Diesel Generator Engine Installation Method

Statement Procedure
Prior to commencement of DG set installation work all shop drawing will be submitted for
approval and approval will be obtained from the consulting engineer. Approved shop drawing
will show the routes with reference numbers as well as the supporting requirements. Only
approved shop drawing will be used at the site for installation. All materials to be used in this
system will be submitted for Engineers Approval in forms of material submittal or Product
data. Only approved materials will be stored ant used at the site.

Prerequisites for Diesel Generator DG Set

Installations
Make sure that the Generator Room is ready to accept the generator set.
Advertisement

Confirm that the access to the generator room is free from any obstacles.
Move the Generator set in place following the manufacturer handling instruction.
Lifting the generator set
Allocate trained personnel to ensure the lifting and transportation of the generatorin a safe
manner and in accordance to local guidelines. Before lifting the generator set, lifting points,
angle of slings, mass access to intended site and the distance of movement should all be taken
into account when organizing suitable crane/hoist.
Positioning Generator set using a Forklift Truck
The dimension, mass and route to be taken onto account when selecting an appropriate lifting
trucks. After get the appropriate truck, position the arm of the forklift under a frame or
pallet. Lift and handle the equipment slowly. Set down the generator set in final position slowly

Access to Diesel Generator DG Set

Provide at least 1 meter (3.3 feet) of clearance on all sides of the diesel generator set for
maintenance and service access. A raised foundation or slab of 152mm (6 inches) or more above
floor level will make servicing easier. Lighting should be adequate for operation, maintenance
and service operations and should be connected on the load side of the transfer switch so that it is
available at all times. Mount the generator set on a substantial and level base such as concrete
pad. A non-combustible material must be used for the pad. Use 16mm or anchored mounting
bolts to secure the generator The 38mm x 152mm pipe inserted over the mounting bolts to align
them to the holes in the bedframe. (see fig. below)
Vibrator Isolator Installation
Place the vibrator isolator (FSR Mounting Free Standing Bolted) under the support point of the
equipment, ensure that the load is uniformly distributed over the top plate of the vibration
isolator as shown in Figure A and B below:

Adjust the FSR mounting: With the 6 mm spacer in position as shown, tighten the positioning
nut. Turn, adjusting bolt of the spring counter-clockwise to load the spring. Load all the FSR at
the same time to ensure that the total load is uniformly spread onto all the FSR mounts. Continue
until the spring the spring load equal to the load of the requirement. When the equilibrium point
is reached, the 6 mm spacer can be removed from the FSR mount (see fig B above).
Moving the Generator Set
Ensure that the crane operating area is able to support the mass of the crane and the generator
set. Attach the lifting device to the lifting points only, using suitable shackles, chains and
spreader bars. Slowly tighten the slings. Inspect the lifting attachments before commencing a full
lift to ensure they attached correctly. Hoist generator set slowly using the indicated lifting points
only. Guide the generator set with ropes at a safe distance, to prevent uncontrolled rotation when
positioning the generator set. Move the generator set on the desired location and place in
position, bring the set down slowly. Loosen the slings, unhook and remove the shackles.

Mechanical Connections to Diesel Generatot DG Set

Fuel system: Cleanliness is of the utmost importance. Make every effort to prevent entrance of
moisture, dirt or contaminants of any kind into the fuel system. Clean all fuel system components
before installing
Fuel Return Restriction Limit: Fuel return drain restriction between the engine injector return
line connection and the fuel tank must not
exceed the limit stated in the model-specific generator set specification sheet.
Fuel Lines Routing: A flexible fuel hose or section of flexible fuel hose must be used between
the engines fuel system and the fuel supply and return lines to protect the fuel system from
damaged.
Engine Fuel Connection: Identification tags are attached to the fuel supply line connection. All
generator set require a fuel return line from injector to the tank.
DC Control Wiring
TB1 Remote Monitor I Control Connection Customer monitor/control connections are attached
to terminal block TB1. Optional Equipment such as sensing devices used to monitor generator
set operation, remote start/stop switches, etc. are also attached to TB1.
TB1 Wiring: Digital Connection. Connection points, other than relayed outputs and network are
considered digital connection to terminal strip TB1. The type/gauge wire to used for these
connection are:

Less then 305 meters, (1000 feet) use 20 gauge stranded copper wire

305 to 610 meters (1000 to 2000 feet), use 18 gauge stranded copper wire

Relay Due to wide variety of devices that can be attached to the relay outputs of TB1, installer
must determine the gauge of the stranded copper wire will be used at the site installation.
AC Electrical Connections
Before making any AC electrical connections, ensure that the generator set cannot be
accidentally started. Make sure the operator panel is in OFF mode. Turn off or remove AC power
from the battery charger and then removed the negative(-) battery cable from the set starting
battery.
Transfer switch: Transfer switch must be used for switching the load from normal power source
to the generator set (see figure below)

Load Connection: All loads are connected to the generator by bolting stranded load wire to the
appropriate terminals on the generator re-connection terminal block or circuit breaker lugs. The
terminal are marked U, V, W and N to indicate the line and neutral connection (reference: U, V,
W and N correspond with L1, L2 and L3; and N with LO respectively)
Grounding: The figure below shows the description of system and equipment grounding of
permanently installed AC generators within facility wiring system. It also illustrates typical
system grounding for a 3 pole ATS, note that the generator neutral is connected to the ATS and it
is not bonded to the grounded at the generator. In the 4 pole ATS system, a grounding electrode
conductor and a bonding jumper are used to connect the generator neutral to ground.