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Hyundai Diesel Generator. Manual - part 3

User manual

1~1.5 m of distance from the generator set and
1.5~2m above the generator set.

◆The generator set working room shall be furnished

with fire extinguish hydrant which conform to the
specified standard.

◆Emergency lighting facilities shall be installed in the

generator set working room for the convenience of
operation and maintenance.

◆No combustible and explosive materials are allowed

to be placed in the generator set working room.

Below is the layout for the open system generator set
working room.

(Foundation drawing Refer to APPENDIX B )

Note:
Our  company  can  make  drawings  and  design
installation  dimensions  for  generator  set  working
room according to customer’s special requirements.

Below is the layout for the canopy system generator
set working room.

(Foundation drawing Refer to APPENDIX C )

Note:
Canopied  generator  set  can  work  outdoor  directly.  If
users  wants  to  operate  the  generator  set  indoor,
above  diagram  can  be  taken  as  reference.  we  can
design the layout of generator set working room and
installation dimension according to customer’s special
requirements.

2.5

Installation of Generator Set

2.5.1

Locate the position of generator set

Vibration  reduction  units  have  been  installed  on  our
generator  sets  (except  a  few  generator  sets  don’t
have this kind of facility). Users can take reference on
the  installation  diagram,  correctly  install  the
generator set on a flat and hard foundation, use the
expansion bolts to tightly fix the generator set to the
concrete foundation through the installation holes on
the  base  frame.  When  no  special  requirement  is
needed,  we  don’t  suggest  customers  to  install
additional vibration reduction units.

Soft connection is needed to connect the parts of the
generator  set  to  outside.  For  example:  corrugated
vibration  reduction  pipe  has  been  used  to  connect
exhaust  pipes,  air  exhaust  path,  fuel  inlet  pipe,  fuel
return  pipe  and  busbar  cable  etc.,  all  of  these  parts
need to use soft connections. Only in this way we can
reduce the adverse effect caused by the vibration of
generator set to the minimum extent.

2.5.2

Ventilation

When a generator set with a complete set of radiator
assembly has been installed in the working room, the
basic  principle  is  to  discharge  the  hot  air  in  the
working  room  to  outside  and  let  in  the  low
temperature  air  from  outside,  and  try  you  best  to
avoid the hot air come in from outside.
The diagram in the right side demonstrates the ideal
position of a generator set in the working room.
The  purpose  of  this  arrangement  is  to  get  cold  air
from the lowest point as much as possible, and force
them to pass through the radiator core, and then lead
them out.

Users  can  use  metal  plate  or  canvas  to  make  a  wind
guide  cover,  the  connection  between  wind  guide
cover  and  the  radiator  shall  be  soft  connection,  so
that to cut off the transmission of vibration from the
generator set, and also ensure the hot air exhaust to
outside thoroughly.
The  effective  circulation  sectional  area  inside  of  the
wind  guide  cover  shall  be  bigger  than  1.25  times  of
the front face area of the radiator core. And the wind
guide  cover  shall  be  smooth,  no  sharp  angle  and
camber so that to reduce the resistance to the wind.
At  the  same  time,  the  effective  circulation  sectional
area in the air inlet opening shall also be bigger than
1.25 times of the front face area of the radiator core.
When the users have installed mesh cover or shutters
in  the  air  inlet  /outlet  opening  or  there  is  too  many
cambers  in  the  air  inlet/outlet  opening,  the  effective
air  circulation  sectional  area  will  be  reduced  and
resistance  will  increase,  and  therefore,  it’s  necessary
to further increase air circulation area.

User manual

Under  normal  conditions,  the  air  volume  generated
from  the  radiator’s  fan  is  enough  to  meet  the
requirement of the working room ventilation.
The air inlet temperature of the engine shall be below
30  degree  Celsius.  If  the  air  inlet  temperature  keep
rising  above  30  degree  Celsius,  the  engine’s  output
power  will  be  reduced,  and  therefore  fresh  air  from
outside  shall  be  introduced  into  the  generator  set’s
working room in a timely manner.
If  the  generator  set  is  furnished  with  a  remote
radiator,  forced  air  circulation  for  the  generator  set
working  room  is  a  must.  The  forced  air  circulation
need  two  fans,  one  fan  is  responsible  for  air  intake,
another  is  air  exhaust,  which  exhausts  hot  air  to
outside.
When the engine is furnished with propelled fan, it is
recommended  that  a  separate  pipe  is  needed  to
exhaust the gas which generated from the crankcase
to  outside.  Otherwise  the  exhaust  gas  from  the
crankcase will accumulate on the radiator, which will
cause  the  radiator  stuck  by  dirty  material,  and  as  a
result, the heat‐sinking capacity will be reduced.

2.5.3

Exhaust

Our  standard  configuration  diesel  generator  sets
provide  accessories  such  as  industry  heavy  silencer,
soft corrugated pipe and elbow etc. Users can design
the  exhaust  system  of  generator  set  working  room
by  themselves.  When  design  and  install  the  exhaust
system, please consider the following aspects:
◆Ensure the total exhaust backpressure no higher than

the  maximum  allowed  value  specified  by  the
engine(usually  generator  set’s  maximum  exhaust
backpressure  is  no  more  than  5Kpa)  Fix  the  exhaust
system  to  make  sure  the  exhaust  manifold  and
turbo‐charger are not subject to the vertical pressure

and side stress.

◆ Reserve some space for hot shrinkage and cold

expansion.

◆Reserve space for generator set vibration.
◆Reduce exhaust noise level.

Overload of exhaust backpressure will cause
following adverse effect:

◆Output power loss
◆Fuel efficiency reduce
◆Exhaust gas temperature rise

Note:
When  more  than  one  generator  set  are  installed,  try
not  to  discharge  all  of  the  generator  sets’  gas  from
one  exhaust  path.  If  no  separated  exhaust  pipe  is
allowed,  under  the  condition  that  the  total
backpressure will not exceed the generator sets’ total
backpressure  a  moveable  separate  panel  shall  be
installed  inside  of  the  branch  exhaust  pipe  so  that  to
prevent the gas from return.

In  the  exhaust  system,  soft  corrugated  pipe  shall  be
used  to  connect  the  exhaust  pipe  with  the
turbocharger,  this  pipe  has  three  functions  as
follows:
◆Separate  the  diesel  engine  with  vibration  and  the

weight of exhaust pipe.

◆Compensate the heat expansion of exhaust pipe.
If  the  diesel  generator  set  is  installed  on  the
anti‐vibration  base  frame,  the  corrugated  pipe  can
compensate sideway movement when engine start or
stop.

Note:
1.  Serious  damage  will  occur  when  rain or  condensed

water  enter  into  engine’s  exhaust  system.
Therefore,  one  water  discharge  opening  shall  be
installed  in  the  long  exhaust  pipe,  the  position  of
which shall be close to the generator set.

2. When the top of the exhaust pipe is above the

architecture, lightening protection is needed
(connect to the ground)

2.5.4

Noise reduction

When diesel generator set is running, normally it will
generate noise level of 90～110dB, and the more the
load, the higher the noise level.
In order to meet the noise level standards established
by the local environmental protection bureau and to
prevent  the  noise  pollution  caused  to  ambient
environment,  which  will  affect  people’s  normal  life,
to  reduce  noise  level  of  diesel  generator  set  is  also

User manual

very important.
Noise  reduction  engineering  is  a  comprehensive  and
professional  engineering.  During  the  process  when
users  try  to  design  the  scheme  for  noise  reduction
project,  at  the  same  time  please  fully  consider  the
bottom  limit  of  air  inlet/outlet  volume  needed  by
engine’s  normal  running  and  the  maximum  allowed
value  for  exhaust  backpressure  etc.  Otherwise,  the
noise reduction project will seriously affect generator
set’s  output  power,  and  make  generator  set’  s
temperature  rise,  cause  frequent  malfunction  of  the
generator  set,  and  even  it  will  shorten  the  life
expectancy of generator set.

Note:
HYUNDAI  Power  can  provide  customers  with  overall
sound proof generator set.

2.6

Cooling system

Our standard configuration diesel generator sets are
closed  cycling  water  chilling  units  with  fan  and
radiator  installed.  Closed  water  chilling  engine  drive
the  cooling  pump  to  generate  circulation  power,
which  keep  the  anti‐freeze  in  the  paths  of  cylinder
body  and  cover  continuous  circulation  and  heat
elimination. Engine’s cooling pump, radiator (or heat
exchanger)  forms  a  closed,  pressure  cycling  and
cooling system.
The  most  common  cooling  system  is  cooling  fan
directly  driven  by  radiator  and  engine,  which  can  be
replaced  by  heat  exchanger,  remote  radiator  or
remote  cooling  tower  etc.  If  the  installation  position
of  the  remote  cooling  fan  is  relatively  higher,
transmission  radiator  is  needed  to  prevent  the
damage of heat exchanger caused by too big internal
pressure.

Note:
The  dirty  material  stay  in  the  radiator’s  core  will
greatly  affect  radiator’s  cooling  capacity.  And
therefore it is necessary to clean the radiator often.

2.6.1

Coolant

Cooling  system  shall  use  the  coolant  which  can
protect the engine from contamination and freezing.
Coolant  shall  be  a  mixture  of  pure  water  and
anti‐freeze  or  pure  water  and  anti‐rust  fluid.  In  this
mixture,  water  PH  value  shall  be  between  6～8,
usually  suggest  to  use  distilled  water.    The  specific
mixing ratio shall be according to local weather, and
that  of  the  coolant  recommended  by  the  engine
supplier, and reference to the operation (preparation)
manual  of  the  coolant.  Mix  the  liquids  in  a  separate
container  evenly  and  then  add  the  mixture  into  the

radiator, ensure the anti‐freeze will not freeze under
low  temperature.  In  the  area  when  there  is  low
possibility of freezing, the coolant can be a mixture of
water  and  anti‐rust,  according  to  the  anti‐rust  which
recommended by the engine supplier and refer to its
operation  manual,  mix  the  liquids  in  a  separate
container  evenly  and  then  add  the  mixture  into  the
radiator. At the first time when anti‐rust is added, the
generator set shall be kept running until it get to hot
so that to achieve the best effect of anti‐corrosion.

Engine’s  coolant  shall  have  three  functions  listed  as
below:
◆Provide enough heat transmission capacity
◆ Prevent  all  metal  material  and  sealing  material

within the cooling system from corrosion(Cave
corrosion)

◆Provide sufficient anti‐freeze capacity

Warning:
! To choose the anti‐freeze which is recommended and

approved by the qualified engine supplier is the
critical point to ensure engine’s normal running.

! Do not mix the anti‐freeze and anti‐rust of any types,

this will generate a large amount of bubble and
reduce the coolant’s performance.

! If the anti‐freeze used in the generator set is of bad

quality  and  not  approved  by  the  engine  supplier,
which  cause  the  malfunction  of  the  generator  set
(water  leakage,  contamination  and  etc.),  this
malfunction(s)  does  not  belong  to  the  scope  of
warranty.

2.6.2

Change of coolant

The effect of anti‐freeze and anti‐rust will decrease by
the time period of service. And therefore periodically
change  of  anti‐freeze  is  a  must.  The  mixture  of
anti‐freeze  shall  be  changed  in  every  two  years.  The
mixture of anti‐rust shall be changed at least one time
every  year.  And  if  filter  of  the  coolant  is  installed,  at
least this filter shall be changed in every half of year
(please refer to the engine operation manual for the
specific intervals of the changes required).
When  it  is  time  to  discharge  the  coolant,  make  sure
the generator set has been shut down and the engine
has been fully cooled down, then open the radiator’s
liquid  adding  hole.  After  that  open  the  discharge
valve  installed  in  the  radiator  and  in  the  engine
respectively to discharge the water. If the generator
set  is  furnished  with  coolant  filter,  it  shall  be
detached from the engine and be changed.

2.6.3

Cleaning of cooling system

User manual

When change the coolant, cleaning is needed for the
cooling system, the cleaning procedures are
suggested as follows:
◆Empty the cooling system
◆Use water to rinse cooling system
◆Feed 15%~20% condensed coolant to the cooling

system, timely run the generator set for one or two
times then discharge the coolant

◆Empty the cooling system then use normal mixed

liquid to rinse

◆If contaminant still exists, then repeat the cleaning

procedure until no contaminant exists in the system

◆After the system has been fully rinsed, feed new

coolant which has been mixed according to specified
proportion

Note:
If the cooling system is cleaned periodically, only rinse
it with small amount of additives or clean water is
enough.

2.6.4

Feeding of coolant

◆Before adding coolant to the coolant system, please

make sure the radiator ‘s discharge valve and the
engine’s discharge valve are tightly closed.

◆Add the coolant to the system in a proper speed so

that to avoid air cock being formed in the system.

◆Air shall be discharged through the adding hole or

the discharge valve in the engine body. If the cooling
system is furnished with heater, the control valve for
the heater shall be opened. Ensure ventilation of the
unit when adding the coolant.

Note:
The  air  discharge  valve  in  the  engine  body  shall  be
located in the top point of the water path or near the
thermostat  or  water  temperature  sensor,  or  you  can
slightly  loose  the  water  temperature  sensor  and
re‐tighten  it when  you  see  coolant  run  out  from  it  so
that to discharge the air.

◆When  adding  the  coolant,  the  surface  of  liquid  shall

reach  to  the  level  that  is  5  centimeters  below  the
radiator’s  welded  surface  (or  shall  reach  the  level
indicating  Line).  Be  sure  that  the  generator  set  has
stopped  and  become  fully  cooled  before  adding
Coolant.  Before  the  system  is  capable  of  ventilation
and  the  liquid  is  added  to  the  required  level,  please
don’t start the generator set. After the coolant being
fed, please start and pre‐heat the generator set, and
at  the  same  time  check  the  liquid  level  and  add
coolant  if  needed.  The  coolant  which  needs  to  be
added  to  the  radiator  shall  be  of  the  same
specification as that existing in the radiator.

◆For some generator sets installed with coolant filter,

please open the filter’s valve before put into use.

2.7

Lubricant system

Lubricant  system  is  composed  of  oil  pan,  oil  pump,
strainer,  oil  pipe,  oil  cooling  unit,  oil  filter  unit,  and
the  oil  path  inside  of  the  engine  and  all  kinds  of
lubricant parts which are in relative motion etc.    The
main  purpose  of  the  lubricant  system  is  to  provide
sustained tempered oil film between the parts which
are in motion so that to reduce friction and wear, and
draws  off  part  of  the  heat  absorbed  by  the  parts,
bath  mechanical  part,  improve  sealing  effect  and
prevent rust from each part’s surface.
Users can determine the model of lubricant according
to  the  specific  working  environment  and  conditions.
For  the  first  time  lubricant,  normally  users  shall
change  it  within  100  hours  upon  and  from  the  time
when the generator set first started. (details refer to
engine maintenance manual)

Note:
The critical point is to use qualified lubricant oil which
is  with  proper  viscosity  and  conform  to  the  engine’s
requirement, and periodically change the lubricant oil
and  oil  filter  so  that  to  ensure  the  generator  set’s
normal  working.  The  malfunctions  caused  by  wrong
model of lubricant oil with low quality or long time no
change  of  lubricant  oil,  or  oil  filter  do  not  belong  to
the scope of warranty.

We  recommend  that  high  quality  multi  grade  SAE
15W/40  high  service  engine  oil  in  diesel  engines  are
used.  At  ambient  temperatures  above  ‐15  degree
Celsius  is  15W40.  The  minimum  API  oil  quality  levels
recommended  for  use  is  CH  /  CI‐4,  CH  or  CI‐4  can  be
used  in  areas  where  CF4  oil  is  not  yet  available,  but
the  oil  interval  must  be  reduced  API  CA,  CB,  CC,  CD,
CE, CG4 categories not recommended, do not use.

2.8

Fuel system

Our  generator  sets  requires  the  fuel  ‐  diesel  shall  be
clean,  without  air  and  water  and  with  proper
pressure,  of  which  all  kinds  of  parameters  such  as
sulphur  content  etc.  shall  meet  national  standards,
and  end  use  temperature  grade  meet  the
requirement  of  customer’s  working  environment.
Generally  generator  set’s  fuel  system  includes  two
parts,  that  is,  engine’s  fuel  system  and  external  fuel
system.  HYUNDAI  is  only  responsible  for  installation
of  the  external  fuel  system  which  includes  fuel  tank
and connecting fuel pipes etc.

2.8.1

Fuel Recommendations

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