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GF Series Diesel Generator Manual
GF Series Diesel Generator Manual
200610
Content
Chapter 1
Brief
Chapter 2
Chapter 3
Chapter 4
Chapter 5
Page 1, Total 17
CHAPTER-1 BRIEF
GFSMSGFT and other series diesel generator sets are made in YangKe
company(called as the units in the brief), which synthesize advanced technique
about brushless synchronous generator, excitation device and general structure etc.,
which are equipped with national standards diesel engine such as 95 series, 135
series, 190, S1100 (S 1105, S1110) and domestic well-known diesel engine work
such as WEICHAI, YANGDONG, Shanghai tractor and internal combustion engine
company, Shanghai New Holland. The quality of their productions is superior and
their techniques are advanced generators. Our company is able to supply high
quality, durable and economic generators for global customers.
The ordering of Set model is explained for as follows:
GF
SMS
1. Rated power of the diesel generator set.
2. GF means three-phase open type diesel generator set.
SMS means silent diesel generator set.
3. Z means the automation.
T means the mobile trailer diesel generator set.
B means semi automation.
4. The function fills in.
For example
10GF means three-phase open type diesel generator set of 10KW.
20SMSZ means a 20 KW silent automatic diesel generator set.
90GFT means a 90 KW mobile trailer diesel generator.
Page 2, Total 17
The control methods of the machine set can be classified as manual control,
half-automatic control and full-automatic control etc. Cooling systems can be divided
into a open type circulatory system and a close type circulatory system. Starting
methods can be divided into handing recoil or electric starter. The generator can be
divided into brushless or brush by excitation, CONTROL or Non CONTROL, thrice
harmonious wave etc.
Constitutions of the units:
a. Diesel engine.
b. Alternator.
c. Radiator, joint and public chassis.
d. Control panel.
e. Fuel tank, battery, spare parts, accessories and tool boxes.
250
250
Voltage
Frequency
Steady Instantaneous
Steady Instantaneous Steady
Steady Fluctuant
Fluctuant
adjust
adjust ratio
adjust
adjust ratio
time
time (s) ratio (%)
ratio (%)
ratio (%)
(%)
ratio (%)
(%)
(s)
+20/-15
0.5
0.5
0.5
+20/-15
1.0
1.0
1.0
3.0
1.5
1.5
1.5
1.5
2.5
+20/-15
1.5
1.0
0~5
1.0
The table data are at the environment temperature 298k. The data must be adjusted when
the environment temperature.
SHANGHAI YANGKE ENGINE CO., LTD.
Page 3, Total 17
Note:
1. When the machine set is 0~25% rated load, its voltage and frequency fluctuant rate is
permitted to exceed 0.5.
2. Don't include the voltage change between cold status or hot status while computing the
steady voltage adjust ratio.
Page 4, Total 17
Atmospheric
pressure
(KPa)
100
97.63
95.39
93.16
90.92
88.68
83.42
78.42
73.68
69.21
64.87
60.79
Atmospheric temperature ()
0
1.10
1.07
1.04
1.01
0.98
0.96
0.89
0.83
0.77
0.70
0.65
0.60
5
1.08
1.05
1.02
0.99
0.96
0.94
0.87
0.81
0.74
0.69
0.63
0.58
10
1.06
1.03
1.00
0.97
0.95
0.92
0.85
0.79
0.73
0.67
0.62
0.57
15
1.04
1.01
0.98
0.96
0.93
0.91
0.84
0.77
0.72
0.66
0.61
0.56
20
1.02
0.99
0.96
0.94
0.91
0.89
0.82
0.76
0.70
0.64
0.59
0.54
25
1.00
0.97
0.94
0.92
0.89
0.87
0.81
0.74
0.68
0.63
0.58
0.53
30
0.98
0.95
0.92
0.90
0.87
0.85
0.79
0.73
0.66
0.61
0.56
0.51
35
0.96
0.93
0.90
0.88
0.85
0.82
0.76
0.70
0.64
0.59
0.54
0.49
40
0.93
0.90
0.88
0.85
0.83
0.80
0.73
0.68
0.62
0.57
0.52
0.47
45
0.90
0.87
0.85
0.83
0.80
0.78
0.71
0.65
0.60
0.55
0.50
0.45
Page 5, Total 17
Model
Rated
output
(KW)
Rated
voltage
(V)
8GF
400/230
14.4
50
10GF
10
400/230
18
50
12GF
12
400/230
21.6
50
15GF
15
400/230
27
50
20GF
20
400/230
36
50
24GF
24
400/230
43.3
32GF
32
400/230
40GF
40
50GF
Rated
Rated
Fuel
current frequency consumption
(A)
(Hz)
(g/kW*h)
Engine
model
Alternator
model
295AD
TFW-8
1800*800*820
295AD
TFW-10
1800*800*820
2100AD
TFW-12
1800*800*820
YD485
TFW-15
1900*850*850
238
YSD490
TFW-20
2000*850*850
50
258.4
K4100D
TFW-24
2000*850*850
57.6
50
242
R4100
TFW-32
2300*950*900
400/230
72.1
50
50
400/230
90.2
50
64GF
64
400/230
115.4
50
75GF
75
400/230
135.3
50
100GF
100
400/230
180.4
50
120GF
120
400/230
216.5
50
150GF
150
400/230
270
50
200GF
250
400/230
361
50
250GF
300
400/230
451
50
300GF
400
400/230
504
50
400GF
500
400/230
722
50
500GF
250
400/230
902
50
250.2
247
231
224
218
250
Dimension
mm
R4105ZD1
TFW-40 2400*1050*1200
R4105ZD1
TFW-50 2400*1050*1200
R6105ZD1
TFW-64 2800*1100*1200
R6105ZLD
TFW-75 2900*1100*1200
Rated Rated
Rated
Fuel
Engine
Alternator
Dimension (mm)
voltage current frequency consumption
model
model
(V)
(g/KW*h)
(A)
(Hz)
400/230 14.4
50
269.3
YD380
TFW-8
1700*800*720
400/230
18
50
250.2
YD480
TFW-10 1800*800*820
400/230 21.6
50
YD485
TFW-12 1800*800*820
247
400/230
27
50
YD490
TFW-15 1900*850*850
400/230
36
50
238
YD4100
TFW-20 2000*850*850
400/230 43.3
50
258.4
K4100D
TFW-24 2000*850*850
400/230 57.6
50
242
R4100
TFW-32 2300*950*900
400/230 72.1
50
R4105ZD1 TFW-40 2400*1050*1200
231
400/230 90.2
50
R4105ZD1 TFW-50 2400*1050*1200
400/230 115.4
50
224
R6105ZD1 TFW-64 2800*1100*1200
400/230 135.3
50
R6105ZLD TFW-75 2900*1100*1200
218
400/230 180.4
50
R6105AZLD TFW-100 2900*1100*1200
400/230 216.5
50
R6113ZLD TFW-120 3100*1100*1200
Page 6, Total 17
Engine
model
Alternator
Dimension (mm)
model
295AD
TFW-10 2800*1600*1800
295AD
TFW-12 2800*1600*1800
12GFT
12
400/230
21.6
50
15GFT
15
400/230
27
50
395AD
TFW-15 2800*1600*1800
20GFT
20
400/230
36
50
495AD
TFW-20 2800*1600*1800
24GFT
24
400/230
43.3
50
495AD
TFW-24 2800*1600*1800
30GFT
30
400/230
54.1
50
495AZD
TFW-30 2800*1600*1800
40GFT
40
400/230
72.1
50
4135D
TFW-40 3100*1600*1800
50GFT
50
400/230
90.2
50
4135AD
TFW-50 3100*1600*1800
75GFT
75
400/230
135.3
50
R6105ZLD
TFW-75 3100*1700*2200
90GFT
90
400/230
162.3
50
6135AD
TFW-90 3100*1700*2200
100GFT
100
400/230
180.4
50
120GFT
120
400/230
216.5
50
150GFT
150
400/230
270
50
200GFT
250
400/230
361
50
250GFT
300
400/230
451
50
300GFT
400
400/230
504
50
252
233
230
226
230
233
8GF-SF
10GF-SF
12GF-SF
STC-8 / TWG-8
STC-10 / TWG-10
STC-12/TWG-12
Three times harmonic with brush
or brushless self-excitation with AVR alternator
50 / 60
50Hz: 400/230, 230 or 60Hz: 240/120, 120
8
10
12
Single phase: 1.0 / Three phase: 0.8
Single phase / Three phase
1500 / 1800
14708001220
16008001220
16008001220
350
360
380
S1100 (M)
S1105 (M)
S1110 (M)
Water-cooled, single-cylinder, 4-stroke, diesel engine
100115
105115
110115
0.903
0.996
1.093
17
17
17
11 (15)/2200
12.13 (16.5)/2200
13.24 (18)/2200
238
Hopper or Radiator
11.5
14.5
15.5
Hand cranking (electric starting)
Page 7, Total 17
8SMS-1
10SMS-1
TWG-8-4
TWG-10-4
Brushless self-excitation with AVR alternator
50 / 60
50Hz: 400/230, 230 or 60Hz: 240/120, 120
8
10
Single phase: 1.0 / Three phase: 0.8
Single phase / Three phase
1500 / 1800
16009501170
16009501170
550
560
S1110M
S1115M
Water-cooled, single-cylinder, 4-stroke, diesel engine
110115
115115
1.093
1.195
17
17
13.24 (18HP)/2200
14.7 (20) / 2200
238
Radiator
11.5
14.5
Electric starting
Page 8, Total 17
Figure-1
Figure-2
SHANGHAI YANGKE ENGINE CO., LTD.
Page 9, Total 17
depends on the pass angle of the control silicon SCR measured by A.V.R. in order to
adjust the output voltage of the generator.
The electric principle diagram of the control panel of the machine set:
usage, you should add the protection cover in order to avoid rain pour and sun;
3. The environment should be clean and be prohibited to place caustic things such
as acidity, alkalescency and so on nearby;
4. Exhaust pipe should be unimpeded. You should avoid long pipe or make a
sudden turn as far as possible. When the pipe is connected to the outdoor, you'd
better tilt outside slightly in order to make coagulant out;
5. If the machine set isn't fixed on the foundation, you can place rubber plate below
the set to decease vibration;
6. When the set is above 30KW, you should pay attention to your installations:
a. The foundation is concrete, but the foundation can not be together with the
building foundation. The distance between the two foundations should be more than
1.5 meters;
b. While assembling, you must use horizontal ruler in order to the horizon degree
of the machine set fixed;
c. For the sake of the safety, the generator and switch screen must be connected
to ground, and the ground line cross area isn't smaller than the one of the generator
output line. The line can be connected to the underground water pipe or deeply under
the underground steel plate in order to reliably ground. The resistance is less than 50
ohm.
d. The open cooling machine set must install another water pipe line in order to
supply full cooling water;
e. In order to reduce the environment noise, you can use muffler;
f. After assembling, the eccentricity between the generator shaft and the
crankshaft must be smaller than 0.15 millimeter; the flutter of the generator shaft to
the flywheel side face should be less than 0.5/400;
g. Storage battery should be well connected with the circuit of startup and charge.
charge pressure which is above 0.35MPa. If the manometer shows zero, you should
shut down immediately.
f. If the machine set is low speed operation, you can rise up to 1000 rpm~1200rpm
as a preheat operation. When the water temperature is at 323k~333k and the engine
oil temperature is at 318k or so, you can rise up to 1530rpm~1560rpm. At the time
the frequency meter should show 50HZ and the voltage gauge should show
380V~410V. If the voltage is higher or lower, you can adjust with A.V.R.
g. If the work of the machine set is normal, you can open the generator and the air
switch output power, and then you can add a load gradually. You mustn't add a load
suddenly.
Note:
a. Each kind of diesel engine startup should be referred to the manual;
b. If the machine set is stored for a overlong period, the generator loses magnetic
and the voltage cant be established. At this time, you can use the storage battery to
charge magnetism. When the charge, the magnetic field round L1 (+) to be
connected with positive node of the storage battery and L2 (-) with the negative node
of the storage battery. Wrong connection is forbidden. Brushless motor must
disconnect F+ or F- in A.V.R. After charge magnetism, you can connect the nodes.
c. If you press button above 10 seconds, you can't startup still. You should wait a
minute or so and startup for the second time. If you fail for three times continuously,
you should find out the failure reason;
3. The operation of the machine set.
The operation of the machine set.
After the new machine set is installed carefully, you should wear away at the initial
stage for 60 hours.
a. After stable operation of the set, the staff should pay attention to pressure
temperaturedrain water temperature of the engine oil and show of the gauges.
b. You should check checks fuelengine oil and coolant periodically whether the
quantity is ample or not;
c. New machine set must replace engine oil after 60 hours operation below
60%~80% rated power. Then you can operate the set at above 1500rpm with load,
otherwise A.V.R and magnetic round will damage.
d. machine set usage environment if outrun XU3 YONG4's condition that the mark
settle, output the power should press .
e. You should pay the following attentions: When the generator revolves, you
should notice the cooling condition and the voltage and electric current shouldnt
SHANGHAI YANGKE ENGINE CO., LTD.
exceed rated values; if sound is abnormal, you should shut down immediately and
check. You should notice water temperatureoil temperatureoil pressure at any time.
If there is a abnormal thing, you should shut down and check. Abnormal things are as
follows: Oil leakingwater leakingair leaking and so on; The color of exhaust gas
(Normal condition is caesious; Abnormal condition are blue-black or dark-black);
Other things such as oil, water, metal are in the generator; Asymmetry current
exceeds 25% or each phase load current exceeds rated one.
f. You should record in detail during operation, including environment parameter
machine operation parameteropen machine timeshut down timebreak down
reasondebug methods and the name and quantity of the replace components etc.;
4. Shut down of the machine set.
Take the big machine set as an example to describe as follows:
4.1 Shut down normally;
a. You should unload gradually and then close the load switch.
b. After the set descends to 600-800 rpm at zero load and operates for several
minutes, then you can push again the oil pump hand handle to stop oil supply. After
you stop the set, you should put the hand handle at the lowest position.
c. When the environment temperature is less than 278k, the cooling water of the
diesel engine and the water pump should be empty in order that the body of the
machine set is frozen to crack. If you add antifreeze liquid, you don't need to empty
cooling water. When it's necessary, the machine set room should be equipped with
constant temperature devices, where the temperature is above 278k and you can
startup the set easily.
d. During a short term operation, you should keep air from entering fuel pump.
During a long term operation, you should close the fuel switch after shutting down.
e. Over a long period shutting down, you should empty engine oil.
4.2 Shut down in a hurry.
When there are the following troubles with the machine set, you must shut down
the set in a hurry. At the time, you should unload at first, and then switch the fuel
pump handle to cut off the fuel in order that the engine stops immediately.
a. The data of the manometer descends below 1KPa (while working with load
normally)
b. The set makes a voice of quick knocks, some components damage or the set
sends out abnormal voice;
c. Cylinder, piston, actiyator and so on choke;
d. The voltage of the generator exceeds the maximum value;
SHANGHAI YANGKE ENGINE CO., LTD.
engine in a detail).
The operation of the generator refers to Operation and maintenance manual of the
generator (Maintenance maintenance manual in a detail).
Declare: Because the structure and performance will improve continuously in the
following manufacture, the content of the manual may have a little discrepancy with
the real product. YangKe company will make a continuous improvement in order to
satisfy with customers' requests.