Abz Aggregate-Bau: Genset Manual

ABZ AGGREGATE-BAU GmbH
GENSET MANUAL
ABZ AGGREGATE-BAU GmbH

GUTENBERGSTRASSE 11
D-24558 HENSTEDT-ULZBURG
GERMANY
Tel.: +49 (0) 4193 90 36–0

Fax: +49 (0) 4193 9 34 73
e-mail: info@abz-power.com
homepage: www.abz-power.com
page 1.2 ISSUE 11/2000
GENSET MANUAL Installation • Operation • Maintenance
Part 1 GENERAL INTRODUCTION
CONTENTS Page
Part 1 GENERAL
INTRODUCTION
1 .1 General introductory notes 1.6

1 .2 General safety instructions 1.7
1 .3 Using the equipment
according to its original
intended purpose 1.9
Part 2 INSTRUCTIONS
2.1 Transport 2.1

Lifting points 2.1
2.2 Setting-up 2.2

2.2.1 Setting-up room 2.2
2.3 INSTALLATION 2.3
2.3.1 Mounting of Genset 2.3

2.3.2 De-preservation 2.3
2.3.3 Exhaust equipment 2.3
2.3.4 Fuel tank system 2.4
2.3.5 Battery system 2.5
2.3.6 Electric system 2.6
Power cables 2.6
Control wiring 2.6
Earthing, potential
compensation 2.6
Overvoltage protection 2.6
2.3.6.1 Gensets with built-on
switchboard 2.7
2.3.6.2 Gensets without switchboard 2.7
2.3.6.3 Operation in parallel 2.7
page 1.3
2.4 STARTING-UP 2.8
Introductory note 2.8

2.4.1 Diesel engine 2.9
2.4.2 Fuel system 2.9
2.4.3 Starter battery and control
battery 2.9
2.4.4 Switchboard 2.10
2.4.5 Pre-heating of cooling water 2.10
2.4.6 Starting the genset for the
first time 2.10
2.4.7 Ventilation system 2.11
2.4.8 Function test with
switchboard 2.11
2.5 OPERATING
INSTRUCTIONS 2.12
Warning 2.12
2.5.1 Genset in working order 2.13
2.5.1.1 Fuel level 2.13
2.5.1.2 Lubricating oil level 2.13
2.5.1.3 Engine temperature 2.13
2.5.1.4 Cooling water level 2.13
2.5.1.5 Battery voltage 2.13
2.5.2 Operation 2.14

Information 2.14
2.5.2.1 Manual start 2.14
2.5.2.2 Manual stop 2.14
2.5.2.3 Setting voltage and
frequency 2.14

2.5.3.1 Filling the tanks 2.15
2.5.3.2 Fuel gauge 2.15
2.5.3.3 Leakage indicator 2.15
2.5.3.4 Tank for daily consumption 2.15
2.5.3.5 Fuel injection system 2.16
2.5.4 Battery 2.16
2.5.5 Ventilation 2.16
page 1.4
2.6 MAINTENANCE AND

SERVICE 2.17
Introductory notes 2.17

2.6.1 Genset room 2.18
2.6.2 Genset 2.18
2.6.3 Engine 2.18
2.6.4 Elastic elements 2.19
2.6.5 Coupling 2.19
2.6.6 Cooling water pre-heater 2.19
2.6.7 Ventilation 2.19
2.6.8 Cooling system 2.19
2.6.10 Exhaust gas system 2.21
2.6.11 Alternator 2.21
2.6.12 Battery 2.21
2.6.13 Switchboard 2.21
Part 3 OTHER RELEVANT

DOCUMENTS APART
FROM THIS
INSTRUCTION MANUAL
3.1 Diesel engine

3.1 .1 Operating instructions
3.1.2 Spare parts list
3.1.3 Fuel and lubricant regulation
3.1.4 Speed governor
3.2 Alternator
3.3 Cooling device
3.4 Coupling
3.5 Battery
3.6 Switchboard
3.6.1 Wiring diagram
3.6.2 Descriptions of equipment
3.7 Testing documents
page 1.5
1.1 GENERAL INTRODUCTORY NOTES
This documentation was written with the intention of being read, understood
and observed by staff that are responsible for
transport,
setting up,
operation,
serviceability and
maintenance
of the genset.
One copy of this documentation should always be kept close to the genset
so that essential information is available on site at any time.
Only by understanding the information contained in this documentation

mistakes in operating the genset can be avoided and smooth operation be
ensured. It is therefore absolutely essential that this documentation is
brought to the knowledge of the operating staff.
The instructions should be read before setting-up and putting into

operation, as no liability can be undertaken for damages or breakdowns
caused by not observing the information in this documentation.
In order to better understand the entire unit, this documentation sometimes

refers to components not supplied by ABZ. Explanations concerning these
components are not binding and are supplied according to the best of our
knowledge. No claims can be made on the basis of these explanations.
If any points in this documentation remain unclear or are found to be

inconsistent, we should be contacted without delay for clarification.
This documentation is not supposed to alter any existing agreements or

legal positions. All obligations result from the supply contract that includes
the effective warranty regulations. These contractual regulations are not
extended or limited by the contents of this operating manual.
The copyright in this documentation remains with ABZ. The documentation

is meant for staff concerned with setting-up, operating and supervising the
equipment. It includes technical regulations, drawings and information that
must not be reproduced, circulated or utilised for competitive ends or be
communicated to others without authorisation.
page 1.6
1.2 GENERAL SAFETY INSTRUCTIONS

The equipment is state-of-the-art technology and can be operated safely.
Dangers can arise, however, if the equipment is operated by untrained staff
in an improper way or for undue purposes.
Dangers can arise threatening

- the users or other persons life and limb,
- impairing the equipment and other material assets of the user,
- dangers to the efficient operation of the equipment.
The equipment must only be operated by trained and authorised staff. The
respective responsibilities for operating the equipment must be laid down
clearly and must be observed, in order that from a safety point of view
responsibilities do not become unclear. The staff concerned must receive
special instruction as to possible dangers.
The genset has been equipped in the manufacturing works with all
necessary safeguards. These safeguards must not be removed or modified,
as then safety cannot be guaranteed and dangers to life and limb will arise.
The genset room must not be operated in any way that impairs its safety.
The company operating the unit must ensure that no unauthorised staff
work with the unit.
The company operating the equipment must ensure that the unit is only
operated in perfect condition.
The company operating the equipment has the duty to check at least once
a day whether any damages or defects can be seen from the outside of the
unit. Any changes (incl. operation performance) that impair safety must be
reported immediately.
The company operating the unit must issue instructions and carry out
checks in order to ensure that the unit is clean and tidy.
The genset room must not be used for other than the original purposes and
must not be used for storing any parts or equipment that are not part of the
unit.
Unauthorised conversions or modifications that impair the safety and

functioning of the unit are forbidden.
No work may be carried out on the unit while it is ready for operation and
not secured against unintended start-up.
Escape routes that have been laid out according to the regulations of the
building supervisory boards must not be obstructed in any way.
page 1.7
Exhaust gases are poisonous!
The exhaust system must not have any leaks. Any smell of exhaust gases
must be reported immediately!
Do not stay before the exhaust gas outlet you may get burned or poisoned!
-
Exhaust gases are hot!
They can reach temperatures of over 600 °C. For the most part the exhaust
system is insulated. Due to technical requirements some small spots on the
engine and exhaust may not be insulated completely. These spots must not
be touched.
The starter and control batteries are filled with a caustic acid or solution. Do
not touch. Always wear protective gloves when working on the battery.
Do not disconnect the battery as long as the equipment is ready for

operation. Before disconnecting secure the mains switch from unintended
switching-off.
Switch the charger off before disconnecting the battery.
Always wear protective ear-set while staying in the genset room when the
genset is running.
Diesel oil and lubricating oil are inflammable. Store only in containers and in
places intended for this purpose.
Be careful when dealing with fuels and lubricants.

Do not let any fuel, lubricating oil or anti-freezing agent reach the ground or
the sewerage. Used oils and anti-freezing agents must be dealt with
according to regulations. Do not spill any fuels and lubricants. Spilled fuels
and lubricants must be removed immediately.
Cleaning utensils and agents (cleaning rags, oil binding agents etc.) must
be kept in the containers intended for this purpose. Used rags and binding
agents soiled with oil must be treated as special waste, they must not be
burned.
The equipment must not be modified in any way that changes its emission
characteristics, such as sound, vibration or exhaust gases.
Beware of voltage!
Do not remove any protective covers from electric devices and parts, do not
work with voltage. If working with voltage cannot be avoided, special
precautions must be taken.
page 1.8
1.3 USING THE EQUIPMENT ACCORDING TO ITS

ORIGINAL INTENDED PURPOSE
The purpose of the equipment is to generate electric energy on the basis of

the values and tolerances given in the technical data by using the fuel
provided for and according to the ambient conditions agreed upon in the
contract.
The company operating the unit has the right to and is advised to carry out
functional checks (test runs) in regular intervals. Test runs are to be carried
out under load.
The operating characteristics of the unit have been adjusted to the rated
operating characteristics. It is not allowed to run the genset at any other
frequency (speed) or voltage.
The functions and operation of all equipment components have been

adjusted to each other. They may only be used and operated in the present
state. It is not allowed to operate individual components for other
purposes. No alterations may be carried out as the desired effectiveness
and safety of the unit may be affected.
The genset should only be run at over-capacity for corrective adjustment

purposes. Making use of the unit to any other than the purposes described
above is not in accordance with its original purpose.
The unit is to be installed by staff with specialised training and it is to be

operated by specially instructed staff.
page 1.9
Part 2 INSTRUCTIONS
2.1 TRANSPORT
Whenever transporting or shipping the equipment do not step under the

suspended weights and keep out of the slewing range of cranes!
Take notice of the signs indicated on the packing:

top
fragile
keep dry
protect from heat
centre of gravity
lifting point
The packing is made for the intended way of transport and the expected
duration of storage. The openings sealed in the factory (exhaust gas
outlets, cooling water pipes etc.) must only be opened when installing the
equipment.
LIFTING POINTS
All ABZ-gensets can either be lifted using a fork-lift or by lifting it with a

crane at the lifting points.
When lifting with a fork-lift, the unit may only be lifted from under its base-
frame. Take care that the genset keeps its position of the centre of gravity,
secure the genset against slipping from the edges. Take special care that
components protruding from the base frame of the genset are not
damaged.
The base frame of all standard ABZ-gensets has 4 lifting points. The genset
may only be lifted at these points.
The genset must not be lifted at the lifting eyes of the engine or
alternator. These are only designed for lifting individual components.
When fixing ropes, take care that no protruding parts of the genset such as
air filters, oil filters etc. are damaged.
On a smooth level surface the genset can be moved on heavy-duty rollers

or tubes. The genset may be pulled only at its base frame.
page 2.1
Part 2 INSTRUCTIONS
2.1 SETTING - UP
The genset is designed according to ISO 3046. If there are differing

conditions on the setting-up location, then the capacity of the genset must
be adjusted to these setting-up conditions.
If the ambient conditions require reducing the type capacity, then the
genset may only be operated at this reduced capacity. Doing
otherwise may result in weaker performance, higher wear and serious
damage to the genset.
2.2.1 SETTING-UP ROOM
Foundation work:
The foundations for setting-up ABZ-gensets must be smooth and level and
must be able to support its weight. The supporting capacity required
depends on the total weight and dynamic load. The surface must be level
and may not exceed a maximum diagonal tolerance of ±2 mm per metre.
When fixing the genset with foundation bolts, foundation holes must be
provided according to the genset drawings.
The calculation of safe dimensions of the foundation works is the duty of

the company operating the equipment.
Dimensions of setting-up room:
The dimensions of the setting-up room depend on the size of the genset.
The genset must be accessible from all sides. The walk around the genset
used for operation and maintenance should be 1 .5 to 2 metres wide
(depending on genset size). For safe and convenient operation wider walks
may be required. Sufficient escape routes must be provided.
The height of the genset room should measure at least twice the height of
the genset itself, in any case it should not be lower than 2.2 m.
Openings:
Opening for bringing the genset inside (and later outside): width x height of
the genset +10%.
Entrance: as required
Ventilation openings: for intake air and discharge air
page 2.2
Part 2 INSTALLATION
2.3 INSTALLATION
2.3.1 MOUNTING OF GENSET
There are two ways for mounting the genset:
Gluing
Provided that the foundations’surface is clean and smooth, the base frame
of the genset can be glued onto the foundation. This can be done by using
epoxy resin glue or self-adhesive fabric building boards.
Dowelling
The base frame of the genset has holes for fixing the genset onto the
foundation with dowels. Preferably metal heavy-load dowels or epoxy-resin
glue dowels should be used.
2.3.2 DE-PRESERVATION
If the genset was delivered in a preserved state, de-conservation must be

carried out according to the regulations of the engine manufacturer.
See engine operation manual for further details.
2.3.3 EXHAUST GAS EQUIPMENT
Exhaust gases are poisonous!

The exhaust gases of the engine must be conducted in such a way that any
danger to persons can be excluded.
The exhaust gases must be conducted into open air. Relevant local
regulations must be observed.
Exhaust gases are hot!

They can reach temperatures of over 600 ° C. Safety measures must be
Residual taken against accidental touching.
danger Do not reach into the exhaust fume flow!
For the most part the engine exhaust conduit is insulated. Due to technical
requirements some small spots may not be insulated completely. These
spots must not be touched.
page 2.3
Part 2 INSTALLATION
If the exhaust conduit is continued from the genset, the compensator

supplied must be installed beyond the exhaust gas outlet of the engine. By
installing an extended exhaust conduit the exhaust manifold or
turbocharger must not come under mechanical stress. Beyond the
compensator the diameter of the exhaust conduit must be enlarged.
Exhaust silencers must be installed behind the compensator and as close

to the engine as possible. The total exhaust conduit must be kept as short
as possible. The permissible exhaust gas counter-pressure (total of all
drags of the installed exhaust equipment) must not exceed a permissible
value.
Exceeding the permissible exhaust gas counter-pressure may result

in weaker performance of the genset, higher wear and serious engine
damages.
For installing extensive exhaust systems counter-pressure calculations are

essential.
When installing several gensets, the exhaust conduits must not be joined
together (separate conduits must be installed for each individual genset).
If defined sound insulation requirements have to be met, the silencer must

be adjusted to the engine.
2.3.4 FUEL TANK SYSTEM
The fuel tank system may only be installed by a certified specialist.
Tank incorporated in the base frame
No further installations are required. However, safety measures must be

taken against fuel leakages. Leakages may occur eg when refuelling or with
damages.
Any infiltration of diesel oil into the ground must be absolutely

avoided. The company operating the equipment is fully responsible
for any damages to the environment.
page 2.4
Part 2 INSTALLATION
2.3.5. BATTERY SYSTEM

a) Batteries installed on the base frame
The batteries have been installed ready for operation, no further installation
is required. Before pulling into operation the battery cables must be
clamped. Batteries supplied dry must be filled.
b) Uninstalled batteries
12 Volt 24 Volt The batteries must be installed as close to the engine (starter) as possible,
keep cable distances short. It is recommended to keep the batteries in a
safety box to avoid damages. Avoid vibrations and strong heat radiation
+ - + - + - when installing the batteries. Cover the battery poles.
12 V 12 V 12 V
Connect the batteries according to opposite diagram.
Do not change polarity!

Battery connection for - positive pole is to be connected to starter (and switchboard)
12 V and 24 V system - negative pole is to be connected to earth (and to switchboard, see
connecting diagram of switchboard)
False polarity can cause damage to the electric equipment of the

genset and to the switchboard.
If the starter battery supplies an auxiliary control (eg emergency power

control), voltage tap for this control must be effected directly from the
battery poles. The connecting cables must be laid to be short-circuit proof
or necessary safety measures must be taken.
page 2.5
Part 2 INSTALLATION
2.3.6 ELECTRIC SYSTEM
Electric installation work may only be done by specialists or with direct

guidance by specialists.
When connecting cables and wires these must be largely free of

mechanical stress. The genset is subject to mechanical vibrations and
swings. All wires must be laid in such a way that no mechanical stress is
caused on the connecting terminals. It is recommended to use flexible
wires. It is also recommended to support the wires above the base frame.
Wire inlets and lead-ins must be insulated in such a way that the protective
system of the unit is not impaired.
Wires with differing voltage levels must not be laid together.
Power cables
The lay-out of the power cables must correspond to the rated current of the
unit and to the permissible voltage drop.
If the unit is operated at temperatures higher than 40°C or if conducting

cables are laid as bunch conductors, then the cross section of the wires
must be increased accordingly.
Control wiring
Connect the control wires according to the connecting diagram of the

switchboard.
Earthing, potential compensation
The earthing of the unit must be done according to the planned use of the
unit. Mains characteristics and safety measures must be taken into
account. The responsible choice of necessary measures is the duty of the
company operating the unit.
All unit components must be included in potential compensation.
Overvoltage protection
The unit is not equipped with overvoltage protection (protection against

atmospheric discharges). If such a protection is deemed necessary, it must
be installed within the current supply of the building.
page 2.6
Part 2 INSTALLATION
2.3.6.1 Gensets with built-on switchboard
Genset and switchboard are interconnected and ready for operation.

The power cables must be connected to the alternator circuit breaker.
2.3.6.2 Gensets without switchboard
Wire connections according to genset connecting diagram
The power cables must be connected directly to the alternator terminal box.
The control wires are concentrated in the main genset terminal box.
The customer’ s switchboard must be equipped with at least the following

protective devices and monitoring circuits:
alternator overcurrent
alternator short-circuit
alternator undervoltage / overvoltage
cooling agent overtemperature
lubricating oil underpressure
overspeed
cooling water level
According to the planned use of the unit additional protective devices may
be required.
When planning the protective measures for the alternator and the selectivity
of the consumer’ s mains, the short-circuit performance of the alternator,
network structure and load performance of the driving engine must be taken
into account. Safety fuses are generally no appropriate protective means.
Further information on alternator and genset performance can be supplied

on request.
2.3.6.3 Operation in parallel
If the genset is to be run in parallel with another genset or the mains, the
manufacturer must be consulted in advance unless the genset is explicitly
suited for this mode of operation.
page 2.7
Part 2 STARTING-UP
INTRODUCTORY NOTE
Starting up the genset must be done under the guidance of a specialist with
genset construction experience. The following information is meant as an
advice to the operator. Responsibility remains with the operator at site with
his expert knowledge and his decision. Observe special instructions in the
instruction material of the individual components (eg engine operating
instructions).
The precondition for starting up is that installation has been totally

completed. All pipes must have been cleaned, the preservative material
and transport guards must have been removed.
Electrical installation work must be completed that voltage can be switched

on.
page 2.8
Part 2 STARTING-UP
2.4 STARTING-UP
2.4.1 DIESEL ENGINE
Fill lubricant oil up to “max.”mark of oil dip-stick, keep another 10- 20% of
the total quantity ready for refilling later.
Fill turbocharger, speed governor and injection pump with oil
(see lubricant regulations of engine manufacturer for details on fillings and
oil types).
- fill oil-bath air cleaner with filtering oil (eg viscinol) or lubricating oil
- wet air cleaner of wet type
- insert cartridge into air filter of dry type
Check pipes and tubes for leaks.
Prepare cooling water outside the engine, soften the water if necessary
(see engine instruction manual for details on preparing the cooling water).
Mix water with anti-freezing agent or anti-corrosive oil outside the engine
(do not mix the two), then fill and vent the engine cooling system.
Do not fill too quickly so that the air can escape from all chambers of the
system. The air from components that do not vent on their own must be
vented by opening the hand valves (eg cooling water pre-heater, charge-air
cooler, complex pipe conduits).
See engine operating instructions for mixing ratios.
2.4.2 FUEL SYSTEM
Fill tank for daily consumption; suck in using hand pump first, then fill up
using motor pump. Check all the fittings for leakages. Fill up tank to max.
90% of its capacity.
Vent the diesel engine fuel system (see engine operating instructions).
When using automatic filling devices test the functions of the pump control
(automatic switching on and off of fuel pump, controlled by float switches
installed inside the tank). The emergency switching-off device of the fuel
pump must be tested using an additional float switch or overfill safeguard
device.
2.4.3 STARTER BATTERY, CONTROL BATTERY
Fill batteries with acid or solution; adjust acid density acc. to ambient
temperature. Test battery charge, recharge if necessary.
When using NiCd-batteries carry out formation charge. If the charger
installed in the switchboard does not allow formation charging, use a
separate charger (see battery instructions for details, Part 3).
Pre-charged lead batteries should only be filled do not charge.

-
page 2.9
Part 2 STARTING-UP
2.4.4 SWITCHBOARD
Check that all cables and wires on the switchboard are connected correctly,
check earthing and potential compensation,
measure earthing resistance (resistance value acc. to local regulations),
connect mains voltage (if applicable),
connect battery,
test and adjust battery charger (if applicable),
check settings of overcurrent circuitbreaker and short circuit tripping device,
put auxiliary drives into operation one after the other,
check direction of rotation of all electric drives:
louvres,
fans,
cooler (if electric driven),
cooling water pump (if applicable),
prelubricating pump (if applicable),
cooling water pre-heater, circulating pump,
fuel filling pump (if applicable).
In addition:
overfill safeguard for tank for daily consumption (if applicable), ´
oil-water warning device (if applicable),
lubricating oil pre-heater (if applicable),
test stop command for diesel engine (EMERGENCY STOP),
test function of mechanical engine stop lever (if applicable).
2.4.5 COOLING WATER PRE-HEATER
Vent pre-heater first, then switch on incl. circulating pump (if applicable)
Heat cooling water to 50 55 degrees C; this can take several hours.
-
Test switching-on point and switching-off point of thermostat (approx.

45-55°C).
2.4.6 STARTING THE GENSET FOR THE FIRST TIME
Crank the engine by using the turning device and make sure the engine
turns freely.
Caution: before starting for the first time it is essential to test

manual shutdown device and overspeed protection!
Secure escape routes.
Check lubricating oil and cooling water level.
Pre-pump fuel into the injection pump, vent the injection conduits, pre-
lubricate engine (if necessary) - start the engine.
Lubricating oil pressure must build up within a few seconds, otherwise stop
engine immediately.
Let engine run for a few seconds, then turn off.
If all pipes, filters and fittings are filled with oil, then fill oil up to the top mark
of the dip-stick.
page 2.10
Part 2 STARTING-UP
Restart genset and adjust rated speed and rated voltage

(see operating instructions of genset and engine for details),
check oil and water pressure,
check entire unit for leakages,
check all mounted components for undue vibrations.
2.4.7 VENTILATION SYSTEM
Check that all ventilation outlets are clear,

adjust louvres,
if decorative grids have been fitted to the air openings check that lamellas
do not stand too close;
take lamellas out if necessary,
check blowing direction of ventilators
2.4.8 FUNCTION TEST WITH SWITCHBOARD
Perform manual start,

test EMERGENCY STOP
Turn alternator switch on,

test monitoring system:
approx. 10 seconds after start-up the monitoring system is ready for
operation (stand-by light is on).
- signal test - all lights are on,
alarm sounds,
Test the monitoring circuits by bridging the alarm contacts.
- oil pressure too low - engine off, alternator switch off
- cooling agent temperature too high - engine off, alternator switch off
- alternator overload - alternator switch off
- EMERGENCY STOP - engine off, alternator switch off
Charge genset slowly with load until it gets operational temperature and
reaches rated load. With gensets with extensive exhaust systems measure
exhaust gas counterpressure and compare to permissible value.
During load run the entire exhaust gas system must be checked.
Risk of fire if insulation has not been carried out properly, especially
near wall and ceiling openings.
Compare measured values to manufacturer’ s test reports.

Install all protective equipment according to regulations for the prevention
of accidents.
Keep protective earsets ready.
Starting up gensets with synchronising equipment:

see separate instructions.
page 2.11
Part 2 OPERATING INSTRUCTIONS
WARNING
This genset may only be operated by specially instructed staff.

Operating the genset requires a thorough understanding of the
operating instructions and additional documentation. Especially the
safety precautions and warnings of dangers must be observed.
When operating without a thorough understanding of the genset and

its effects on subsequent units, there is the danger of causing
malfunctions and damages on the genset itself as well as on the
subsequent units; these can result in death or severe injuries.
page 2.12
2.5.1 GENSET IN WORKING ORDER
The checks listed here are meant as a short test. It is assumed that the
genset is well maintained.
2.5.1.1 Fuel level
The tank for daily consumption must always be filled-up. Check also that
the storage tank is full. Only then you have sufficient reserves for operation.
2.5.1.2 Lubricating oil level in diesel engine
When engine has stopped the oil level must always reach the top mark of
the dip-stick.
See manufacturer’
s lubricating oil specifications for oil types to be used!
2.5.1.3 Engine temperature
(if cooling water pre-heater installed)

The engine is supposed to start-up quickly and smoothly. Engine
temperature should therefore not be less than 45°C.
2.5.1.4 Cooling water level
When the engine has cooled down open the lid of the header tank on the
cooler. You should be able to see the water-surface clearly. The tank need
not to be “full to the brim”, as water expands when heated. The excess
water will be pressed out of the overflow pipe.
If there are several cooling circuits, the water level in each circuit must be
checked.
2.5.1.5 Battery voltage
Acid level or solution level should always reach the top mark. The battery
should always be fully charged.
page 2.13
2.5.2 OPERATION
INFORMATION
Before you put the unit into operation, make sure you know how to
stop the unit.
2.5.2.1 Manual start
Gensets without switchboard
Start the engine with the key switch on the engine control box. Watch the
monitoring instruments. The oil pressure gauge should show immediately at
least 2 bar. Let the engine run warm until the temperature indicator shows a
value in the green sector or shows 60°C. Then the genset can slowly be
charged until it reaches the rated load.
2.5.2.2 Manual stop
To stop the engine keep pressing the push-button STOP until the engine
has come to a complete stop.
Do not release the button too soon, otherwise the engine might start again.
Gensets with switchboard
See brief instruction of switchboard for details on operation (Part 3)
2.5.2.3 Setting Voltage and Frequency
See operating instructions of engine and alternator for details on settings.
In order to set voltage and frequency, the genset must be running. Setting
can be done when the genset is running without load or under load. The set
values can vary according to load.
If the alternator supplies no or only low voltage, there will be no indication of

frequency.
page 2.14
2.5.3.1 Filling the tanks
The storage tanks are filled from a tank lorry. The filler neck of the tank
must always be closed and secured by a lock, it should only be opened for
filling. It may only be filled with a limit indicator connected. The limit
indicator stops the filling process as soon as the tank is full.
2.5.3.2 Fuel gauge
Pneumatic indicator
In order to determine fuel level, pull the pump knob of the level indicator
with force, then release. The pointer begins with reading. If the pump knob
has reached its normal position while the pointer is still moving, then the
pumping process must be repeated.
Dip-stick
You can also measure fuel level directly at the tank by using a dip-stick.
Open the screw-cap of the dome lid and pull the dip-stick out with the chain.
You can see the fuel level from the wet part of the dip-stick. According to
the dip table provided you can determine the content in litres from the filling
level read with the dip-stick.
2.5.3.3 Leakage indicator
When the tank is full, the leakage indicator must be switched on and the
yellow signalling lamp must be on. If the red signalling lamp alights and the
horn sounds, then there may be a tank leakage. In this case contact us
immediately or any other specialised company.
In this case there must be no delay. If there actually is a leakage and

fuel contaminates the ground, being the operator of the unit you will
be held fully responsible for the damage to the environment thus
caused.
2.5.3.4 Tank for daily consumption
The tank for daily consumption is filled from the storage tank.
You can also fill this tank by hand. However, you must take care that the
tank is not overfilled. You can fill the tank for daily consumption also by
using barrels or cans.
When filling the tank automatically observe the safety instructions written on
the tank! See also 2.4.2, page 2.9 “Automatic filling device”.
page 2.15
2.5.3.5 Fuel injection system (Diesel Engine)

see engine instructions (Part 3)
As long as the engine is running smoothly it is not necessary to handle the

engine in any way. If due to some reason the engine has stopped because
of fuel shortage, the injection system must be vented thoroughly, otherwise
the engine will not start again. See the corresponding chapter in the engine
operating instructions for details.
2.5.4 BATTERY
The battery itself need not be operated in any way. The battery is charged
by the charging generator of the engine or the battery charger.
While in operation the battery must never be disconnected. Before
disconnecting the battery always switch off the battery charger first (if
applicable).
2.5.5 VENTILATION
The engine room must be ventilated in such a way that room temperature
does not exceed the temperature stated according to the stipulated ambient
conditions even if the unit is operated at full load. Particularly the
temperature at the air-inlet of the alternator and of the combustion air filter
of the engine must not exceed the permissible value.
page 2.16
Part 2 MAINTENANCE AND SERVICE
INTRODUCTORY NOTES
Cleanliness and keeping the entire unit clean and tidy are essential factors
in keeping the unit in good conditions!
The unit may only be serviced by competent and specially trained staff.
Before beginning with servicing work, switch unit off and secure it against
accidental restart.
Residual material such as used oil, cooling fluids, leaked oil, leaked fuel,
condensate, oil binding agents, cleaning rags etc. must be treated
according to the relevant regulations. Under no circumstance may such
material be let into the sewerage system or be treated as domestic waste.
Even if a servicing contract has been concluded with a specialised

company, the company operating the unit still has certain servicing
responsibilities. Here a distinction must be made between servicing work
required and servicing work laid down in a servicing contract.
i
Obvious defects such as leakages, fault indications or mechanical damages
must be resolved or a specialised company must be charged immediately
with resolving these faults. Notice must be given within operating
company’ s organization of faults that impair safe operation of the unit.
The unit must undergo daily visual checks.
A servicing book must be kept to record all work carried out and any
occurrences in order that there are always complete supervisory records of
the unit for a period of at least two years. Such a servicing book has been
provided with the unit.
page 2.17
Work to be done:
2.6.1 GENSET ROOM
Keep the room dust-free,

remove any objects that do not belong directly to the unit,
keep escape routes absolutely clear,
defective lights must be repaired without delay,
check that signs and safety instructions are complete,
check floor and ground-joists for damages (fuel resistance),
keep light shafts,
air shafts and air inlets clear,
keep cable ducts and pipe ducts clean,
check that accessories and spare parts are complete,
test function of battery safety lamp,
test room heater.
2.6.2 GENSET
Keep genset clean, if genset regularly gets highly soiled, check for cause,
check that all screws are tight, touch-up paint damages, adjust voltage and
frequency.
2.6.3 ENGINE
Carry out maintenance work according to engine operating instructions.

The maintenance intervals are partly given in hours of operation. An
operating hours counter has been installed inside the genset switchboard.
The individual durations of operation are recorded in the servicing book.
Test all automatic sensors (temperature, pressure, speed etc.), adjust set
values if necessary, check that mechanical protective devices are firm.
Speed governor
Check settings acc. to operating instructions.
page 2.18
2.6.4 ELASTIC ELEMENTS
Check elements for tears and signs of decomposition. Check that rubber
and metal parts adhere to each other properly. If damages can be seen,
replace parts.
2.6.5 COUPLING (if applicable)
Check elastic parts for signs of wear.
If abrasion of rubber can be seen in the flange housing, determine the

cause and replace coupling or parts of it. The genset must not be operated
in this condition.
2.6.6 COOLING WATER PRE-HEATER
Test heating elements and all connections for leakages. Check tubes and
rubber hoses for tears and signs of wear, replace if necessary (see also
“cooling system”).
Check temperature settings and function of thermostat.
2.6.7 VENTILATION
Louvres
Lubricate bearings,
check lamellas for damages and tight closure, adjust if necessary.
Sound attenuators
Keep dust-free.
Fans
Keep dust-free,
check that protective grids are firm.
2.6.8 COOLING SYSTEM
Check cooler, header tank, flanged connections, tube connections and

pipes for leakages,
check that protective grids are firm,
check cooler lid for damages,
check rubber hoses for tears and signs of wear, replace if necessary.
page 2.19
Check cooling water level, fill up with prepared water if necessary, if water
level has dropped visibly, check for the cause and also fill up with anti-
freezing agent.
Check anti-freezing agent content, fill up with anti-freezing agent if

necessary, change coolant according to regulations of engine
manufacturer.
Keep cooler lamellas dust-free!
Storage tank:
Check content, fill up if necessary,
check tank for external damages,
repair damaged parts,
clean dome shaft (underground),
check tank for leakages (above ground);
drain water (treat used water acc. to regulations),
test function of level sensor,
check level of liquid in the leakage container, fill up if necessary,
pull leakage probe to cause leakage alarm, test level indicator.
Tank for daily consumption:

Check content, fill up if necessary,
check tank for external damages,
repair damaged parts,
drain off mud (treat acc. to regulations!),
test level sensor,
test level indicator,
test leakage indicator,
test overfill safeguard device,
test oil-water warning device (if applicable).
Clean fuel drip pan,

check paint for damages,
check pipes, tubes and connections for leakages (also within conduits!),
check function of fuel pump.
page 2.20
2.6.10 EXHAUST GAS SYSTEM
Check flange connections for leakages,

replace sealings if necessary,
check compensators for cracks,
check that mounting supports are firm,
check insulation for damages,
repair damages,
check that protective grids are firm,
drain off condensate (treat acc. to regulations!),
check wall and ceiling openings,
check deflector hood (birds’nests).
2.6.11 ALTERNATOR
see alternator operating instructions (Part 3)
2.6.12 BATTERY
Check electrolyte level,

fill up with distilled water if necessary,
check electrolyte density,
check battery charge,
check charging current,
check voltage controller,
carry out formation charge (Ni-Cd-battery),
clean poles and grease slightly.
Carry out loading test (lead battery).
2.6.13 SWITCHBOARD
Carry out signalling test,

replace signal bulbs if necessary,
check all settings,
readjust if necessary,
set zero point on all measuring instruments,
test all safety tripping devices,
adjust if necessary,
test remote indicators.
Test functions:
carry out trial start preferably with mains changing-over,
carry out test run under load.
report to operating control-book (servicing book).
page 2.21

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ABZ AGGREGATE-BAU GmbH

ABZ AGGREGATE-BAU GmbH

Tel.: +49 (0) 4193 90 36–0

Part 1 GENERAL INTRODUCTION

1 .1 General introductory notes 1.6

2.1 Transport 2.1

2.2 Setting-up 2.2

2.3 INSTALLATION 2.3

2.3.1 Mounting of Genset 2.3

Part 1 GENERAL INTRODUCTION

2.4 STARTING-UP 2.8

Introductory note 2.8

2.5.2 Operation 2.14

2.5.3 Fuel tank system 2.15

2.5.4 Battery 2.16

2.5.5 Ventilation 2.16

Part 1 GENERAL INTRODUCTION

2.6 MAINTENANCE AND

Introductory notes 2.17

Part 3 OTHER RELEVANT

3.1 Diesel engine

3.3 Cooling device

3.7 Testing documents

Part 1 GENERAL INTRODUCTION

1.1 GENERAL INTRODUCTORY NOTES

Only by understanding the information contained in this documentation

The instructions should be read before setting-up and putting into

In order to better understand the entire unit, this documentation sometimes

If any points in this documentation remain unclear or are found to be

This documentation is not supposed to alter any existing agreements or

The copyright in this documentation remains with ABZ. The documentation

Part 1 GENERAL INTRODUCTION

1.2 GENERAL SAFETY INSTRUCTIONS

Dangers can arise threatening

Unauthorised conversions or modifications that impair the safety and

Part 1 GENERAL INTRODUCTION

Exhaust gases are poisonous!

Exhaust gases are hot!

Do not disconnect the battery as long as the equipment is ready for

Switch the charger off before disconnecting the battery.

Be careful when dealing with fuels and lubricants.

Part 1 GENERAL INTRODUCTION

1.3 USING THE EQUIPMENT ACCORDING TO ITS

The purpose of the equipment is to generate electric energy on the basis of

The functions and operation of all equipment components have been

The genset should only be run at over-capacity for corrective adjustment

The unit is to be installed by staff with specialised training and it is to be

Whenever transporting or shipping the equipment do not step under the

Take notice of the signs indicated on the packing:

All ABZ-gensets can either be lifted using a fork-lift or by lifting it with a

On a smooth level surface the genset can be moved on heavy-duty rollers

The genset is designed according to ISO 3046. If there are differing

2.2.1 SETTING-UP ROOM

The calculation of safe dimensions of the foundation works is the duty of

Dimensions of setting-up room:

Ventilation openings: for intake air and discharge air

2.3.1 MOUNTING OF GENSET

There are two ways for mounting the genset: