 21: ...fuel Pump Contact to KOEL Service Dealer Injector needs adjustment Contact to KOEL Service Dealer Faulty governor setting Contact to manufacturer or KOEL Service Dealer Load at the time of starting Start generator at no load Choked fuel line Clean and clear fuel line Dirt choked fuel filter Contact to KOEL Service Dealer Control lever setting wrong Contact to KOEL Service Dealer Engine overloading...

Page 22: ...Change the lube oil as per KOEL specification Dirt choked suction tube strainer Clean the tube strainer Clogged oil passage Check and clear oil passage Contact to KEOL service dealer Radiator fins choked Clean the radiator fins Loose V Belt Contact to KOEL Service Dealer Air leakages through radiator shroud Block air passage and ensure no air recirculation No coolant or level low in radiator Top u...

Page 23: ...OEL Service Dealer Dust entry in air inlet system Make necessary arrangement to stop dust entry without any modification in air inlet arrangement Dirt clogged air cleaner Clean air cleaner Wrong grade of lube oil used Change the lube oil as per KOEL specification Excessive oil in the sump Check and rectify lube oil level upto High mark only External internal fuel leakage Check for any leakage and ...

Page 24: ...ong adjustment Contact to manufacturer or KOEL Service Dealer AVM pad broken or wrong fitment Replace if AVM Pad broken Gap between foundation and base frame i e foundation level is not proper Ensure proper foundation Level should be proper Fluctuation in load Uniform load should be on Genset Faulty governor setting Contact to manufacturer or KOEL Service Dealer Loose mounting bolts Contact to man...

Page 25: ...R failed Replace fuses AVR Defective Replace AVR Rotating diode faulty Check rotating diodes and replace faulty diodes Prime mover Adjust prime mover Prime mover speed is low Adjust prime mover speed to rated speed V Trim pot incorrectly set Adjust voltage by V Trim pot in AVR Low prime mover speed Adjust prime mover speed Loose or no connection to U terminals of the AVR Check and correct Incorrec...

Page 26: ...ly Coupling and foundation bolts loose Tighten the bolts Bearing defective Replace bearing Incorrect assembly of bearing Re assemble correct Bearing damaged Replace bearing Prime mover speed droop improperly set Set prime mover speed properly Droop Governor characteristic of engines Quadrature droop incorrect Set quadrature droop correctly by QDC Pot in AVR QDC CT Polarity reversed Interchange CT ...

Page 27: ...t terminal 1 and 2 inside panel It should be 12 24 V If not check circuit or get the battery charged before making further attempts as battery may be weak Ø The Engine cranks but fails to run Check the fuel supply line Check connection of fuel pipe at fuel tank it may open Air in fuel line Faulty fuel pump Water mixed with fuel Load is disconnected TROUBLE SHOOTING GUIDE FOR MANUAL PANEL 23 JAKSON...

Page 28: ...Ø Check battery terminals They should be properly tightened and should not be corroded Ø Check LLOP connection it should be properly connected on engine terminal Ø Check all wiring connection should be properly tighten and all should be in order as per drawing l The battery connection may be loose or corroded Check and correct the problem l If the MAINS supply is available set the battery charger ...

Page 29: ...rol MCBs these should be in ON position l Check if all three phases RY YB and BR of Mains supply are available All three phases should be available and voltage should be more that the setting of mains voltage monitor or AMF Relay KG Controller l If required lower the voltage setting of mains voltage monitor and differential setting or setting in AMF relays KG Controller Increase the voltage settin...

Page 30: ...26 JAKSON CO BY KIRLOSKAR POWER JAKSON COMPANY 550 13 ...

Page 31: ...27 JAKSON CO BY KIRLOSKAR POWER JAKSON COMPANY 550 13 ...

Page 32: ...nge are mandatory Air Intake Exhaust system Open cylinder heads check the condition of liner piston top for rust formation any damage scratch marks foreign material entry or any abnormality and initiate the corrective action accordingly Air filter rubber hoses and belts can be checked and to be replaced if needed Check the turbocharger rotational freeness axial and radial play of turbocharger If t...

Page 33: ...vity as per KOEL Policy The replacement of the parts will purely be restricted to the most desired one the labour cost charged towards revalidation activity must be as per KOEL recommendation The Customer should be well educated on warranty policy CSP schedule operation and maintenance practices safety tips etc during the Revalidation activity Ensuring minimum down time of Genset through adequate ...

Page 34: ...barcode sticker is altered or defaced in any manner whatsoever f Battery defect is caused by faulty electrical systems improper handling service by unauthorized dealers auto electricians wilful abuse destruction by fire collision theft or recharging g Breakage of container and cover h Damage to the battery caused due to contamination of the electrolyte 8 Warranty settlement is based on the report ...

Page 35: ...POWER JAKSON CO ...

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Jakson & Company JakPower Kirloskar Koel Green 2R1040 G1, Installation, Comissioning & Operator Manual

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