YorPower GENERATORS OPERATORS HANDBOOK

Yorpower Ltd

YorPower GENERATORS
OPERATORS MANUAL

YorPower Generator Operation Manual

 YorPower GENERATORS OPERATORS HANDBOOK

Contents

INTRODUCTION

GENERAL INFORMATION SECTION 1

INSTALLATION, HANDLING, TOWING AND STORAGE SECTION 2

GENERATING SET MAINTENANCE SECTION 3

CONTROL SYSTEM & OPERATION SECTION 4

AUTO TRANSFER SWITCHES (WHERE APPLICABLE) SECTION 4A

BATTERY SYSTEM SECTION 5

YorPower Generator Operation Manual

 INTRODUCTION

These details refer specifically to the unit you have :-

YORPOWER REFERENCE 02674/14

SERIAL NUMBER SC10012S/100F
RATED POWER 150 KVA PRIME
120 KW PRIME
0.8 COS 
RATED VOLTAGE 400/230 V
PHASE THREE
RATED FREQUENCY 50 Hz
MAXIMUM ALTITUDE 152.4 M
MAXIMUM AMBIENT TEMP 27 °C
RATED R.P.M. 1500

Name and Address of Owner / Operator : Name and Address of Generating Set Dealer / Distributor :
ALKTOT ALTATH FOR INDUSTRIAL FOR YORPOWER LTD
EQUIPMENT LTD UNIT 2
HURRICANE CLOSE
SHERBURN IN ELMET
LS25 6PB

YorPower Generator Operation Manual

 INTRODUCTION

Introduction How to use this Operators Handbook

The purpose of this handbook is to lay down It is recommended the individual steps contained
operating guidelines for YorPower (YML) in the various maintenance or repair operations
generating sets. are followed in the sequence in which they
appear.
The specification details given apply to a range of
generators and not to any one particular engine, When a generating set is operating or being
in cases of difficulty the user should consult the overhauled there are a number of associated
local YML Distributor or Dealer for further advice practices which may lead to personal injury or
and technical assistance. product damage.

The information, specifications, illustrations, Your attention is drawn to the symbols shown and
instructions and statements contained within this described below which are applied throughout this
publication are given with our best intentions and publication.
are believed to be correct at the time of going to
press.
CAUTION
Our policy is one of continued development and
we reserve the right to amend any technical This caution symbol draws attention to special
information with or without prior notice. instructions or procedures which, if not correctly
followed, may result in damage to or destruction
Whilst every effort is made to ensure the accuracy
of equipment.
of the particulars contained within this publication
neither the Manufacturer, Distributor or Dealer
shall in any circumstances be held liable for any
inaccuracy or the consequences thereof. WARNING
The information given is subject to the Company's
current Conditions of Tender and Sale, and is for This warning symbol draws attention to special
the assistance of users and is based upon results instructions or procedures which, if not strictly
obtained from tests carried out at the place of observed, may result in personal injury.
manufacture. This Company does not guarantee
that the same results will be obtained elsewhere
under different conditions. WARNING
Parts that have not been approved by the YML
organisation cannot be relied upon for correct A WARNING SYMBOL WITH THIS TYPE OF
material, dimensions or finish. This Company TEXT DRAWS ATTENTION TO SPECIAL
cannot therefore, be responsible for any damage INSTRUCTIONS OR PROCEDURES WHICH, IF
arising from the use of such parts and the NOT STRICTLY OBSERVED, MAY RESULT IN
guarantee will be invalidated. When purchasing SEVERE PERSONAL INJURY, OR LOSS OF
parts or giving instructions for repairs users LIFE.
should, in their own interests, always specify
Genuine YML parts with the GenSpare mark. Note:
A note is used to draw your attention to
additional or important information.

YorPower Generator Operation Manual

 YorPower GENERATOR FEATURES

1 3
8

11
7

4 2

10

ITEM DESCRIPTION ITEM DESCRIPTION ITEM DESCRIPTION

1 DIESEL ENGINE 5 CONTROL PANEL 9 BATTERY RACK
2 ALTERNATOR 6 OUTPUT CIRCUIT BREAKER 10 VIBRATION ISOLATORS
3 RADIATOR 7 STARTER MOTOR 11 RATING PLATE
4 BASEFRAME AND FUEL TANK 8 AIR FILTER

*Typical unit shown, positions of items and options may differ.

YML Generator Operation Manual

YorPower GENERATOR FEATURES

battery rack (item 9) which may also be located on

Generating Set Description and the floor next to the set for some of the larger
Identification generating sets, and a battery charging alternator.
Most sets are provided with lead-acid batteries
which are discussed more fully in Section 5,
This generating set has been designed as a however other types of batteries may be fitted if
complete package to provide superior they had been specified.
performance and reliability. Figure 1 identifies the
major components. This figure is of a typical Cooling System
generating set. However, every set will be slightly
different due to the size and configuration of the The engine cooling system is comprised of a
major components. This section briefly describes radiator (item 3), a high capacity pusher fan and a
the parts of the generating set. Further thermostat. The alternator has its own internal fan
information is provided in later sections of this to cool the alternator components. Note that the
manual. air is "pushed' through the radiator so that the
cooling air is drawn past the alternator, then past
the engine and finally through the radiator.
Each generating set is provided with a Rating
Plate Label (item 11) generally affixed to the
alternator housing or control panel enclosure.
This label contains the information needed to Alternator
identify the generating set and its operating
characteristics. This information includes, but is The output electrical power is normally produced
not limited to, the model number, serial number, by a screen protected and drip-proof, self-exciting,
output characteristics such as voltage, phase and self regulating, brushless alternator (item 2) fine
frequency, output rating in kVA and kW, and tuned to the output of this generating set.
rating type (basis of the rating). Mounted on top of most alternators is a sheet
steel terminal box.

For reference, this information is repeated on the

Technical Data Sheet provided with this manual.
The model and serial numbers uniquely identify
Fuel Tank and Base frame
the generating set and are needed when ordering
spare parts or obtaining service or warranty work The engine and alternator are coupled together
for the set. and mounted on a heavy duty steel baseframe
(item 4). Except for the largest sets, this
baseframe includes a fuel tank with a capacity of
Diesel Engine approximately 8 hours operation at full load. An
extended capacity fuel tank of approximately 24
The diesel engine powering the generating set hours operation may be fitted. Where a fuel tank
(item 1) has been chosen for its reliability and the is not provided with the baseframe, a separate
fact that it has been specifically designed for fuel tank must be provided.
powering generating sets. The engine is of the
heavy duty industrial type with 4 stroke
Vibration Isolation
compression ignition and is fitted with all
accessories to provide a reliable power supply.
These accessories include, among others, a The generating set is fitted with vibration isolators
cartridge type dry air filter (item 8), a turbocharger (item 10)which are designed to reduce engine
fitted on some engines, and a mechanical or vibration.
electronic close control engine speed governor.

Silencer and Exhaust System

Engine Electrical System
An exhaust silencer is provided loose for
The engine electrical system is negative installation with the generating set. The silencer
ground/earth and either 12 or 24 volts DC and exhaust system reduce the noise emission
depending on the size of the set. This system from the engine and can direct exhaust gases to
includes an electric engine starter battery and safe outlets.

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 GENERAL DESCRIPTION

Control System (Identification)

One of several types of control systems and

panels (item 5) may be fitted to control the
operation and output of the set and to protect the
set from possible malfunctions.
Please refer to the control panel manual for the
specific system fitted to your machine.

Output Circuit Breaker

To protect the alternator, a suitably rated circuit

breaker (item 6) selected for the generating set
model and output rating is supplied mounted in a
steel enclosure. In some cases the output circuit
breaker may be incorporated in the automatic
transfer system or control panel.

YML Generator Operation Manual

 GENERAL DESCRIPTION

1. General Information

Contents

1.1 Safety Precautions

1.2 Safety Symbols

1.3 Generator Identification

1.4 Engine Details

1.5 Alternator Details

1.6 Engine Oil

1.7 Engine Coolant

1.8 Fuel Specification

YML Generator Operation Manual

 GENERAL INFORMATION 1
The information contained in this section is 1.1.2 Installation, Handling, and Towing
intended as a general guide only and does not
apply to any particular generating set. Section 4 of this manual covers procedures for
installation, handling, and towing of generating
It is suggested that the local YML distributor or sets. That chapter should be read before
dealer be consulted in cases of difficulty or when installing the generating set, moving/lifting the
more comprehensive information is required. generating set, or towing a mobile set. The
following safety precautions should be noted:
1.1 Safety Precautions

The generating set is designed to be safe when

used in the correct manner. Responsibility for
WARNING
safety, however, rests with the personnel who ! Make electrical connections in compliance
install, use and maintain the set. The following with relevant Electrical Codes, Standards or
safety precautions, if followed, will minimise the other requirements. This includes
possibility of accidents. Before performing any requirements for grounding and groundlearth
procedure or operating technique, it is up to the faults.
user to ensure that it is safe. The generating set
should only be operated by personnel who are ! For stationary generating sets with remote
authorised and trained. fuel storage systems, make sure such
systems are installed in compliance with
1.1.1 General relevant Codes, Standards or other
requirements.

! Engine exhaust emissions are hazardous to

WARNING personnel. The exhaust for all indoor
generating sets must be piped outdoors via
! Read and understand all safety precautions leak-free piping in compliance with relevant
and warnings before operating or performing Codes, Standards and other requirements.
maintenance on the generating set Ensure hot exhaust silencers, piping and
turbochargers, if equipped, are clear of
! Failure to follow the instructions, procedures, combustible material and are guarded for
and safety precautions in this manual may personnel protection per safety requirements.
increase the possibility of accidents and Ensure that fumes from the exhaust outlet will
injuries. not be a hazard.

! Never start the generating set unless it is safe ! Never lift the generating set by attaching to
to do so. the engine or alternator lifting lugs. Use a
sling with a “spreader bar" connected to the
! Do not attempt to operate the generating set baseframe.
with a known unsafe condition.
! Ensure the lifting rigging and supporting
! If the generating set is unsafe, fit danger structure is in good condition and has a
notices and disconnect the battery negative capacity suitable for the load.
(-) lead so that it cannot be started until the
condition is corrected. ! Keep all personnel away from the generating
set when it is suspended.
! Disconnect the battery negative (-) lead prior
to attempting any repairs or cleaning inside ! Make sure all personnel are out of the
the enclosure, if equipped. generating set canopy or container, if
equipped, before closing and latching
! Install and operate this generating set only in enclosure doors.
full compliance with relevant National, Local,
or Federal Codes, Standards or other ! When towing a mobile generating set,
requirements. observe all Codes, Standards or other
regulations and traffic laws. These include
those regulations specifying required
equipment and maximum and minimum
speeds. Ensure brakes, if fitted, are in good
order.

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 GENERAL INFORMATION 1
! Do not permit personnel to ride in or on ! Do not attempt to operate the generating set
the mobile generating set. Do not permit with any known leaks in the fuel system.
personnel to stand or ride on the drawbar
or to stand or walk between the ! The excessive build-up of unburned fuel
gases in the exhaust system can create a
generating set and the towing vehicle
potentially explosive condition. This build-up
can occur after repeated failed start attempts,
! Do not install or use the generating set in air flap valve testing, or hot engine shutdown.
any classification of hazardous Open exhaust system purge plugs, if
environment unless it has been equipped, and allow the gases to dissipate
specifically designed for that environment. before attempting to restart the generating
set.
1.1.3 Fire and Explosion
1.1.4 Mechanical
Fuels and fumes associated with generating
sets can be flammable and potentially The generating set is designed with guards
explosive. Proper care in handling these for protection from moving parts. Care must
materials can dramatically limit the risk of fire still be taken to protect personnel and
or explosion. However, safety dictates that equipment from other mechanical hazards
fully charged BC and ABC fire extinguishers when working around the generating set.
are kept on hand. Personnel must know how
to operate them.

WARNING
WARNING
! Do not attempt to operate the generating set
! Ensure the generating set room is properly with safety guards removed. While the
ventilated. generating set is running do not attempt to
reach under or around the guards to do
! Keep the room, the floor and the generating maintenance or for any other reason.
set clean. When spills of fuel, oil, battery
electrolyte or coolant occur, they should be ! Keep hands, arms, long hair, loose clothing
cleaned up immediately. and jewellery away from pulleys, belts and
other moving parts.
! Never store flammable liquids near the Attention: Some moving parts can not be
engine. seen clearly when the set is running.
! Store oily rags in covered metal containers. ! Keep access doors on enclosures, if
equipped, closed and locked when not
! Do not smoke or allow sparks, flames or other required to be open.
sources of ignition around fuel or batteries.
Fuel vapours are explosive. Hydrogen gas ! Avoid contact with hot oil, hot coolant, hot
generated by charging batteries is also exhaust gases, hot surfaces and sharp edges
explosive. and corners.

! Turn off or disconnect the power to the battery ! Wear protective clothing including gloves and
charger before making or breaking hat when working around the generating set.
connections with the battery.
! Do not remove the radiator filler cap until the
! Keep grounded conductive objects, such as coolant has cooled. Then loosen the cap
tools, away from exposed live electrical parts, slowly to relieve any excess pressure before
such as terminals, to avoid arcing. Sparks removing the cap completely.
and arcing might ignite fuel or vapours.

! Avoid refilling the fuel tank while the engine is

CAUTION
running. ! Ethyl Ether starting aids must not be used on
YML generating sets.

YML Generator Operation Manual

 GENERAL INFORMATION 1

1.1.5 Chemical

Fuels, oils, coolants, lubricants and battery WARNING

electrolyte used in this generating set are
typical of the industry. However, they can be ! The generating set must be connected to the
hazardous to personnel if not treated load only by trained and qualified electricians
properly. who are authorised to do so, and in
compliance with relevant Electrical Codes,
Standards and other regulations. Where
required, their work should be inspected and
accepted by the inspection agency prior to
WARNING operating the generating set.

! Do not swallow or have skin contact with fuel, ! Ensure the generating set, including a mobile
oil, coolant, lubricants or battery electrolyte. If set, is effectively grounded / earthed in
swallowed, seek medical treatment accordance with all relevant regulations prior
immediately. Do not induce vomiting if fuel is to operation.
swallowed. For skin contact, wash with soap
and water. ! The generating set should be shutdown with
the battery negative (-) terminal disconnected
! Do not wear clothing that has been prior to attempting to connect or disconnect
contaminated by fuel or lube oil. load connections.

! Wear an acid resistant apron and face shield ! Do not attempt to connect or disconnect load
or goggles when servicing the battery. If connections while standing in water or on wet
electrolyte is spilled on skin or clothing, flush or soggy ground.
immediately with large quantities of water.
! Do not touch electrically energised parts of
1.1.6 Noise the generating set and/or interconnecting
cables or conductors with any part of the body
Generating sets that are not equipped with or with any non insulated conductive object.
sound attenuating enclosures can produce
! Replace the generating set terminal box cover
noise levels in excess of 105 dBA. as soon as connection or disconnection of the
Prolonged exposure to noise levels above 85 load cables is complete. Do not operate the
dBA is hazardous to hearing. generating set without the cover securely in
place.

! Connect the generating set only to loads and/

WARNING or electrical systems that are compatible with
its electrical characteristics and that are within
! Ear protection must be worn when operating its rated capacity.
or working around an operating generating
set. ! Be sure all electrical power is disconnected
from electrical equipment being serviced.
1.1.7 Electrical ! Keep all electrical equipment clean and dry.
Replace any wiring where the insulation is
Safe and efficient operation of electrical cracked, cut, abraded or otherwise degraded.
equipment can be achieved only if the Replace terminals that are worn, discoloured
equipment is correctly installed, operated and or corroded. Keep terminals clean and tight.
maintained.
! Insulate all connections and disconnected
wires. Use only Class BC or Class ABC
extinguishers on electrical fires.

YML Generator Operation Manual

 GENERAL INFORMATION 1
1.1.8 First Aid For Electric Shock 4. If the victim must be left to get help, give 1 0
breaths first and then return quickly and
continue.
WARNING 5. Check for pulse after every 10 breaths.
! DO NOT TOUCH THE VICTIM'S SKIN WITH
BARE HANDS UNTIL THE SOURCE OF IF NO BREATHING AND NO PULSE:
ELECTRICITY HAS BEEN TURNED OFF.
1. Call or telephone for
 Switch off power, if possible. medical help.

 Otherwise pull the plug or pull the cable away

2. Give two breaths and start
from the victim.
chest compression as
follows:
 If this is not possible, stand on dry insulating
material and pull the victim clear of the
conductor, preferably using insulated material 3. Place heel of hand 2
such as dry wood. fingers breadth above
ribcage / breastbone
 If victim is breathing, turn the victim into the junction.
recovery position described below.
4. Place other hand on top
 If victim is unconscious, perform resuscitation and interlock fingers.
as required:
5. Keeping arms straight,
OPEN THE AIRWAY: press down 4-5 cm (1.5-2
1. Tilt the victim's head back and inch) 15 times at a rate of
lift the chin upwards. 80 per minute.
2. Remove objects from the
mouth or throat (including false
6. Repeat cycle (2 breaths, 15 compressions)
teeth, tobacco, or chewing until medical help takes over.
gum).
7. If condition improves, confirm pulse and
BREATHING: continue with breaths. Check for pulse
1. Check that the victim is breathing by looking, after every 10 breaths.
listening and feeling for the breath.
8. When breathing restarts, place the victim
CIRCULATION: into the recovery position described
below.
Check for pulse in the victim's
neck. RECOVERY POSITION:
1 . Turn the victim onto the
side.
IF NO BREATHING BUT PULSE IS
PRESENT: 2. Keep the head tilted with the
1. Pinch the victim's nose firmly. jaw forward to maintain the
open airway.
2. Take a deep breath and seal
your lip victim's lips. 3. Make sure the victim cannot roll forwards or
backwards.
3. Blow slowly into the mouth 4. Check for breathing and pulse regularly.
watching for the chest to rise. If either stops, proceed as above.
Let the chest fall completely.
Give breaths at a rate of 1 0 WARNING
per minute.
DO NOT GIVE LIQUIDS UNTIL VICTIM IS
CONSCIOUS.

YML Generator Operation Manual

 GENERAL INFORMATION 1

1.2 Safety Symbols

This section identifies the ISO8999 symbols currently used by YML.

ELECTRIC SHOCK HAZARD

USE FAN GUARDS

HOT EXHAUST GAS LOW OVERHEAD OBJECTS

DO NOT TAMPER WITH UNLESS

YOU HAVE READ THE
INSTRUCTION MANUAL

DIESEL FUEL RATED SPEED

SUPPLY LINE

NO NAKED FLAMES WEAR EAR EMERGENCY/

PROTECTION PANIC EXIT

ELECTRIC
TERMINALS
DIESEL FUEL
HOT SURFACES

PROTECTIVE EARTH ENGINE COOLANT

ENGINE COOLANT
(GROUND)
PRESSURE

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 GENERAL INFORMATION 1

1.3 Generator Identification

The serial numbers and models for the alternator
A generator serial number is given on the are provided on a plate affixed to the main body of
generator rating plate attached to the machine. the alternator.
These will be required when ordering parts.
This serial number is necessary to identify the
generator for maintenance and spare parts
reference.
1.6 Engine Oil

1.3.1 Serial Number Details The engine is shipped filled with oil to the
correct grade and this should be changed in
The serial number is required to obtain spare accordance with our recommendations
parts from YML. detailed later in this manual.
Please refer to the Engine User’s Handbook
1.3.2 Rating Details for engine oil capacity.

The rating on the rating plate has been carefully

calculated for each machine to give maximum life
and use.
CAUTION
These rating calculations have been done at
27°C, 60% relative humidity and 150 Metres Do not overfill with lubricating oil as this may have
above sea level. Should your unit be operating in a detrimental effect on engine performance and
conditions above these, please consult our office can harm the engine.
for rating information.

1.4 Engine Details

1.7 Engine Coolant
With the generator manual pack you will have
received an engine operator handbook and this
should be consulted for any matter in regard to CAUTION
the engine.
Detailed workshop manuals and parts catalogues Most units are shipped without coolant water.
are available at extra cost for all engines and can Ensure that the engine is filled with the correct
be obtained through YML. coolant concentrate (antifreeze) / water solution
prior to operation
1.4.1 Engine Serial Number
The engine serial number is either on a plate
affixed to the engine block or is directly stamped CAUTION
into the block.
The engine operators handbook gives the location Use a coolant concentrate with an ethanediol
of where the serial number is fitted to the engine. base (ethylene glycol) with a corrosion inhibitor. It
is recommended that the corrosion inhibitor is of
1.5 Alternator Details the sodium benzoate or sodium nitrate type

Three different makes of alternator are generally

fitted to our machines, these are:- WARNING
Leroy Somer
Newage Stamford
Coolant concentrate must not be allowed to come
Mecc Alte
into contact with the skin; adhere to the
manufacturers instructions and precautions
Each of these brands have been chosen for their
legendary performance in the world market.
On YML gensets a coolant concentration of 25 to
Alternator handbooks are provided with every
machine giving control, part details and simple 50% may be added dependant on ambient and
fault finding. frost protection required. Typically we would
recommend a 33% antifreeze mix to give
approximate protection to –10°C*

*Check protection with the supplier of the concentrate.

1.5.1 Alternator Serial Numbers
YML Generator Operation Manual
 GENERAL INFORMATION 1

Lister powered units should always be filled with a

40% mixture under all conditions.

1.8 Fuel Specification

The engine must only be used with diesel fuel

oil which conforms to one of the following :-

a. BS 2869:1988 Class A2
b. BA EN590:1995 Class A1
c. USA Specification ASTM D-975-77 Grades
No.1-D and 2-D
d. BSMA 100 Class M1 for marine use

The fuel must be distillate, and not residual oil

or blend.
Vaporising oils are not suitable as fuels for
generating sets.

CAUTION
Always use fuel free from water and contaminants
in the utmost importance. Fuel injection systems
are manufactured to accurate limits and the
smallest particle of dust or dirt will destroy its
efficiency.

YML Generator Operation Manual

 GENERAL INFORMATION 1

2. Installation, Handling, Towing And Storage

Contents

2.1 General

2.2 Enclosures

2.3 Moving the Generating Set

2.4 Location

2.5 Foundations and Vibration

2.6 Combustion Air Inlet

2.7 Cooling and Ventilation

2.8 Exhaust

2.9 Fuel System

2.10 Fire Precaution

2.11 Starting Batteries

2.12 Electrical Connection

2.13 Acoustic Silencing

2.14 Towing (Portable Generating Sets)

2.15 Storage

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 INSTALLATION, HANDLING, TOWING AND STORAGE 2

2.1 General
 Ensuring that fumes from the exhaust outlet
This section discusses factors important in the will not be a hazard especially when wind is
effective and safe installation of the generating taken into account.
set. Further information is available in the
Generating Set Installation Manual which is  Electrical grounding of the generating set at
available upon request. all times.

2.2 Enclosures  Providing access to refill the fuel tank when

required.
Installation and handling is greatly simplified
when the generating set has been equipped with  Protecting electrical cables installed between
an enclosure. Two basic types may be fitted. The the generating set and the load. If these are
first type is a close fitting canopy enclosure. This laid on the ground ensure they are boxed in or
may be a weatherproof version or designed for covered to prevent damage or injury to
sound attenuation. The other enclosure type is a personnel.
walk-in type container, similar to a shipping
container. It may also be weatherproof or sound If the enclosed generating set is installed
attenuated. These enclosures provide a self inside a building, adequate fresh cooling air must
contained generating set system that is easily be provided and the engine exhaust and hot
transportable and requires minimal installation. coolant air exhaust must be ducted outside the
They also automatically give protection from the building. The ducting and exhaust pipework must
elements and protection from unauthorised be designed to minimise back pressure which
access. would have a detrimental effect on generating set
performance.

2.3 Moving the Generating Set

CAUTION
The generating set baseframe is specifically
! Make sure all personnel are out of the designed for ease of moving the set. Improper
canopy or container, if equipped, before handling can seriously damage components.
closing and latching enclosure doors.
Using a forklift, the generating set can be lifted
or carefully pushed/pulled by the baseframe. If
! Before closing canopy or enclosure pushing, do not push the baseframe directly with
doors, ensure all obstructions (especially fork. Always use wood between forks and the
hands and fingers) are clear to prevent baseframe to spread the load and prevent
damage or injury. damage. If the set will be regularly moved, it
should be fitted with the optional 'Oil Field Skid"
Because the canopied generating sets are which provides fork lift pockets in the baseframe
along with eyes for pulling. The smaller sets have
easily transportable and may be installed and
fork lift pockets in the baseframe as standard.
operated in a temporary location, many of the
fixed installation details given in this chapter may
not apply. The following considerations must be
still given when temporarily installing the
generating set: WARNING
 Locating the generating set where it will be
! NEVER LIFT THE GENERATING SET
protected from damage and away from
exhaust fumes from other engines or other BY ATTACHING TO THE ENGINE OR
airborne contaminants such as dust, lint, ALTERNATOR LIFTING LUGS.
smoke, oil mist or vapours.
! ENSURE THE LIFTING RIGGING AND
 Locating the generating set on firm, level
SUPPORTING STRUCTURE IS IN
ground that will support the weight of the
generating set and avoid movement due to
GOOD CONDITION AND IS SUITABLY
the vibration of the operating set. RATED.

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 INSTALLATION, HANDLING, TOWING AND STORAGE 2

! KEEP ALL PERSONNEL AWAY FROM 2.4 Location

THE GENERATING SET WHEN IT IS
SUSPENDED. Selecting a location for the generating set can
be the most important part of any installation
procedure. The following factors are important in
For ease of lifting, canopied sets have a single determining the location:
point lifting facility as standard.
 Adequate ventilation.
For a single lift such as lifting the set to install it,
the lift points provided on the baseframe may be  Protection from the elements such as rain,
used. Points of attachment should be checked for snow, sleet, wind driven precipitation, flood
cracked welds or loose nuts and bolts before water, direct sunlight, freezing temperatures,
lifting. A spreader bar is required to prevent or excessive heat.
damaging the set (see Figure 2). It should be
positioned over the centre of gravity (nearer the  Protection from exposure to airborne
engine), not the centre of the set, to allow a contaminants such as abrasive or conductive
vertical lift. Guide ropes should be used to dust, lint, smoke, oil mist, vapours, engine
prevent twisting or swinging of the set once it has exhaust fumes or other contaminants.
been lifted clear of the ground - do not attempt to
lift in high winds. Place the generating set down  Protection from impact from falling objects
on a level surface capable of supporting its such as trees or poles, or from motor vehicles
weight. This manner of lifting should only be used or lift trucks.
for a single lift for installation.
 Clearance around the generating set for
Generating sets to be air lifted by helicopter cooling and access for service: at least 1
should be lifted by sling. metre (3.3 feet) around the set and at least 2
metres (6.6 feet) headroom above the set.

 Access to move the entire generating set into

the room. Air inlet and outlet vents can often
be made removable to provide an access
point.

 Limited access to unauthorised personnel.

If it is necessary to locate the generating set

outside of the building, the generating set should
be enclosed in a weatherproof canopy or
container-type housing which is available for all
sets. These enclosures are also useful for
temporary installations inside or outside the
ITEM building. DESCRIPTION
1. SPEADER BAR

Figure 2. Proper lifting arrangement for

installing the generating set

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 INSTALLATION, HANDLING, TOWING AND STORAGE 2

Item Description
1. Vibration Isolators
2. Flexible Exhaust Coupling
3. Flexible Air Discharge Duct

Figure 3. Typical Installation Highlighting Vibration Reduction Techniques

2.5 Foundations and Vibration Isolation 2.5.3 Vibration Isolation

The generating set is shipped assembled on a o minimise engine vibrations being transmitted
rigid baseframe that precisely aligns the alternator to the building, the generating set is fitted with
and engine and needs only be bolted down to a vibration isolators. On small and medium sized
suitably prepared surface (see Figure 2). sets these isolators are fitted between the
engine/alternator feet and the baseframe. This
2.5.1 Foundation allows the frame to be rigidly bolted to the
2.5.2 foundation. On larger sets the coupled
A reinforced concrete pad makes the best engine/alternator is rigidly attached to the
foundation for the generating set. It provides a baseframe and the vibration isolators are supplied
rigid support to prevent deflection and vibration. loose for fitting between the baseframe and the
Typically the foundation should be 150 mm to 200 foundation. In all cases the sets should be
mm (6 to 8 inches) deep and at least as wide and securely bolted to the ground (either through the
long as the generating set. The ground or floor baseframe or through the vibration isolators) to
below the foundation should be properly prepared prevent movement.
and should be structurally suited to carry the
weight of the foundation pad and the generating Vibration isolation is also required between the
set. (if the generating set is to be installed above generating set and its external connections. This
the ground floor the building structure must be is achieved by use of flexible connections in the
able to support the weight of the generating set, fuel lines, exhaust system, radiator air discharge
fuel storage and accessories.) Relevant building duct, electrical conduit for control and power
codes should be consulted and complied with. If cables and other externally connected support
the floor may be wet from time to time, such as in systems (see Figure 4.2).
a boiler room, the pad should be raised above the
floor. This will provide a dry footing for the On mobile sets the generating set should be
generating set and for those who connect, service mounted using 'captivation mounts". These
or operate it. It will also minimise corrosive action mounts minimise vibration and include a
on the baseframe.

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 INSTALLATION, HANDLING, TOWING AND STORAGE 2

captivation feature that prevents the set breaking

away in case of road accident.

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 INSTALLATION, HANDLING, TOWING AND STORAGE 2

2.6 Combustion Air Inlet the hot air outside the room, the fan will tend to
draw that hot air around and back through the
Air for engine combustion must be clean and as radiator, reducing the cooling effectiveness.
cool as possible. Normally this air can be drawn
from the area surrounding the generating set via The air inlet and exit openings should be large
the engine mounted air filter. enough to ensure free flow of air into and out of
the room. As a rough guide the openings should
However, in some cases due to dust, dirt, or heat, each be at least 1.5 times the area of the radiator
the air around the set is unsuitable. In these core.
cases an inlet duct should be fitted. This duct
should run from the source of clean air (outside Both the inlet and exit openings should have
the building, another room, etc.) to the engine louvres for weather protection. These may be
mounted air filter. Do not remove the air filter and fixed but preferably should be movable in cold
mount it at a remote location as this can increase climates so that while the generating set is not
the possibility of dirt leaking through the ductwork operating the louvres can be closed. This will
and into the engine inlet. To ensure that this type allow the room to be kept warm which will assist
of installation will not have a detrimental effect on starting and load acceptance. For automatic
the operation of the generating set, the design of starting generating sets, if the louvres are
the inlet duct should be approved by the factory. movable they must be automatically operated.
They should be programmed to open immediately
2.7 Cooling and Ventilation upon starting the engine. The force of radiator air
should not be depended upon to open the louvre
The engine, alternator, and exhaust piping radiate vanes unless the system has been specifically
heat which can result in a temperature high designed for this.
enough to adversely effect the performance of the
generating set. It is therefore important that When a remote radiator or heat exchanger cooling
adequate ventilation is provided to keep the system is used, the radiated heat from the
engine and alternator cool. Proper air flow, as generating set must still be removed from the
shown in Figure 4, requires that the air comes in room.
at the alternator end of the set, passes over the
engine, through the radiator and out of the room
via a flexible exhaust duct. Without the ducting of

Item Description
1. Air Inlet Opening
2. Air Exit Opening

Figure 4. Air Ventilation

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 INSTALLATION, HANDLING, TOWING AND STORAGE 2

Item Description
1. Exhaust Silencer
2. Wall Sleeve and Expansion Joint
3. Rain Cap
4. Silencer / Pipework Supports

Figure 5. Typical Exhaust System Installation

2.8 Exhaust
WARNING
The purpose of the engine exhaust system is to
direct the exhaust outside to a location and height
where the fumes and odours will not become an ! Engine exhaust emissions are hazardous to
annoyance or hazard, and to reduce noise. A personnel.
suitable exhaust silencer must be incorporated
into the exhaust piping to reduce the noise level ! The engine exhaust for all indoor generating
from the engine. It can be fitted either inside or sets must be piped outdoors via leak-free
outside the building (see Figure 5). Canopied piping in compliance with relevant Codes,
generating sets include exhaust system within the Standards and other requirements.
enclosure.
! Ensure hot exhaust silencers, piping and
Open generating sets will generally be supplied turbochargers, if fitted, are clear of
with a loose industrial class silencer, a stub pipe combustible material and are guarded for
and a bellows (if required). An optional personnel protection per safety requirements.
"Overhead Mounting Kit" includes a bend, silencer
support brackets and a bellows (if not standard). ! Ensure that fumes from the exhaust outlet will
An optional "Silencer Installation Kit" includes the not be a hazard.
wall sleeve, bend and rain cap for directing the
exhaust outside (see Figure 5). In all cases, the In designing an exhaust system, the primary
straight sections of pipe and screw rods for the consideration is to not exceed the allowable back
support brackets are supplied by the customer. pressure permitted by the engine manufacturer.
Excessive back pressure seriously affects engine
output, durability and fuel consumption. To limit
the back pressure the exhaust piping should be as
short and straight as possible. Any required
bends should have a curve radius of at least 1.5
times the inside diameter of the pipe. Any
designed exhaust extensions over 3 metres
should be approved by the factory.

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 INSTALLATION, HANDLING, TOWING AND STORAGE 2

Other exhaust design criteria are as follows: 2.9 Fuel System

 Exhaust components including turbochargers The fuel system for the generating set must be
can be very hot and must be guarded where capable of delivering a clean and continuous
they could be accidentally touched. supply of fuel to the engine. For most
installations, this will include a small day tank
 A flexible connection between the exhaust (usually incorporated in the baseframe), a bulk
manifold and the piping system should be storage tank and the associated pumps and
used to prevent transmission of engine plumbing.
vibration to the piping and the building and to
allow for thermal expansion and any slight
misalignment of the piping. (See Figure 3)
CAUTION
 Ensure that the silencer and all pipes are well
supported to limit strain on the connectors For stationary generating sets with remote fuel
which could result in cracks or leaks. storage systems, make sure such systems are
installed In compliance with relevant Codes,
 Exhaust system components located within Standards or other requirements.
the generator room should be insulated to
reduce heat radiation and noise levels. Pipes
and the silencer, whether located inside or
outside the building, should be located well WARNING
clear of any combustible material.
DO NOT SMOKE OR ALLOW SPARKS, FLAMES
 Any long horizontal or vertical piping should OR OTHER SOURCES OF IGNITION AROUND
slope away from the engine and include drain FUEL. FUEL VAPOURS AND OIL VAPOURS
traps at their lowest points to prevent water ARE EXPLOSIVE.
from reaching the engine or silencer.

 On generating sets above 150 kVA the

2.9.1 Day Tank
silencer installation must include a purge plug
for venting of the exhaust system in the event Day tanks provide a readily available supply of
of difficult starting. The plug should be fuel directly to the generating set and should
located adjacent to the exhaust flange and therefore be located within the generator room.
positioned to allow access. The steel baseframe of all but the largest sets are
designed with a steel or polyethylene day tank
 Where the pipe goes through a wall there built in with the engine fuel lines connected.
should be a sleeve in the opening to absorb These "basetanks' provide for at least 8 hours
vibration and isolate combustible material operation at full load or approximately 24 hours if
from the hot pipes (See Figure 5). There an extended capacity basetank has been fitted.
may also be an expansion joint in the pipe to
compensate for lengthwise thermal expansion
or contraction.
CAUTION
 The outer end of the exhaust pipe, if
horizontal, should be cut at 60' to the
Never connect a remote fuel system to
horizontal or should be fitted with a rain hood
polyethylene fuel tanks incorporated In the
or cap, if vertical, to prevent rain or snow from
baseframe on smaller generating sets.
entering the exhaust system.
For Lister units only use FUEL SYSTEM 3
 The exhaust pipe must not be connected to
exhausts from other generating sets or other
equipment, such as a furnace or boiler. 2.9.2 Bulk Storage Tanks

For extended operation, a separate bulk fuel

storage tank is required. Especially for standby
generating sets it is not advisable to depend on
regular delivery of fuel. The emergency that
requires use of the standby set may also interrupt
the delivery of fuel.

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 INSTALLATION, HANDLING, TOWING AND STORAGE 2

The bulk tank should generally be located

outside the building where it will be convenient for Fuel System 1 – Perkins Only
refilling, cleaning and for inspection. It should not,
however, be exposed to freezing weather
For installations where the bulk tank is located
because fuel flow will be restricted as viscosity
below floor level a pumped fuel supply from the
increases with cold temperatures. The tank may
bulk tank to the basetank is required (see Figure
be located either above or below ground.
6).
A vent must be installed on the bulk tank to relieve
The basetank must include an overflow, extended
the air pressure created by filling the tank or
vent, sealed gauges and no manual fill. All other
created by evaporation and expansion. It will also
connections on top of the tank must be sealed to
prevent a vacuum as the fuel is consumed. The
prevent leakage.
tank bottom should be rounded and placed on a
21 tilt to assure a concentrated settling of water
The position of the fuel tank should take into
and sediment. A sludge drain valve should be
account that the maximum suction lift of the fuel
installed at the low point to allow removal of water
transfer pump is 3 metres and that the maximum
and sediment on a regular basis. Underground
restriction caused by the friction losses in the
tanks should have this water and sediment
return fuel line should not exceed 2 psi. A 1.4m
pumped out regularly.
extended vent pipe will be required on the
basetank to prevent overflow.
2.9.3 Fuel Lines

The fuel lines can be of any fuel compatible

material such as steel pipe or flexible hoses that
will tolerate environmental conditions.

CAUTION
Do not use galvanised pipe or fittings for the fuel
Item Description Item Description
system.
1. Below Floor Level Bulk Tank 6. Supply Line
2. Control Panel 7. Return Line
Fuel delivery and return lines should be at 3. AC Fuel Pump 8. Strainer
least as large as the fitting sizes on the engine, 4. Fuel Level Switches 9. Level Guage
5. Extended Vent
and overflow piping should be one size larger.
For longer runs of piping or low ambient Figure 6. Typical Layout With
temperatures the size of these lines should be Fuel System 1
increased to ensure adequate flow. Flexible
piping should be used to connect to the engine to The YML kit for Fuel System 1 includes an AC
avoid damage or leaks caused by engine fuel pump with mounting bracket, fuel strainer, 4
vibration. position float switch and controls for the fuel pump
mounted in the generating set control panel. In
The fuel delivery line should pick up fuel from a addition, with this kit the basetank is modified by
point no lower than 50 mm (2') from the bottom at the removal of the manual fill facility. All other
the high end of the tank (away from the drain items including fuel lines, bulk tank, extended
plug). vent, etc. are supplied by the installer.

2.9.4 Remote Fuel Systems

Most sets are supplied equipped with a diesel fuel

tank in the baseframe. Certain installations,
however, require the addition of remote fuel
supplies. YML recommends the 5 types of
systems detailed below. It must be noted that
polyethylene fuel tanks are not compatible with
remote fuel systems, so a metal fuel tank must be
fitted.

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 INSTALLATION, HANDLING, TOWING AND STORAGE 2

Fuel System 2 – Perkins Only Fuel System 3 – Lister and Perkins

Where the location of the bulk tank is higher It is possible to have the engine supplied
than the generating set, a gravity fuel supply from directly from a high level bulk tank, bypassing the
the bulk tank to the basetank is required (see basetank incorporated in the baseframe (see
Figure 7). Figure 8).

The basetank must include an overflow, Distance 'A' in Figure 7 is limited to:
extended vent, sealed gauges and no manual fill.
All other connections on top of the tank must be Model Height
sealed to prevent leakage. YP22 - YP275 3300mm
YP300 – YP880 6000mm
Distance 'A' in Figure 4.6 is limited to 1400mm YP850 - YP2200 2500mm
for all metal basetanks except for models YP550 -
YP880 where this distance can be increased to Note
3700mm. These are maximum heights. These heights may
need to be reduced depending on further
The YML kit for Fuel System 2 includes a DC restriction caused by pipeline sizes, length and
motorised valve with mounting bracket, fuel obstruction in the return line.
strainer, 4 position float switch and controls for the
motorised valve mounted in the generating set
control panel. In addition, with this kit the
basetank is modified by the removal of the manual
fill facility. All other items including fuel lines, bulk
tank, etc. are supplied by the installer.

Item Description
1. High Level Bulk Tank
2. Supply Line
3. Return Line
4. Isolating Valve

Figure 8. Typical Layout With

Fuel System 3

Item Description Item Description

1. High Level Bulk Tank 6. Supply Line
2. Control Panel 7. Strainer
3. DC Motorised Valve 8. Isolating Valve
4. Fuel Level Switches 9. Level Guage
5. Return Line (Continuous Rise)

Figure 7. Typical Layout With

Fuel System 2

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 INSTALLATION, HANDLING, TOWING AND STORAGE 2

Fuel System 4 – Perkins Only Fuel System 5 – Perkins Only

Some installations may require a system where In some installations it is necessary to use a
fuel is pumped from a free standing bulk tank (see separate day tank supplied via a pumped system
Figure 9). This pumped system would only be from a bulk tank (see Figure 10).
used if gravity feed is not possible from the bulk
tank to the basetank. The day tank should be designed to take into
account the head 'A' of the bulk tank and the
The basetank must include an overflow, extended friction losses in the overflow line. Normally the
vent, sealed gauges and no manual fill. All other tank design head is approximately 3 metres
connections on top of the tank must be sealed to although this will vary with each layout. The day
prevent leakage. tank should be designed generally in accordance
with BS799 Part 5 to take account of the design
Distance 'A' on Figure 9 is limited to 1400mm for head. The day tank should be positioned, relative
all metal basetanks except models YP550 - to the engine, as per the following maximum
YP880 where this distance is extended to limits. Distance 'A' in Figure 10 is limited to:
3700mm. Note that the maximum restriction
caused by friction losses and height of the return Model Height
line should not exceed 2 psi.
YP22 - YP275 3300mm
The YML kit for installing this system includes an YP300 - YP880 6000mm
AC fuel pump with mounting bracket, a DC YP850 - YP2200 2500mm
motorised valve with mounting bracket, fuel
strainer, 4 position float switch and controls for the In the event that the bulk tank overfills the day
fuel pump and motorised valve mounted in the tank, engines with unit injector systems may
generating set control panel. In addition, with this experience leakage into the cylinders. It is
kit the basetank is modified by the removal of the essential that before restarting the engine this fuel
manual fill facility. All other items including fuel is removed from the cylinders.
lines, bulk tank, etc. are supplied by the installer.

Item Description Item Description

1. Bulk Tank 8. Supply Line to Engine
2. Day Tank 9. Return Line from Engine
3. Fuel System Control 10. Overflow / Vent Rising
Panel Continuously
4. AC Fuel Pump 11. Isolating Valve
5. DC Motorised Valve 12. Strainer
Item Description Item Description 6. Fuel Level Switch 13. Isolating Valve
1. Above Ground Bulk Tank 6. Supply Line 7. Supply Line to Day Tank
2. Control Panel 7. Return Line
3. AC Fuel Pump (Continuous Rise)
4. Motorised Valve 8. Strainer Figure 10. Typical Layout With
5. Fuel Level Switch 9. Isolating Valve Fuel System 5
10. Level Gauge
The exact specification for the YML kit for this
Figure 9. Typical Layout With type of complex fuel system will vary depending
Fuel System 4 on the installation. When designed, the kit will
include pumps, valves controls etc. and the
installer will supply the fuel line, bulk tanks, vents
etc.

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 INSTALLATION, HANDLING, TOWING AND STORAGE 2

2.10 Fire Precautions 2.12.1 Cabling

When designing the generating set installation the Due to movement of generating sets on their
following points should be considered: vibration mounts, the electrical connection to the
set should be made with flexible cable. This will
 The room should be designed so that there is prevent transmission of vibrations and possible
an easy escape route for operating personnel damage to the alternator or circuit breaker
in the event of fire within the room. terminals. If flexible cabling can not be used
throughout the installation then a link box should
 Supply a Class BC or Class ABC fire be installed close to the set with a flexible
extinguisher and/or fire extinguishing system. connection to the set.

 Gravity operated fire valves released by The cable should be protected by laying it in a
temperature operated fusible links mounted duct or cable tray. However, the duct or tray
above the engine can be installed in the fuel should never be rigidly connected to the
lines. generating set. When bending cable, reference
must be made to the recommended minimum
2.11 Starting Batteries bending radius.

The cable must be suitable for the output voltage

of the generating set and the rated current of the
set. In determining the size, allowances should
WARNING be made for ambient temperature, method of
installation, proximity of other cables, etc. When
DO NOT SMOKE OR ALLOW SPARKS, FLAMES single core cables are used the gland plates must
OR OTHER SOURCES OF IGNITION AROUND be of non-ferrous material such as aluminium,
BATTERIES. HYDROGEN GAS GENERATED brass or a non-metallic material such as tufnol.
BY CHARGING BATTERIES IS EXPLOSIVE. Alternatively slots can be cut between gland holes
of cables to prevent circulating (eddy) currents in
The starting batteries should be located as close magnetic gland plates.
as possible to the generating set while still being
accessible for servicing. This will prevent All connections should be carefully checked for
electrical losses from long cables that could integrity. Phase rotation must be checked for
impact on the engine starting capability of the compatibility with the installation. This is vitally
batteries. See Section 5. important when connection is made to an
automatic transfer switch, or if the machine is to
2.12 Electrical Connection be paralleled.

Onsite electrical installation will generally consist 2.12.2 Protection

only of connecting up the site load to the
generating set output terminals. Only fully The cables connecting the generating set with the
qualified and experienced electrical technicians distribution system are protected by means of a
should carry out electrical installation, service and circuit breaker to automatically disconnect the set
repair work. in case of overload or short circuit.

2.12.3 Loading

When planning the electrical distribution system it

WARNING is important to ensure that a balanced load is
presented to the generating set. If loading on one
Make electrical connections in compliance with phase is substantially higher than the other
relevant Electrical Codes, Standards or other phases it will cause overheating in the alternator
requirements. This includes requirements about windings, imbalance in the phase to phase output
grounding and ground / earth faults. voltage and possible damage to sensitive 3 phase
equipment connected to the system. Ensure that
no individual phase current exceeds the current
rating of the generating set. For connection to an
existing distribution system, it may be necessary
to reorganise the distribution system to ensure
these loading factors are met.

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2.12.4 Power Factor

A 50OV Megger or similar instrument should be
The power factor (cos () of the connected load used. Disconnect any earthing conductor
should be determined. Power factors below 0.8 connected between neutral and earth and megger
lagging (inductive) can overload the generator. an output terminal to earth. The insulation
The set will provide its kilowatt rating and operate resistance should be in excess of 5M to earth.
satisfactorily from 0.8 lagging to unity power factor Should the insulation resistance be less than 5M
(1.0). the winding must be dried out. See the Alternator
Manual for procedures.
Particular attention must be given to installations
with automatic or manual power factor correction 2.13 Acoustic Silencing
equipment such as capacitors to ensure that a
leading power factor is never present. This will Control of generating set noise is becoming very
lead to voltage instability and may result in important in most installations. There is a range
damaging overvoltages. Generally, whenever the of options available to control the noise level.
generating set is supplying the load any power
factor correction equipment should be switched
off.

2.12.5 Grounding Requirements WARNING

Regulations vary for different locations. The Ear protection must be worn when operating or
frame of the generating set must be positively working around an operating generating set.
connected to an earth ground. Since the set is
mounted on vibration isolators, the ground 2.13.1 Exhaust Silencers
connection must be flexible to avoid possible
breakage due to vibration. On the majority of self As discussed in Section 2.8 the exhaust silencer
contained sets the ground connection is located will decrease sound levels from the engine.
inside the circuit breaker box. Varying degrees of sound attenuation are
available from different types of silencers. These
Ground connection cables or straps should have levels are often described by terms such as
at least full load current carrying capacity and industrial, residential, critical or supercritical.
meet applicable regulations.
2.13.2 Enclosures
2.12.6 Alternator Reconnection
Section 2.2 discusses enclosures that are
Most alternators can be reconnected to suit available in either weatherproof or sound
different output voitages. The reconnection attenuating versions. These enclosures can be
procedures are given in the Alternator Manual. designed to meet a specific sound level
Ensure that all other components such as circuit requirement.
breakers, current transformers, cables and
ammeters are suitable before operating at a
2.13.3 Other Sound Attenuation
different voltage.
For installations in buildings there are other types
2.12.7 Parallel Running of equipment such as acoustic louvers, splitter
vents and fan silencers, as well as sound
Extra equipment must be fitted for the standard absorbing wall coverings, that can be used to
generating sets to be operated in parallel with reduce the noise levels of generating sets.
other generating sets or with mains power.

2.12.8 Insulation Test

Before starting the generating set after

installation, test the insulation resistance of the
windings. The Automatic Voltage Regulator
(AVR) should be disconnected and the rotating
diodes either shorted out with temporary links or
disconnected. Any control wiring must also be
disconnected.

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2.14 Towing (Portable Generating Sets) 2.14.2 Towing

2.14.1 Preparing to Tow Whenever towing a mobile generating set,

remember that the set may approach or exceed
Inspect all components of the coupling equipment the weight of the towing vehicle so
on the towing vehicle and the generating set for manoeuvrability and stopping distance will be
defects such as excessive wear, corrosion, affected.
cracks, bent metal, or loose bolts. Ensure that the
towing vehicle is rated for towing a load of at least
the weight of the mobile generating set plus a
10% safety factor.
WARNING

Couple the towing vehicle to the trailer and ensure ! When towing a mobile generating set,
the coupling device is engaged, closed and observe all Codes, Standards or other
locked. Attach electrical connector for indicator regulations and traffic laws. These include
lights, etc. Attach chains, if provided, by crossing those regulations specifying required
them under the drawbar and attaching to the equipment and maximum and minimum
towing vehicle. Attach any "break away" safety speeds.
wire, if fitted.
! Ensure brakes, if fitted, are in good order.
Fully retract the front screw jack, if equipped, and
secure with the pin or locking device. Lock the ! Do not permit personnel to ride in or on the
front castor wheel, if equipped, in the full up mobile generating set. Do not permit
position. Ensure that the rear stabiliser jacks, if personnel to stand or ride on the drawbar or
equipped, are raised and locked. to stand or walk between the generating set
and the towing vehicle.
Inspect tyres for condition and proper inflation.
Check all tail lights, if equipped, are operating
properly and that all reflectors are clean and Avoid gradients in excess of 15' (27%) and avoid
functional. potholes, rocks or other obstructions and soft or
unstable terrain.
Ensure load and grounding/earthing cables are
disconnected and that all windows, access doors, Ensure the area behind and under the mobile set
and tool box covers are closed, latched and is clear before reversing.
locked. Ensure any external fuel pipes are
disconnected. 2.14.3 Parking

Release trailer parking brakes, if equipped, and Park the set on a dry level area that can support
remove any blocks or chocks under the wheels. it's weight. If it must be located on a slope, park it
across the grade so that it does not tend to roll
downhill. Do not park the set on grades
exceeding 15' (27%).

Set the parking brake and block or chock both

sides of all wheels. Lower front screw jack, castor
wheel and/or rear stabiliser jacks, as fitted.

Unhook chains, it equipped, from the towing

vehicle, disconnect electrical connection,
disconnect the coupling device and move the
towing vehicle clear of the mobile generating set.

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 INSTALLATION, HANDLING, TOWING AND STORAGE 2

4.15 Storage

Long term storage can have detrimental effects on

both the engine and alternator. These effects can
be minimised by properly preparing and storing
the generating set.

2.15.1 Engine Storage

The engine should be put through an engine

"preservation' procedure that includes cleaning
the engine and replacing all the fluids with new or
preserving fluids. See the Engine Manual for the
proper procedure.

2.15.2 Alternator Storage

When an alternator is in storage, moisture tends

to condense in the windings. To minimise
condensation, store the generating set in a dry
storage area. If possible use space heaters to
keep the windings dry.

After removing the generating set from storage,

perform an insulation check as discussed in
Section 2.12.8. If the readings are lower than prior
to storage, it may be necessary to dry out the
windings. See the Alternator Manual for
procedures.

If the megger reading is below 1 M after

drying, the insulation has deteriorated and should
be reconditioned.

2.15.3 Battery Storage

While the battery is stored, it should receive a

refreshing charge every 12 weeks (8 weeks in a
tropical climate) up to a fully charged condition.

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 INSTALLATION, HANDLING, TOWING AND STORAGE 2

3. Generating Set Maintenance

Contents

3.1 General

3.2 Preventative Maintenance

3.3 Removal of the Engine / Alternator

3.4 Engine Maintenance

3.5 Radiator Maintenance

3.6 Alternator Maintenance

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 GENERATING SET MAINTENANCE 3

3.1 General 3.2.3 Every Month

A good maintenance programme is the key to (For standby sets that have not been run on load.)
long generating set life. Maintenance and service Perform an operational and load check on the
should only be carried out by qualified generating set by starting and running the set on
technicians. Records of this work should be kept at least 50% load for 1 to 2 hours.
to aid in developing an efficient maintenance
programme. 3.2.4 Every Six Months or 250 Hours
Repeat the daily procedures plus the
In general, the generating set should be kept
following:
clean. Do not permit liquids such as fuel or oil film
to accumulate on any internal or external surfaces
1. Check all control system safety devices by
or on, under or around any acoustic material, if
electrically simulating faults.
fitted. Wipe down surfaces using an aqueous
industrial cleaner. Do not use flammable solvents
2. Clean all battery cap vents.
for cleaning purposes.
3. Tighten all exhaust connections.
Any acoustic material with a protective covering
that has been torn or punctured should be
4. Tighten all electrical connections.
replaced immediately to prevent accumulation of
liquids or oil film within the material.
5. Perform other engine maintenance as specified
in the Engine Manual.
3.2 Preventative Maintenance
6. Start the engine and observe the instrument
Depending on the application of the generating panel to ensure that all gauges and meters are
set, requirement for preventative maintenance will operating properly.
vary. The preventative maintenance requirements
associated with the engine are detailed in the 7. If a spark arrestor has been fitted, this should
Engine Manual which should be reviewed in be removed and thoroughly cleaned to remove
conjunction with this section. Maintenance any carbon build-up.
intervals for the engine may be more frequent
than those shown in this section. 3.2.5 Alternator Preventative Maintenance
3.2.1 Daily or at Each Startup There is no routine maintenance required on the
alternator, however periodic inspection of the
(For standby sets these procedures may be alternator winding condition and periodic cleaning
performed weekly.) A walk around inspection is recommended. See the Maintenance section of
should be performed on a daily basis and prior to the Alternator Manual.
starting the engine. The pre-start checks
contained in Section 4.3 should be performed 3.2.6 Engine Preventative Maintenance
during this walk around. Procedures for
performing the checks on the engine can be found See the Engine Manual provided with this manual
in the Engine Manual which may contain for information on regular maintenance required to
additional requirements to those in Section 4.3. keep the engine operating efficiently.

3.2.2 Every Two Weeks

For standby sets that have not been run.) Perform

an operational check on the generating set by
starting and running the set for only 5 minutes.

WARNING
Do not run diesel engines at low loads for long
periods.

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 GENERATING SET MAINTENANCE 3

3.3 Removal of Engine and / or Alternator 9. The engine is now moved forward until it is
clear of the alternator and may be lifted away
The following procedures should be used for from the base.
removal of the engine and/or alternator.

1. Isolate and disconnect electrical power supply 3.3.2 Alternator Removal Only
to auxiliary equipment such as a water heater.
1. If the alternator only is to be removed, the
2. Isolate the battery charger supply.
rear of the engine must be firmly
Disconnect the battery (negative lead first)
and remove if necessary.
supported.

3. If the generating set is equipped with a 2. Remove the wiring loom.

canopy, remove the fixing bolts on each side,
disconnect the exhaust system and then
remove the canopy. 3. Remove the bolts holding the alternator to
the baseframe. Loosen the engine bolts
4. Isolate and disconnect the control panel and as well.
remove together with stand from the
generating set, ensuring that all cables have
been adequately identified to facilitate 4. Remove the alternator fan covers and
reconnection. support the rotor and the front of the
alternator. Ensure that the rotor is
5. If the engine and alternator are both to be positioned with a pole at the bottom
removed, they may be lifted out as one unit centre line. This is to avoid any damage
using the lifting eyes provided on both the to the bearing or exciter by limiting the
engine and alternator. First the bolts holding
the engine/alternator to the baseframe have
rotor movement to that of the air gap.
to be removed.
5. Uncouple the alternator from the engine
3.3.1 Engine Removal Only as per Section 3.3.1.
1. If only the engine is to be removed, the wiring
loom should first be removed from the engine. 6. Support the alternator using a sling or
similar device and slide the complete
2. If the alternator is fitted with only one set of alternator back on the base before lifting.
feet then the front end of the alternator will
have to be firmly supported before removing 3.4 Engine Maintenance
the engine.
The Engine Manual supplied with this
3. Remove the bolts holding the engine to the
manual contains detailed information on
base. It may also be advantageous to loosen
the alternator mounting bolts. maintaining the engine. It also includes a
comprehensive Trouble Shooting guide for
4. Remove the alternator fan guards. engine faults.

5. Support the rotor assembly using a sling or 3.5 Radiator Maintenance

wooden supports taking care not to damage
the fan. 3.5.1 General Notes

6. Remove the bolts between the flexible Corrosion in the radiator can be a prime
coupling and the engine flywheel. cause of failure. This is prompted by air in
the water. Always ensure pipe connections
7. Support the rear of the engine using an
are free of leaks and bleed air from top of the
overhead crane or similar device.
radiator regularly to keep the system "air
8. Remove the coupling housing bolts. free".

Radiators should not be left standing in a partially

filled condition. Radiators left partly filled with

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 GENERATING SET MAINTENANCE 3

water will suffer much more rapidly from the 3. Allow several minutes for mixing, then heat
effects of corrosion. For an inoperative the solution to 49'C (120'F) maximum.
generating set, either drain the radiator completely
or ensure that it is maintained full. Wherever 4. Run the solution slowly into the radiator via
possible, radiators should be filled with distilled or the filler cap or a branch in the manifold.
naturally soft water, dosed with suitable corrosion Effervescence will occur. When it ceases, fill
inhibitors. the radiator completely with the heated
solvent.

5. Allow to stand for several minutes; then drain

WARNING the solvent back into the original container
through the bottom manifold or drain plug.
Radiator coolant is normally very hot and under
pressure. Do not work on the radiator or 6. Examine the interior of the headers. If scale
disconnect pipework until it has cooled. Do not remains repeat the process outlined above
work on the radiator or remove any guarding while with the solvent strength increased to 8%.
the fan is in motion.
7. After descaling the acid solution has to be
3.5.2 External Cleaning neutralised as follows:-
Fill the mixing container with fresh water, heat
In dusty or dirty conditions the radiator fins can to boiling point then add common washing
become blocked with loose debris, insects, etc. soda crystals at the following strength: 0.5 kg
and this fouling will have an effect on the of soda to 20 litres water (1 lb. soda to 4
performance of the radiator. gallons water). Fill the radiator with this
solution, then drain it back into the container.
For regular removal of light deposits use a low
pressure steam jet. More difficult deposits may 8. Flush the radiator in this manner several
need a detergent with a low pressure hot water times, finally leaving the radiator full for at
hose. Spray steam jet or water from the front of least an hour. Drain until empty and wash out
the radiator towards the fan. Spraying in the the radiator with hot fresh water.
opposite direction will force debris further into the
core. Covering the engine/alternator during this 9. Before putting the radiator into service again,
process will keep them clean. fill with water and apply a test pressure equal
to twice that of the working pressure.
Stubborn deposits, which cannot be removed by Examine carefully for any leaks which may
the above methods may require removal of the have been revealed by descaling.
radiator and immersion in a heated alkali
degreasing solution for about 20 minutes and then 10. Prior to recommissioning, the coolant must be
washing off with a hot water hose. dosed with any necessary corrosion inhibitors
and/or the correct proportion of antifreeze.

3.5.2 Internal Cleaning

If, due to leaky joints for instance, indiscriminate

topping-up with hard water has been carried out
for some time, or if the generating set has been
run without inhibitors the system may become
fouled by scale.

To descale the radiator, use the following

procedure:

1. Drain the water system and disconnect and

blank off the pipe connections to the engine.

2. Prepare a 4% solution of inhibited acid

solvent and fresh water. Add the acid to the
water, never vice versa.

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 GENERATING SET MAINTENANCE 3

3.6 Alternator Maintenance

Although maintenance is rarely required, periodic

inspection and cleaning is recommended.

Perform a winding insulation test according to

procedures provided in the Alternator Manual
before the initial start, after generating set
storage, and every 3 to 6 months depending on
humidity levels (more often in higher humidity). In
high humidity areas, installing space heaters to
operate when the generating set is not running will
help keep the windings dry.

The alternator air filters, if fitted, should be

inspected regularly depending on site conditions.
If cleaning is necessary, remove the filter
elements from the filter frames. Immerse or flush
the element with a suitable detergent agent until
the element is clean. Dry the elements thoroughly
before refitting.

Additionally the alternator unit should be

cleaned on a regular basis. The frequency of
such clearings depends on the environmental
conditions of the operating site. The following
procedure should be followed when cleaning is
necessary: Disconnect all power. Wipe dust,
dirt, oil, water and any other liquids from the
external surfaces of the alternator unit and from
the ventilation screens. These materials can work
their way into the windings and may cause
overheating or insulation breakdown. Dust and
dirt is best removed using a vacuum cleaner. Do
not use compressed air, steam or high pressure
water!

The separate Alternator Manual provided with this

manual contains more detailed information on
alternator maintenance. It also includes a trouble
shooting guide for alternator faults.

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 GENERATING SET MAINTENANCE 3

5. Battery System
Contents

Page

5.1 Battery Theory 5.2

5.2 Battery Maintenance 5.2

5.3 Charging the Battery 5.3

5.4 Jump Starting Procedure 5.4

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 BATTERY SYSTEM 5

5.1 Battery Theory

5.1.4 High or Low Temperatures
5.1.1 General
In tropical climates (frequently above 32°C (90°F))
a fully charged battery with a lower specific gravity
The battery is an assembly of "cells" containing a
of 1.240 is used. This milder strength electrolyte
number of plates, immersed in an electrically
increases the service life of the battery. If
conductive fluid. The electrical energy from the
subjected to low temperatures the battery will not
battery comes from chemical reactions taking
have the same cranking power due to the lower
place within the cells. These reactions are
concentration of sulphuric acid, but this situation
reversible which means that the battery can be
should not occur in tropical climates.
repeatedly charged and discharged.
Batteries prepared for service in extremely cold
5.1.2 Electrolyte weather use stronger electrolyte. In some
instances specific gravity's of 1.290 to 1.300 are
used. The cold cranking performance increases
The electrically conductive fluid, called electrolyte, as the specific gravity increases.
in a lead-acid battery is a diluted sulphuric acid
solution. It aids the chemical reactions occurring 5.1.5 Temperature Correction
at the plates and it acts as the carrier for the
electrical current. The hydrometer is calibrated to indicate properly
for a specified electrolyte temperature, often 25°
5.1.3 Specific Gravity C (77° F). For temperatures higher or lower than
the reference temperature, a correction must be
Specific gravity is a unit of measurement for made. For each 5.5° C (10° F) above the
determining the sulphuric acid content of the reference add 0.004 to the reading. For each 5.5°
electrolyte which compares the weight of the C (10° F) below the reference, subtract 0.004
electrolyte compared to the weight of pure water. from the reading.
At 25° C (77° F) a fully charged battery should
have a specific gravity of 1.270. The lower the 5.2 Battery Maintenance
concentration of sulphuric acid, the lower the
specific gravity.

As the battery is discharged, the chemical

WARNING
reactions lower the specific gravity of the
electrolyte. Therefore, this measurement can be Wear an acid resistant apron and face shield or
used as a guide to the state of charge of the gaggles when servicing the battery. If electrolyte
battery. is spilled on skin or clothing, flush immediately
with large quantities of water.
5.1.4 Hydrometer
5.2.1 Filling
Specific gravity can be measured directly using a
hydrometer. This device is a bulb-type syringe The battery will often be shipped dry. Pre-mixed
which will extract electrolyte from a cell in the electrolyte of the correct specific gravity will have
battery. A glass float in the hydrometer barrel is to be added.
calibrated to indicate the specific gravity.
Remove the vent plugs and fill each cell with the
Hydrometer readings should not be taken electrolyte until the level is 8 mm (5/16 inch)
immediately after water is added to the cell. The above the top edge of the separators. Allow the
water must be thoroughly mixed with the battery to stand for 15 minutes. Check and adjust
underlying electrolyte, by charging, before the level as necessary.
hydrometer readings are reliable. Also, if the
reading is being taken immediately after the
battery has been subjected to prolonged cranking,
the reading will be higher than the true value. The
water formed in the plates during the rapid
discharge will not have had time to mix with the
electrolyte above the plates.
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 BATTERY SYSTEM 5

5.2.2 Initial Charging 5.3 Charging the Battery

Within 1 hour of filling, the battery must be

charged for 4 hours at the current indicated below.
This will ensure that the acid is sufficiently mixed WARNING
within the battery. Failure to give this charge at
this time may impair the capacity of the battery. ! Always ensure battery charging is carried out
in a well ventilated area away from sparks
Battery Charge and naked flames.
Reference Current (Amps)
! Never operate a battery charger where
E017 9 unprotected from rain or snow. The charger
E312 14 should never be used near water.
E644/E643 16
E324 20 ! Always switch the charger off prior to
disconnecting the battery.
You can record the type and connection of your
battery system here:- The engine driven alternator and or a static
battery charger, if fitted, should maintain the
QTY TYPE CONNECTION TYPE batteries in a charged state. However, if the
battery has recently been filled or recharging is
required the battery may be disconnected from
the generating set and connected to an external
The above 4 hour charge period may need to be battery charger.
extended as follows: to 8 hours if the battery has
been stored for 3 months or more at temperatures 5.3.1 Charger and Battery Connections
in excess of 30°C (86°F) or humidity above 80%,
to 12 hours if the storage has exceeded 1 year. The battery charger should be connected to a
suitable mains supply (13 Amps minimum) using a
If the charger output is not sufficient then a lower plug connected as indicated below.
current, which should not be less than 113 of that
given above, may be used but the time increased Mains Connection
in proportion (8 hours at 7 Amps instead of 4 Live Brown/Red Lead
hours at 14 Amps). Neutral Blue/Black Lead
Earth Green/Yellow Lead
At the end of the charging period, the electrolyte
levels should be checked and restored if Also ensure that the battery terminals are
necessary by addition of sulphuric acid electrolyte connected as indicated below:
at the correct specific gravity. The vents should
then be replaced.

5.2.3 Topping Up

Normal operation and charging of the battery will

cause some of the water to evaporate. This will
require occasional topping up of the battery.

Clean the battery first to avoid contamination and

remove the vent plugs. Add distilled water, until
the level is 8 mm (5116 inch) above the
separators. Replace vent plugs.

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 BATTERY SYSTEM 5

5.3.2 Charger Operation

Battery Connection
Positive (+) Terminal Red Lead After the charger has been connected to the
Negative (-) Terminal Black Lead mains and the battery connected to the charger as
indicated above, the charging procedure can be
Connect the batteries to the charger as per the followed:
following chart:
Remove the battery filler caps or vent cover
during charging. Check electrolyte levels and
adjust as necessary using distilled water.

Switch on the charger and observe rate of charge

for normal operation. The charging rate depends
on the Ampere-hour capacity z)f the battery, the
condition of the battery and the present level of
charge. The charging current will decrease as the
battery starts charging and will continue to
decrease as the battery voltage rises.

To check the state of charge, allow the battery to

settle for a short period with the charger switched
off. Then check the specific gravity of each cell
using a hydrometer.

The battery charger should not overcharge or

damage the batteries. High temperature,
however, can damage the batteries. Care should
be taken when charging batteries, especially in
hot climates, that the battery temperature never
rises above 45°C (113° F).

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 BATTERY SYSTEM 5

5.4 Jump Starting Procedures

8. Connect one end of the other jumper cable to
the grounded negative terminal of the battery
in the starting vehicle. If jump starting a 24
WARNING volt generating set and the starting vehicle is
provided with two 12 volt batteries, then
Do not attempt to jump start a battery if the connect the jumper cable to the negative
electrolyte is frozen or slushy. Bring the batteries terminal of the battery that is grounded.
up to at least 5°C (41°F) before attempting a jump
start. 9. Check the connections. Do not attempt to
start a 24 volt generating set with one 12 volt
If the generating set battery has insufficient battery in the starting vehicle. Do not apply
charge to start the generating set, a 'jump start" 24 volts to one 12 volt battery in the
from another battery is possible. Use the generating set.
following procedures:
10. Connect the other end of this second jumper
1. Remove all vent caps from the battery or cable to a clean portion of the generating set
batteries in the generating set. Do not permit engine block, away from fuel lines, the crank
dirt or foreign matter to enter the open cells. case breather opening or the battery.

2. Check the battery fluid level. If low add 11. With the engine of, the starting vehicle
distilled water to bring it to the proper level. running, start the generating set in
accordance with the normal procedures.
3. Attempt to jump start only with a vehicle with Avoid prolonged cranking.
a negative ground electrical system with the
same voltage and that is equipped with a 12. Allow the generating set to warm up. When
battery or batteries of comparable size or the set is warm and operating smoothly at
larger than those supplied with the generating normal RPM, disconnect the negative jumper
set. cable from the engine block on the generating
set. Then disconnect the other end of the
4. Bring the starting vehicle along side the same cable from the battery in the starting
generating set but do not allow metal to metal vehicle. Then disconnect the other cable for
contact. the positive terminal of the generating set
battery and finally disconnect the cable from
5. Place the starting vehicle in neutral or park, the starting vehicle battery.
turn off all non-essential accessory loads and
start the engine. 13. Replace vent caps.

6. Connect one end of clean, heavy duty jumper

cables to the positive battery terminal of the
starting vehicle. If jump starting a 24 volt
generating set and the starting vehicle is
provided with two 12 volt batteries, then
connect the jumper cable to the positive
terminal of the battery that is not grounded.

7. Connect the other end of the same jumper

cable to the positive terminal of the battery in
the generating set. When jump starting 24
volt generating sets, connect to the positive
terminal of the battery that is not grounded.

YML Generator Operation Manual

 Yorpower Limited, Registered office – Unit 2, Hurricane Close, Sherburn In Elmet LS25 6PB

Telephone: +44 (0) 1977 688155 Facsimile: +44 (0) 1977 688158
Email: [email protected]

YML Generator Technical Operation and Maintenance Manual 6.26