WEICHAI WPG13.5 Manual de usuario
Operation & Maintains Manual of Weichai Group
Diesel Gen-set
Version No.: V01
Weichai Heavy Machinery Co., Ltd.
Foreword
Before operating the Gen-set, please read this Operation Manual carefully. This
user manual is mainly used to guide customers how to use this equipment, describes
structural composition, operation and use, daily maintenance and care, fault diagnosis
and measures that shall be taken in details, is helpful for operators and maintenance
personnel to use and maintain the Gen-set correctly and contributes for judgment
analysis and troubleshooting when the Gen-set malfunctions, in order to ensure that
the equipment can be put into normal operation rapidly.
Please refer to and read diesel engine’s operation manual, alternator’s user
manual and drawings and documents of control part, etc. provided with the Gen-set
whiling reading this manual, in order to prevent accidental operations and
misjudgment on faults.
Precautions in this manual are basic principles that the operators must follow
and perform strictly. The purpose of safe and effective operation can be realized only
if the equipment is operated and maintained correctly. Occurrence of many accidental
injuries often is caused by the reason that basic safety rules are not observed.
Contents
CHAPTER 1 SAFETY ......................................................................................... 1
I. SAFETY RULES............................................................................................ 1
II. SAFETY SYMBOLS .................................................................................... 2
CHAPTER 2 OPERATING CONDITIONS AND PURPOSES .................................. 5
I. DESCRIPTION ON MODEL OF THE GEN-SET ........................................ 5
II. DESCRIPTION ON POWER OF THE GEN-SET....................................... 5
III. ENVIRONMENT ADAPTABILITY OF THE GEN-SET .......................... 6
IV. POWER CORRECTION OF THE GEN-SET ............................................. 6
V. RANGE OF APPLICATION ......................................................................... 7
CHAPTER 3 OVERVIEW ON MAIN STRUCTURE OF THE GEN-SET ................ 8
I. DIESEL ENGINE ........................................................................................... 8
II. ALTERNATOR.............................................................................................. 8
III. CONTROL PANEL.................................................................................... 16
CHAPTER 4 MAIN SPECIFICATIONS AND TECHNICAL PARAMETERS OF
THE GEN-SET ........................................................................................................... 28
CHAPTER 5 TRANSPORTATION OF THE GEN-SET ........................................... 31
CHAPTER 6 INSTALLATION OF THE GEN-SET ................................................. 32
I. PREPARATIONS BEFORE INSTALLATION............................................ 32
II. REQUIREMENTS FOR INSTALLATION OF THE GEN-SET................ 32
III. STANDARD EQUIPMENT ROOM ARRANGEMENT OF THE
GEN-SET................................................................................................................ 42
CHAPTER 7 COMMISSIONING OF THE GEN-SET ............................................. 43
I. INSPECTIONS BEFORE COMMISSIONING........................................... 43
II. PREPARATIONS BEFORE COMMISSIONING ...................................... 44
III. COMMISSIONING OF THE GEN-SET................................................... 50
CHAPTER 8 OPERATION OF THE GEN-SET........................................................ 55
I. PREPARATIONS AND INSPECTIONS BEFORE OPERATION .............. 55
II. OPERATION OF THE GEN-SET .............................................................. 56
CHAPTER 9 MAINTENANCE AND CARE OF THE GEN-SET ........................... 60
I. MAINTENANCE AND CARE SCHEDULE .............................................. 60
II. MAINTENANCE AND CARE OPERATION ........................................... 61
CHAPTER 10 COMMON FAILURES AND TROUBLESHOOTING..................... 72
CHAPTER 11 SERVICE COMMITMENT ............................................................... 87
I. SERVICE CONCEPT................................................................................... 87
II. SERVICE COMMITMENT ........................................................................ 87
III. PRINCIPLE AND PROVISION OF QUALITY WARRANTY (“THREE
GUARANTEES”)................................................................................................... 87
Diesel Gen-set Operation Instructions
1
Chapter 1 Safety
I. Safety rules
Before starting the Gen-set, be sure to read this Operation Manual carefully and know
this equipment well. The purpose of safe and effective operation can be realized only
if the equipment is operated and maintained correctly. Occurrence of many accidental
injuries often is caused by the reason that basic safety rules are not observed. The
Gen-set equipment must be operated only by trained electricians. The following rules
are provided to remind operators and maintenance personnel of the danger situations
that may occur:
1. Electric shock may cause injuries of operators
1.1 Casing of Gen-set must be grounded, in order to prevent endangerment to
personal safety of operators caused by live casing. Because Weichai Gen-set is
designed with safe grounding system, customers only need to install as per local
electric power rules and regulations;
1.2 Do not open cover plate of alternator during operation of the Gen-set, or injuries
or even death may be caused by electric shock;
1.3 The air switch shall be turned to switching-off position and the Gen-set shall be
stopped when operators perform maintenance on wiring harness of the equipment, or
injuries or even death may be caused by electric shock;
1.4 Do not handle electrical failures while wearing wet clothes (especially wet shoes)
or having wet skin.
2. Fire hazard may cause injuries or even death of operators
2.1 Open flames and smoking must be prohibited in equipment room of the Gen-set.
Battery and fuel of the Gen-set are inflammable, especially lead-acid battery may
generate explosive hydrogen when being charged, and may cause personal injuries or
Diesel Gen-set Operation Instructions
2
even death because hydrogen may immediately cause an explosion if it contacts with
electric arc or spark;
2.2 When the Gen-set is operating or hot, do not add fuel into fuel tank. It would be
very dangerous if fuel contacts with hot body of diesel engine and exhaust pipe, etc.
3. Rotating parts may cause injuries or even death of operators
3.1 All rotating parts of Gen-set shall be equipped with protective cover, for example,
flywheel, fan and charging alternator, etc. shall be equipped with protective cover. In
addition, fastening condition of these rotating parts shall be inspected at a regular
interval;
3.2 Do not get close to rotating parts when wearing loose clothes because these would
be wrapped in rotating parts and cause personal injuries, or even death;
3.3 Keep your hands away from rotating parts when the Gen-set is operating.
4. High-temperature parts may cause injuries of operators
4.1 Do not open radiator cap when the Gen-set is operating or immediately after the
Gen-set is stopped, or splashed high-temperature liquid would cause injuries of
operators;
4.2 Do not try to touch exhaust pipe, turbocharger, high-temperature coolant and
other high-temperature parts of the Gen-set with your hands when the Gen-set is
operating, or your hands would be burnt;
4.3 Owing to the temperature of exhaust pipe is high and in order to prevent burns,
the pipe shall be wrapped with heat-resisting materials (e.g. glass fiber or aluminum
silicate, etc.), in order to complete thermal insulation. In addition, exhaust terminal
and exposed part of exhaust pipe shall be kept away from woods or other flammable
substances, especially the fuel piping.
II. Safety symbols
Diesel Gen-set Operation Instructions
3
Following safety symbols used on Weichai Gen-set are used to remind operators and
maintenance personnel of the fact that serious personal injuries or significant property
losses would be caused if they do not follow these warnings. Meanings that these
safety symbols express are as shown in Table 1-1.
Table 1-1 Meanings of safety symbols used on Weichai Gen-set
No. Symbols Description
1
A warning meaning that there is some
immediate danger that may cause serious
injuries or even death if cannot be
avoided.
2
A warning meaning that there is some
potential danger that may cause serious
injuries or even death if cannot be
avoided.
3
A warning meaning that a potential risk
that may cause minor or moderate injuries
if cannot be avoided.
4
No lifting
5
No smoking
6 No switching-on
7
Beware of burns
Diesel Gen-set Operation Instructions
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8
Beware of hot surface
9
Beware of electric shock
10
Beware of rotating parts
11
Beware of auto starting
12 Must be grounded
13 Lift up the Gen-set from here
14
Transport with a forklift from here
Diesel Gen-set Operation Instructions
5
Chapter 2 Operating Conditions and Purposes
Diesel Gen-set is a diesel-fueled small-size electro-mechanical power generation
equipment in which alternator produces electric energy under driving of diesel engine
(prime motor). It converts heat energy (combustion of diesel oil) into mechanical
energy (power inverse rotation) and electric energy (AC alternator cuts magnetic field)
finally. In this process, fuel is its raw material and electric energy is its product.
I. Description on model of the Gen-set
Model of the Gen-set consisting of four parts is named as per following rules:
II. Description on power of the Gen-set
1. Rated power: it refers to the maximum power that the Gen-set is able to provide
continuous power supply to variable loads without limitation in annual running time
between specified maintenance intervals and under specified environmental
conditions.
Its allowable average output power in an interval of 24h shall not be greater than 70%
of rated power.
An interval of 1h overload power supply is allowable in every 12h operation of
Weichai Gen-set and its overload capacity is 10% of rated output power.
Structure form code, ‘B’ represents common
open-type and ‘F’ represents common chassis fuel
tan
k
t
yp
e.
Series code
Reserve capacity of the Gen-set, kVA
Weichai Power Generation
Diesel Gen-set Operation Instructions
6
2. Rated capacity: for the Gen-set whose power factor is 0.8 (lagging), its rated
capacity shall be 1.25 times of rated power.
3. Reserve capacity: reserve capacity of Weichai Gen-set is 1.1 times of rated
capacity.
III. Environment adaptability of the Gen-set
Under following environmental conditions, the Gen-set shall be able to operate
normally and output rated power.
Ambient temperature: 25℃
Range of altitude: 0~1000m
Relative air humidity: 30%~60%
Under non-standard environmental conditions, the Gen-set shall be able to operate
normally. But, rated power of the Gen-set must be corrected.
IV. Power correction of the Gen-set
When the Gen-set is going to operate under non-standard environmental conditions,
rated power of the Gen-set shall be corrected. If the load power of the Gen-set during
operation is greater than corrected rated power, the diesel engine will belch a lots of
black smoke and become overheating. If operation like this is kept for a long period
of time, diesel engine will malfunction seriously or be damaged, so this situation must
be avoided.
When ambient temperature is extremely high, air density would decrease, amount of
oxygen provided during combustion of diesel engine will decrease. As combustion
efficiency reduces and mechanical output power of diesel engine will reduce
accordingly; at the same time, winding needs to be cooled by air during operation of
alternator, thus cooling performance will decrease and internal temperature of
alternator winding will raise when ambient temperature is extremely high. Therefore,
in order to ensure that temperature of alternator winding is kept within an allowable
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