Long Run Oil System™
The oil reservoir capacity has been enlarged to allow the engine
to operate for a period of 3,000 hours. Consideration was given to the normal
oil consumption of the engine under any load conditions, as well as to the
maximum oil consumption expected as the engine wears.
An oil suction strainer extends into the reservoir to sufficient
depth to ensure that the engine will to continue to have adequate lubrication
throughout the extended service interval. Baffles, located in the oil
reservoir, provide the engine with warmed oil in cold operating conditions.
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Other features of the oiling system include a heat exchanger to
normalise the oil temperature with the coolant bypass circuit. In high ambient
operating conditions this will cool the oil, while in low ambient temperatures
the heat exchanger will warm the oil even when the thermostat is closed. Large
capacity, full flow, lube oil filters (2) are easily accessed for servicing. An
internal oil pressure relief valve regulates engine oil pressure. As well, the
duplex oil filter assembly is equipped with individual relief valves on the
filters. Should one filter become plugged, the other will remain operational.
The initial oil fill is made with synthetic oil. This oil is
compatible with non-synthetic oils. It is strongly recommended that the same,
or equal lubricating oil be used when topping up or replacing the oil.
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When the oil and filters are being changed, at 3,000 hour
intervals, the spin-on filter elements should be pre-filled with oil before
installation. After filling the oil reservoir, the set should be run up for
five minutes, shut down and the oil level should be brought up to the full mark
on the dipstick. DO NOT OVERFILL
THE OIL RESERVOIR. The oil will expand as it warms so there
needs to be air space above the oil level. Filling the reservoir above the high
mark indicated on the dipstick will cause the engine to shut down due to "high
oil level" fault. WHEN SETTING UP THE GENERATOR SET
FOR USE, IT SHOULD BE INSTALLED AS LEVEL AS POSSIBLE. THIS PREVENTS A FALSE
"HIGH" OR "LOW" LEVEL SHUTDOWN FAULT. |
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Cooling System
The cooling system consists of two electrically operated fans, a
thermostat for engine coolant, an electrically driven coolant circulation pump
and various components to signal and monitor the cooling system. These elements
are matched to provide the engine with proper cooling even under conditions of
severe heat or cold.
Essentially, the flow circuit consists of a circulating pump
drawing coolant, (50/50 water/low silicate antifreeze) from the radiator and
discharging the coolant through the engine's cooling passages. A thermostat in
the return to the radiator regulates the engine's temperature. A bypass circuit
redirects some coolant through a heat exchanger to warm or cool the engine oil.
When the engine reaches its normal operating temperature the thermostat allows
most of the coolant flow to return to the radiator where waste heat is
exchanged to atmosphere by one or both of the electric fans, as
required. |
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The primary fan, located in the engine enclosure, is powered by
the same 115 VAC supply circuit as the circulating pump. This low flow fan
maintains the engine's temperature even in extremely cold operating conditions.
A high flow, secondary fan is thermostatically controlled. It cycles on or off,
as dictated by ambient temperature and engine load conditions. The large volume
cooling system allows for degradation caused by foreign materials (within the
system or on radiant surfaces). |
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It is recommended that the antifreeze mix be flushed and replaced
every two years or 10,000 hours, whichever occurs first. A pre-mixed solution,
suitable for diesel engines may be used. A 50/50 mix of low silicate antifreeze
and de-ionized water is acceptable. An air bleed vent is located on the top of
the heat exchanger to help purge air from the system when refilling (see photo
of overflow bottle).
Each time the set is serviced (3000 hours) the fans should be
inspected for dust or dirt clogging the motors. As well, the hoses, clamps,
water pump seal and all fittings should be checked for leakage.
Other cooling system items include an overflow bottle for the
radiator's coolant, which should be kept at the indicated level. The secondary
fan motor, located in the plenum chamber, is cooled by the fan's air flow. This
motor should be cleaned annually with compressed air. (More often if operated
in dusty conditions) The radiator cap, the engine's thermostat and the
circulating pump's seal should be replaced every 10,000 hours. |
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Fuel System
A single fuel filter is located "upstream" from the mechanical
fuel transfer pump. There is a priming bulb located on the filter head. The
element should be replaced every 3000 hours. Any water or dirt should be
drained from the sediment bowl. Use only the exact replacement element part
number.
Care should always be taken when refuelling that no water or dirt
enters the fuel storage. The main tank on the base frame is angled slightly to
allow water to drain away from the engine's suction and return fittings which
are located near the bottom of the fuel tank. If necessary, any water can be
drained from the tank via the drain valve. |
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Air Intake System
A pre-filter, designed to remove 95% of moderate to heavy dust is
located on the air filter inlet. The air cleaner element should be replaced
every 10,000 hours. More frequent element replacement may be required in dusty
conditions. Tree needles and some seeds can be a problem to both the cooling
and air intake systems. If the set is operating in an area where these
circumstances might be found, check and service the air cleaner, cooling fans
and intake and exhaust louvers as required. |
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DC Electrical System
There are two, paralleled, 12 volt lead acid batteries for the
starting circuit. An automatic, 3 amp, battery charger, located in the rear
control panel, maintains both batteries. When the set is running there is very
little DC load. Do not add DC loads such as lighting without contacting the
manufacturer to ensure adequate charging is available. Frequent starting cycles
may also require an increase in battery charger output. |
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Enclosure
The enclosure is designed to allow sufficient air to flow to the
unit even if one side should become blocked. (Ice storm, leaf build-up etc.)
The panels at the radiator end are removable for servicing the main cooling fan
and motor. Always replace these panels after servicing.
The enclosure is "rodent proof", as supplied. It is very
important, both for safety and for operating reasons, that all sheet metal and
guarding remains properly fastened and in good condition. The powder coated
outer and inner surfaces protect the metal from deterioration. Touch up
scratches and chips with automotive enamel paint. |
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AC Electrical Equipment
The generator is brushless and has a solid state automatic voltage
regulator. Generally, no generator maintenance is required before the engine is
due for major overhaul.
A main circuit breaker protects the generator from electrical
faults and branch circuit breakers are provided on all circuits.
All components of the electrical system
are bonded and a grounding lug is supplied. The unit must be grounded in
accordance with local regulations. |
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Control and Metering
A control module is installed which provides engine and generator
monitoring functions. As, well the control module supplies signals to various
engine subsystem tasks. For details, the specific manual is provided. Wiring
details are shown on the wiring schematics.
A reset feature can be used to count down hours to the engine's
service intervals. As well, the control module stores accumulated kilowatt
hours and total running time
Fault monitoring, with adjustable parameters, allows the control
module to alert a designated operator, via wireless modem should an alarm or
critical fault occur. |
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The fuel tank is a single wall reservoir with approximately 500 US
gallons of capacity. A 2" NPT filler neck is surrounded by a splash guard. One
fuel level sender is provided to pre-alarm low fuel level. Locks are provided
to protect the contents.
Extreme care should be exercised when filling the tank to prevent
foreign materials from entering the fuel system. Under normal warming and
cooling cycles, condensation will form within the tank. This water will settle
and can be drained off the bottom of the tank via the drain valve supplied.
Situations that would result in an engine failure are monitored and, at
a predetermined point, will result in the shutdown of the generator set. These
conditions are; low oil level, high oil level, low oil pressure, high coolant
temperature, engine over-speed and engine under-speed.
In addition to the shutdown points there are predetermined alarm
parameters. At the alarm point, a signal can be generated to notify the
operators of potentially dangerous conditions. These conditions include; low
fuel level, over-cranking of the starting motor, sender failure (oil pressure,
coolant temperature), high or low speed signal, low battery voltage, battery
over-voltage, generator overload and scheduled maintenance due.
