Kirloskar DG Set Manual

Dear Customer,
We are happy to welcome you to the community of thousands of satisfied users of Kirloskar Green Power
Ideas diesel generating sets.
Each Kirloskar Green genset is a result of painstaking research by us over decades. The research takes
into consideration the arduous operating conditions and user practices to create a world class reliable
product.
We have not only designed the genset, but also its major aggregates – Kirloskar Green AC Generator,
Sound Proof Outdoor Enclosure and Control Panel.
This Users Manual of Kirloskar Green Power Ideas genset has been prepared by keeping in mind needs
of most of the users. Thus, the manual only illustrates user serviceable maintenance practices and
parts. In case you desire more detailed information about the genset, its engine, AC generator, or control
panel, please let us know. Also note that this manual is applicable only to those KGPI Genset users
having Kirloskar HA, R1040/R1080 and SL90 series of diesel engines.
We are sure, Kirloskar Green Power ideas genset will serve you well for years as you continue to
maintain it as presented in this manual.
Yours faithfully,
For Kirloskar Oil Engines Ltd.,
Pune, INDIA
P. M. Sardey
Customer Support
Global Head
Enriching Lives
While asking for assistance to our Authorised Service Dealer,

please provide the following information.
Your Name & Phone or Mobile Number.
Engine Serial Number.
Name of the Company.
Engine Location.
General Description of assistance required.
And the service will be on its way.
O FOR EMERGENCY CONTACT O

In the very unlikely event of you are not receiving the prompt attention
from our field force, following are the contact details of our Help Desk
and area office for your assistance.
HELP DESK TOLL FREE NUMBER - 1800 233 3344

HELP DESK LAND LINE NUMBER - 020 - 66084608
AREA OFFICE CONTACT DETAILS

KOEL Delhi - 011 23718544 KOEL Ludhiana - 0161 2531372
KOEL Lucknow - 0522 27895565 KOEL Jaipur - 0141 2361789
KOEL Kolkatta - 033 2172265 KOEL Guwahati - 0361 2529284
KOEL Bhubanwswar - 0674 2588047 KOEL Pune - 020 66084260
KOEL Ahemadabed - 079 27480922 KOEL Indore - 0731 2531402
KOEL Chennai - 044 23744624 KOEL Bangalore - 080 25587570
KOEL Cochin - 0484 2316653 KOEL S’bad - 040 27819563
KIRLOSKAR OIL ENGINES LTD.

LAXMANRAO KIRLOSKAR ROAD, KHADKI, PUNE - 411 003.
PHONE : +91-020-25810341 O FAX : +91-020-25813208, 25810209
MAIL ID - [email protected]
http://www.koel.co.in
PREFACE
This manual deals with the KGPI genset operation and detailed briefs of all those
components and parts which a user can service on his own. The maximum performance of the
genset largely depends on its proper maintenance and upkeep. So, please be sure to maintain
your genset properly as per the instructions and schedule given in this manual. This user manual
is divided into 6 Sections related to Genset, Diesel Engine, Alternator, Warranty, Customer Service,
Area Office Contacts and Check Call Cards. Here follows the synopsis of each section to give
you a quick feel of what this book has in store for you.
Section A – Genset Warranty
The Warranty Section is most important for you to understand completely. It gives you
description of all the “ifs and buts” of the warranty clauses and the means to get benefit from
KGPI extended warranty. It also contains a log sheet that you need to fill religiously. Please
record the daily running of the DG set and various parameters.
Section B – Customer Service Package
To ensure maximum life and best performance of your genset, we provide free installation
and maintenance checks. Kirloskar Service Dealer will carry out free service checks as mentioned
in the package. Please keep in mind that you would be required to pay for the consumables like
lube oil filters, fuel filters, lube oil, etc.
Section C – Genset User Manual
This Section takes you through to understand each aspect of the genset, its major
components and their operation. Chapter 3 tells you about the installation procedures and
subsequent chapter take care of the electrical control systems and optional equipment that can
be used. You must read Chapter 6 and 7 thoroughly to understand the maintenance procedures
for genset and batteries.
Section D – Engine User Manual
This part of the manual gives you a complete understanding of the engine operation and
maintenance from a user perspective. All the fluid systems, namely, lube-oil, fuel oil, cooling
liquid flows have been described because the upkeep of these three systems is significant to
obtain optimum performance from the engine. Later in this section, you must go through to
comprehend the trouble-shooting, remedial and engine preservation measures. This section
takes care of all the models of engines used in a KGPI genset. Efforts have been made to highlight
those specific areas which are unique to a particular engine model.
Section E – Alternator
Here we have given you a brief knowledge about the Kirloskar Green Alternator coupled to
the diesel engine. KG alternators come in two variants – brushtype and brushless. The exploded
views and illustrations give you in-depth detailing of what lies underneath. User needs to read the
safety requirements and all the “do’s & don’ts”. The brushtype alternator also has brushes and
sliprings which user needs to replace after they wear out. In the end, you are provided with the
fault, cause and repair tables so that every time you don’t need to rush to a mechanic.
Section F – Service Network
Kirloskar Green Power Ideas takes care of you anywhere everywhere. And this last section
contains the information (contact details) of our 5 zonal offices, 17 area offices and 176 service
dealer locations. Each time you run into a problem with your genset. Just look for your nearest
office/service dealer location in this section and KGPI will take care of the rest.
Intimation Card
Please ensure that your manual has intimation card. We request you to fill the required
details completely in the intimation card and post it to us immediately.
CONVENTIONS
Each warning/most important instruction in the manual succeeds the sign .
All the significant procedures are highlighted in bold letters in the manual.
All the illustrative diagrams in the manual show only the user-serviceable parts. The
numbers in the round boxes for every part are described below the illustration.
The logo displayed at the top corner of each page is the Kirloskar Green Power Ideas
brand logo.
USER MANUAL - SERVICE NETWORK
NORTH ZONE
DELHI, UTTAR PRADESH, PUNJAB, HARYANA, RAJASTHAN, HIMACHAL PRADESH, J&K, AND
UTTRANCHAL
ZONAL OFFICE
KIRLOSKAR OIL ENGINES LTD., +91-011-23718544 (O)

UCO BANK BUILDING, +91-011-23719490 (O)
PARLIAMENT STREET, +91-011-23319473 (O)
NEW DELHI – 110 001 +91-011-23710159 (F)
Service Manager 09971115383 (M)
09871172824 (M)
09923450110 (M)
AREA OFFICES

408, SAVITRI COMPLEX, +91-0161-543848 (O)
4TH FLOOR, G. T. RD, +91-0161-543847 (F)
LUDHIANA – 141 002 Service Manager 09216523012 (M)

498/143-K, NEAR IT COLLEGE CROSSING +91-0522-2323130 (O)
FAIZABAD ROAD +91-0522-2789633 (O)
LUCKNOW – 226 007 +91-0522 -2789764 (F)
[email protected] Service Manager 09219635518 (M)

D-24,DURLABH NIVAS +91-0141-2363389 (O)
SUBHASH MARG , C SCHEME +91-0141-2360528 (F)
JAIPUR - 302 001 Service Manager 09829064750 (M)
SERVICE LOCATIONS
Delhi, Noida, Gurgaon, Bahadurgarh, Samalkha, Karnal, Faridabad, Panipat, Damtal, Mandi, Jammu, Srinagar, Leh,
Chandigarh, Ludhiana, Jalandar, Amritsar, Udaipur, Bhilwara, Rajnagar, Kesarijai, Kota, Alwar, Rewari, Ajmer, Jaipur,
Jodhpur, Bikaner, Lucknow, Varansi, Gorakhpur, Kanpur, Allahabad, Agra, Gaziabad, Dehradun, Moradabad, Barrelly.
1
WEST ZONE
GOA, GUJRAT, MAHARASHTRA, MADHYA PRADESH, & CHATISGARH
ZONAL OFFICE
KIRLOSKAR OIL ENGINES LTD. +91-020-25810341 (O)
(CORPORATE HEAD QUARTERS) +91-020-25813208 (F)
LAXMANRAO KIRLOSKAR ROAD, +91-020-25810201 (F)
Khadki, Service Manager 09881495639 (M)
PUNE - 411 003
AREA OFFICES
KIRLOSKAR OIL ENGINES LTD. +91-079-27480922 ( O)

NEW NATRAJ COMPLEX +91-079-27450237 (O)
GURUKUL ROAD +91-079-27447113 (O)
MEMNAGAR +91-079-27447112 (F)
AHMEDABAD - 380 052 Service Manager 09879000901 (M)

APARTMENT NO.405/406 A +91-0731-2532528 (O)
4TH FLOOR, INDUSTRY HOUSE. +91-0731-2535075 (O)
15TH AB ROAD, Service Manager 09826026463 (M)
INDORE - 452 007.
SERVICE LOCATIONS
Ahmedabad, Surat, Jamnagar, Baroda, Ankleshwar, Bhavnagar, Silvassa, Satna, Jabalpur, Indore, Bhopal, Raipur,
Jhansi, Gwalior, Goa, Pune, Nasik, Kolhapur, Ratnagiri, Chiplun, Panvel, Vashi, Solapur, Latur, Pandharpur, Thane,
Akola, Nagpur, Aurangabad
2
SOUTH ZONE - 1
ANDHRA PRADESH AND KARNATKA
ZONAL OFFICE
KIRLOSKAR OIL ENGINES LTD., +91-080 – 5587570 (O)
2ND FLOOR, SHRI LAXMI COMPLEX +91-080 – 5587562 (O)
15,St. MARKS ROAD +91-080 – 5587566 (O)
NEXT TO FORD SHOWROOM +91-080 – 5587569 (O)
BANGALORE – 560 001 +91-080 – 5587559 (F)
AREA OFFICES
1-7-27 TO 34, 216 TO 228 +91-040-27819561 (O)
UNITED BUILDING COMPLEX +91-040-27897873 (O)
II FLOOR BLOCK B’, S.D.ROAD +91-040-27898243 (O)
SECUNDERABAD – 500 003 +91-040-27721511 (F)
SOUTH ZONE - 2
TAMILNADU & KERALA
ZONAL OFFICE
KIRLOSKAR OIL ENGINES LTD. +91-044-23744624 (O)
NELSON TOWERS, +91-044-23744661 (O)
1ST FLOOR, 2ND WING, +91-044-23744874 (O)
NO.51,NELSON MANICKAM ROAD, +91-044-23744625 (F)
AMINJIKARAI Service Manager 09444990295 (M)
CHENNAI – 600 006
AREA OFFICES
G-259, 2 nd FLOOR +91-0484-2316687 (O)
PANAMPILLY NAGAR +91-0484-2316652 (F)
PANAMPILLY AVENUE Service Manager 09744716767 (M)
COCHIN – 682 036
SERVICE LOCATIONS
Cuddapah, Anathpur, Tirupati, Nellore, Chittor, Rajamundry, Vijaywada,Warangal, Secunderabad, Vishakapatnam,
Gulburga, Bangalore, Mysore,Hubli, Bellary, Tumkur, Manglore, Belgum, Udapi, Davangiri, Cochin,Calicut,
Trivandrum, Kottarakkara, Kollam, Idduki, Palakkad, Pondichery, Coimbatore, Tirupur, Pollachi, Erode, Kunoor,
Dharapuram, Sathymangalam, Trichy, Dindigul, Karur, Karaikal, Thiruchengodu, Thanjavaur, Krishnagiri, Vellore,
Sivakasi, Tirunerveli, Nagarcoil, Tuticorin, Madurai, Chennai, Salem, Coimbatore
3
EAST ZONE
BIHAR JHARKHAND ORRISA WEST BENGAL AND NORTH EASTERN STATES
ZONAL OFFICE
KIRLOSKAR OIL ENGINES LTD.,
POONAM BUILDING +91-033-217-2265/66 (0)
8TH FLOOR, FLAT NO 8 A SSB, +91-033-217-0858 (0)
S/2 RUSSEL STREET, +91-033-217-0860 (0)
KOLKATTA - 700 107. +91-033-217-0861 (0)
+91-033-217 -0859 (F)
AREA OFFICES
KIRLOSKAR OIL ENGINES LTD., +91-0361-529284 (0)
BHANGAGARH, +91-0361-451587 (0)
G.S.ROAD., +91-0361-529894 (F)
GUWAHATI - 781 005 Service Manager 09435119345 (M)
KIRLOSKAR OIL ENGINES LTD., +91-0674-588047 (F)

1/A, UNIT III, STATION SQUARE +91-0674-588021 (O)
BHUANESHWAR - 751001. Service Manager 09437920980 (M)

MEENA PLAZA, SOWTH MESEUM ROAD, +91-0612-2220412 (O)
BUDH MARG, Service Manager 09334383111 (M)
PATNA - 800 001.
SERVICE LOCATIONS
Guwahati, Tinsukia, Tezpur, Aizwal, Silchar, Patna, Ranchi, Dhanbad, Jamshedpur, Sambalpur, Angul, Asansol, Kolkatta,
Siliguri, Rourkela, Bhubaneshwar, Balasore,
HEAD OFFICE
KIRLOSKAR OIL ENGINES LTD.,

L. K. ROAD, KHADKI, PUNE - 411 003.
A. P. UPADHYE - 9881209205 RAKESH PARDESHI - 9822599877

020 - 66084532 020 - 66084134
D. B. DESHPANDE - 9822001420 P. M. SARDEY - 9922416893
020 - 66084533 020 - 66084596
4
INDEX
Section A - Warranty
Section B - Customer Service
Section C - Genset
Section D - Diesel Engine
Section E - Alternator
Enriching Lives
WARRANTY
IMPORTANT
1. This warranty is applicable for Kirloskar Green Power Ideas gensets manufactured
by Kirloskar Oil Engines Limited (KOEL).
Before commissioning of the genset, please go through the contents of this

Warranty Section carefully.
2. For details of KOEL Authorised Service Dealer for your genset, please contact
either your supplier of genset or nearest KOEL Area Office.
3. For availing the warranty services, please ensure following :
a) Produce this warranty booklet to KOEL authorised Service Dealer, when

requested.
b) Carry out first service check through KOEL Authorised Service Dealer within
seven days of installation, followed by second service check within 250 Hrs
or 3 months from the date of first service check, whichever is earlier.
c) Use recommended grade of lube oil and ensure periodic change of lube oil,
as recommended.
d) Use genuine air filter elements, lube oil filter elements, fuel filter elements,
coolant and additives, sourced from KOEL Authorised Service Dealer.
e) Please maintain the log-book for the genset at your end. The suggested
format for log-book is provided on page no. A-6.
f) Carry out repairs of genset, through KOEL Authorised Service Dealer, only.
g) The performance of genset depends on the quality and grade of lub oil and
periodic preventive maintenance. To ensure the genuinity of oil, KOEL has
launched the lube oil branded as K-Oil. Please use K-Oil and genuine filters
sourced through KOEL authorised parts and service dealer and avail
extended warranty.
A-1
WARRANTY
Please provide following details to our Authorised Service Dealer.

It will help him for quick restoration of your genset.
— Genset Model & serial No. :
— Engine serial No. :
— Detailed site address :
— Contact Person and

Telephone/Mobile No.
— No. of Hrs. run till date :
— Nature of failure :
A-2
WARRANTY
GENSET MODEL AND SR. NO. __________________________________________
ENGINE MODEL & SR. NO. ______________________________________________
KG ALTERNATOR SR. NO.

MAKE & TYPE __________________________________________________________
PANEL SR. NO. _________________________________________________________
G1 (1ST SERVICE) CHECK

CARRIED OUT ON ______________________________________________________
G2 (2ND SERVICE) CHECK

CARRIED OUT ON ______________________________________________________
SERVICE DEALER’S
STAMP AND SIGNATURE
A-3
WARRANTY
Use K. Oil, Kirloskar Genuine filters, K Cool super plus and avail two years warranty
KIRLOSKAR GREEN D.G. SET

WARRANTY
For Power Generation non Cellular Application Engines - per the maintenance schedule given by Kirloskar Oil
Engines Ltd.
This warranty is applicable to R/HA/R1040/R1080/SL90/K series
Kirloskar Green Genset. The warranty is for 18 months from date 3. If K Cool Super plus engine coolant is not used for
of dispatch of engine and alternator from Kirloskar Oil Engines, water-cooled Genset.
Ltd. Pune or from 12 months from the date of commissioning or
3600 hours of operation whichever is earlier. 4. Damage due to improper installation of the parts,
components and accessories.
Customers can also avail extended warranty of 2 years from
the date of installation or 5000 operating hours or 30 5. For the parts supplied under warranty or voluntarily or
calendar months from date of dispatch whichever is earlier, at special rates or free of charge, the warranty will be
subject to use of Kirloskar K Oil, Kirloskar genuine filters, K applicable only to the unexpired portion of D G Set
cool super plus and services sourced through KOEL warranty.
authorised Service Dealer. 6. Damage due to use of improper lubricant or the
For Power Generation Cellular Application Engines & KG lubricant used other than suggested by Kirloskar Oil
Alternator Engines Ltd.
Within 24 Calendar Months from Date of Dispatch from KOEL 7. Normal wear and tear of the components of Kirloskar
or 2500 operating hours Which ever occurs first if customer Green Genset / Engine.
source the filters, K-Oil Super, K cool super plus and avail the
services from KOEL Authorised Service dealer. 8. For resale of Kirloskar Green Genset or if the Kirloskar
Green Genset purchased is second hand.
Kirloskar Oil Engines Ltd. hereby warrants that this Kirloskar
Green Genset is free from defects in material, design and Warranty period for DG set components is as below.
workmanship. For Power Generation Non Cellular Application -
This warranty shall be limited for repairs and replacement under O Proprietary parts not manufactured by Kirloskar oil
normal use, regular check up and maintenance of the Kirloskar engines like
Green Genset as per our maintenance schedule and purchase o Starter
and servicing of the Kirloskar Green Genset through our o Alternator
authorised dealer. o Fuel injection pumps
18 Calendar Months from Date of Despatch or 3600
This warranty is the only document given by us warranting the operating hours or 12 calendar months from date of
Kirloskar Green Genset. No other document giving any warranty installation
terms conflicting these contents shall be considered and
entertained. The warranty is subject to analysis of defect by the
respective authorised dealer of manufacturer.
Kirloskar Oil Engines Ltd. is not liable to service, or repair of
Kirloskar Green Genset free of costs during the warranty period, O Kirloskar Green Alternators
for the Kirloskar Green Genset purchased from person other 30 Calendar Months from Date of Despatch or 5000
than an authorised person or DG set Dealer or AGOEM of operating hours or 24 calendar months from date of
Kirloskar Oil Engines Ltd. installation Whichever occurs first
O All other Electrical Components supplied along with
Kirloskar Oil Engines Ltd. is not liable for any loss or damage, Genset like
direct or consequential, labour charges or the effect of any o Electrical Gauges
accident resulting from defective material, faulty workmanship o Electrical Hour Meters
or otherwise. In any case the liability of Kirloskar Oil Engines Ltd. o Sensors
will not exceed the Kirloskar Green Genset price or the market o Switches
value of the Kirloskar Green Genset whichever is lower and shall o Engine Safety Units
be without interest. o Actuator
This warranty does not apply for the following: o Controller card
1. The Kirloskar Green Genset or engine failure due to operating hours or 12 calendar months from date of
any misuse including improper shutdown, improper installation Whichever occurs first
handling and adjustments, negligence, over speeding, **Warranty is not applicable for fuse & charging bulb.
alteration of specification and due to accident or Act. of
God.
O Kirloskar Green canopy Components supplied along
with Genset like
2. Kirloskar Green Genset or engine if not maintained as
Use K. Oil for your Gensets, for details of K. Oil, please contact our Authorised Service Dealer
A-4
WARRANTY
Use K. Oil, Kirloskar Genuine filters, K Cool super plus and avail two years warranty
o Locks O Kirloskar Green canopy Components supplied along

o Hinges with Genset like
o Fuel level gauges o Locks
o Exhaust fan o Hinges
o AVM
operating hours or 12 calendar months from date of 18 Calendar Months from Date of Despatch or 2500
installation Whichever occurs first operating hours Whichever occurs first
**Warranty is not applicable for foam, bulb, and tubes **Warranty is not applicable for foam, bulb, and tubes
O Kirloskar Green Control Panel Components supplied O Kirloskar Green Control Panel Components supplied
along with Genset like. along with Genset like.
o AMF module o AMF module
o Relay card / board o Relay card / board
o LVM / GVM o LVM / GVM
o Current transformer o Current transformer
o Battery chargers o Battery chargers
o KWH meters o KWH meters
o Switches o Switches
o MCB o MCB
o Contactors o Contactors
18 Calendar Months from Date of Despatch or 3600 12 Calendar Months from Date of Despatch or 2500
operating hours or 12 calendar months from date of operating hours Whichever occurs first
installation Whichever occurs first **Warranty is not applicable for fuse & charging bulb
**Warranty is not applicable for fuse, charging bulb & & contactor coil.
contactor coil Any claim or obligation in connection with the sale or
For Power Generation Cellular Application - performance of Kirloskar Green Genset shall be subject
to Pune Jurisdiction.
O Proprietary parts not manufactured by Kirloskar oil
engines like Conditions precedent to Kirloskar Green Genset warranty.
o Starter The Kirloskar Green Genset warranty given by the company is
o Alternator subject to the below condition which are to be observed by
o Fuel injection pumps every purchaser/user of Kirloskar Green Genset, without which
o Battery the warranty claims if any will be rejected.
o Exhaust Fan A. Proper installation of the Kirloskar Green Genset is the
For Power Generation Cellular Application - 15 sole responsibility of the owner of the Kirloskar Green
Calendar Months from Date of Dispatch or 2500 Genset / purchaser of the Genset.
operating hours Which ever occurs first B. Operation & Maintenance as recommended by the
The warranty is subject to analysis of defect by the company within the limits mandated by the
respective authorised dealer of manufacturer. specifications.
C. Any defective part claimed, to be returned to Kirloskar
O All other Electrical Components supplied along with Oil Engines Ltd., if such part is replaced by the company
Engine like– under warranty, the returned part becomes the property
o Electrical Gauges of the company, this transportation charges to be paid
o Electrical Hour Meters by the customer.
o Sensors
o Switches D. Incase of interchange of part between Kirloskar Green
o Engine Safety Units Gensets / Engine shall void the warranty. Unauthorised
o Fuel level gauge repair work will make the warranty null & void.
E. For the proprietary parts not manufactured by Kirloskar
12 Calendar Months from Date of Despatch or 1000 Oil Engines Ltd., such as Fuel Injection Equipments,
operating hours Which ever occurs first Electrical Equipments and Instruments etc. the warranty
**Warranty is not applicable for fuse & charging bulb terms of respective supplier will be applicable.
The warranty detailed above is offered for the Kirloskar green power ideas Diesel Genset consisting of Kirloskar
Engine, Kirloskar Green AC Generator & sound proof enclosure branded Kirloskar Green and control panel.
To meet specific customer needs, your Genset may not contain Kirloskar green power ideas AC Generator,
soundproof enclosure, or control panel. If so warranty for such aggregates may please be availed from the
manufacturers of these aggregates. The seller of the Genset will be happy to provide you the details.
Use K. Oil for your Gensets, for details of K. Oil, please contact our Authorised Service Dealer
A-5
WARRANTY
LOG SHEET (Sample for use)

The user is requested to maintain a separate log book registering the following mentioned parameters in the table.
Following tables are meant for providing a reference to you.
Engine__________________________________ RPM_______________________________ HP________________________
Date
Daily use in hrs.
Hour meter reading
Cooling Water Temp (°C)
Pressure (Kg/cm2)
Lub. Oil
Temp (°C)
Fuel added (ltr.)
Lub. oil added (cc)
Engine (rpm)
Current (Amp) 3-phase
Voltage
Frequency (Hz)
PF & kW if provided
kWH meter reading if provided
Remarks - Record events of

maintenance / repairs
A-6
WARRANTY
Date
Daily use in hrs.
Hour meter reading
Pressure (Kg/cm2)
Lub. Oil
Temp (°C)
Fuel added (ltr.)
Lub. oil added (cc)
Engine (rpm)
Voltage
Frequency (Hz)
PF & kW if provided

A-7
WARRANTY
Date
Daily use in hrs.
Hour meter reading
Pressure (Kg/cm2)
Lub. Oil
Temp (°C)
Fuel added (ltr.)
Lub. oil added (cc)
Engine (rpm)
Voltage
Frequency (Hz)
PF & kW if provided

A-8
WARRANTY
Date
Daily use in hrs.
Hour meter reading
Pressure (Kg/cm2)
Lub. Oil
Temp (°C)
Fuel added (ltr.)
Lub. oil added (cc)
Engine (rpm)
Voltage
Frequency (Hz)
PF & kW if provided

A-9
Time FIRST SERVICE CHECK (G1) - ENGINE SIDE Date
D G Set Parameters ( Within 3 months from the date of installation or first 50 Hrs. of Genset run whichever is earlier. ) S. R. Number :
Engine Type : Application Code / Sr. No. :

Radiator Sr. No. : Turbocharger Sr. No. :
FIP Sr. No. : Electronic Governor Sr. No. :
Installation Dt : Commissioning Date:
Hours run and the date of visit :
Make of Alternator : Rating : Sr. No. :
Phase : Single / Three Type : Brushless / Brush Type Frame :
Alternator Control Panel : AMF / Non AMF Make : Sr. No. :
Type of Load : Resistive / Inductive / Capactive /
Canopy : Sr. No. :
DG Set Tested on full load for hours.
Current
Lube Oil Pressure : Lube Oil Temp. : Voltage : R: Amp.
Y: Amp.
Water Temp. : Abnormal Noise : Frequency : B: Amp.
Ambient temp. (air temp. near air-cleaner element) :
Safeties :Low Lube Oil Pressure – Working / Not Working

High Lube Oil / Water Temp – Working / Not Working
V Belt Failure – Working / Not Working
Leakages, if any and the corrective action
Overall Performance of DG Set OK / Not OK.
Remarks of the service dealer representative :
Educated Customer on routine maintenance to be carried out :

• Cleaning of Air Cleaner (Dry / Oil Bath), Restriction Indicator operation. Yes / No
• Lube Oil & Oil Filter Change Yes / No
• Fuel / Filter Element Change Yes / No
• Cleaning of Radiator Cooling fins Yes / No
• Cleaning of Liner & Cylinder Head Fins in case of Air Cooled Engine. Yes / No
Customer Remarks : Customer Name :
Site Address :
Tel. No.
Name, Signature & Designation of AGOEM Name & Address Name, Signature & Designation of
Customer Representative. Service Dealer Representative.
N.B. - Please fill the information, as applicable. Page No. 1 of 3

1) KOEL HEAD OFFICE COPY
ALTERNATOR CHECK POINTS - DURING G1 CHECKS
Sl No. Service Point Remark
1 Alternator Checks to be carried out during stop condition for
Main Stator Winding leads tightness at Main Terminal. OK / NOT OK
All AVR connections tightness. OK / NOT OK
Outgoing cable connections tightness. OK / NOT OK
2 Check for Seperate Earthing connections for neutral & Genset body,
both should be connected to earth pit. OK / NOT OK
Pour sufficient water in to Earth pit. DONE / NOT DONE
Check outgoing main cable connection at terminal. OK / NOT OK

Observe proper lugs, crimping & glands.
3 Start the Set and observe the following parameter-
Check for stable out put voltage from Alternator. OK / NOT OK
Check for Balance load. ( unbalance should not be more than 10 % of total load ) Balance / Unbalance
Current ( Amp ) - R- Y- B- N- phase respectively
Voltage (Volts ) - RY - YB- BR-
Power factor ( if available )-
4 Connected Load details - Unit - KW/ KVA
Total Motor load connected -
AC / DC Drive ( 3 ,6,12 pulse ) load connected.
UPS connected -
Other load details like fan / lights. -
Total Load connected -
Site Address :
Tel. No.

CHECK FOR CONTROL PANEL - DURING G1 AND G2 CHECKS
Sl No. Service Point Status
1. Check the tightness of crimping of cables -
Mains cable tightness & lugs crimping & gland in control panel . OK / not OK
Generator cable at control panel and alternator terminal. OK / not OK
Correct cable size with correct lugs. OK / not OK
Connection are tight. (All power & control cable) OK / not OK
2. Check the Earth connection of control panel. OK / not OK
Check control panel is mounted on AV mounting or check vibration. OK / not OK
3. Accessories -
AMF module type
MCCB ( make & rating )
Mains contactor ( make & rating )
Generator contactor ( make & rating )
4. Check for tightness of following connections -
Connection at main terminal board are tight with proper lugs or solder end. OK / not OK
Power connection at both Contactors are tight. OK / not OK
Connection at all fuses or MCB are tight. OK / not OK
Check the proper tightness of all relays at relay base with proper relay locking clips. OK / not OK
5. Check the Battery voltage and ensure that battery is fully charged OK / not OK
Battery voltage
Specific Gravity of battery solution ( required 1.270 ) OK / not OK
Ensure all cells of battery are filled with electrolyte battery solution to max. level OK / not OK
Ensure charging of battery by charging alternator (if provided) or by Battery charger OK / not OK
Check Battery terminal for cleanliness and tightness. OK / not OK
6. Checking of electrical accessories -
Simulate the fault like LLOP, HCT etc. and check engine tripping with alarm. OK / not OK
Check all the gauges are working. OK / not OK
Check the exhaust fan working and direction of fan. OK / not OK
Check solenoid supply is not more than 15-20 sec. OK / not OK
7. Check all the meters for working on control panel working. OK / not OK
8. Mains voltage ( EB Power ) -
Mains current ( EB Power ) -
9. Generator voltage -
Generator current-
10. Ensure AUTO / MANUL mode operation of AMF pannel. OK / not OK
Site Address :
Tel. No.

Time SECOND SERVICE CHECK (G2) - ENGINE SIDE Date
( Within 6 months from installation date or second oil change ) S. R. Number :
1 Application Code & Engine serial no & Type :
2 Customer Name :
3 Date of service check : G1 G1 S. R. Number
4 Installation date : Commissioning date :
5 No. of Hours run :
Service points: Action taken
1 • Change the engine lube oil. • Done

(Drain the Engine Oil when the Engine is warm. Top up 0.5 liters more for
2,3,4 cylinder engines or as applicable to compensate Lube Oil Filter Capacity.
• Replace the Lube Oil filter Element cartridge with the oil change. • Done / OK
2 • Incase of oil bath type air cleaner, clean air cleaner & refill it with fresh lube oil. • Done / OK
Clean the precleaner bowl.
• In case of dry type air cleaner element follow the practice mentioned in O & M manual. • Done / OK
3 For Air Cooled Engines :

• Check for proper cowling fitment for effective cooling of the engine. • Done / OK
• Clean the cylinder liner & cylinder heads fins. Clean by removing main cowling & • Done / OK
direct compressed air flow on the fins, or clean with brush.
For Water Cooled Engines :
• Check up coolant level in radiator, compensatory tank or heat exchanger • Done / OK
& top up if required.
(For initial filling add Radiator coolant as recommended. Keep the filling cap
open after topping up & run the engine on low idle speed to remove air pocket.)
(Do not top up cooling system with plain water, use only recommonded coolant.)
• Check whether radiator fins are choked. Educate customer on how to clean the • Done / OK
radiator externally.
4 • Check button filter in the banjo bolt of feed pump. If choked, clean it. (educate customer) Cleaned.
• Drain the water from Water Separator, if provided Cleaned.
• Change fuel filter element as per O & M schedule. • Done / OK
hence not
necessary.
5 Check for all External Fasteners as per Specified torques. Tightened

(Tighten all foundation bolts)
6 Check battery lead connections, check specific gravity of electrolyte. OK/ corrected
7 Check Belt Alignment and belt condition, & adjust if required. Replaced/
Corrected/OK
8 If the engine is turbocharged, check for

• Leakages in air intake/exhaust piping • Done / OK
• Hose connections tightness • Done / OK
SECOND SERVICE CHECK (G2) - ENGINE SIDE
( Within 6 months from installation date or second oil change )
DG Set Tested during inspection for hours. Current
Lube Oil Pressure : Lube Oil Temp. : Voltage : R: Amp.

Y: Amp.
Water Temp. : Abnormal Noise : Frequency : B: Amp.
Ambient temp. (air temp. near air-cleaner element) :

Safeties : Low Lube Oil Pressure – Working / Not Working
High Lube Oil / Coolant Temp – Working / Not Working
V Belt Failure – Working / Not Working
Leakages, if any and the corrective action
Overall Performance of DG Set OK / Not OK.
Remarks of the service dealer representative :
Educated Customer on routine maintenance to be carried out :

• Cleaning of Air Cleaner (Dry / Oil Bath), Restriction Indicator operation. Yes / No
• Lube Oil & Oil Filter Change Yes / No
• Fuel / Filter Element Change Yes / No
• Cleaning of Radiator Cooling fins Yes / No
• Cleaning of Liner & Cylinder Head Fins in case of Air Cooled Engine. Yes / No
Site Address :
Tel. No.

ALTERNATOR CHECK POINTS - DURING G2 CHECKS
1. Check for Abnormal noise during running. OK / Not OK
2. Check the ventilation grill is clean and free from dust for proper cooling . OK / Not OK
3. Check power cables connected at terminal are tight and proper lugs condition. OK / Not OK
4. Check for tightness of External Fastener of Coupling and Adaptor. OK / Not OK
5. Put water in the Earth Pit. OK / Not OK
6. Check for Proper Earthing connections. OK / Not OK
Check the tightness of AVR connections. OK / Not OK
7. Start the Set and observe the following parameter-
Check for stable out put voltage from Alternator. OK / Not OK
Check for Balance load. (unbalance should not be more than 10 % of total load) Balance / Unbalance
Current ( Amp ) - R- Y- B- N- phase respectively
Voltage (Volts ) - RY - YB- BR-
Power factor (if available) -
8 Canopy Checks
Check Canopy doors for proper fitment and alignment OK / Not OK
Check Canopy for external & internal rusting. OK / Not OK
Check Canopy locks for proper operation. OK / Not OK
Check temperature difference between canopy inside & outside by closing the Difference -
doors and running the Genset on full load for atleast 30 minutes.
Site Address :
Tel. No.

CHECK FOR CONTROL PANEL - DURING G1 AND G2 CHECKS
Sl No. Service Point Status
1. Check the tightness of crimping of cables -
Mains cable tightness & lugs crimping & gland in control panel . OK / not OK
Generator cable at control panel and alternator terminal. OK / not OK
Correct cable size with correct lugs. OK / not OK
Connection are tight. (All power & control cable) OK / not OK
2. Check the Earth connection of control panel. OK / not OK
Check control panel is mounted on AV mounting or check vibration. OK / not OK
3. Accessories -
AMF module type
MCCB ( make & rating )
Mains contactor ( make & rating )
Generator contactor ( make & rating )
4. Check for tightness of following connections -
Connection at main terminal board are tight with proper lugs or solder end. OK / not OK
Power connection at both Contactors are tight. OK / not OK
Connection at all fuses or MCB are tight. OK / not OK
Check the proper tightness of all relays at relay base with proper relay locking clips. OK / not OK
5. Check the Battery voltage and ensure that battery is fully charged OK / not OK
Battery voltage
Specific Gravity of battery solution ( required 1.270 ) OK / not OK
Ensure all cells of battery are filled with electrolyte battery solution to max. level OK / not OK
Ensure charging of battery by charging alternator (if provided) or by Battery charger OK / not OK
Check Battery terminal for cleanliness and tightness. OK / not OK
6. Checking of electrical accessories -
Simulate the fault like LLOP, HCT etc. and check engine tripping with alarm. OK / not OK
Check all the gauges are working. OK / not OK
Check the exhaust fan working and direction of fan. OK / not OK
Check solenoid supply is not more than 15-20 sec. OK / not OK
7. Check all the meters for working on control panel working. OK / not OK
8. Mains voltage ( EB Power ) -
Mains current ( EB Power ) -
9. Generator voltage -
Generator current-
10. Ensure AUTO / MANUL mode operation of AMF pannel. OK / not OK
Site Address :
Tel. No.

USER MANUAL - GENSET
SECTION C
INDEX
Chapter 1. General Description of Genset 5
Chapter 2. Technical Data Sheet 9
Chapter 3. Installation 11
Chapter 4. Control System & Operations 20
Chapter 5. Optional Equipment 31
Chapter 6. Maintenance 35
Chapter 7. Batteries 37
Chapter 8. Closed Coupled Genset Assembly 42
Chapter 9. Step by step instructions 47
Chapter 10. Warning 48
C-3
NOTES
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C-4
CHAPTER - 1
GENERAL DESCRIPTION OF GENSET

1.0 INTRODUCTION coupled to the engine with a flexible steel disc type
coupling (on some models, the alternator is coupled to
Your new genset is designed to provide you with superior
the engine flywheel via a flexible rubber element
performance and reliability, allowing you to avoid
coupling) and the package is arranged so that the
annoying maintenance programmes which would prevent
you from getting the job done. alternator is the first component to come into contact with
the cooling air flow as it passes over the genset. As the
The genset is a complete system that incorporates air flows over the unit, the fan pushes it through the
advanced engineering concepts which are backed by 55 radiator. As this air flow passes over the engine. This
years of experience. method of cooling allows the alternator fan to pull a
portion of the cooling air through the alternator. Both the
Your Genset is fitted with an alternator which will produce
the correct voltage with optimum wave form, fast response engine and alternator are therefore kept at their proper
and precise voltage regulation. operating temperature.
As you continue reading, you will learn how the machine b) AIR COOLED ENGINE
is operated and cared for. With proper care during
maintenance and operation, your genset will be ready to The engine is cooled by a high capacity high efficiency
respond to your emergency standby or prime power cooling air blower mounted on engine. The blower forces
needs. air over cylinder liners and cylinder heads to keep the
1.1 DESCRIPTION OF GENSET PACKAGE engine temperature optimum for best performance. Hot
air leaving engine after cooling is ducted away by using
Refer to figure 1A. The major components of the genset air guide ducts.
are clearly shown. Stationary or mobile units are available
with each package including an alternator, diesel engine, For enclosed gensets ventilation is achieved by using
exhaust, cooling system, and a control system. special fans to remove radiated heat from engine and
alternator and ensuring that there is no hot air recirculation.
The engine is equipped with a close control governor
which will hold the engine speed within the tolerance
necessary to deliver the rated power and frequency as All engines, when used to drive alternators to provide
per ISO 3046, DIN 6271 AND BS 5514. either emergency standby or prime power, require careful
attention to air flow. The notes provided in the Installation
1.2 ENGINE Section of this manual should be consulted before
selecting a location for your genset.
The engine incorporated in the generating set is of
proven reliability and is specifically designed to
1.2.2 ENGINE GOVERNOR
operate in conjunction with an alternator. The engine is
of the heavy-duty industrial type 4-stroke compression
ignition and fitted with all accessories necessary to The primary function of the governor system is to maintain
provide a reliable power supply. engine speed in relation to varied load requirements.
This is accomplished by the governor which senses
1.2.1 COOLING SYSTEM engine speed and controls the engine fuel rate, in order
to maintain practically constant speed. The engine speed
a) WATER COOLED ENGINE
governor maintains engine speed within limits regardless
The engine cooling system comprises of a radiator, high of the steady load. As the alternator load increases, the
capacity pusher fan and thermostat. The alternator is engine speed is reduced.
C-5
Because the speed must remain relatively constant, the the operator to reconnect the genset to obtain a variety
governor, sensing engine speed, will increase fuel flow to of three phase voltages up to 480 volts. Single phase
the engine, thus adjusting horsepower to a point sufficient units supply current through a two or three lead
to maintain engine speed and compensate for the load connection offering a variety of voltages from 120-250V.
change. The same principle is applied when the load Units can be supplied in 50 Hz outputs. See Alternator
decreases. As the load is reduced the speed would Maintenance Section for further details of connections
increase, the governor will then reduce fuel delivery thus available.
decreasing the horsepower to maintain the proper speed.
A brushless alternator is a synchronous rotating field
1.3 BRUSHLESS ALTERNATOR type unit, which produces alternating current. This
alternator unit is completely self-contained and is
As per the requirements of the customer, we provide an designed and constructed to provided trouble free
option of brushless or brush type alternator for KGPI operation, ease of maintenance and long service life.
genset. The following paras mention both in brief.
Brushless excitation type alternator eliminates the 1.4 BRUSH TYPE ALTERNATOR
maintenance associated with slip rings and brushes. The
internal components of the alternator are designed so as It is of salient port, self-excited or self regulated type.
to assure efficient and economical operation. They are designed to operate at 1500 rpm. The alternators
can be supplied for foot cum flange mounting and for
The control system consists of an automatic voltage different voltages. They comply with BS 5000, IS 13364
regulator (within the alternator), protective circuits and and IS 4722 standards.
the necessary instruments to allow you to monitor the
operation of genset. On most models current is supplied
through twelve leads enabling
AIR CLEANER
DIESEL ENGINE
RADIATOR
CONTROL PANEL
FUEL FILTER
ANTIVIBRATION
MOUNTING
LUBE OIL FILTER ALTERNATOR FUEL FILLING

BASEFRAME SPOT
NOTE : In case of Genset with acoustic enclosure, the positions of some peripherals may change. (Example -
Control Panel, Fuel filling spout, Fuel level indicator etc.)
Figure 1 A Major Genset Components
C-6
1.5 VIBRATION ISOLATION 1.9 GENSET CIRCUIT BREAKER
All gensets are fitted with anti vibration mountings To protect the alternator winding, a suitably rated moulded
which are designed to reduce vibration being transmitted case or miniature circuit breaker (depending on the
from the rotating mass of the genset to the foundation on genset model) is supplied mounted in a strong fabricated
which the genset is mounted. Vibration isolators are steel enclosure.
selected to suit the particular duty and are fitted between
Current transformers are fitted on each of the phases on
the engine, alternator feet and the base frame. On some
the cabling to the circuit breaker enclosure for current
of the models the vibration isolators are fitted between
measurement. In some configurations the main circuit
the base frame and the foundation depending on the
breaker may be incorporated in the automatic transfer
system requirement.
panel.
1.6 FUEL TANK AND BASE FRAME 1.10 SYSTEM PROTECTION
The design of the base frame incorporates removable An additional and substantially important function of the
fuel tank with a capacity of approximately 8 hours control system is the protection of the engine against
operation. The tank is provided with fittings to facilitate faults such as high temperature, low oil pressure, over
either manual or automatic filling. The base frame is speed or other malfunctions.
manufactured from heavy gauge sheet steel and welded
to form a rigid assembly. To prevent damage to the cranking motor and deep
discharge of the starting battery, a crank limiting circuit
1.7 SILENCER AND EXHAUST SYSTEM is included on all automatic start sets.
A detailed explanation of these systems is included in

Exhaust silencer is provided to reduce noise emission Section 4.
from the engine and designed to direct exhaust gases
to areas where they will not be objectionable. 1.11 CONTROL PANEL POWER SUPPLY
On ‘stand alone’ open gensets, the exhaust silencer is Engine instruments and the control panel are supplied
generally placed outside the Genset room, with suitable from the battery fitted to the genset. This battery also
extension piping from engine. Stainless steel expansion provides power for operation of the cranking motor to
bellow is provided on the engine, to facilitate the start the engine and for the stop solenoid.
exhaust piping. For generating sets with acoustic
enclosure, residential type silencer is fitted inside or The stop solenoid is of the ‘energised to stop’ or run type
requiring a DC supply to energise the solenoid for
outside the enclosure with flange fitting at the outlet to
stopping the engine or requiring supply to start the
enable discharge of exhaust gases at desired location,
engine.
through extension piping, as required.
1.12 CONTROL PANEL MOUNTING
1.8 CONTROL PANEL
The control panel and main circuit breaker are normally
All control panels are mounted in welded steel enclosures mounted on a separate base frame mounted stand thus
equipped with a sealed hinged door for easy access and ensuring vibration free running. Floor standing control
servicing. panels are provided for more complex control systems.
The control panel is available in several variations to suit For acoustic enclosures the control panel is fitted inside
the requirement of the installation. The Control System is the enclosure. Suitable glass cover opening is provided
fully described in Section 4. on the enclosure to see the instruments.
C-7
NOTES
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C-8
CHAPTER - 2
TECHNICAL DATA SHEET

GENSETS WITH ACOUSTIC ENCLOSURE
WATER COOLED GENSETS :
Genset Engine Rated Maximum recommended Representative Approx.

Model Model output Genset rating at 0.8 pf Dimensions Weight
at 1500 rpm (KVA) [Length x Width]
(bhp) continuous standby (mm) (kg)
KG30W 3R1040 42 30 39 2350X1090X1440 1289
KG40W 4R1040 56.3 45 50 3100X1100X1350 1509
KG62.5W 4R1040T 83 62.5 75 3250X1150X1400 1675
KG82.5W 4R1040TA 105 82.5 100 3335X1375X1600 1922
KG100W 6R1080T 127 100 ~ 3750X1400X1600 2500
KG125W 6R1080TA 156 125 ~ 3750X1400X1600 2700
KG140W 6SL9088TAI 166 140 ~ 3900X1550X1650 3580
KG160W 6SL9088TA 198 160 ~ 3900X1550X1650 3720
KG180W 6SL1500TAI 235 180 ~ 4000X1600X1700 3870
KG200W 6SL1500TA 254 200 ~ 4000X1600X1700 3966
KG250W 6SL8800TA 310 250 ~ 4000X1600X1750 4252
AIR COOLED GENSETS :

at 1500 rpm (KVA) [Length x Width]
(bhp) continuous standby (mm) (kg)
KG15A HA 294 19 15 16.5 2250X1110X1850 1107
KG25A HA 394 32 25 28. 2400X1110X1850 1347
KG30A HA 494 43 30 ~ 2700X1200X1900 1494
KG35A 35 39 2700X1200X1900 1494
KG45A HA 494 T 56 45 50 2750X1200X1900 1455
KG55A HA 694 65 55 55 3300X1400X1900 1775
KG62.5 HA 694 T 83 62.5 75 3500X1400X1900 1954
KG70A HA 694 T Sr. I 83 70 75 3500X1400X1900 1954
KG75A HA 694 T Sr. II 91 75 ~ 3500X1400X1900 1954
C-9
GENSET WITHOUT ACOUSTIC ENCLOSURE

WATER COOLED GENSETS :

at 1500 rpm [Length x Width
x Height]
(bhp) (KVA/kW) (mm) (kg)
KG30W 3R1040 42 30/24 1950X725X1150 870
KG40W 4R1040 56.3 45/36 2180X725X1200 975
KG62.5W 4R1040T 83 62.5/50 2100X725X1200 1060
KG82.5W 4R1040TA 105 82.5/66 2500X900X1480 1230
KG100W 6R1080T 127 100/80 2980X1060X1730 1640
KG125W 6R1080TA 156 125/100 2980X1060X1730 1640
KG140W 6SL9088TAI 166 140/112 3100X1200X1920 2000
KG160W 6SL9088TA 198 160/128 3100X1200X1920 2000
KG180W 6SL1500TAI 235 180/144 3200X1200X1980 2150
KG200W 6SL1500TA 254 200/160 3250X1200X1980 2150
KG250W 6SL8800TA 310 250/200 3510x1240x1880 2362
AIR COOLED GENSETS :

at 1500 rpm [Length x Width
x Height]
(bhp) (KVA/kW) (mm) (kg)
KG15A HA 294 19 15/12 1670x725x1120 775
KG25A HA 394 32 25/20 1800x725x1120 860
KG30A HA 494 43 30/24 1930x725x1120 900
KG35A 35/28
KG45A HA 494 T 56 45/36 1930x725x1120 920
KG55A HA 694 65 55/44 2250x725x1175 1050
KG62.5 HA 694 T 83 62.5/50 2250x725x1175 1100
KG70A HA 694 T Sr. I 83 70/56 2200x725x1175 1100
KG75A HA 694 T Sr. II 91 75/60 2250x725x1175 1150
C-10
CHAPTER - 3
INSTALLATION
3.1 LOCATION For acoustic enclosures ensure that the openings
provided for fresh air inlet and outlet are not blocked.
Selecting a location for the genset is very important part
of any installation procedure. Always locate the genset in 3.2 FOUNDATION
an area that will provide adequate ventilation and physical
Refer to Figure 3-1. A reinforced concrete pad makes the
protection for the unit. For the purpose of simplifying
best foundation. A pad with sufficient mass in proportion
maintenance and inspection requirements it will also be
to the size of the genset will provide the rigid support
important to place the genset in such a position so as to
necessary to minimize deflection and vibration. Typically
allow easy movement around the machine without
this should be 150 mm to 200 mm deep and a mass at
overcrowding. Generally, 1.5 to 2.0 meters space all
least equal to that of the gensets.
around the genset should be ensured.
The foundation may be located on soil, structural steel,
The location should be clean, dry and have good drainage building floors etc., provided the total weight of the
capabilities. Should the location be outdoors protect the foundation and genset package does not exceed the
genset with a weatherproof enclosure (available as an allowable bearing load of the support. Allowable bearing
optional retrofit item). loads of structural steel can be obtained from Engineering
Handbooks while local building codes will provide the
Another point to keep in mind is the space required to allowable bearing loads for different types of soil.
undertake major overhaul or service operations. In some
cases it may be necessary to remove major components. 3.2.1 Isolation
It is advisable that the principal foundation of each
genset rests on bedrock or solid earth completely
independent of other foundations, cement work, walls or
operating platforms.
3.2.2 Vibration
The design of the genset is such that only minimal
vibration is transmitted to the foundation. Anti vibration
mounts are fitted between engine, alternator and
baseframe or in larger capacity gensets vibration isolators
are mounted below the baseframe.
In generator rooms situated on upper floors special
attention to vibration isolation is necessary. Often spring
type vibration isolators will be needed.
It is necessary to ensure that building structures are
capable of supporting the genset, fuel storage and
Figure 3.1 - Foundation
accessories.
Doors must be sized to allow access in and out for the Refer to figure 3-2 for Typical ventilation arrangement for
complete generator set and major accessories. Air inlet water-cooled engines.
and outlet vents can often be made removable to floor
level to provide an access point.
C-11
RAIN CAP A ALTERNATIVE RAIN COVER
EXHAUST SILENCER
EXHAUST PIPE TO SLANT DOWNWARDS
TOWARDS CONDENSATION TRAP
SUPPORT FOR EXHAUST PIPE
HOT AIR OUTLET

HOT AIR OUTLET
CONDENSATION
TRAP EXHAUST PIPE
TO BE COVERED
WITH ASBESTOS
ROPE OR CLOTH
WINDOWS WITH LOUVERS WINDOWS WITH LOUVERS
FOR HOT AIR OUTLET FOR HOT AIR OUTLET
1500
MIN. DISTANCE
REQUIRED TO
FACILITATE HAND
STARTING
ALTERNATOR
FRESH AIR INLET
STARTING WINDOWS WITH LOUVERS WINDOWS WITH LOUVERS

HANDLE FOR FRESH AIR INLET FOR FRESH AIR INLET
CONCRETE BASE FOR
GEN. SET FOUNDATION
M14x15 THREADS FOR GEN. SET GROUNTING IN CONCRETE LUBE OIL DRAIN
FOUNDATION BOLT FOUNDATION
REMOVABLE DUCTING SLIGHTLY LARGER

INSIDE THAN RADIATOR CORE
Figure 3.2 - A Typical Ventilation arrangement for Water Cooled Engines
This layout drawing shows a typical genset installation. It is meant as a guide only. Full details of the particular unit should
be assessed and the installation layout designed to suit the requirements of your site.
Notes :
• The circuit breaker position can vary according to the requirements of the installation. It may also be mounted
remote from the genset.
• The control panel can be made to allow wall mounting.
• Depending on cable routing to the genset room and terminal points at the generator, the power cables may be
installed for bottom from ducts or floor trenches.
• Openings should be provided behind the alternator for incoming cold air and directly in front of the radiator for
outgoing hot air. The cold air first passes over the alternator, then the engine, picking up radiant heat as it passes.
It then passes through the radiator and is discharged through a duct to the outside of the genset room.
• A temperature rise of 5-15 Deg C (9-27 Deg F) in the cooling air can be expected at full load.
Canopy Temperature
Air temperature near air cleaner should not exceed 5 o C above ambient. Sufficient window opernings required to
maintain air inlet temperature within the limit.
C-12
3.3 GROUNDING (Indian Electricity rules) as big as the radiator core area but, as a guide, an
area on 150% of the core area of the radiator should
Grounding should be done in accordance with applicable
be allowed for.
National, Local Code or Regulation.
3. For weather protection, louvers should be fitted to
3.4 AIR INLET
the intake and exhaust openings. These can be
Engine inlet air must be clean and as cool as possible. either of the fixed or movable type.
These conditions will drastically effect both engine life
and performance. Manually operated movable louvers may be acceptable
in some cases, but they are not acceptable for automatic
Normally the inlet can be taken from the area surrounding
standby units.
the installation site. However, in some cases the condition
of the air surrounding the machine may warrant ducting Radiator air should not be depended upon to move the
the air from outside or another room. louver vanes.
When it does become necessary to duct air in, the air filter
3.6 EXHAUST
should remain mounted to the engine as opposed to a
remote mounting (such as on a roof or in another room). The exhaust system is used to direct exhaust gases to
This will eliminate the possibility of dirt leaking through non-confined areas and reduce the noise to tolerable
the duct work upstream of the air filter. levels. When designing a system the main objective is to
minimize back pressure. Excessive back pressure in an
3.5 COOLING AND VENTILATION exhaust system will create horsepower loss and increase
the engine operating temperature, and emissions.
The radiated heat given off by the engine, generator and
exhaust piping can result in a temperature high enough When bends are required in an exhaust system, always
to adversely affect operating and maintenance personal make the radius at least 150% of the inside diameter of
or the performance of the genset. Locate the genset in a the pipe. As most exhaust system designs are governed
room or area that will provide or allow sufficient ventilation by the physical characteristics of the building or room in
to remove this heat as well as the heat radiated from the which they are located, it is of the utmost importance that
engine cooling water by the radiator. Preferably provide the exhaust pipe be routed in a path offering the least
exhaust fans to drive hot air outside. amount of turns or bends so not to increase back
pressure more than 50 mm of Hg.
If acoustic enclosures are placed in an enclosed place,
Be sure that all pipes are well supported and that springs
ensure that enclosure is well ventilated and exhaust
or other dampers are used at points of high vibration.
gases are driven out of the enclosure.
Due to the heat radiation of the exhaust pipes it is
recommended that all pipes be located at least 250 mm
Points to remember in any type of installation:
from any combustible material. Wrapping the exhaust
1. Ensure that hot air is positively discharged from the pipes with high temperature insulation or installing fitted
building by fitting a flexible connection between the insulated sections will aid in preventing excessive heat
radiator and the duct radiation within the room.
2. The size of the openings should be calculated to At points where the piping passes through a wall or roof,
ensure that excessive restriction is not imposed on a metal thimble guard 300 mm in diameter slightly larger
the flow of cooling air. Openings should at least be than the pipe should be installed.
C-13
Revolving Flange (Kept free on Exhaust Piping side)
Fixed Flange (Engine side)
CAUTION :
1. During installation of bellow, fixed flange of bellow should be located on the engine side, while revolving
flange should be kept free.
2. Provide an additional bellow in the horizontal piping if the length between supports is than 4.0 meters.
3. Always use MS pipe for Fuel and exh. Piping as recommended by KOEL
4. Please ensure that you have removed all welding splashes inside the exh. Pipe to save turbo charger
from damage due to foreign particles.
5. Always use long bend in exh. water and fuel piping.
Use appropriate dia of pipe considering resistance of pipe and no of bends as KOEL Norms specified.
6. For further details of exhaust pipe dimensions, no of bends, length of pipe etc please Refer the Gen set
manual by KOEL.
C-14
Typical Fuel circuit diagram
Recommended Fuel Connections on Fuel Tank
Typical Fuel Installation
C-15
As shown in Figure 3.3 bevel the end of the pipe at a 30- 3. It allows for some movement of either the genset or
45 degree angle. Should the pipe end be horizontal, exhaust system components.
bevel the pipe from the top back to the bottom. This will
not only reduce the noise levels at the outlet but will also Long piping runs should be divided into sections
minimize entrance of precipitation on horizontal pipes. separated by additional flexible connections. This will
also compensate for the expansion and contraction of
The level or height at which the outlet is situated should the piping itself due to temperature change. Any insulation
be sufficient to prevent fumes and odours from becoming material used for a flexible connection should allow for
an annoyance or potential hazard. Also, an exhaust the expansion and contraction of the connections, due to
pressure actuated raincap is recommended for use on temperature changes.
vertical outlet pipes.
Generating sets with acoustic enclosure are provided
with exhaust outlets having connecting flanges. Exhaust
Any long horizontal or vertical piping should include
gases from the outlet can be routed away to desired
water legs and drain traps at their lowest points so that
location. For up to 3 meter distance exhaust pipe size
water does not reach either the silencer or the engine. It
same as provided on the outlet can be used. For longer
is also recommended that a slight slope downward from lengths total exhaust system assessment should be
the silencer to the water leg or rain trap be added to done by competent person. In no case, exhaust back
assure the proper removal of water. pressure should exceed 50 mm of Hg when measured at
exhaust manifold of engine, at rated load.
By locating the silencer as close to the engine as possible
you will be able to minimize the noise level in the 3.7 FUEL SYSTEMS
exhaust piping. Each genset installation should have it’s
The fuel system must be capable of delivering to the
own exhaust system and should not be connected to a
engine a clean and continuous supply of fuel. When
system accommodating more than one genset as the
designing a fuel system, always incorporate the
possibility of exhaust gas and condensation backflow
requirements of Local, State, or National Codes, which
may cause permanent damage to an idle engine.
may pertain to either the fuel system or the electrical
apparatus utilized by the system.
Note: Health warning: Inhalation of exhaust fumes is
potentially lethal. The correct installation of exhaust 3.7.1 Diesel Fuel Bulk Storage
systems to prevent accumulation of exhaust gas
cannot be over emphasized. Additionally, prolonged Bulk fuel storage is the most preferable method of
exposure to engine exhaust noise can be damaging providing fuel supply. This method allows bulk fuel
to hearing. A genset should never be operated without purchases which will minimize dirt and contamination
a fully installed exhaust system and all personnel in possibilities, especially when the fuel is seldom used.
The bulk storage tank may be located either above or
close vicinity should wear ear protection.
below the ground.
3.6.1 FLEXIBLE CONNECTIONS
A vent must be installed on the main tank to relieve the air
The exhaust piping should be connected via a flexible pressure created by filling the tank as well as preventing
joint located on the engine exhaust outlet. This connection a vacuum within tank as fuel is consumed. The tank
serves three purposes. bottom should be rounded and placed on a 2 degree tilt
to assure a concentrated settling of both water and
1. It relieves some of the weight of the exhaust piping
sediments. At the low point of the tank a drain valve
from the engine. should be installed to remove water that may accumulate
2. It isolates the exhaust system from vibration. due to condensation.
C-16
Underground tanks must be pumped periodically to All standard gensets with acoustic enclosure are provided
remove this water. This is best done by placing a tube with tank fitted in the baseframe. This day tank will
through the filter pipe to the low end of the tank. For these produce a ready fuel supply.
reasons it is imperative that the tank be placed in or on
stable ground to assure that eventual settling does not 3.7.3. Filters and Traps
change the location of the low point of the tank. Burying Clean fuel will aid in attaining maximum engine life and
the tank below the frost line will help in avoiding seasonal dependability. Primary filters are recommended for use
settling. between the engine filters and the transfer pump. Water
and sediment traps should also be included upstream
Another consideration to be made when locating the of the transfer pump. However, on border line pump
main tank is the height difference between it and the installations do not increase fuel line restrictions to a
auxiliary tank (day tank). The maximum vertical lift point exceeding the capabilities of the pump.
capabilities of a standard electric motor driven fuel transfer
pump is 5m. Do not place either tank at a level that would 3.8 FIRE PRECAUTIONS
exceed the pump lift capabilities. Also keep in mind the
When designing a genset installation the following points
possibilities of pressure drop created by excessive
should be noted:
horizontal distances and pipework bends.
– The room should be designed so that there is an
The fuel delivery line carrying fuel to the engine and the
easy escape route for operating personnel in the
fuel return line for carrying excessive fuel back to the tank
event of fire within the room.
should be no smaller than the fitting sizes on the engine.
For longer runs or extremely low ambient temperatures
– A recommended type of fire extinguisher or fire
increase the size of these lines to ensure adequate flow. extinguishing system should be provided to fight the
fire.
The fuel lines can .be made of any fuel compatible
material such as steel pipe or fuel line tube that will – Gravity operated fire valves operated by fusible links,
tolerate ambient conditions. Overflow piping should be mounted above the engine, can be installed in the
of the same material and one size larger. fuel lines.
The fuel return line should enter the tank at the top and – The room should be kept clean and free from
contain no shut-off valve. This line should be designed accumulated rubbish which can be a fire hazard.
with a minimum amount of bends or dips to prevent an air
lock in the system. The fuel delivery line should pick up 3.9 STARTER BATTERIES
the fuel from the point no lower than 20mm from the
Resistance in the starting circuit has a significant effect on
bottom of the tank. If at all possible locate this line at the
the starting ability of the engine. Therefore, the batteries
end of the tank opposite that of the return line and at the
should be located as close as possible to the genset
high end of the tank. Flexible fuel lines should be used at
(batteries should be accessible for servicing).
a point between the tank and engine (preferably adjacent
Maintenance procedures should be carried out rigorously
to the genset) to avoid the potential damage that could be
since the batteries have to be in perfect condition to start
created by vibration.
the diesel engine.
3.7.2 Day Tanks

Auxiliary tanks or day tanks as they are commonly
referred to are recommended. Refer figure 3-4 for typical
fuel installations.
C-17
Note: Batteries emit inflammable 3.10.1 Protection

gas. Do not smoke or create sparks or naked
flames adjacent to batteries. The cables connecting the genset with the distribution
system should be protected by means of a circuit breaker,
3.10 ELECTRICAL CONNECTION fuses or other means to disconnect the genset in case of
overload or short circuit.
Only fully qualified and experienced electrical technicians
should be allowed to carry out electrical installation work. 3.10.2 Loading
The electrical connection to the genset should be made When planning your distribution system it is important to
with flexible cable to prevent the transmission of vibration ensure that a balanced load is presented to your genset.
and possible damage to the alternator or circuit breaker If loading on one phase is excessive in comparison to the
terminals other two phases this will cause overheating in the
alternator windings, imbalance in the phase to phase
If it is not convenient to use flexible cable throughout voltage output and possible damage to sensitive 3 phase
then a link box can be installed close to the set with a equipment connected to the system. Ensure that no
flexible connection between it and the set. phase current exceeds that of the current rating of the
genset.
The cable may be laid in a duct or on cable tray. When
bending cable reference must be made to the It may be necessary to reorganize the electrical distribution
recommended minimum bending radius. system if a genset is to be connected to an existing
installation.
No rigid connection should be made between the set and
the cable support system, eg, cable tray. 3.10.3 Power Factor
When single core cables are used the gland plates must The power factor (cos phi) of the connected load should
be of non-ferrous material, eg, aluminum, brass or a non- be determined. Power factors below 0.8 will overload the
metallic material such as teflon. generator. The genset will provide its kilowatt rating and
will operate satisfactorily from 0.8 to unity power factor.
The cable must be suitable for the voltage being used and Particular attention must be given to installation with
adequately sized to carry the rated current with automatic or manual power factor correction equipment
allowances made for ambient temperature, method of to ensure that a leading power factor is not present under
installation, proximity of other cables, etc. any conditions. This will lead to voltage instability on the
generator output and may result in damaging
All electrical work should be carried out in accordance overvoltages.
with any applicable National, Local Standards, Codes or
Regulations. 3.10.4. Grounding Requirements
(See Paragraph 3.3)
All connections should be carefully checked for integrity.
Regulations vary and advice should be sought from the
Phase rotation must be checked for compatibility with the
local supply utility as to their requirements. The factory
installation. This is vitally important when connection is
connects the frame of the alternator to the frame of the
made to an auto transfer switch, or if the machine is to be
genset therefore the complete mass of the genset is at the
paralleled.
same potential. The connection if required of the generator
winding star point / neutral to earth is the responsibility of
the installation technicians.
C-18
* Warning: Never attempt to work on live – The designed noise level at a fixed distance, normally
wiring. Always stop the genset and open the 1m or 7m.
circuit breaker on the load cables before working on
the alternator or it’s connectors. – Environmental conditions, ambient temperature etc.
3.10.5 Start Up Noise emissions from diesel gensets (without acoustic

treatment) are at sound pressure levels of between 100
Before attempting to start the genset refer Chapter 4 of
dB(A) and 110 dB (A) at 1m. Kirloskar Gensets with
this Section.
acoustic enclosures have a typical noise pressure level of
75 dB(A) or less (average) at a distance of 1 meter from
3.11 NOISE CONTROL
the enclosure.
Your genset can be supplied with accessories and
components to reduce noise emissions. Typically Intermediate levels of treatment will prove more economic
available are residential and super critical silencers, and are often satisfactory depending only on the nature
acoustic louvers and splitter vents, fan silencers and and type of installation. Hospital Care Areas will require
acoustically treated enclosures. more attention than the normal commercial / industrial
installation.
The requirements for each site vary enormously and for
any critical installation we recommend you consult your
dealer at an early stage. The information needed to
select acoustic equipment is:
– The model and capacity of genset
– The location and overall site plan.
C-19
CHAPTER - 4
CONTROL SYSTEMS AND OPERATIONS

4.1 CONTROL SYSTEM Important
The Control System consists of:- Adequate grounding of the genset is necessary for both
stationary and wheel mounted units to prevent the
A) Control Panel providing a means of starting and possibility of injury or death in the event of electrical fault.
stopping the Generator Set, monitoring its operation
and output, and causing the engine to automatically When filling the fuel tank, do not smoke or use an open
shut down in the event of a circuit fault condition flame in the vicinity. Also the tank should never be filled
when the Genset is operating or while the engine is hot.
arising from low oil pressure, high coolant
Spilled or vaporized fuel could be ignited easily.
temperature, over speed, low fuel level (optional).
Never attempt to disconnect a load connection or perform
B) An Alternator Circuit Breaker providing a means of
maintenance while the Genset is in operation.
switching the Generator output, and automatically
disconnecting the load in event of short circuit. To avoid an accidental start of the engine, always
disconnect the battery when performing major operations.
4.2 CONTROL SYSTEMS AND OPERATIONS As the battery system is negative earth. The negative
Preparing for Operation connection should be disconnected first and reconnected
last.
Before starting your DG set be sure that it is positioned on
The cover of the control panel should not be removed
a level surface so that proper liquid levels can be obtained.
while the genset is in operation. The cover, when removed,
Check engine oil, radiator coolant, battery electrolyte exposes live electrical connections. Maintenance on the
and fuel levels. control panel should only be carried out by a qualified
Be sure that the Genset will be operated in a well technician.
ventilated area with all exhaust fumes piped away.
Important
Before connecting batteries, ensure control panel is Always shut down the Genset and switch off circuit
switched off. breaker prior to connecting, or disconnecting load cables.
Only restart when a sound connection has been made.
Prolonged inhalation of exhaust fumes may result
in serious illness or death.
Prolonged exposure to the noise levels of a diesel engine 4.3 INITIAL START-UP
can impair hearing unless proper ear protection is worn. The following procedure should be used to make initial
Before any attempt is made to operate the machine, be start-up of the Genset.
sure that engine and alternator are properly earthed. These steps are critical and must be followed closely to
avoid complications in operating the Genset.
Local and national regulations for the grounding of
gensets should be adhered to as well as those regulations 4.3.1 Check the engine oil and coolant levels replenishing
which describe the methods of connection and minimum if necessary.
sizes of grounding conductors based on the size of the 4.3.2 Fill the fuel tank.
load cables.
C-20
4.3.3 The following procedure should be used when 4.3.3.10 The frequency of the output voltage should also
starting the Generator for the first time or when it has been be checked on the panel meter. No load frequency is
out of service for a time for maintenance purposes. approx. 52 Hz, for 50 Hz units.
4.3.3.1 Ensure the key switch is turned OFF. 4.3.3.11 When the generator is producing voltage,
check the phase rotation of the generator by connecting
4.3.3.2 Ensure the circuit breaker is switched OFF. a phase rotation meter to the terminals on the generator
side of the circuit breaker. (Caution: DO NOT close the
4.3.3.3 Connect the batteries to the engine with correct circuit breaker). This check should be carried out by a
polarity. qualified technician and the result noted for use later if
Generator is to be connected to an existing system.
4.3.3.4 Prime the fuel system using the hand priming
pump and bleed entrapped air from the fuel filter-see 4.3.3.12 After the voltage and frequency checks have
engine manual for details. been made, shut the machine down by pressing “O” on
genset control panel.
4.3.3.5 Turn the Key switch to start Position “ON”. Engine
control system will be switched on. IMPORTANT
In manual mode, allow an interval of approximately 10 Always shut the genset down prior to connecting, or
Seconds between cranking attempts, and should the disconnecting, load cables. Only restart when a sound
engine still not have started after four cranking attempts, connection has been made.
refer to the engine manual to determine the cause of
failure to start. 4.4 SHUTDOWN PROCEDURE
4.3.3.6 After the engine has been started check for any To shut down the Genset, turn off the load using the
abnormal noise or vibration circuit breaker, and press button the “O” (as per
applicable) position. In case of an emergency where
4.3.3.7 Check fluid leakage or high temperature. immediate shut down is necessary press the emergency
off push button.
4.3.3.8 Check the control panel for indications of abnormal
operation, in particular above normal engine temperature 4.5 NORMAL START-UP PROCEDURE
or below normal oil pressure. (For manual operation)
4.3.3.9 Immediately the engine reaches full operating On subsequent starts follow the procedure explained
speed the voltmeter should be checked to ensure that below. This start up procedure must be strictly adhered to.
the voltage has reached the correct operating level. The
voltage is factory set at the voltage regulator and needs ENSURE KEY SWITCH IS TURNED, TO POSITION
no further adjustment. Should the output voltage be “OFF”.
incorrect, adjustment of the voltage should only be
carried out by a Qualified technician. 4.5.1 Make a visual check of the entire Genset. Watch for
signs of leaks from the engine i.e. fuel system, cooling
Voltage adjustment is achieved by varying the setting of system and lubrication system.
a potentiometer mounted inside the automatic voltage 4.5.2 Check engine oil, water and fuel levels, replacing
regulator which is fitted in the alternator terminal box. if necessary. Check the battery terminals for corrosion,
cleaning where necessary. Check the battery electrolyte
level and fill with distilled water if necessary.
C-21
4.5.3 Turn ON. DC ON switch unit will get DC power. For 4.5.12 Drain condensate traps in the exhaust system, if
manual starting press the start button on genset control so equipped, and check for exhaust leaks.
unit.
If engine does not start in first attempt allow an interval of
4.5.4 Starter supply will disconnect automatically after approximately 10 Seconds between cranking attempts,
getting supply from AC alternator. This will be sensed by and should the engine still not have started after four
genset control unit. cranking attempts, refer Section D to determine the
cause of failure to start.
4.5.5 Lub. oil pressure gauge will show lub. oil pressure
and low lub. oil pressure switch contact will get opened. 4.5.14 Check for any abnormal noise or vibration.
4.5.6 Once the engine is started battery charging alternator 4.5.15 Switch on the Alternator Circuit Breaker. Load
starts charging the battery and charging current is may be applied immediately to the Genset. However, the
indicated on DC ammeter. maximum step load that can be accepted in anyone step
is dependent on the operating temperature of the Genset.
4.5.7 Run the set on no load for atleast 2-4 minutes. Put With the Genset cold (not more than 20 degrees C/68
the Main Current Circuit Breaker ON. Genset output is degrees F) the maximum step load acceptance is
available to load. approximately 50% of rated output. However, with genset
at normal operating temperature (approx 80 degrees C/
4.5.8 Water temperature gauge is provided which 176 degrees F) the maximum load that can be accepted
indicates engine water temperature.. For healthy condition depending on the type of engine in one step is 60-100%
this needle is should be in green zone. of the Genset rating. These figures are given as a guide
only and the relevant technical data sheet should be
4.5.9 AC voltmeter will show alternator output voltage.
consulted when in doubt.
AC ammeter will show load current depending upon the
connected load. WARNING: Always shut down the Genset prior
to connecting, or disconnecting, load cables.
4.5.10 Refer to Section D for specific engine maintenance
Only restart after proper connections has been made.
requirements.
If at any time the generator stops because of a fault, the
4.5.11 Dispose off any loose items or debris in the vicinity fault should be rectified before trying to restart the
of Genset that may inhibit operation or could cause generator.
injury.
C-22
Low Lube Oil Pressure.
High Water Temperature
Start
Enmgine Running
Engine Idle
Stop
Battery charging indicator
mode.
Timer setting indicator for auto
Fig. 4-1 :
Centre button (with Hand symbol) : This button is used to start the set in manual mode. By pressing the
button START output will get On & starter will get the supply through start relay at the same time fuel
solenoid will also get energiged. Starter will automatically Will disconnect after getting supply from
alternator (Phase & neutral).
Left button (with“O” symbol) is used to stop the set, to reset the fault & to terminate the AUTO mode.
C-23
4.6 CONTROL SYSTEM FUNCTIONAL DESCRIPTION All alarms are indicated by high visibility red LED’s.
The 703 is an engine auto start and protection module. The module’s microprocessor provides a comprehensive
It utilises advanced surface mount construction list of timers and configurable functions. Parameter
techniques to provide a compact, yet highly specified settings can be adjusted using the front panel push
module. buttons once in Configuration Mode. PI see installation
procedure.
Operation is via three push-buttons mounted on the front
panel with STOP, MANUAL START and AUTO positions. FEATURES
• Micro-processor based design
OPERATION • Automatic Engine Starting and Stopping
• Automatic Shutdown on fault condition
Stop mode - This is used to stop the engine when it is • Configurable via front panel
running and to cancel ‘Auto’ mode. It is also used to
• Simple push-button controlled operation
reset any Shutdown Alarm condition.
• 10-30V DC operating voltage
Manual mode - This mode is used to manually start and • Configurable Digital Inputs
run the engine, which can be stopped by pressing the • Configurable Solid State Outputs
Stop button. • Configurable Timer Settings
• Solid State Fuel and Crank outputs
Auto mode - (for AMF application only) This selects the • External Remote Start input
automatic mode of operation, in which the module will • LED Alarm indication
await the remote start signal. Once received, the module • Stop Delay Timer
will initiate its pre-configured Start Sequence, observing • Energise to Stop timer
the start delay timer before starting the engine. When the • Pre-heat Timer
remote start signal is removed, the module will initiate its
pre-configured Stopping Sequence.
• Over Speed Shutdown
• Optional Underspeed Protection
The module monitors the engine and provides the • Low Oil Pressure Shutdown
following functions: • High Engine Temp Shutdown
• In Auto mode Automatic Start with 3 attempts and The 700 series modules have been designed for front
Automatic Crank Disconnect - with adjustable Start panel mounting. The module is fitted into the cut-out,
and Stop Timers and Fail to Start indication. and screw holes are provided for secure fixing.
• Configurable Pre-heat and Energise to Stop
functions. 4.7 OPERATION
a) Carry out Pre-start Checks:-
• Low Oil Pressure and High Engine Temperature
Alternator Circuit Breaker Off
Shutdown.
Engine coolant level
• Overspeed (frequency) protection. Engine oil level
Fuel level
• Charge Fail Alarm
All electrical contacts secure
• Two fully configurable auxiliary inputs. 1st Auxiliary Control panel key switch in the Off Position.
input is connected to Low fuel shutdown. 2nd auxiliary b) Switch off the Alternator Circuit Breaker.
input is connected to emergency stop condition .
4.7.1 Do not crank the engine for more than 5- 7 seconds
if the engine fail to start.
C-24
Allow an interval of approximately 10-15 Seconds between THE FREQUENCY METER indicates the frequency of the
cranking attempts, and should the engine still not have generator output. The engine maintains a relatively
started after four cranking attempts, refer to the engine constant speed under governor control so as to provide
manual to determine the cause of failure to start. proper operating frequencies of 50Hz or 60 Hz when the
generator is operating at full rated load. At partial loads
At this point your genset should be running normally; the the frequency will be some percent higher than normal,
protective switches i.e. low oil pressure and high engine depending on the droop of the governor. In practice at no
coolant temperature will be open and sensing their load, frequencies of approximately 52 and 62.4 Hertz
respective operating conditions. In the event of a fault the
respectively are normal.
relevant fault circuit will operate and shut down the
Genset.
4.8.2 Engine Instrumentation
4.8 CONTROL PANEL EQUIPMENT
The engine instrumentation is as follows:-
The control panel is matched with an instrument panel 1 no. engine lube oil pressure gauge.
consisting of the following: 1 no. engine coolant temperature gauge.
4.8.1 Generator Instrumentation 1 no. ammeter (To indicate charging current)
1 no. battery voltmeter (optional)
The A.C. instrumentation provided is as follows: -
The following description explains the function of each
1 no. ammeter with selector switch, to monitor the current instrument and gives the proper reading for normal
in each phase or 3 ammeter (optional). operation.
1 no. voltmeter and selector switch to monitor the phase The ENGINE WATER TEMPERATURE is connected to
to phase and phase to neutral output voltage.
the engine at an access port which allows it to sense the
temperature of the engine coolant. This gauge
1 no. frequency meter monitoring the frequency of the
alternator output. continually monitors the temperature of the coolant
during operation. The normal temperature should be
1 no. hours run meter monitoring the running time of the approximately 85 Deg C (green zone). This is an electrical
engine (useful for establishing maintenance periods). device operating from the genset battery when the engine
is running.
The following description explains the function of each
instrument:- The ENGINE OIL PRESSURE GAUGE monitors engine
oil pressure from the moment the engine is cranked. The
The A.C. VOLTMETER Indicates the voltage the Genset proper engine oil pressure rating should be approx. 3 bar
is supplying to the load. The reading indicated by the - 4.5 bar at 1500 RPM. (Under full or 75% load condition)
voltmeter will vary depending on the connections made
inside the alternator terminal box, the setting of the DC ammeter - This indicates battery-charging current
voltage regulator, and the position of the voltmeter selector
when the engine is running and charging alternator is
switch. It should not, however, vary when the set is
developing the voltage.
operating.
The A.C. AMMETER indicates current being delivered Battery voltmeter (optional) - This indicates battery voltage.
which is dependent on the connected load. The ammeter This also indicates battery condition when engine is
displays current on each phase which is selected by cranking. If battery voltage is not proper during cranking
means of the ammeter selector switch. In case of 3 then check the battery and its connections.
ammeters selector switch is not required.
C-25
4.8.3 Fault Lights 4.10 MAINTENANCE
The FAULT LIGHTS indicate that a shut down has been No regular maintenance is required for the control system.
initiated by the protective circuitry. However, to ensure that the generating set is always
available for service when required, the following is
4.9 ALTERNATOR CIRCUIT BREAKER recommended:-
The moulded case circuit breaker (MCB/MCCB) is 4.10.1 Every two weeks, carry out an operational test
of sufficient rating for the genset output. The genset on the system as illustrated in paragraph 4.7a. check and
output is switch able through this device, handle up replace fuel levels.
being “on”. The breaker will carry its rated current
continuously. Breaker will trip to the mid-position if the 4.10.2 Every four weeks, carry out an operational test
rating of any one phase is exceeded for a period on the system. The genset should be operated on at least
depending on the percentage overload and the MCB/ 50% load for 2-3 hours.
MCCB characteristics. The breaker must then be moved
to the “off” position before re-closing. 4:10.3 Every six months, check tightness of all
connections, tighten if necessary.
C-26
FUNCTIONS AND PARAMETERS TABLE

Function 11 12 Value (Default in Italics)
Pre-heat Timer m m m m l m m m 0 Seconds
m m l 5 Seconds
m l m 10 Seconds
m l l 15 Seconds
l m m 20 Seconds
l m l 30 Seconds
l l m 60 Seconds
l l l 180 Seconds
Start Delay m m m l m m m m 0 Seconds
m m l 5 Seconds
m l m 10 Seconds
m l l 15 Seconds
l m m 20 Seconds
l m l 30 Seconds
l l m 60 Seconds
l l l 180 Seconds
Stop Delay m m m l l m m m 0 Seconds
m m l 5 Seconds
m l m 10 Seconds
m l l 15 Seconds
l m m 20 Seconds
l m l 30 Seconds
l l m 60 Seconds
l l l 180 Seconds
Energise to m m l m m m m m 0 Seconds
Stop Timer m m l 5 Seconds
m l m 10 Seconds
m l l 15 Seconds
l m m 20 Seconds
l m l 30 Seconds
l l m 60 Seconds
l l l 180 Seconds
Normal Frequency m l m m m m m m 50 Hz (O/S + 14%)
m m l 60 Hz (O/S + 14%)
Nominal DC Voltage m l m m l m m m 12V DC (CF 8V)
m m l 24 DC (CF 16V)
LOP Switch Contact m l m l m m m m Close on Fault
m m l Open on Fault
HET Switch Contact m l m l l m m m Close on Fault
m m l Open on Fault
C-27
Function 11 12 Value (Default in Italics)

Crank disconnect on m l l m m m m m Disabled
Oil Pressure m m l Enabled (2 Second delay)
Underspeed detection m l l m l m m m Disabled
m m l Enabled (U/S – 20%)
Auxiliary Input 1 l m m m m m m m Immediate Warning Close
Function m m l Immediate Warning Open on
m l m Immediate Shutdown Close
m l l Immediate Shotdown Open
l m m Delayed Warning Close on
l m l Delayed Warning Open on
l l m Delayed Shutdown Close on
l l l Delayed Shutdown Open on
Auxiliary Input 2 l m m m l m m m Immediate Warning Close
Function m m l Immediate Warning Open on
m l m Immediate Shutdown Close
m l m Immediate Shutdown Open
l m m Delayed Warning Close on
l m l Delayed Warning Open on
l l m Delayed Shutdown Close on
l l l Delayed Shutdown Open on
Auxiliary Input 1 l m m l m l l l Not used
Function m m l Pre-heat
m l m Engine Running
m l l Common Warning
l m m Common Shutdown
l m l System in Auto
l l m Common Alarm
l l l Energise to Stop
Auxiliary Input 2 l m m l l m m m Not used
Function m m l Pre-heat
l m l Engine Running
m l l Common Warning
l m m Common Shutdown
l m l System in Auto
l l m Common Alarm
l l l Energise to Stop
C-28
TROUBLE SHOOTING
Sr. Problem Check & Action to be taken
1 No. DC voltage after DC ON switch is Check battery supply.

turned ON. Bad electrical connections.
(to “ON” position) Check the MCB to ‘ON’ position.
When engine stand still.
2 The engine panel draws relatively very small current

when the dc on switch is turn on. However, when
one attempts to start the engine, the starters would
draw a much Higher current. If the batteries are
Weak, then the battery voltage will droop to a very low
value and the engine will not crank.
Possible Causes and Remedies

Engine dose not CRANK while start Batteries are very weak.
PB pressed. Check the start relay operates.
Use Properly charged batteries.
OR
Fault in starter motor.
The engine doesn’t start but cranks. Air lock in fuel system.
Restriction in a fuel pipe.
Before engine starting ensure that load switch (mccb)
is off.
3 High Water temp. Indication lights and Temp. switch end wire is may be body earth. May be
engine stop. temp. switch is faulty. Actual water temp. is high. No
water in radiator. Water circulation system may be faulty.
4 Charge fail indication ‘ ON’ Check ‘IND’ terminal connected properly. Check the
wiring.
Check alternator is developing voltage or not.
5 Low fuel level indication lights Check fuel level in tank and fill as required.
Check Float switch. Check wiring.
6 Engine fires and stops after sometime Lop switch is not working properly
and LOP indication lights Actual Lub oil pressure is not developed
Pressure switch connection wrong
Wiring is not correct.
No oil in engine.
Lub oil pipe not connected to gauge.
7 Engine overspeed indication Check gen. Supply to control unit.

(Frequency based) Check engine rpm.
Check for loose connections
C-29
Sr. Problem Check & Action to be taken
8 Emergency stop STEP

P.B. pressed.
1. Check the emergency stop P.B. pressed on
Panel and Canopy.
2. Check wiring to P.B. for body earth.

Switch may be faulty.
ONCE THE FAULT HAS BEEN IDENTIFIED AND

RECTIFIED.
RESET BY PRESSING ON “0” UNIT BUTTON.
9 NO VOLTAGE PRODUCED STEP

WHEN GENERATOR IS
RUNNING 1. CHECK VOLTMETER SELECTOR SWITCH IS NOT
SWITCHED OFF.
2. CHECK FUSES F2, F3 ANDF4.
3. CHECK VOLTAGE AT ALTERNATOR TERMINALS

WITH INDEPNDENT METER. IF VOLTAGE IS
CORRECT CHECK WIRING BETWEEN
ALTERNATOR AND PANEL. CHECK VOLTMETER.
REPLACE IF NECESSARY.
4. CHECK AVR AND ROTATION DIODES-REFER TO

ALTERNATOR MANUAL FOR DETAILS.
5. CHECK ENGINE SPEED IS CORRECT.
10 GENERATOR DOES NOT STOP STEP
1. CHECK KEY SWITCH OPERATION
2. CHECK FUEL CONTROL SOLENOID (FCS).

REPLACE, IF NECESSARY.
11 GENERATOR DOES NOT GO ON LOAD STEP
1. CHECK CIRCUIT BREAKER IS SWITCHED ON.
2. CHECK GENERATOR IS PRODUCING VOLTAGE.

IF NOT, SEE SECTION ON “NO VOLTAGE
PRODUCED”.
C-30
CHAPTER - 5
OPTIONAL EQUIPMENT
5.0 INTRODUCTION These heaters are all automatically disconnect on engine
start-up. Control switches (ON/OFF) are not normally
Standard panels may be fitted with a variety of optional
fitted but are available as a further option.
equipment during production of the generating set to
meet specific requirement. Your panel may contain one NOTE: An auxiliary supply of 220-240V AC is required for
or more of the following options. this option.
5.1 BATTERY TRICKLE CHARGERS 5.3 FUEL TRANSFER PUMPS
These chargers are designed to ensure that the starter Where a fuel transfer pump is required to transfer fuel
batteries maintain their charge even if the generator is from bulk storage tanks to the generator day tanks, a
not operated for long periods. 220/240V AC single phase pump is fixed to the baseframe,
float switches are fitted in the day tank and control relays,
The chargers are available in two sizes (5 Amp nominal
switches, lamps and overloads are fitted in the control
rating and 10 Amp nominal rating). A 10A charger is
panel.
generally located in a separate box placed adjacent to
the control panel. Control switches are not normally The controls on the panel door consist of two illuminated
fitted but the chargers are automatically disconnected push-button. The red is a combined trip lamp and stop
on generator start-up. When the engine is running the button, with the green being a run lamp and manual start
batteries are charged from the engine driven automotive- push-button.
type alternator. The absence of a switch mean that the
trickle charger cannot be inadvertently switched off. For automatic pump operation the red illuminated
push-button must be in the ON (out) position. The pump
However if considered essential as ON/OFF control may be manually started at any time, provided the red
switch can be provided. To monitor the charging current push-button is in the ON position, by pressing the green
a suitably scaled moving coil DC ammeter can be push button. The pump will only run in the manual mode
provided. if the green push-button is kept depressed.
NOTE: Batteries which have a very low charge should Inside the panel is a DC relay (PR) which is energized by
not be connected to these chargers as damage may a low level switch in the day tank and de-energized by a
result. An auxiliary supply of 220-240V AC is required for high level float switch. A contact of this relay is in the
this option. pump contactor circuit and will cause the pump to run
when “PR” is energized and the pump controls are set for
5.2 HEATERS automatic operation.
Immersion type heaters working on mains supply (110/ The pump contractor is fitted with an electrical overload
220 V) can be fitted in the engine water system to ensure which operates if the current drawn by the pump is
that the engine is kept warm easy to start and able to take significantly higher than normal. If this overload operates
load quicker. Heaters are provided with an integral non- the trip lamp (red) will illuminate. The green lamp is
adjustable thermostat set at approximately 40°C (100°F). illuminated when the pump contactor is energized.
The rating of the heaters in kilowatts (kW) varies depending
on the size of engine. Normally the heaters with 1 kW NOTE : An auxiliary supply of 220-240V AC is required for
capacity are used. Anti-consideration heaters in the form this option. These pumps must be primed with fuel
of “heat-tracing” tape can be fitted to the alternator stator before initial running to ensure that the bearings are
winding. These operate at a relatively low temperature lubricated. Care should be taken to ensure that the
and do not require a thermostat. pumps never run when bulk tanks are empty or when the
fuel fill lines are closed.
C-31
5.4 METERS 5.6 SPEED /VOLTAGE CONTROL
Where more information is required as regards generator Volts Adjust Potentiometer

loading, the following meters may be added.
To allow minor adjustments of voltage to be made from
1. Three ammeters instead of one ammeter and a the control panel, a single turn 5k Ohm potentiometer
selector switch. This provides continuous indication can be fitted. This allows an adjustment of upto 5% about
of the running current in each phase. the rated voltage.
2. Kilowatt (kW) meter. Speed adjust Potentiometer

These are generally three phase unbalanced load
moving coil meters. The meter is fitted on the panel This option can only be used when the engine speed is
front, with the transducer mounted on the chassis. being controlled by an electronic governor. The engine
This provides accurate readings of the load being speed/ frequency can be varied using this potentiometer.
supplied by the engine.
5.7 ALARM SIGNALLING
3. Digital RPM and Hour meter
This is optional to the standard frequency meter. Two options are available to supplement the standard
fault indications on the panel. These are:
5.5 GAUGES
1. A set of volt free contacts which changeover in the
To give further information on engine performance the
event of a generator fault. These contacts remain in
following gauges may be fitted.
the “alarm” condition until the fault is reset.
1. Oil Temperature Gauge
This is an electrical device operating from the genset 2. A siren which sounds in the event of a generator fault
battery, which monitors the lubricating oil condition. The siren (D.C. operated) is supplied
temperature when the engine is operating.-The loose for fitting in a convenient location. The siren
normal operating temperature should be can be switched off by pressing the MUTE push-
approximately ‘Ambient temperature + 80°C for air- button on AMF panels, or by turning the key to the
cooled engines and ‘Ambient temperature + 65°C OFF position on Keystart panels.
for water cooled engines, though this will vary between
engine models. 5.8 AUTOMATIC MAINS FAILURE
2. Ammeter for Engine Driven Charger OPTIONS

This gauge monitors the current flow to and from the
battery. It is primarily used to observe the charging Mains Sensing Relay Option
current being supplied from the engine driven battery
charging alternator. When the batteries are fully When an AMF panel is supplied without a changeover
charged this charging current will be small (less than panel the mains sensing relay, which is normally located
5 Amps) but with a partially discharged battery or just the changeover panel, may be fitted in the set mounted
after an engine start this current may be as high as 30 control panel.
Amps.
This relay requires a three phase from the incoming side
of the mains switch. The relay can then be adjusted such
that it will de-energise and start the set when the mains
voltage drops below the set point.
C-32
This includes following parts electrically interlocked so as both the contactors will
not get ‘ON’ simultaneously, (mechanical interlock
1) Mains sensing module
is optional).
2) Timer modules
5) Selector Switch - This is used for selecting the mode
3) Relay module of operation.
4) Load Transfer contractor Auto Mode - In this mode, load will gets automatically
connected to either mains or genset depending up
1) Three phase mains is applied to the LVM unit. This to the status of mains. In this mode, genset control
senses for mains under voltage, phase sequence, unit should be also in ‘Auto.’
and phase missing. If all the conditions are OK, this
Man Mode - In this mode, load can be switched ‘ON’
gives mains healthy signal. This signal is used for
or ‘OFF’ on either on mains or on genset depending
starting and stopping the set.
upon the mains or genset supply available.
2) Different timers are used for
Off Mode - Load will get switched off.
(a) Mains restore delay. If mains restores correctly
Test Mode - Genset can be tested for start and stop
Mains ON contactor will get ON after this delay.
using test ON and test OFF buttons.
(b) Genset start delay after the mains fail.
Mains / Genset selector Switch - This switch is used
(c) Set warming delay. After this delay genset to. check the voltage of either main or genset.
contactor will get ‘ON’.
Voltage selector switch - Ph-Ph or Ph-N (RYB, N)
(d) Set cool down delay. After load change over on voltage can be seen on voltmeter with the help of this
mains. Set will run on ‘No load’ for a time set by switch.
this timer.
Indications
3) Relay modules - This includes electro- mechanical
1) Load on mains - This will get ‘ON’ when mains
relays with appropriate current rating. This controls
contactor gets ‘ON’.
outputs such as start, stop, common alarm. Mains
contactor ON and generator contactor ON outputs 2) Load on genset - This will get ON when genset
are options. contactor gets ON.
4) Load transfer contactors - 3 pole (4 pole optional) 3) Mains Fail - This lamp will gets ON when mains fails
contactors are used for automatic load transfer to or mains phase sequence is not proper.
either mains or generator. These contactors are
C-33
5.10 FAULT FINDING
This section can be used to assist in finding the cause of faults listed under “Additional Alarm / Shutdowns”. It
must be read in conjunction with the Trouble Shooting chapter of Section 4 of this manual and also the separate
engine and alternator manuals.
FAULT INDICATION CHECKS
1. Battery Charger Failure 1. Check the mains voltage.

2. Check the fuse provided.
3. Check the voltage at the output of charger.
2. Low Fuel Level 1. Check fuel level in day tank and fill as required
2. Ensure Fuel Transfer Pump (if fitted) is operating as
described in Chapter 4A.3.
3. Earth Fault 1. Check all cable and wiring for bad connections or
shorts to earth.
2. Check alternator winding as described in the
Alternator Manual.
4. Earth Leakage 1. Check outgoing cabling and wiring for faults.

2. Do not re-start generator until fault has been cleared.
5. Overvolts 1. Disconnect generator from load and restart.

2. Check voltage on panel meters. If voltage is normal
ensure that the load is non capacitive (power factor
correction equipment may lead to a capacitive load).
3. If voltage remains high and cannot be adjusted to the
normal level refer to the alternator manual.
6. Undervolts 1. Check the voltage of panel.

2. Check the engine rpm.
3. If voltage remains low and cannot be adjusted to
normal level refer alternator manual.
C-34
CHAPTER - 6
MAINTENANCE
6.1 GENERAL 13. Refer to the engine maintenance section for specific
engine maintenance requirements.
A good maintenance programme is the key to long
genset life. Below is a program that should keep your 14. Start the machine after all checks have been made.
machine in top running condition. Also included in this 15. Drain condensate traps in the exhaust system, if
programme are routine maintenance operations required so equipped, and check for exhaust leaks.
for the engine and alternator (see Engine Maintenance 16. Check for any abnormal noise or vibration.
and Alternator Maintenance Sections). 17. Check for fluid leakage or high temperature.
It is good practice to have all of the maintenance and 18. Dispose of any unnecessary items in the vicinity of
service operations performed by trained personnel the genset that may inhibit operation or represent
familiar with genset maintenance. This, along with a cause of potential injury.
good service records system, should aid in developing 19. Check the control panel for indications of abnormal
an efficient maintenance program. The service records operation.
of each genset should include information such as
6.1.2 Maintenance Every Six Months or 250 Hours
complete nameplate data with model and serial numbers,
all drawing and wiring diagrams, spare parts stock lists, 1. Repeat the daily requirements.
as well as a service schedule and a copy of this manual. 2. Check all safety devices by electrically simulating
These records will allow quick reference and may help to a fault to ensure that all systems will function properly
diagnose a problem in the future. in the event of a fault.
3. Clean all battery cap vents.
6.1.1 Daily Maintenance or at Each Start Up 4. Start the genset and observe the instrument
Standby applications may lengthen these requirements panel to be sure that all gauges and meters are
to weekly. operating properly.
1. Make a visual check of the entire genset. Watch for 5. Tighten all exhaust connections.
signs of potential leaks from the engine fuel system, 6. Tighten all electrical connections.
cooling system or lubrication seals. 7. Refer to the engine maintenance section, for further
2. Check the alternator for obstructions in the cooling details.
air ventilation screens. 6.2. ALTERNATOR UNIT CLEANING
3. Check the alternator and control box for heavy
The alternator unit should be cleaned inside and out on
accumulation of dust and dirt. Clean any heavy
a regular basis. The frequency of such cleanings depends
accumulations as electrical hazards, as well as
on the environmental conditions of the operating site.
cooling problems, could arise.
The following procedure should be applied when cleaning
4. Check the air filter. Clean or replace if necessary. is necessary:-
5. Check the fuel level.
Disconnect all power. Wipe dust, oil, water or any other
6. Check the engine coolant level. liquids from the external surfaces of the alternator unit. All
7. Be sure that the radiator air flow is not obstructed. of these materials can work their way into the windings
8. Check the condition of the fan and alternator belts and may cause overheating or insulation breakdown.
and their tension Remove these same materials from the ventilation screens
9. Check all hose connections and hose conditions. around the circumferences of the unit.
10. Check the engine oil level. Do not permit such material to accumulate on these
11. Check the battery terminals for corrosion. screens as this will obstruct air flow. Such debris is best
12. Check the battery electrolyte level and fill with distilled removed with a vacuum cleaner as a vacuum cleaner will
water if necessary. not redeposit these materials on other parts of the
C-35
equipment. DO NOT USE COMPRESSED AIR, STEAM 6.3.3.2 INTERNAL (Preferably call specialist)
OR A HIGH PRESSURE WATER CLEANER.
If, due to leaky joints for instance, indiscriminate topping-
A vacuum cleaner should also be used to clean the up with hard water has been carried out for some time, or
windings of the alternator unit. This will remove dust from if the generator set has been run without inhibitors the
the coils that cannot be reached with a wiping cloth. system may become fouled by scale.
6.3. Radiator Maintenance To descale the radiator call KOEL authorised service
dealer being a specialised job.
6.3.1 Introduction
The procedure is as follows:
The radiator supplied with your generator set is designed
and constructed to give many years of trouble free 1. Drain the water system and disconnect and bank off
operation in industrial environments. There are, however, the pipe connections to the engine.
several points of maintenance that will ensure trouble
2. Prepare a 4% solution of inhibited acid solvent and
free operation.
fresh water. Add the acid to the water, never vice
6.3.2 GENERAL OPERATING NOTES versa.
WARNING: Radiator coolant is normally very 3. Allow several minutes for mixing, then heat the solution
hot and under pressure. Do not work on the to 49°C (120°F) maximum.
radiator or disconnect pipework until it has cooled down.
4. Run the solution slowly into the radiator via the filler
Do not work on the radiator or remove any guarding while
cap or a branch in the manifold. Effervescence will
the fan is in motion.
occur; when it ceases, fill the radiator completely
Corrosion in the radiator can be a prime cause of failure. with the heated solvent.
This is prompted by air in the water. Always ensure pipe
5. Allow to stand for several minutes; then drain the
connections are free of leaks and bleed air from top of the
solvent back into the original container through the
radiator regularly to keep the system “airfree”.
bottom manifold or drain plug.
Radiators should not be left standing in a partially filled
6. Examine the interior of the headers. If scale remains
condition. Radiators left partly filled with water will suffer
repeat the process outlined above with the solvent
much more rapidly from the effects of corrosion. For an
strength increased to 8%.
inoperative generator set, either drain the radiator
completely or ensure that it is maintained full. Whenever 7. After descaling the acid solution has to be neutralized
possible, radiators should be filled with distilled or naturally as follows:-
soft water, dosed with suitable corrosion inhibitors.
Fill the mixing container with fresh water, heat to
boiling point then add common washing soda crystals
6.3.3 CLEANING
at the following strength; 0.5 kg of soda to 20 litres
6.3.3.1 EXTERNAL water (1 lb soda to 4 gallons water). Fill the radiator
with this solution, then drain it back into the container.
In dusty or dirty conditions the radiator fins can become
blocked with loose debris, insects, etc. and this fouling 1. Flush the radiator in this manner several times,
will have an effect on the performance of the radiator. finally leaving the radiator full for at least an hour.
Drain until empty and wash out the radiator with hot
For regular removal-of light deposits use a low pressure
fresh water.
stream jet. More difficult deposits may need a detergent
with a low pressure hot water hose. 2. Before putting the radiator into service again, fill with
water and apply a test pressure equal to twice that of
Stubborn deposits, which cannot be removed by the
the working pressure. Examine carefully for any
above methods may require removal of the radiator and
leaks which may have been revealed by descaling.
immersion in a heated alkali degreasent solution for
about 20 minutes and then washing off with a hot water 3. Prior to recommissioning, the coolant must be dosed
hose. with any necessary corrosion inhibitors and/or the
correct proportion of antifreeze.
C-36
CHAPTER - 7
BATTERIES
7.1 SAFETY BATTERY
Red................. Positive+
ALWAYS ensure battery charging is carried out in a well
ventilated area away from sparks or naked flames. A Black............... Negative -
clear notice should be displayed stating “NO SMOKING
Connections must be clean and free from corrosion.
OR NAKED LIGHTS PERMITTED IN THIS AREA”.
NEVER operate the charger where unprotected from

rain or snow. The charger should not be used near water.
Ensure that the mains supply has been correctly
terminated and the GREEN/YELLOW lead MUST be
connected to a good earth (Ref. 8.2)
ALWAYS switch charger off before disconnecting battery

and ensure that there is no sparking or naked flames, as
concentration of fumes in the area can cause the battery
to explode.
NEVER group batteries close together around the charger

as damage and premature failure to components will be
caused by the corrosive fumes.
ALWAYS handle batteries with care and wash hands

after contact to prevent the possibility of acid burns.
Wear suitable protective clothing and display first aid
notices. 7.3 CHARGER OPERATION
7.3.1 GENERAL
NEVER permit unauthorized personnel in the battery
charging area except under supervision. Follow the safety recommendations outlined in 8.1.
Check battery and charger are connected as described
7.2 CHARGER AND BATTERY CONNECTIONS in 8.2.
Ensure that secure and proper connections are made to Remove the battery filler caps or vent cover during
a suitable mains plug with the following colour code: charging. Check electrolyte level and adjust if necessary,
following the procedures in 8.4.
MAINS Switch on charger and observe charge rate for normal
operation. If any problem is encountered refer to Fault
LIVE....... ....marked ‘L’ ....... .Brown lead Finding 8.5.
NEUTRAL....marked ‘N’ .........Blue lead
7.3.2 STATE OF CHARGE
EARTH......marked ‘E’ .. ...Green/Yellow lead
Allow the battery to settle for a short period with charger
NOTE: Power supply rating must not be less than 13 switched off before checking the specific gravity of each
AMPS. of the battery cells. Using -a hydrometer, the reading
should be approximately 1.27 for each cell at a nominal
temperature of +15°C.
C-37
7.3.3 CHARGING RATE tighten vent plugs. Dry top of battery.
The charging rate depends on the Ampere-hour capacity ELECTROLYTE AND SPECIFIC GRAVITY
(its size) of the battery, the condition of the battery and the
level of charge present. The electrolyte in a lead-acid storage battery is a dilute
sulphuric acid solution. A battery with a fully charged
The initial charging current will decrease as the battery specific gravity of 1.265 corrected to 80°F (26.7°C)
starts charging and the charging current will continue to
contains an electrolyte with approximately 36% sulphuric
decrease (or taper) as the battery voltage rises.
acid by weight or 25% volume. The remainder of the
IMPORTANT: With proper use, by following the electrolyte is water. Pure (concentrated) sulphuric acid
instructions, the Automatic Battery Charger should not has a specific gravity of 1.835. The sulphuric acid in the
overcharge and damage batteries. A lead acid battery electrolyte is one of the necessary ingredients in the
will be damaged if the temperature of the battery rises chemical actions taking place inside the battery. It
above 52°C (125°F) by overcharging. Care should be supplies the sulphate (804) which combines with the
taken when charging batteries that are hot, particularly active material of the plates. It is also the carrier for the
in tropical countries, where charging should always be electric current as it passes from plate to plate. When the
carried out in a cool shaded area. Consult the battery battery terminals are connected to an external load, the
manufacturer’s information and always check the specific
sulphate combines with the active materials of the
gravity with a hydrometer.
positive and negative plates forming lead sulphate
7.4 BATTERY MAINTENANCE (PbS04) and releasing electrical energy. Electrons flow
from the negative terminal to the load (such as fuel
7.4.1 GENERAL solenoid), and back to the positive terminal.
The “battery” is an assemble of cells containing a number Specific gravity is a unit of measurement for determining
of positive and negative electrodes or “plates” immersed the sulphuric acid content of the electrolyte. The
in an electrically conductive fluid or electrolyte (sulphuric recommended fully charged specific gravity of most 12-
acid). The electrical, energy released during discharge volt batteries today is 1.265 corrected to 80°F (26.7°C).
is derived from the chemical reactions taking place within water has arbitrarily been assigned a value of 1.000.
the cells. These reactions are reversible which means the
therefore, electrolyte with a specific gravity of 1.265
battery can be repeatedly charged and discharged.
means it is 1.265 times heavier than pure water.
7.4.2 TOPPING UP AND FILLING
If it should become necessary to dilute concentrated
WATER sulphuric acid to a lower specific gravity always pour the
The most satisfactory water to use when preparing acid into the water - do this slowly - never pour water into
electrolyte is distilled water. This is also true for routine acid. A dangerous “spattering” of the liquid would result.
water additions to the battery. Generally speaking, any This is caused by extreme heat which is generated
water that is safe to drink (excluding mineral waters) is whenever strong acid is mixed with water. Stir the liquid
safe to use in a battery. Do not use water of a known high continually while acid is being added.
mineral content. Avoid the use of metallic containers
(except lead or lead-lined containers). Metal impurities in FILLING
the water will lower the performance of the battery.
Add electrolyte until level is 5 to 10 mm above the top
TOPPING UP
edge of the separators. Allow battery to stand for 20
Clean top of battery to avoid contamination and remove minutes. Check and adjust level as necessary. Replace
vent plugs. Add distilled water until level is 5-10 mm and tighten vent plugs. The quantity of electrolyte required
above the top edge of the separators. Replace and can be determined from the following table:
C-38
7.4.3 HYDROMETER-DESCRIPTION AND Never take a hydrometer reading immediately after water
is added to the cell. The water must be thoroughly mixed
HOW TO USE with the underlying electrolyte, by charging, before
The state-of-charge of a lead acid battery can be hydrometer readings are reliable. If a reading is being
determined by the specific gravity of the electrolyte (its taken immediately after the battery has been subjected
weight compared to water). The specific gravity can be to prolonged cranking, it will be higher than the true
measured directly with a hydrometer or determined by value. The water formed in the plates during the rapid
the stabilized voltage. discharge has not had time to mix with the higher specific
gravity acid above the plates.
A hydrometer is a bulb-type syringe which will extract
electrolyte from the cell. A glass float in the hydrometer 7.4.4 INITIAL CHARGING
barrel is calibrated to read in terms of specific gravity. A
common range of specific gravity used on these floats is Within 24 hours of filling, or if battery stands inactive for
1.160 to 1.325. Do not assume a battery will not take a more than 6 months, charge for at least 2 hours at the
charge because you have been charging it for a time and approximate current in amperes shown above. This
the float will not rise. The battery may have been fully charge will have to be carried out on a workshop type
discharged and will require considerable charging before charger.
reaching the minimum specific gravity on the float such
as 1.160 (approximately 1/4 charged). The lower the float 7.4.5 CLIMATE
sinks in the electrolyte, the lower its specific gravity. The
barrel must be held vertically so the float is not rubbing TROPICAL CLIMATES
against the side of it. Draw an amount of acid into the
barrel so that with the bulb fully expanded, the float will Most batteries used in temperate climates have a fully
be lifted free, touching neither the side, top or bottom charged specific gravity in the 1.250 to 1.280 range. A
stopper of the barrel. Your eye should be on a level with fully charged electrolyte specific gravity of 1.210 to 1.230
the surface of the liquid in the hydrometer barrel. Disregard is used in tropical climates. A tropical climate is considered
the curvature of the liquid where the surface rises against one in which water never freezes. This milder strength
the float stem and the barrel due to surface tension. Keep
electrolyte does not deteriorate the separators and grids
the float clean. Make certain it is not cracked.
as much as the higher strength electrolyte. This
increases the service life of the battery. The lower specific
The following table illustrates typical specific gravity
gravity decreases the electrical capacity of the battery,
values for a cell in various stages of charge with respect
to its ability to crank an engine. A fully charged specific especially the cold cranking performance. However,
gravity-of 1.265 corrected to 80°F (26.7°C) is assumed. these losses are offset by the fact that the battery is
operating at warm temperatures where it is more efficient
TYPICAL OPEN CIRCUIT VOLTAGE AND and cold cranking performance is not required.
SPECIFIC GRAVITY VALUES
The following chart shows the approximate specific
CHARGE SPECIFIC VOLTAGE gravity values of batteries at various states of charge.
LEVEL GRAVITY One column shows values for batteries whose electrolyte
specific gravity has been prepared for use in a temperate
100% 1.265 12.7
climate; the other column for batteries prepared for use
75% 1/225 12.4 in a tropical climate. It illustrates that batteries may be
fully charged and yet have different values of specific
50% 1.190 12.2
gravity. The values shown are for a cell in various states
25% 1.155 12.0 of charge with respect to its ability to crank an engine at
DISCHARGED 1.120 11.9 80°F (26.7°C). The specific gravity values shown will vary
depending on the ratio of electrolyte volume to active
material and the battery construction.
C-39
7.4.7 TEMPERATURE CORRECTION

State of Specific Specific
charge Gravity Gravity
Hydrometer floats are calibrated to give a true reading at
Temperate Tropical
one fixed temperature only. A correction factor must be
Climates Climates
applied for any specific gravity reading made when the
electrolyte temperature is not 80°F (26.7°C). Some
Fully charged 1.265 1.225
standard hydrometers use a reference temperature of
75% charged 1.225 1.185 60°F (15.5°C). A temperature correction must be used
because the electrolyte will expand and become less
50% charged 1.190 1.150
dense when heated. The float will sink lower in the less
25% charged 1.155 1.155 dense solutions and give a lower specific gravity reading.
The opposite occurs if the electrolyte is cooled. It will
Discharged 1.120 1.080
shrink in volume, becoming more dense. The float will
rise higher and read too high.
Batteries prepared for service in extremely cold weather
use stronger electrolyte. In some instances specific
Regardless of the reference temperature used as a
gravities of 1.290 to 1.300 are used. The cold cranking
standard a correction factor of 0.004 specific gravity
performance increases as the specific gravity is increased.
(sometimes referred to as 4 “points of gravity”) is used
for each 10°F (5.5°C) change in temperature. Four
7.4.6 ELECTROLYTE
“points of gravity” (0.004) are added to the indicated
reading each 10°F (5.5°C) increment above 80°F (26.7°C).
Use only pure dilute sulphuric acid, of the correct specific
This correction is important at extremes of temperature
gravity to suit temperature of operation:
because it can become a substantial value.
COLD OR TEMPERATE TROPICAL
The thermometer should be of the mercury-in-glass type
CLIMATE CLIMATE
with a scale reading as high as 125°F (52°C). The smaller
the club immersion the better, but it should not exceed 1"
1.270 Kg/L 1.230 Kg/L
(25mm). The electrolyte should be drawn in and out of
the hydrometer barrel a few times to bring the temperature
Check specific gravity with a good quality hydrometer
of the hydrometer float and barrel to that of the electrolyte
and correct readings as follows. If electrolyte temperature
in the cell.
differs from the hydrometer’s calibrated temperature:
7.5 FAULT FINDING
For each 10°C above add 0.007 to observed reading.
FAULT LOCATION
For each 10°C below subtract 0.007 from observed
reading.
WARNING : REMOVAL OF THE COVER FROM THE
CHARGER WILL EXPOSE DANGEROUSLY HIGH
For each 10°F above add 0.004 to observed reading.
VOLTAGE TERMINALS. TESTS ON THE CHARGER
WITH THE COVER REMOVED MUST ONLY BE
For each 10°F below subtract 0.004 from observed
CARRIED OUT BY A COMPETENT ELECTRICIAN
reading.
USING SUITABLE INSTRUMENTS.
(This can make a substantial difference at extreme
temperatures).
Adjust specific gravity using distilled water.
Note - for safety always add acid to distilled water.
C-40
SYMPTOM - POSSIBLE FAULT ACTION
NO. CHARGING CURRENT
A) Incorrect or bad battery connections. Check connections and clean terminals.
B) Old or sulphated battery with very low Remove battery and charge on specialist
terminal voltage. equipment.
C) No mains supply Check mains supply to charger.
D) Blown mains fuse Replace fuse.
NO CHARGING CURRENT SHOWN ON INDICATOR
Faulty indicator Check charging current with standard meter.
CHARGING RATE TOO LOW (SEE NOTE*)
A) Low mains voltage Check mains voltage supply.
B) Incorrect mains supply tapping Check the mains supply tapping with the supply
voltage.
C) Loose heavy current connections Check and tighten connections if necessary.
NOTE : Level of charging current will depend on size and state of charge of battery.
Charging current is automatically reduced as the battery is charged.
CHARGING CLAMPS GET HOT
A) Faulty connections to battery terminals Clean and remake battery connections.
B) Loose screws in clamps Clean and tighten screws in charging clamps.
MAINS SUPPLY FUSE FLOWS REPEATEDLY
A) Incorrect fuse rating Replace with correct fuse.
B) Wiring short Check and remake all connections.
CHARGER RATE DOES NOT TAPER
A) Old or damaged battery Battery will not rise to full charge voltage.
Test battery and replace as necessary.
C-41
NOTES
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C-42
CHAPTER - 8
CLOSED COUPLED GENSET ASSEMBLY

Note on Assembly of close coupled genset with Following rules should be followed as a guideline
single bearing Alternator while selection/positioning of the antivibration
mountings
1) Base frame:
Frequent relocation, initial installation ease, vibration 2.1) The number & type of the mounting should be
isolation or isolating from mounting surfaces, such selected such that the static deflection of each
as trailers, are major uses of fabricated bases. No mount, for the weight under consideration should
base should be rigidly connected to flexing surfaces. be 2 to 3 mm. This will insure about 80% of vibration
1.1) Base frame should be rigid enough for the isolation.
selected engine/alternator combinations so that 2.2) The anti vibration mountings should be positioned
it will not deflect during handling/operation of equidistance from center of gravity of the set to
ensure equal weight distribution & uniform
the set.
deflection.
1.2) Provision should be made in the base frame for
2.3) Ref. the table1 KOEL part nos. of AVMs to be used
lifting of the set.
below engine GE & alternator.
If the pads are provided on base frame for anti
vibration mounts then these should have machined
Please ref. the Table 2 Engine models , flywheel
surface.
housing used & alternator housing & disc coupling
1.3) KOEL recommends that engine & alternator
required.
assembly should be mounted on antivibration
mount. Table 2
1.4) KOEL recommended typical baseframe is shown in
fig1. Drawings of baseframe as recommended by Sr. Engine Model Engine Alternator Housing & disc
KOEL for various combinations with single bearing No. flywheel coupling
KG alternator has been prepared & made available housing
as required.
1 HA294 SAE-2 SAE-2 & DISC SAE-11.5
2 Anti vibration mountings
2 HA394 SAE-3 SAE-3 & DISC SAE-11.5
Table 1 3 HA494 & HA494 TC SAE-3 SAE-3 & DISC SAE-11.5
4 HA694 & HA694TC SAE-3 SAE-3 & DISC SAE-11.5
Sr. Engine Model KOEL part nos. KOEL part nos. 5 3R1040 SAE-3 SAE-3 & DISC SAE-11.5
No. for AVM below for AVM below 6 4R1040 & 4R1040T SAE-3 SAE-3 & DISC SAE-11.5
engine GE alternator 7 4R1040TA SAE-3 SAE-3 & DISC SAE-11.5
Qty. 2 Qty. 2/4 8 6R1080T & 6r1080TA SAE-3 SAE-3 & DISC SAE-11.5
9 6SL 9088TA(140–160) SAE-1 SAE-1 & DISC SAE-14
1 HA294 02.432.02.0.00 02.432.01.0.00 10 6SL 1500TA(180-200) SAE-1 SAE-1 & DISC SAE-14
2 HA394 02.432.02.0.00 02.432.01.0.00 11 6SL8800TA (250) SAE-1 SAE-1 & DISC SAE-14
3 HA494 & HA494 TC 02.432.02.0.00 02.432.01.0.00
4 HA694 & HA694TC 02.432.01.0.00 48.497.02.0.00 3) Recommended Assembly procedure for Close
5 3R1040 02.432.02.0.00 02.432.01.0.00 Coupled Genset
6 4R1040 02.432.02.0.00 02.432.01.0.00
3.1) All the fasteners used for assembly should be 8.8
7 4R1040T 02.432.02.0.00 02.432.01.0.00
high tensile strength. Bolt length should be such
8 4R1040TA 02.432.02.0.00 48.497.02.0.00
that minimum thread engagement in the respective
9 6R1080T/TA 48.497.02.0.00 48.497.02.0.00
tapped holes is 1.5 times the size of bolt. (That is for
10 6SL 1500TA(180-200) F6.626.02.0.00 F6.626.02.0.00
M10 bolt minimum thread engagement 15mm)
C-43
3.2) Check the crankshaft end play with the help of the alternator adapter housing. Mount firmly
magnetic based dial it should be alternator adapter with engine bell housing with the
help of 12 bolts.
For R1040/R1080/HA series between
3.11) Remove the taper pins & fix the disc coupling of
0.19 to 0.36 mm.
alternator to flywheel with suitable bolts. For bolts
For 6SL90 series between 0.12 to 0.33 mm. on the disc coupling suitable machined hard
washers should also be used.
3.3) Mount the specified AVMs on base frames on
engine gear end side & alternator side. Clamp 3.12) Remove the temporary support given below the
AVMs firmly on the base frame with suitable bolts & bell housing & mount firmly the alternator on
nuts as shown in fig 1. alternator support channel.
3.4) Mount the alternator support channel on two AVMs 3.13) After assembly, check again the crank shaft
on alternator side with suitable bolts. This channel end play it should be same as that measured on
is used to support the alternator & to maintain the bare engine (3.2). Normally the alternator shaft
center height has about 2 mm free axial movement on
eitherside of nominal position of disc coupling
3.5) Remove the fastners for clamping coupling disc to
to allow for variation in the interfacing dimension
alternator body (for transport purpose).
i.e. distance between disc coupling & meting
3.6) Mount the engine with suitable bolts on AVM face of adapter. Incase the crank shaft end play
(mounted on base frame) with temporary support is not observed as mentioned above the
to bell housing as shown in fig 2. alternator service person should call for
checking the alternator.
3.7) Remove the alternator front both sides’ air outlet
covers . (fig 3) 3.14) This will complete the close-coupled assembly.
Ref fig 3.
3.8) Assemble two taper pins with threading or
M10X1.5X50 long studs on flywheel, on
Important : Do not run the set if there is a variation in
diametrically opposite tapped holes to guide the
Crank shaft end play after alternator assembly. To do
disc coupling when the alternator is being
so will cause engine failure.
assembled on engine.
3.9) Locate the alternator adaptor-housing spigot to Please ref. table below for tightening torque for
bell housing of engine. At the same time ensure Standard straight shank bolt with threads lubricated
locating pins are aligned with holes on alternator 8.8 tensile grade.
disc coupling. The alternator needs to be supported
M10 5.0 kgm
by lifting tackle during this process.
M12 8.7 kgm
3.10) The bolts for alternator adapter & disc coupling can
M14 14.0 kgm
be accessed through the air ventilation window on
M16 21.0 kgm
C-44
TYPICAL BASE PLATE FOR
CLOSE COUPLED GEN. SET USER MANUAL - GENSET
SECTION A-A
C-45
C-46
TYPICAL INSTALLATION FOR
CLOSE COUPLED GEN. SET
STEP BY STEP INSTRUCTIONS FOR MOUNTING, ALIGNING AND

SETTING OF THE SINGLE COIL, 12 V / 24 V STOP SOLENOID
â Remove the two star screws, which are already a) Loose the lock nut on link rod.
mounted on fuel, pump with the help pump stop
b) Roate the ball joint clockwise or anticlockwise as
lever.
required so that linkage lever hole matches.
â Remove spring in fuel pump stop lever.
c) Lock the lock nut on linkage firmly.
â Mount stop solenoid bracket assembly on the fuel
pump location and tighten with M6*50*2no. hex
head screws. â When alignment and solenoid setting is correct
according to above position and solenoid operation
â Attach the tie bar at place shown with the help of
then tighten the connecting link bolt with the help of
M6*10*1no.hex head screw this will fit the solenoid
nylock nut and suitable force. Ensure that when
on pump.
solenoid is in normal coondition the gap between
â Confirm all the mounting screws are tighten firmly. fuel pump body and C type lever top edge should
be approx. 1.5 to 2mm.
â When mounting is complete don’t inserted the
connecting link in fuel pump stop lever (keep lever
free for solenoid setting). When solenoid is not proper then adjust the solenoid
setting according to following point.
â Give battery supply to the solenoid according to
operating D.C.Voltage of solenoid. â Loosen the lock nut of solenoid connecting link.
â Connect battery-VE to solenoid bracket assembly â Remove the link screw from stopping lever.
(o1)
â Rotate the ball joint with required direciton up to
And connect battery + VE to solenoid terminal (02) position or setting disrupted in point is not occurred.
â Confirmed that solenoid polarity with respect to â At the time of solenoid setting do not distrub the tie
battery is not opposite bar setting of solenoid.
â Battery voltage should be 12V for 12 V stop soleniod â After change in setting is complete tighten the lock
nut and again supply is given to solenoid.
â When stroke is complete, means solenoid links goes
down to max position, push stop lever of FIP to down â Check the operation through ESU / KRB, it should
most direction manually. remain on for only 20 sec max.
â If solenoid plunger ball joint link bolt is not exactly â The solenoid will get hot for this period as the current
matching then adjust the linkage up or down is high.
Part No. Voltage Resistance Current Where used
4H.150.10.0.000 12V 0.42 26-28 amp R
02.477.01.0.00 12V 0.9 15 amp HA , 6R
F6.570.11.0.00 24V 1.2 20 amp SL - 90
C-47
WARNING !
OPERATIONAL PROCEDURE
UPDATE
Warning: The excessive build up of unburned fuel gases in the exhaust system of diesel powered generating
sets can create a potentially explosive condition which could cause personnel injury and/or equipment
damage. Please follow the procedures below:
FUEL PRIMING HOT ENGINE SHUTDOWN
The fuel system on all engines should be completely If the engine shuts down due to a fault condition such as
primed to ensure immediate starting. Excessive cranking high water temperature or low oil pressure, etc., do not
with an unprimed fuel system may cause a build up of restart immediately. Remove the plug on exhaust outlet
unburned fuel gases in the exhaust system. Engine elbows or stub pipes to disperse fuel gases. Once these
priming procedures can be found in the engine operation have disappeared and the shutdown fault has been
manual. cleared, restart the engine.
FAILURE TO START OIL PRIMING
If during initial start or during normal starting the engine The oil system on all engines should be completely
fails to start after the initial 3 crank attempts, stop cranking primed to ensure safe operation. To ensure that engine
and unscrew the plugs on the exhaust outlet elbows or cranking for priming the oil system does not cause
stub pipes. White smoke (unburned fuel) will usually be unburned fuel to build up in the exhaust system, first
present. Once all signs of unburned fuel have disappeared disconnect the supply to the fuel solenoid or actuator
and any other problems causing the failure to start have then crank the engine until a positive oil pressure is
been rectified, replace the plugs and repeat the cranking registered on the gauge. Do not crank the engine for
procedure. more than 5-7 seconds should the oil pressure fail to
build up and indicate.
If it is necessary to demonstrate air valves closing when
the engine is running this should be done at no load. The Allow an interval of approximately 10 seconds between
engine should absolutely not be restarted immediately cranking attempts, and should the oil pressure still not
afterwards. The closing of the flap valves can cause oil have built up after three cranking attempts, investigate
carry over into the exhaust system which is highly volatile. the reason for lack of oil pressure prior to further cranking.
The engine should be left for a period of time to allow
these gases to dissipate.
During normal cranking attempts, the unburned fuel gases will generally not build up to a dangerous level
before the standard batteries are depleted. In cases where additional “fresh” batteries or an outside source
of power are used, extra care must be taken.
C-48
USER MANUAL - DIESEL ENGINES
SECTION D
INDEX
1. Engine Numbering System 5

2. Illustrations 6
3. Engine lifting 9
4. Lube Oil 11
5. Fuel Supply System 11
6. Cooling Systems 12
7. Electrical Systems 13
8. Commissioning 14
9. Starting 16
10. Electric Starting with Engine
Safety Device (KRB 01) 17
11. Electric Starting with Engine 21
Safety Device (Pricol)
12. Hand Starting
(Alternative to Electric Starting)
for HA 294 & HA 394 engines only 33
13. Maintenance Shedule 35
14. Maintenance of Lube oil Systems 38
15. Maintenance of Fuel Systems 43
16. Maintenance of Cooling Systems 44
17. Maintenance of Electrical Equipment 50
18. Trouble-Shooting & Remedial Measures 53
19. Engine Preservation 60
20. Tightening Torques 61
D-3
NOTES
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D-4
1.1 ENGINE NUMBERING SYSTEM : 2.1.3 Model Designation :

1.1.1 Engine Name Plate The engine model is punched on name plate in column
“TYPE”. The first two digits indicate engine series (i.e.
Engine serial number is punched on the Name Plate
HA), the digit after first two digits indicates number of
which is fixed on crankcase. Fig. 2.1/1 show the engine
cylinders while last two digits indicate piston
name plate.
displacement in litre per cylinder.
Example :
HA 2 94
94 - 0.94 Lit/cyl.
2 - No. of cylinders
HA - HA Series (air-cooled)
2.1.2 Engine Number

F6 or 3H or 03 1004 / 02 00001
Engine Serial Number
Year of manufacture
Application Code No.
02 for HA294
03 for HA394
04 for HA494
06 for HA694
3H - 3R1040
4H - 4R1040
5H - 4R1190
6H - 6R1080
F6 - SL90
D-5
2.2 ENGINE ILLUSTRATIONS
Your Kirloskar Green Power Ideas genset is powered by one of the three Kirloskar diesels – HA, SL90 or
R1040/R1080. Given as follows are the line illustrations of the user, serviceable parts of the diesel engines
used in a KGPI genset.
Air-Cooled Kirloskar HA diesel engine
Fig. 2.2.1 HA Engine (Service Side) Fig. 2.2.2 HA Engine (Exhaust Air Side)
1. Cooling Blower 16. Air intake manifold

2. Guard for blower and Alternator V-belts. 17. Exhaust manifold
3. Fuel Injection Pump 18. Exhaust air ducting
4. Flywheel 19. Alternator
5. Crank Pulley 20. Starter
6. Automatic Belt tension unit 21. Crankcase
7. Oil Filter neck 22. Crankcase breather
8. Oil Drain Plug (at gear end side on oil sump)
9. Oil Sump
10. Fuel Feed Pump
11. Dipstick
12. Lub. Oil Filter
13. Fuel Filter
14. Air Cowling
15. Rocker Cover
D-6
Liquid cooled Kirloskar SL90 Diesel Engine.
2.2.3 Air Inlet Manifold Side 2.2.4 Exhaust Manifold Side
1. Air cleaner 16. Bese frame

2. Fuel Pump 17. Crank case
3. Centrifuge filter 18. Engine mounting foot (Starter Side)
4. Alternator 19. Exhaust manifold
5. Lube oil cooler header 20. Gear casing
6. Engine safety unit 21. Radiator with CAC
7. Engine mounting foot (FIP Side) 22. CAC outlet
8. Fuel feed pump 23. Rocker Cover
9. Fuel filter 24. Starter
10. Water outlet manifold 25. Turbocharger
11. Bell housing
12. Air inlet manifold
13. Lube oil sump
14. Lube oil filter
15. Air cleaner monunting
D-7
Liquid cooled Kirloskar R1040 / R1080 Series

3 1 2 21 20
15
5 7
16
10 6 9 8 23 19 17 18
2.2.5 Inlet Manifold Side 2.2.6 Exhaust Manifold Side
1. Air inlet manifold 15. Alternator (for battery charging)

2. Air cleaner 16. Crankcase
3. Oil filling body 17. Engine starter
4. Fuel Pump 18. Engine mounting foot ( Gear end side)
5. Fuel Feed Pump 19. Engine mounting foot ( Flywheel end side)
6. Spin-on Lub oil filter 20. Exhaust manifold
7. Fuel Filter 21. Rocker cover
8. Dipstick 22. Flywheel housing
9. Lub oil sump with drain Plug 23. Flywheel
10. Gear casing
11. Crank pulley User serviceable parts are only on the surface of the
12. Water Pump Pulley engine and incase you wish to buy genuine
13. Thermostat replacement parts for Kirloskar Service Dealer. Please
14. V-belt ask for the parts by providing following information
to Kirloskar Service Dealer –
Notes :
a) Engine Type
z Air cleaner shown is Dry type. The location & type
of air cleaner may change according to specific b) Engine Sr. No.
application needs. c) Part Description
z Fuel filter location may be different for various
applications. as is in the illustrations in this Section.
D-8
2.3 Engine Lifting Device

2.3.1 For Bare Engine
To avoid the bending of the engine lifting
studs, during lifting up of the engine, a distance
piece as shown in the Fig. 2-3/1 is to be used
along with the standard bolt of size m8 x 55
mm long. (lifting hooks and steel plate are
provided with the engine.)
2.4.1 Lubrication System

Force feed lubrication is provided by a ‘G’ rorot type
pump to main bearings, connecting rod big end bearings,
camshaft journals, valve gear and turbo charger bearing.
Other components like small end bearings, liners, gears
are missed and splash lubricated.
The system includes adiquate filtering by replacable filter
Fig. 2.3/1 element. An air cooled lube oil cooler is used in lube oil
circuit to maintain the oil temperature within limits. A relief
Before lifting the engine first fix the lifting hooks on the
valve controls the maximum oil pressure and is
engine, place the above piece on lifting hook by engaging
incorporated on the delivery side of the pump.
two slots of end plates to the neck diameter of the hooks.
Then screw in bolt of m 8 mx 55 mm long in the tap hole The schematic diagram shows the lube oil circuit of HA
provided on the plate. Insert the bar through lifting hooks, 694T engine.
put the wire rope/chain on the bar and then lift the engine,
(see Fig. 2.3/2)
Fig. 2.3 / 2
1. Oil sump 2. Suction pipe
2.3.2 Recommended Lifting Arrangement for Base
3. Oil Pump 4. Pressure valve
Plate Mounted Set.
5. Delivery pipe 6. Pipe to Oil Cooler
The lifting hooks provided on engine are
7. Oil Cooler integral type 8. Oil Filter
meant for lifting bare engine. Use of lifting
9. Safety valve 10. Oil Galary
hooks for lifting up of genset, Pumpset or any other
11. Main Bearing 12. Big End Bearing
similar sets mounted on base plate, results in bending of
13. Camshaft bearing 14. Tappet
the studs for lifting and can cause damage to engine/set
15. Push Rod 16. Rocker arm bearing
in event of breakage. Hence, we recommend the use of
17. Metering plug 18. Push rod cover tube
proper sling/tackle arrangement for lifting up of such
19. Restrictor hole 20. Nozzle for piston cooling
base plate mounted sets. (Fig.2.3/3) shows the
21. Oil pipe to turbo charger 22. Oil Return pipe
recommended lifting arrangement.
23. Oil pressure gauge.
D-9
Lube Oil Pressure :- Level C.I. Sump Sheet metal sump

(Industrial application (Gen-set application)
Minimum 2 kg /cm2 4R1040 3R1040 4R1040 6R1080
First Fill 11.5 lit 9 lit 11.5 lit 15 lit
If the pressure at any time drops below 2kg/ Max. 9.5 lit 7.5 lit 9.5 lit 13 lit
cm2 at operating speed of 1500 rpm, under Min. 7.5 lit 5.5 lit 6.5 lit 10 lit
loaded condition, then replace the lube oil
filter element/cartridge and check the
pressure. If the pressure is still low, then Level SL 90
contact our authorised Service Dealer for the First Fill 23.5 lit
services of their technicians. Refill (lit.) 21.0 lit
Note : 1. First fill = Sump Capacity + Gallery Capacity + Lub oil Filter Capacity.
2. Fill the lub Oil Filter before fitting on the engine.
2.4.3 Lube Oil consumption 3. Do not forget to fill the lub oil filter whenever you replace the filter.
4. Whenever lube. Oil filter is drained off, add as per lub oil filter capacity
Lube oil consumption varies according to engine e.g. 0.5 lit./1.1 litre. Extra lube Oil in the sump to maintain correct oil
level.
operating conditions, but would not normally exceed
0.7% of actual fuel consumption for a well running
Kirloskar HA engine under normal load condition and
0.3% for Kirloskar R1040/R1080 & SL90 diesels.
2.4.4 Lube Oil Sump Capacity
These approximate values refer to standard cast Iron

and Sheet Metal Oil Sump.
Engine Type HA294 HA394 HA494 HA694
Oil Sump Type C.I. S.M. C.I. S.M. C.I. S.M. C.I. S.M.
Initial Fill (lit.) 5.5 — 9 — 10.5 12.5 15.5 15.5
Refill (lit) 4.5 — 8 — 9 11 13.5 13.5
C.I.= Cast Iron S.M.= Sheet Metal
D-10
Whenever Lube oil Filter is drained off, add as

per lube oil filter capacity in the sump to
maintain correct oil level
OBSERVE OIL LEVEL MARKS ON DIPSTICK.
2.4.5 Lube Oil Specifications :
A) Lube oils of correct viscosity and detergency grades
should be used.
For detergency ‘K’ oil comply to the following
specifications:-
Selection of Lubricating Oil Table
Standard To be used For
Fig. 2.5/1
Naturally aspirated Turbocharged as well
engines as Naturally Aspirated 2.5.2 Fuel Specifications
I.S.10356 1993 E DL2 E DL3 / EDL4 The performance of the engine depends upon supply of
clean and correct grade of fuel. The fuel injection
I.J.S. Military MIL-L-45 199B MIL-L 2104c/2104C plus
equipment is manufactured to very close tolerances and
API CD CF4 slightest amount of dirt in fuel can cause wear on the
CCMC — D4 / D5 injection equipment.
1) API - American Petroleum Institute. A) Always use clean High Speed Diesel having a sulphur
2) CCMC - Association Of Automobile Manufacturer content of below 1%.
of Common Market. In case of diesel fuel containing sulphur more
than 1% the periods between oil changes
For Viscosity, the recommended SAE number should be
should be shortened.
used. SAE J 30o C specifies the viscosity of Lube oils for
each SAE No. The following specification are approved :-
• IS: 1460
Always use oil brands of reputed oil companies. Table • BS:2869-A1&A2
show oil brands of established manufacturers, which are (In case of A2, note sulphur content)
recommended.
• DIN 51601
Too viscous oil causes starting difficulties. The choice of • ASTMD 975-81:1D&2D
the viscosity grade during winter operation should be
governed by the ambient temperature prevailing at the Winter Grade Fuel-
time of starting the engine. Oil changes as a function of At low temperatures, waxing may occur and clog the fuel
ambient temperatures can be avoided by using system, thus causing operational troubles.
MULTIGRADE oils. In the case of ambient temperature below 10° c, use
KOEL recommended K-Oil meets the specification of ‘Winter Grade’ diesel fuel, mixed with Kerosene.
MILC plus & SAE 20W40.
No guarantee claims will be entertained on the grounds
of engine damages due to use of unsuitable engine lube
oils.
2.5 FUEL SUPPLY SYSTEM
2.5.1 Fuel Circuit
Fuel is supplied to the block type fuel pump by a fuel lift
pump (feed pump) incorporated in the fuel pump itself.
A dual type fuel filter consisting of efficient pre and micro
paper filter elements ensures the supply of clean fuel to
the fuel pump. The schematic diagram (Fig. 2.5/1) shows
the fuel circuit of the engine.
NOTE : It the fuel tank is to be installed below the fuel
pump level, then the bottom level of the fuel tank should
be less than 1 meter below the feed pump inlet.
D-11
Proportion of Kerosene to be mixed in Diesel, depends z Use wire brush to clean the fins of cylinder liner,
on the ambient temperature as shown in the graph cylinder heads and lube oil cooler.
(Fig.2.5/2). (Maximum proportion limited to 50%) For (fig 2.6/1 & 2.6/2).
cold starting aid see 3.4.1
PREPARE THE BLEND IN THE TANK ITSELF.
FILL IN THE NECESSARY AMOUNT OF
KEROSENE FIRST, THEN ADD DIESEL FUEL.
2.5.3 Storing Fuel Oil

The storage of fuel oil is of utmost importance since many
engine problems are traced to dirty fuel or fuel stored for
too long a period. Store fuel in a convenient place outside
the building.
It is recommended that the fuel tank should be filled in at
the end of the day’s work. This keeps moisture out of the Fig. 2.6/1
tank.
z Take special care while cleaning, vertical cylinder
To eliminate water from the fuel, drain out small quantity
head fins.
of fuel from fuel tank through a drain plug every day
z If possible use compressed air for cleaning.
before starting the engine.
Start blowing through the engine with compressed
2.6 COOLING SYSTEM air from the exhaust air side, paying particular attention
to the cooling fins and oil cooler.
Cold air is forced on to the cylinder liners, heads Remove any dirt blown into the cooling air ducting.
and lube oil cooler by an axial fan driven by ‘V’ belts on z Remount air cowlings.
the gear end side and is directed through stream lining
cowling. Thus cooling the engine efficiently.
2.6.1 Air Cooled Engine Cooling System
Cleaning Intervals :
z The degree of soiling of the cooling system is
dependent on the type of engine application.
z The danger of contamination is increased due to
residues of oil and fuel on the engine. Check extra
carefully. therfore. for leakages when application
involves high dust fallout.
z More severe contamination can occur, e.g. in case of Fig. 2.6/2
- construction site application due to heavily
dust-laden air. B) Cold cleaning Agent -
- Harvesting work, due to the high proportion of z Remove air cowling.
chaff and chopped straw, for example, in the z Spray engine with a commerical cold cleaning agent
vicinity of the implement. and allow a soaking in period of about 10 minutes.
2.6.1.2 Cleaning the cooling system z Wash engine clean with powerful water jet (taking
care to avoid direct contact of the water jet with
A) Dry Cleaning - sensitive engine components, e.g. alternator, starter
z Release clamps on the injection pump side and etc.)
remove air cowling. Release bolts on the exhaust
z Repeat procedure if necessary.
side and remove exhaust baffle.
D-12
z Remount air cowling. 2.6.2.2 Coolant

z Run engine until warm in order to allow the remaining In summer - Use fresh water with anticorrosion additives
water to evaporate. for the engine cooling system. Water should be clear and
C) Cleaning with High-Pressure Steam Jet - free of any corrosive chemicals formation. Water should
be clear and free of any corrosive chemicals such as
z If a steam-jet is available, this method of cooling is
chloride, sulphates and acids. We recommend to use
preferable to any other one.
coolant blend of soft water and one of the rust preventive
z Remove cooling air cowling. compound as mentioned below -
z Clean engine with steam jet (taking care to avoid
direct contact of the steam jet with sensitive engine *K-Cool Super : 8cc/litre or
compoments, e.g. alternator, starter etc.) . AQUAT-720 : 2.5Ccc/litre or
z Remount air cowling. Nalcool-2000 : 35cc/litre
z Run engine until warm in order to allow the remaining * Available with KOEL authorised parts & service dealers.
water to evaporate.
IN WINTER - Use Ethylene glycol antifreeze diluted with
Clean (by any method) only when engine is coolant blend as mentioned above in the following
stationary and cold. proportion in (radiator) cooling system.
Ambient Temperature °C Ratio by volume of anti freeze
2.6.2 LIQUID COOLED ENGINE COOLING SYSTEM to cooling water blend
2.6.2.1 Radiator System +5 To -5 20:80
The cooling circuit with radiator is recommended where -6 To -15 33:67
the fresh water is available. Fig. 2.6.3 shows the water -16 To -25 40:60
circuit diagram. below -25 50:50 (max. permissible ratio)
z Commercially available ready mixed coolants can

also be used, with Antifreeze and anticorrosion
additives after ascertaining suitability for low ambient
temperature.
z Storage of engine with only fresh water in engine
cooling system should be avoided at ambient
temperature below 5° C. This may cause cracks in
the engine components.
z If the engine is to be transported from normal
ambient areas to Low ambient areas ambient
below +5° C the complete cooling system should be
drained and refilled with Antifreeze + water mixture
Fig. 2.6/3 as mentioned above.
IMPORTANT 2.7 ELECTRICAL SYSTEM

z It is also necessary to ensure proper ventilation to 2.7.1 Electrical Equipment
avoid hot air re-circulation into the cooling system. A) 12V Electrical System -
z For any non-standard installation of radiator system Alternator
(Ex. Remote radiator mounting) Please contact
KOEL OR NEAREST koel AREA OFFICE / KOEL Make Specification
authorised service dealer for necessary AUTOLEC 12V, 55 Amp
recommendation. LUCAS A115-12V, 35 Amp
D-13
Starter * For battery capacity at extreme low temperature i.e.

below -20°C, contact Kirloskar Oil Engines Ltd. Pune,
Make Specification
India.
AUTOLEC 12V
2.7.2.1 BATTERY CABLE
LUCAS 3SM 127, 12V 440/0.45 (70 MM2) minimum
B) 24V Electrical System - Auto lable - 65/0.3, 35 Max. Capacity
This system is used on SL90 series of Kirloskar Diesel - 26/0.3 35 Max Capacity
Engine. 3.1 COMMISSIONING
System voltage - 24V (Floating / -ve earth) Before you start a new or an overhauled engine,
Starter - Autolek attend to the points given below -
Alternator - Autolek 3.1.1 For oil filling volume, see 2.4.4 (initial fill) For oil
Charging Ammeter - 50-0- + 50 range. quality grade and oil viscosity, see 2.4.6.
BATTERY
A) Battery Capacity Ratings
z C.I.M ( Compression ignition Motor) Rating - Minimum
current at 27° C with full charged battery should
sustain for 5 min. 30 sec with cell voltage of 1.33 V/
cell.
z Cranking Performance Rating- It is a minimum current
in amperes which fully charged battery at 27°C will
sustain for a period of 2 minutes and maintain cell
voltage of 1.2V/cell or higher.
z 20 hours capacity rating-it is the capacity in ampere-
hour which the fully charged battery will deliver when
it is discharged at 27°C at a constant current for 20
hour before reaching a final voltage over all of 1.75
V/cell.
Hour Meter Fig. 3.1/1
Since electronic Hour meter is sensitive to temperature, 3.1.2 If oil bath air cleaner is supplied with engine, fill
the maximum operating temperature range is 50 ° C. To oil bowl of air cleaner with engine oil up to the oil
satisfy this condition, rubber isolators for the panel as level mark (Fig. 3.1/2).
well as Hour meter should be ensured. Hour meter is
protected against reverse polarity but operating voltage
should be ensured before connecting. i.e., 12 V should
not be connected to 24 V systems.
2.7.2 Recommended Battery Capacity
Engine Ambient Battery Capacity in Amp-hr. (20 hr. rate)
model Temp. °C 12V 24V
HA294 Above +10 88 2 Batteries of 12 V, 88 Amp-hr in series
HA394 +10 TO -20 135 same as above.
HA494 above +10 100 same as above
HA494TC +10 to -20 150 2 batteries of 12 V, 100 Amp-hr in series
HA694 Above +10 150 2 batteries of 12 V, 88 Amp-hr in sr.
HA694TC +10 to -20 180 2 batteries of 12 V, 120 Amp-hr in sr.
R1040 Above +10 135 2 batteries of 12 V, 88 Amp-hr in sr.
R1080 +10 to -20 180 2 batteries of 12 V, 120 Amp-hr in sr.
Above +10 135 2 batteries of 12 V, 88 Amp-hr in sr.
SL90 Fig. 3.1/2
+10 to -20 180 2 batteries of 12 V, 120 Amp-hr in sr.
D-14
Be sure not to fill oil into the pre cleaners dust lube oil circuit. Hence external lube oil filling is
collector, if provided. not necessary.
Also, if dry type air cleaner is fitted on engine 3.1.4 Fill up the fuel tank after making sure that it is
do not fill lube oil in it. properly cleaned. Use only High Speed Diesel
3.1.3 On HA294 engine only - Fuel. See section 2.5 for fuel quality grade. In
Fill lube oil in the fuel pump and its governor. Use accordance with ambient temperatures, summer
same lube oil quality grade as recommended for or winter grade diesel fuel should be used.
the engine oil. (Fig. 3.1/3). Never fill the fuel tank while the engine is running.
Observe strict cleanliness. Do not spill any fuel
3.1.5 Bleed the fuel system as follows:
A) Loosen the vent screw on the primary fuel filter
(Fig. 3.1/5).
Fig. 3.1/3
To check the oil level, Loosen the oil level control
plug fitted on governor housing. The oil should Fig. 3.1/5
flow through this plug after loosening
(Fig. 3.1/4). B) Operate the fuel lift pump (feed pump) till fuel oil
flows without air bubbles. Keep a tray to arrest
the seepage of fuel on ground.
(Fig. 3.1/6).
Fig. 3.1/4
On all other 3,4 & 6 cylinder Kirloskar Diesels, the Fig 3.1/6
lube oil supply is given directly through engine
D-15
C) Tighten the vent screw on primary filter and then - Check oil level, top up with oil if necessary
similarly bleed the Micro filter by loosening the (see 5.1.2)
vent screw on it. (Fig. 3.1/7) Tighten the vent - Tighten V-belts (see 5.5)
screw. 3.1.7 Belts
Check that the belts are in position and the belt tension
is properly adjusted. If not adjust it as described in
section 5.5.
3.2 STARTING
3.2.1 Electric Starting
Before starting, make sure that no one is
standing in the close vicinity of the engine or
driven machine.
After Repairs -
Make sure that all removed panels and guards have been
MICRO FILTER put back into place and all tools removed from the
AIR VENT engine.
SCREW
Fig. 3.1/7
D) Loosen the banjo bolt of the fuel gallery on the OFF ON
fuel pump and operate the lift pump till the fuel
flows free of air bubbles. Tighten the banjo bolt
(Fig. 3.1/8)
START
Fig. 3.2/1
A) Electric Starting without engine safety device
with “OFF - ON - START” key switch -
z Insert Key
Position OFF = NO operating
voltage.
Fig. 3.1/8
z Turn key clockwise
3.1.6 Other Preparations Position ON = Operating
z Check battery and lead connections. voltage, pilot lamp lights up.
Also, check the cable connections at the starter, and z Turn key further to clockwise against spring
alternator. Loose connections lead to improper pressure.
contact and damage to the terminals. Position START = Engine starts firing
z Trial run z Release key as soon as engine starts firing, Pilot
Upon completing the preparations, run the engine tamp goes out.
for short trial period of about 10 minutes without load. With Start Push Button -
Steps to be taken during and after trial run:
1) Do not use the starter on any occasion for
- Check engine for leakages. more than 20 seconds at a time. Pause for a
With engine stationary: minute between two consecutive operations.
D-16
D-4
2) Never operate the starter for more than 4 6) Aux./EMG : This is one additional input generally
attempts continuously, otherwise battery may used emergency stop PB.
run down. If engine does not start, trace the Testing procedure for ESU.
cause according to fault Diagnosis Chart.
FUNCTIONAL CHECKS
3) On no account should the starter be operated TEST TO BE CARRIED OUT EXPECTED RESULTS
when the engine is running, otherwise serious 1) SWITCH ON/OFF STATUS
damage is likely to occur to both the starter a) Switch on enable.
and the starter ring on flywheel. Any Voltage between 10Volts to 28 Volts dc.
B) Electric Starting with Engine Safety Device : b) Switch off enable.
Voltage will appear at SOL terminal for 18 seconds
One of the following safety units depend on scop of
supply may be applicable for your engine. 2) LOP FAULT TEST & BYPASS TEST
ESU – ENGINE SAFETY UNIT a) Connect a link between lop terminal and -VE &
Put on enable switch
KOEL part no. 02.424.02.0.00
– After switching on the enable after 20 seconds
This unit is installed on the engine panel board, for the LOP lamp will glow to indicate
protecting the engine from The LOP fault and simultaneously the Supply
1) Low lube oil pressure. voltage will appear at the SOL Terminal.
2) High water temperature /Cylinder head for HA series. b) Remove link between LOP terminal and –ve of
3) V- Belt fail. (HA series) Supply .
4) AUX/EMG, spare input to shut off the engine. – LOP- LED will remains “on”.
Operating Voltage: 10 to 28V pure DC supply. c) Connect link between –VE terminal & V-Belt fail,
High temp, Aux/Emg terminals one by one.
Operating temperature: 15 to 55 degree cent.
– LOP-LED will remains “on’
Mech. Dimensions: 72X72X140 mm. d) Remove all the links.
Input: digital switch to ground (4 nos.) – LOP LED will remains “on”
Output: Solenoid relay output battery voltage will be e) Switch off enable.
available if relay gets ON. – LOP-LED will go off.
It is an energize to stop type. Engine will not stop by KEY (as already stop solenoid has
Means if any of the above fault occurs, ESU comes in activated for LOP fault)
action and switch ON the stop 3) TEMP FAULT TEST
Solenoid for 18 seconds and ultimately engine stops. a) Put Enable ON Connect a link between TEMP
(Battery supply will be available at SOL terminal for 18 terminal & -VE terminal
sec.) – The TEMP LED will glow and Supply voltage
There are 6 LED Indications on front panel. will appear at the SOL terminal
Remove link between TEMP terminal & -VE of
1) Fuse blown – as this name indicates fuse is blown Supply.
which is on the backside of the ESU. – The TEMP LED will remain “on”.
2) Charge – if this lamp glows it means battery is not b) Connect link between –VE terminal & V-BELT,
charging by the alternator. This also provides AUX/EMG, LOP terminals one by one.
excitation current to alternator 180ma common for – The TEMP LED will remain “on”.
12V & 24V. d) Remove all the links.
3) Low Lube Oil Pressure – If this lamp is glowing it – The TEMP LED will remain “on”.
means lube oil pressure is not developed. (NC to be e) Switch off enable.
used). This has got override timer which starts after – The TEMP LED will go off.
putting KEY to RUN position (ON). 4) CHARGE INDICATOR TEST
4) High temperature- This indicates that the water a) connect a link between –VE & IND terminal and
temperature has increased above acceptable range. switch on enable.
(to be used NO) – The CHARGE LED will glow
5) V-Belt Fail – This indicates fan belt has failed. When b) Switch off enable.
switch fitted on engine gets closed. (Only for air- – The CHARGE LED will go off.
cooled engines).
D-17
5) REPEAT STEP NO 3 FOR AUX & VBELT FAULT PCB of the KRB 101. If this link is cut, then the battery
Installation and fault finding instructions for KRB 101 relay switches on only if the ‘B+’ and the ‘BAT ON’
ESU Part no: 49.902.02.0.00 terminal is shorted. A switch can be added in this
Operating instructions : circuit to implement a ‘battery master switch’ that can
z Ensure the key switch is in the off position isolate a battery from the engine when not in use.
z The ‘Battery On’ (if fitted) switch is operated first Fuse:
z Turn key switch in the ‘Run’ position – observe the § The supply from the battery relay is available to the
hourmeter and other LEDs lamps coming on. ‘FUSED B+’ terminal via a fused link that opens if
z Turn the key switch to the ‘Start’ position to crank the excessive current flows through due to overload or
engine. short circuits.
z Once the engine starts, observe the ‘Charge’ LED § The fuse link is replaceable by the user by wiring a
going off and no other trip indications coming on. link of 50 Amps between the two posts provided on
z Confirm the hourmeter running by observing the the rear PCB.
flashing decimal point of the right hand display. Hourmeter
z To stop the engine, turn the key switch to the off § The hourmeter starts counting (the decimal point in
position. the right hand display starts flashing) when the oil
z Observe the ‘Stop Solenoid On’ LED coming and the pressure switch opens (i.e. the engine is running).
engine stopping. § The display will blank when the key switch is taken
z Turn off the ‘Battery On’ switch (if fitted) to isolated to the ‘off’ position and also at the time of starting
the battery. when the battery voltage dips.
z If the KRB 101 causes the engine to trip due to any
fault, returning the key switch to off position for a Stopping:
The ‘Energized to Stop’ solenoid will operate for about 30
short time will reset the latched faults.
seconds, incase of,
Connections: The KRB 101 is connected as indicated in § After putting “key’ to OFF the supply is removed from
Fig 1. the ‘Enable’ terminal.
Description of connection: § Low oil pressure, HCT & V belt (for air cooled
engines) trip conditions.
Supply: § The stop timer can be reset within 30 seconds when
§ The KRB 101 can be connected to either 12 V or 24 the key switch is brought to run position.
V battery. The battery is directly connected to the § The fuse is used to protects the supply to the solenoid
‘B+’ and ‘B-‘ terminals. from short circuits and overloads.
Key switch: § Field Excitation current: A constant current of 190 ±
§ Common of the key switch ( 1 ) wire no. “2B” is 10 mA is available at the ‘IND’ terminal to provide
connected to ‘FUSED B+’ terminal, thus protecting excitation of the charging alternator field when the
all the associated connections from overloads and engine is not running.
short circuits. § LED Indication Lamps:
§ Key switch (2) Run terminal wire no. “2A” is connected Supply ON: Indicates that the unit is active.
to the ‘Enable’ terminal of the KRB 101. Battery Reversed: Indicates that the B+ and B-
§ Start terminal (3, momentary /spring return terminal) connections are reversed. Check the polarity of
is connected directly to the starter motor solenoid. battery connections.
Ammeter: Fuse Open: Indicates that the Fuse Link located at
§ The B+ terminal is connected to the Fused B+ the rear of the unit is open.
terminal. Wire Charge: Indicates that the battery charging alternator
§ The L+ terminal is connected to the Alternator + is not producing any supply. This should get on after
terminal. putting key switch to RUN. The lamp would go off
when the engine is running.
Battery relay:
Stop Solenoid On: Indicates the ‘Stop Timer’ running.
§ By default the battery relay is wired to remain on
Low LOP: Indicates tripping due to Low Oil Pressure.
when ‘B+’ and ‘B-‘ is connected. This internal
High Temp: Indicates tripping due to High water or
connection is done by a soldered link on the rear
cylinder head temperature(For HA engines).
D-18
D-4
V-Belt Fail: Indicates tripping due to V – Belt failure( z Hourmeter: Hourmeter display lights up when the
for HA engine). ‘Enable’ terminal is energized. All segments of the
display light up for a short time and then the display
z Terminals:
indicates the hourmeter reading. The hourmeter will
(On 4 mm brass bolts on rear side of unit 4 sqmm run when the ‘ Low Oil Pressure’ switch is open.
wires to be used) z Normal stop: Turning the key switch from run to off
B+ : Connect to Battery + position lights the ‘STOP SOLENOID ON’ LED for
about 30 seconds. During this time the B+ supply
B- : Connect to Battery – will appear at the ‘SOL’ terminal.
FUSED B+: Output of the battery relay and the fuse z Trip condition simulation: short HCT terminal to
link battery -ve, High Temp LED become ON & lights SOL
FUSE (2 nos): fuse wire the fuse link. lamp on front. During this time B+ supply will appear
at SOL terminal. This will goes to ZERO after 30
SOL: Connection to the stop solenoid. second & SOL lamp will OFF. For LOP & V Belt faults
(On terminal strip minimum one sq mm wires to be will cause the similar observation as mentioned
used) above.
z Bypass timer: The LOP and V Belt faults are not
IND: Sources constant current to excite the charging
latched for about 15 seconds after the key switch is
alternator’s field coil when the engine is at standstill.
turned to run position.
ENABLE: Connect to +ve potential via the key switch z Charge: Shorting the IND terminal to B- potential
to switch on. lights the CHARGE LED and sources constant current
TEMP: Connect to High temperature switch shorts to from the terminal.
ground incase of tripping. z Fuse Open: Opening the fuse link lights the FUSE
V- BELT: Connect to V-Belt failure switch. OPEN LED.
z Battery Reversed: Reversing the B+ and B- lights the
LOP: Connect to Low lube oil pressure switch.
BATTERY REVERSED LED and at voltage terminal
z Testing procedure in short: fused B+ will be zero.
Connect the KRB 101 using Fig 1 . z Common problems/observations with suggestions:
Sr.No Fault / Problem Cause / Remedy
1 Unit is dead OR No indication Check the supply to B+ & B-

Check the battery polarity
2 No hour display after putting Key Check the supply at ENABLE
To ON (run ) Terminal If supply is OK ,check
With spare unit.
3 Engine Not stopping with key Check the fuse on backside
Check the SOL lamp on unit. Reset the unit &
try again.
4 Engine not stopping with trip Check any previous trip indication
& sol lamp
5 No Charge indication at engine Check IND terminal wire on alternator. Check
Standstill By grounding the terminal
Important Note : When engine is running No indication of LED should be there except SUPPLY ON
Fig 1: Connection diagram of KRB 101
D-19
Fig. 1 : Connection diagram of KRB 101
OPERATION starter motor circuit] this position is spring-

biased to return to the run position when the
The key start unit is powered from the engine battery or operator releases the key. It gives a positive
similar low voltage dc source. Control of the keystart DC out put rated to 16A when key is used
and engine is by use of a 3 position keyswitch on the front between this out put & starter motor solenoid.
facia :-
CONTROL OUTPUTS
Position Description
z switched +ve run relay ( supply to speed control
0-STOP Remove power from the keystart, stopping
card)and start outputs, used for controlling the engine
the engine and resetting a latched fault
fuel and starter motor circuits.
condition.
I-RUN Energizes the key starts run relay( enabling z A –ve dc ( open collector transistor ), common alarm
the engine fuel) the fault override timer Starts output, used for remotely signaling a fault condition.
as soon a the key is turned to this position. FAULT PROTECTION AND ALARM SYSTEM
Once the engine is fully running, key start After the operator has started the engine and the fault
monitors for faults and shuts down the engines override timer has expired, the keystart monitors for
if a fault is detected. engine faults through engine connected switches..
II-START Maintains fuel supply to engine, and activates Switches at the rear allow the inputs to be configured for
the start output [used for controlling the use with remote contacts which either open or close
D-20
D-4
during fault, with wiring polarity to either +ve or –ve dc., 4.O SPECIFICATIONS
Normal position S2 & S3switches are down (close to –ve) POWER SUPPLY:
&S4 switch down for 24 vdc supply.
Operating Voltage : 8 to 32 VDC
Dedicated inputs are provided for low oil pressure and
Operating Current : 500-mA max.
high engine temperature switch.
1 additional inputs may be used for general purpose PROTECTIONS:
plant fail contact. Transient : Yes
If any of the above faults occur, keystart will:- Reverse Voltage : Yes
z turn off its run output (stopping the engine) ENVIRONMENTAL CONDITIONS:
z indicate the fault on the appropriate front facia led
Ambient Temperature : 0°C TO 70°C
z activate its alarm output ( to remotely signal that a
fault has occurred).the automatic fault shutdowns Humidity : 90% RH AT 40°C
operate on a first up and latching basis-subsequent (Non Condensing)
faults are not indicated and the displayed fault can MECHANICAL DIMENSION:
only be cleared by switching the keystart to stop.
Width : 280mm
CHARGE FAIL WARNING
Height : 120mm
A charge failure warning LED is provided for use with an
engine driven charge alternator. The charge alternators Depth : 121 mm
WL terminal is connected to the keystart,which will in turn
SENSOR SPECIFICATIONS:
monitor the WL voltage and provide the alternator with
excitation current at engine starts up. Temperature and Pressure Sensors supplied along with
the ENGSTAT system are from PRICOL having Part Nos.
3.0 DESCRIPTION as follows :
The ENGSTAT ECK 401 is used to continuously monitor Temperature Sensor : 40°C to 160°C Variable
and control the operation of diesel engines viz. RB series, (C401505) Resistance
HA series and SL90 series.
Pressure Sensor : 0 to 10 bar Variable
The ENGSTAT system displays the critical operating
(C 401435) Resistance
parameters viz. ENGINE RPM, COOLANT
TEMPERATURE, OIL TEMPERATURE (DIGITAL Pressure Switch : 2.0 bar +/- 0.2 bar
READOUT ONLY) OIL PRESSURE, BATTERY VOLTAGE (C401577) Normally closed type
AND CUMULATIVE ENGINE RUNNING HOURS. 5.0 FEATURES
The above parameters of the engine (except
5.1 FRONT PANEL FEATURES :
CUMULATIVE ENGINE RUNNING HOURS, OIL
TEMPERATURE which can be read only in digital mode)
can be viewed both in analog and digital mode. The
setting process is described later.
If a fault occurs, the ENGSTAT System indicates the
nature of the fault and it gives a pre-alarm. If the same
parameter attains the trip value the system automatically
stops the engine.
The system is powered from the engine battery supply be
it 12 or 24 Volts. It accepts supply voltage from 8V
to 32 V.
D-21
D-5
NO. DESCRIPTION FUNCTION CONNECTOR DESCRIPTION RATING

NO. (IF APPLICABLE)
1 KEY LOCK SWITCH TO TURN THE ENGSTAT
1 PRESSURE SENSOR 0-10 BAR
SYSTEM ON AND OFF
(Body is negative)
2 START SWITCH (GREEN) TO START THE ENGINE 2 TEMPERATURE SENSOR 40-160 deg C
(Body is negative)
3 STOP SWITCH (RED) TO STOP THE ENGINE
3 TEMPERATURE SENSOR 40-160 deg C
4 CHARGE LAMP TO INDICATE BATTERY (Body is negative)
CHARGING
4 ‘W’ POINT (BATTERY 70 HZ - 1 KHZ/
5 MODE SELECT SWITCH TO SELECT THE REQUIRED CHARGING ALTERNATOR) 8-32 V DC
MODE OR MAGNETIC PICKUP 10 KHz MAX
[SELECT / EDIT (OR) SET / (FROM FLYWHEEL) 100 MV - 30 V
OPERATE] 5 IND/WL (BATTERY CHARGING ——
ALTERNATOR)
6 RPM ARRAY TO INDICATE RPM WITH
PRE-ALARM (ALM 2) 6 FUEL SOLENOID HOLD COIL 3.5A MAX.
12V/24V DC MAX
7 PRESSURE ARRAY TO INDICATE LUBE OIL
PRESSURE 7 HOOTER COIL 3.5A MAX.
12V / 24V DC MAX
8 TEMPERATURE ARRAY TO INDICATE COOLANT
8 AUTO MODE 240V 0.5A
TEMPERATURE
WITH PRE-ALARM (ALM 1) 9 FUEL SOLENOID PULL COIL 12V DC, 50A
24V DC, 25A
9 VOLTAGE ARRAY TO INDICATE BATTERY
10 STARTER CONTACTOR 12V DC, 50A
VOLTAGE AND BATTERY
24V DC, 25A
CONDITION (ALM 1)
11 BATTERY POSITIVE 8-32V DC
10 & 11 UPPER DIGITAL DISPLAY TO DISPLAY VARIOUS
PARAMETERS AND LOWER 12 BATTERY NEGATIVE 8-32V DC
DIGITAL AND ALL ERROR 24 PRESSURE SWITCH 2 BAR
MESSAGES IN DISPLAY
DIGITAL MODE. 25 AUX. INPUT BATTERY -VE
26 AUTO START BATTERY +VE
z NORMAL FUNCTION IS INDICATED IN GREEN (ALM 1 & ALM 2)
27 AUTO STOP BATTERY +VE
z PRE-ALARM & ALARM CONDITIONS ARE INDICATED IN RED.
5.2 REAR PANEL FEATURES
6.0 OPERATION
CAUTION : DO NOT OPERATE THE ENGINE TILLYOU
HAVE UNDERSTOOD EACH OPERATION CONTROL.
6.1 POWER UP PROCESS
Turn the key switch ON after giving the necessary
connections as per drawing.
WARNING : DO NOT START AND STOP THE ENGSTAT
SYSTEM CONTINUOUSLY. LEAVE 30 SECONDS IN
Connections to the engine with the ENGSTAT system BETWEEN THE STOPPING AND THE STARTING OF
are made through a 12 pin connector. THE SYSTEM.
D-22
D-4
6.3.3 SELECT MODE

The following messages are displayed in upper digital
display and the corresponding values are displayed in
lower digital display during Select mode.
Sl.No. Display Description
1 SEL Displayed on entry of
select mode
2 ESPd Engine Speed
SELF TEST: 3 O-Pr Oil Pressure
4 C-tP Coolant Temperature
When the Key Lock Switch is turned ‘ON’, the system
5 O-tP Oil Temperature
enters into the Self-Test Mode. The LEDs in both the
6 VoLt Battery Voltage
ALMs are turned ON both red and green . The Upper and 7 T.HrS Ten Thousand Hours
Lower Digital Display reads ‘8.8.8.8’. 8 HrS Cumulative Hours
After the self-test the Upper Digital Display will display ‘ 9 Min Cumulative Minutes
rdY’ and the Lower Digital Display will display 0.0 (i.e. 10 SECS Cumulative Seconds
Engine log hours). Temperature sensor fail conditions 11 L.FLt Last Fault Recorded
are also displayed if there is any failure in the sensors. 12 t.Flt Total Number of Faults recorded
(Please refer Section 8.1/10.0/11.0) of this manual). from date of installation
13 U-Lo Battery Low voltage recorded
while cranking
6.4 STARTING ENGINE

z Press the ‘START’ switch provided in the front panel
of the unit.
6.3 DIGITAL DISPLAY:

There are three types of operation modes namely,
a) Operate mode
b) Set/Edit mode z Hooter O/P will be ON for 5 sees for an indication
c) Select mode z “Strt” and “stAb” will appear on upper digital display
till the engine stabilized, and the system enters into
6.3.1 OPERATE MODE ‘RUN’ mode. The Upper Digital Display displays “run”
The following messages are displayed during operate z If the engine fails to start, the above procedure
mode. attempts 3 times to start the engine.
z The ALM 1 indicates Lube Oil pressure, Coolant
Sl. No. Display Description Temperature and Battery Voltage. The ALM 2 indicates
the Engine RPM.
1. rdY Ready to start the engine If any parameter reaches the pre-alarm value
2. Strt Engine starting indication. detailed in sec. 7.1 the corresponding ICON (LED)
will blink red.
3. StAb Engine stabilizing indication. During the alarm condition the engine is automatically
4. Run Engine running ondication. shut off and only after the particular parameter is
corrected and the system is reset, the engine can be
5. StOP Engine stopping indication restarted.
D-23
@ set trip value plus 100 RPM for low RPM.
If the RPM does not reach a min. of 50 RPM within 3

sees, the unit displays “ESPd” in upper digital display SHUT DOWN ALARM
and “Eror” lower digital display. The unit has to be During normal running condition the Upper Digital Display
reset to restart the engine again. indicates ‘run’, lower Digital Display indicates the engine
present running hours. The Engine will be shut down and
the respective red LED will glow on ALM1/ALM2.
The Shut Down Alarm indications shown in Display are as
follows :
Parameters Upper Digital Lower Digital Condition of
6.5 STOPPING THE ENGINE Display Display the engine
Lower Oil Pressure L.OIL triP While running
z The ENGSTAT stops the engine by controlling the

Stop solenoid through hold coil supply. Press the
STOP switch to shut off the engine. Parameters Upper Digital Lower Digital Condition of
z During trip conditions the engine is shut off Display Display the engine
automatically.
High Coolant H.CtP triP While running
7.0 ALARMS Temperature
7.1 PRE-ALARM
Both ALM1 and ALM2 will glow green in ‘normal’ mode.
Under pre- alarm conditions the corresponding ICON
(LED) will blink red. The values at which these pre-alarm
conditions occur are listed below.
Pre-alarm for temperature 5 deg. C below trip value
Pre-alarm for RPM
@ set trip value minus 100 RPM for High RPM
D-24
D-4
Parameters Upper Digital Lower Digital Condition of Example

Display Display the engine
Upper Digital Lower Digital Inference
High Oil Pressure H.OtP triP While running Display Display
L.FLt L.OIL Last fault occurred is due to

low oil pressure

TOTAL FAULT
High RPM (Over OSPd triP While running Press the start switch again to read the total number of
Speed) faults occurred from the date of installation of the System.
Example

Display Display
L.FLt 0015 Total Fault occurred from

the date of installation.

Lower RPM (Over LSPd triP While running

Speed)
V-LOW
Press the start switch again to read the battery low voltage
while cranking the engine to kow the condition of the
battery.
Example

SPECIAL FEATURES Display Display
LAST FAILURE LOG
U-Lo L Last fault occurred is due to
The ECK 401 comes with a unique facility for recording low oil pressure
and showing the previous fault that has occurred through
the Digital Displays. Press MODE switch and select the
SELECT MODE, while pressing the start switch, the
engine parameter are displayed one by one and at the
end of the sequence, the Upper Digital Display reads
’L.FLt’ and Lower Digital Display displays the nature of
the fault as indicated in the table below (refer 6.3.3.)
D-25
D-5
8-1 OTHER FAULTS The Pre-alarm and Shut down alarm indications for
The wire cut condition is sensed and displayed during Coolant temperature, Oil Pressure and Battery Voltage in
RUN mode (or) before starting the engine. The messages ALM1 are given by the blinking of the corresponding
icons in red.
displayed undervarious wire cut conditions are as follows.
This facility is active both in the RUN mode and ‘rdY’ The Pre-alarm and Shut down alarm indication for RPM
mode. in ALM2 is given by the blinking of the corresponding
icons in red.
Conditions Display on Upper Display on Lower
Shut down alarm is activated when the engine attains the
Digital Display Digital Display
trip values.
Coolant Temperature C-tP Error
wire cut Error Message Sensor Fail Condition Action to be taken
C-tP Coolant Temp Wire Cut Check Sensor / connections
Eror
O-tP Oil Temp. Wire Cut Check Sensor connections
Eror
LSPd RPM wire cut Check RPM wire
Eror connections.
The above faults can be trouble shot by checking the
Conditions Display on Upper Display on Lower wires connecting the system and the engine properly.
Digital Display Digital Display RPM wire cut condition is active only when the engine is
running.
Oil Temperature O-tP Error
wire cut Alarm messages displayed in Upper Digital Display and
correspondingly the Lower Digital Display will display the
respective value in Select mode only.
After starting the engine....
Error Message Condition of the Engine Action to be taken
HCtP Coolant Temperature Check the coolant
triP is high Check coolant level
Clean radiator fins
Conditions Display on Upper Display on Lower Check load on engine
Digital Display Digital Display
HOtP Oil Temperature is high Check the oil temperature
RPM wire cut (only LSPd triP triP Check oil level
when the engine is Check load on engine
running.
L.OIL Oil Pressure is low Check the oil pressure

triP Check oil level
Check load on engine
O.SPd RPMishigh (Overspeed) Check the speed of the engine
triP Check governor Check load changes
LSPd Low Speed Check the speed of the engine
18.0 TROUBLE SHOOTING: triP Load beyond step load Unit
Check alternator belt tension
The ENGSTAT system incorporates many self-checks
E.SPd Start Failure Check start contact and ‘W
and engine check features. It also ensures that faults,
Eror point connections point
which may cause engine damage or pose a safety risk
Check alternator belt tension
which are detected and alarm is activated and the
Check battery gravity (it
engine istripped.
should be more than 1200)
D-26
D-4
During the starting of the engine when the RPM could not
Sl. Alarm as Major Cause Remedy
rise above Low Speed trip value within 16 seconds, a No. displayed
message namely ‘LS d’ will be displayed on Upper Digital
Display and ‘triP’ will be displayed on Lower Digital 9 ESPd Eror • Battery Low voltage • Check ‘V.lo’ parameter if it
Display and the system will shut off the engine. Once the is less than half the
battery voltage
RPM level is attained above the Low Speed value, the • Starter fault • Check if battery is charged.
Upper Digital Display will display the respective RPM of • Check starter
the engine and the hour meters on Lower Digital Display • Cable terminals • Check cable terminals, if
will run. corroded required, replace it.
• Alternator ‘V Belt • Tighten the ‘V belt
Don’t START and STOP the ENGSTAT system loose
continuously. Leave 30 seconds in-between the • Battery is not fully • Change the battery
stopping and the starting of the system. charged & hence externally
not able to give
For any other problem, please contact PRICOL/KOEL required current
and the ENGSTAT system must be opened only by the • Starter alignment • Check starter alignment
authorised persons. is not proper
• Starter eccentric • Set the starter eccentric
setting disturbed pin
11.0 DIAGNOSTICS
Sl. Alarm as Major Cause Remedy 14.0 DOs & DON’Ts
No. displayed DO...
1 L.OIL triP • Lube oil pressure • Check oil Filters change Study the manual and understand the operation of
Low Lube Low if required the system and controls.
Oil pressure • Check L.O. Get. Ensure the battery is fully charged and the terminals
2 H.CTP trip • Overloading of engine • Check fan belt tension
are clean and polarity
High Coiolant • Choking of radiator • Check radiator water is correct.
Temp. • High water temp level Ensure the wiring is correct and the terminals are
• Belt Failure • Check load on engine fastened tight.
• Faulty water pump • Clean radiator Make sure that the sensors are connected correctly.
3 H.OtP trip • Engine overload • Use good quality oil Set the correct engine parameter.
High oil temp. • High oil temp Before starting the engine wait till the self check cycle
is over and “rdY” signal is present.
4 OSPd triP • Lever Jam • Check with the In good condition, the engine will start at the first
Overspeed reference value
crank. The cranking cycle is automatically
5 LSPdtriP • Fan belt may be loose • Tighten the fan belt discontinued either on Min. Engine Speed or time.
Lowspeed • Engine should be • Check with the reference If the Engine has not started, switch off & wait for 15
overloaded value of Alternator seconds before cranking again.
• problem with fuel • Reduce the load on the
injection pump engine
Once the engine has started, ensure the parameters
are normal, and display is green.
6 C-tP Eror • Coolant temperature • Check for the loose Follow other engine maintenance procedures.
Coolant wirecut connection at snap on
Temp. fail point DON’T...
• Check continuity
Wire the unit wrongly.
• Check body to battery -ve
earthing connection or Keep any liquid on top or expose the unit to water
replace the sensor spray. Wipe with a wet cloth after straining.
Don’t connect the battery for loads other than the
7 O-tP Eror • Oil temp. wire cut • Check for the loose engine.
Oil temp. fail connection at snap on point
• Check continuity
Drop the Unit.
• Check body to battery Connect additional batteries to start the engine.
negative earthing Attempt to repair the unit unless you are qualified. The
connection or replace the components inside are highly susceptible to static
sensor. voltage & can get damaged.
8 LSPd Eror • RPM wirecut • RPMwirecut when the Enter wrong parameter values. This may result in
No speed engine is running damage.
Start the engine when there is any fault indication.
D-27
15.1 OPERATION FLOW CHART FUEL - 0 (Energise to Run)
D-28
D-4
15.2 OPERATION FLOW CHART FUEL - 1 (Energise to Stop)
D-29
D-5
15.3 OPERATION FLOW CHART FUEL - 2 (Energise to Stop)
D-30
D-4
15.4 OPERATION FLOW CHART TYPE - 1 (Energise to Run)
D-31
D-5
15.5 OPERATION FLOW CHART HEAT - 1 TYPE - 1 (Energise to Stop)
D-32
D-4
3.2.2 Hand Starting (Alternative to Electric Starting) z Do not release the stop lever till the engine is
for HA 294 & HA 394 engines only. completely stopped. If the stop solenoid is fitted on
the engine, press the stop push button till the engine
z Put engine control switch to ‘OFF’ position.
is completely stopped.
z Move decompressor levers to ‘VERTICAL’ position z Charging current lamp lights up when engine has
as shown in Fig. 3.2/2. come to rest.
z Engage starting handle to extension shaft on crank z Turn key anti-clockwise to ‘OFF’ position and
pulley and rotate briskly in clock-wise direction. withdraw, pilot lamp goes out.
z After stopping the engine close the ‘shut-off cock
under fuel tank (if provided).
3.4 OPERATING CONDITIONS

3.4.1 Operation in Winter:
z Lube oil viscosity -
- Select viscosity (SAE grade) as governed by the
ambient temperature prevailing at the time
of starting the engine, see 2.4.6
- Note shorter periods between oil changes when
operating below - 10° C, see 5.1.1.
z Diesel Fuel:
Fig. 3.2/2 - Use winter grade fuel for operation below + 10°
C, see 2.5.2
z Put one by one all decompressor levers to horizontal
position while rotating handle. Once engine starts z Cold starting Aids:
firing and picks up speed, disengage handle. Put - Cold starting of a Diesel engine depends among
engine control switch to ‘ON’ position. other things, on the capacity of the starter motor
3.3 Stopping and that of the battery. Since the starting
equipment of the engine may differ according to
Never stop the engine suddenly from full load running. its application, please consult KOEL, about the
First allow it to idle for 2 to 3 minutes and then stop it. To use of cold starting aid. However, as a general
stop the engine proceed as follows - guide line we are giving below the temperature
z Pull the stop lever 2 with the help of stop-linkage range for cold starting aid -
provided on the engine (see Fig. 3.3/1)
Up to –5°C - No cold starting aid required.
–5° to –20°C - Use flame type heater or start pilot.
Below –20°C - Use flame type heater or start pilot
and hot air blower for preheating the engine oil
sump, cylinder liners etc. (contact KOEL for
details)
z Battery:
- Cold starting requires a good state of charge of
the battery.
- Lowering the starting limit temperatures by 4-5°c
is possible by raising the battery temperature to
about + 20°c. This is achieved by removing the
Fig. 3.3/1 battery and storing it in a warm room.
D-33
D-5
3.4.2 High Ambient Temperature, High Altitude 3.5.2 After first 50 running hours
z With increasing altitude and increasing ambient
z Change engine oil, see 5.1.3
temperature, the density of the air tends to decrease,
which affects the maximum power output of the z Clean lube oil filter bowl & change the element /
engine, the exhaust gas quality, the temperature cartridge, see 5.1.4
level and in extreme cases the starting behaviour.
z Retighten fasteners for lube oil sump.
Where engines are operated at higher altitudes or z Clean fuel filter bowls & change pre-filter element/
higher ambient temperature, they must be derated in cartridge.
accordance with the respective standards. In case of
z Check V - belt tension, tighten if necessary, see 5.5
doubt concerning such engine applications, contact,
your genset supplier or KOEL in right time. z Check valve clearance, readjust if necessary, see
5.6.1
3.5 RUNNING - IN PERIOD
z Check engine for leakages.
3.5.1 Running -In z Check engine mountings, tighten if necessary. Clean
fuel strainer (button filter at feed pump inlet.) see
During the running in phase, approx 200 running hours, 5.2.1
it is recommended to check the engine oil level twice
daily. After the running - in phase, daily checking will z Tighten intake and exhaust manifold fastenings at
suffice. cylinder heads.
During first 50 running hours, never exceed
full load even for a short duration.
D-34
D-4
4.1 MAINTENANCE SCHEDULE - HA SERIES

Every In running hours (h) 1) Check
10th Clean See
Hours/ 1st 50 Renew Section
Daily Hours 125 250 500 750 1000 2000 3000 Job
z Oil level in engine2 5.1.2
z z z z z z z z z z Oil bath and dry type air cleaners3 5.4
z z z z z z z Battery and lead connections3 5.8.1
z z z z z z z Cooling system (depend on engine use)12 5.3
z z z z z z z z Engine oil (depend on engine use) 6 5.1.1 &

5.1.3
z z z z Lub oil filter element / cartridge (depend on oil change period) 5.1.4
z z z z z z z z Fuel strainer (button filter at Feed pump inlet) 5.2.1
z z z Oil level i fuel pump, on HA 294 only (top up,if required)6 5.2.2
z z z z z z z z z Air breather, on HA 294 fuel pump only3 5.2.3
z z Exhaust Silencer3 5.9.1
z z V-Belt tension (Readjust if necessary 5.5
z z Fuel filter insert (pre-filter element/spin on filter)4 5.2.4
z z Fuel filter insert (Micro - filter element)4 5.2.4
z z z z Fastenings10 5.9.2
z z z z Starter, Alternator5 5.8.2 &

5.8.3
z z z z Valve Clearance (Adjust if necessary)10 5.6.1
z z z Injector10 5.2.5
z z Top and Major Overhaul 5.10
z z TC10 6.2.2
z Fuel level ———
1) Max. Permissible guide intervals 7) Depends on rate of deposition of scale

2) Top-up if required 8) TC 10 engine oil change, whichever is earlier
3) Clean if necessary 9) Whenever, restriction indicator indicates
4) Renew dry type air cleaner 10) Every 6 months or 1200-hour whichever is earlier
5) Depends on engine use 11) FIP should be calibrated after 3600 of engine hours run by MICO dealer.
6) Depends on engine oil change period 12) Blow out dust.
D-35
D-5
4.2 MAINTENANCE SCHEDULE - SL90 SERIES

10th Clean See
Hour/ 1st 50 Renew Section
Daily Hours 250 500 1000 1500 3000 Job
z z Engine Oil level2 5.1.2
z z fuel level in tank2 ——
z z Coolant level in radiator2 5.7.1
z z z z Dry type air filter3.4 5.3
z z Rubber hoses 5.4.3
z z Check restriction indicator 5.4.2
z z z z z z z z Pre cleaner of dry type Air cleaner 5.2.1

5.1.1 &
z z z Engine Oil 5
5.1.3
z z z Lube oil filter cartrige5 5.2.3
z z z z z z z Battery lead connection 5.8.1
z z z z z z Primary filter swirel on feed pump3 5.2.4
z z z z z z z V belt condition & tension adjust 5.2.4
z z z z z z Fuel filter element PEC 4

5.8.2
z z z Radiation fins externally12 5.7.1
z z z z Radiator tubes cleaning 5.7.1
z z z z z z z Fuel filter (Micro) 4

5.2.5
z z z Thermostat element 5.7.2
z z z Valve clearance (Adjust)10 5.6.1
z z Indicator
z Fastening10 5.9.2
z z Started / Alternator5 5.8.2 &

5.8.3
z z z Main element of dry type Air cleaner
z z Drain water
z z Exh. Silencer3 5.9.1
z z Fuel pump11 ——
z z z Turbocharger 10
6.2.2
z z Fuel Tank2 10
——

2) Top-up if required 8) 500-hours or at engine oil change, whichever is earlier
6) Depends on engine oil change period 12) Blow out dust
D-16
D-36
D-4
4.3 MAINTENANCE SCHEDULE - R1040 / R1080 SERIES

10th Clean See
Hour/ 1st 50 Renew Section
Daily Hours 100 400 800 1200 2400 3600
Job
z z Engine oil level 2 5.1.2
z z Fuel level in the tank 2 ——
z z Coolant level in radiator 2 5.3.1
z z z z Dry type air cleaner 3 4 5.4.1
z z z z z Rubber hose & clips of dry type and oil bath type air cleaner 5.4.3
z z z z Check the restriction indicator 5.4.2
z z Pre-cleaner of dry type air cleaner 5.4.3
z z z z z z z z z Engine Oil 5 5.1.1 &

5.1.3
z z z z z z z Lube oil filter element / cartridge 5 5.1A
z z z z z z z Primarily filter swivel on feed pump3 5.2.1
z z z z z z Battery & lead connections 5.8.1
z z z z z z ‘V’ Belt Condition and tension (adjust / replace if required) 5.5.1
z z z z z Fuel Filter insert (pre)4 5.2.4
z z z z z z z Radiator fins (depend on site condition) 12 5.7.1
z z z z z z Radiator tybes (depend on type of cooling water)12 5.7.1
z z z z z z Fuel filter insert (micro)4 5.2.4
z z z z Thermostat element (change if necessary) 5.7.2

10
z z z z Valve clearance (adjust if necessary) 5.6.1
z z Starter / Alternator5 5.7.3
z z z z Fastening10 5.9.2
z z z Injector10 5.2.5
z z Fuel tank 10 ——
z z Exhaust silencer3 5.9.1
z Fuel pump11
z z z z Turbo charger10 6.2.2

2) Top-up if required 8) 400-hours or at engine oil change, whichever is earlier
6) Depends on engine oil change period
D-37
D-5
5.1 MAINTENANCE OF LUBRICATION SYSTEM z Pull out dipstick, wipe it with a nonfraying rag and
5.1.1 Oil Change Intervals push it in as far as it will go and then withdraw again
(Fig. 5.1/1).
z The oil change intervals depend on engine application
and on quality of lube oil. Refer table below :-
z The film of oil left on the dipstick should extend to the
z Should, within ONE YEAR, the engine run less than
the hours stated in the table, the oil must be changed upper (max) mark. If the level only reaches to the
at least ONCE A YEAR. lower mark, the oil should be topped-up without
z The table is subject to the following conditions : delay.
- For Diesel fuel max. sulphur content 0.5 % by
weight. Failure to attend to this may result in serious
damage to the engine (piston & bearing
- Prevailing ambient temperature down to
seizure)
-10°C.
z In the case of fuels containing more than 0.5 % to 1
% sulphur or prevailing ambient temperature below
5.1.3 Changing Engine Oil
-10°C, the intervals between oil changes are to be
halved.
z Change engine oil at recommended intervals, See
z In the case of fuels containing more than 1% sulphur,
5.1
ask our authorised service Dealer or KOEL, PUNE.
z Position engine on level surface.
TABLE FOR OIL INTERVALS
z Run engine until warm.
OIL CHANGE (RUNNING HRS.)
(lube oil temp. approx. 80°C)
OIL GRADE OIL GRADE OIL GRADE
z Stop the engine (Fig. 5.1/2)
ENGINE E-DL 2 HD TYPE 5 K-OIL
SERIES (HD TYPE 4) MIL-L-2104 C PLUS
MIL-L-45199 B CD CD PULS E-DL4
(D5)
HA 250 —— 300
R1040/RO1080 —— 400 400
SL90 —— 500 500
5.1.2 Checking Oil Level

z Stop the engine and wait for a while till oil level in the
sump is settled. Ensure that engine is in horizontal
position.
Fig. 5.1/2
Take care when draining off hot oil : Danger of

scalding !
Collect used oil in suitable receptacle ready

for proper disposal to prevent environmental
pollution.
Fig. 5.1/1
D-38
D-4
z Replace new filter element in place of old one and

tighten the centre bolt along with bowl until sealing
ring is evenly seated. Then tighten the centre bolt
firmly.
z Check oil level, oil pressure and leakage through
sealing ring, if any.
B) Spin-on type lube oil filter :
z Release lube oil filter cartridge with special tool and
spin off as shown in fig. 5.1/5.
Fig. 5.1/3
z Place oil tray under engine.
z Unscrew oil drain plug and drain oil completely
(Fig, 5.1/3)
z Refit oil drain plug with new joint washer and tighten
firmly.
z Fill in fresh lube oil. Fig. 5.1/5
- Lube oil specifications : refer 2.4.6
- Lube oil sump capacity : refer 2.4.4 z Clean sealing surface of filter carrier (Fig.5.1/6).
z Apply light film of oil to rubber seal of new cartridge.
5.1.4 Lube Oil Filter z Screw cartridge into place by hand until seal is
Following every oil change, renew lube oil filter element evenly seated.
or spin -on filter (if fitted on engine in place of paper type
lube oil filter).
Fig. 5.1/5
z Tighten lube oil filter cartridge firmly by giving a final
half turn. (Fig-5.1/7).
z Check oil level and lube oil pressure.
z Check seal of lube oil filter cartridge for leaks.
Fig. 5.1/4
A) Paper element type lube oil filter :
z Unscrew the centre bolt at the bottom of the centre
bowl and drain the oil completely
(Fig. 5.1/4).
z Clean the bowl with clean diesel oil.
z Check the condition of sealing ring, if necessary
change it.
z Apply slight oil on sealing ring and replace it on it’s
place. Beware of hot oil. Danger of scalding !
D-39
D-5
C) Centrifuge Cleaner :
Instruction Manual
z Introduction
The Centrifuge Cleaner SCC30 cleans your engine
oil continuously when your engine is running. It
seperates dirt below 1 micron from engine oil thus
lowers wear rate of engine components drastically. It
avoids harmful oil degradation and arrests depletion
of oil additives increasing the oil life. The Centrifuge
Cleaner does not require any spare parts to be
replaced and gives consistent performance
throughout engine oil.
z Cleaning frequency
For consistent performance, the centrifuge rotor
needs to be cleaned periodically as mentioned in this
manual. It is recommended that you service the
centrifuge every 250 hours of working or at every
oil change period.
The volume of dirt collected depends upon engine
application, loading and environment in which engine
is working. Exact period of servicing the centrifuge
can thus vary between 200 hours of working to your
oil change period. Please follow the instructions
given below for cleaning of centrifuge cleaner.
z Identification and location SCC30 SERVICING INSTRUCTIONS
The centrifuge Cleaner is located on the same Instructions
manifold on which full flow oil filter is mounted. The z It is a precision assembly, handle with care.
centrifuge can be easily identified with a dome shaped z Carry out servicing preferably when the engine oil is
cover bearing instruction sticker. The exact location still warm
is as shown in this photograph. z All threaded parts of the centrifuge require following
gadgets : a 13 mm spanner, a blint knife, a small
adjustable pliers and waste cotton for cleaning.
Servicing procedure
z Unscrew top nut with a 13 mm spanner and remove

centrifuge cover. The centrifuge cover nut has a
FULL FLOW FILTER CENTRIFUGE CLEANER puller arrangement so that the cover will be lifted as
you unscrew the top nut.
D-40
D-4
z Hold the rotor in hand

and lift rotor to remove
it completely from
central shaft. The
rotor will contain
about 200 ml of oil,
drain oil from the
rotor. The rotor has
two bushes at its
ends. Take care while
removing rotor from
central shaft. The z Assemble rotor in correct sequence of parts. Match
rotor should not fall; arrow marks on rotor cover and rotor. Tighten rotor
otherwise it will nut firmly by hand. Install rotor on shaft and assemble
damage the bushes. cleaner cover.
z Unscrew rotor nut by holding rotor assembly in NOW YOUR CENTRIFUGE IS READY TO COLLECT
hand. The rotor nut can be opened by hand. if it is MORE DIRT FROM OIL
tight, unscrew it with light
POINTS TO CARE ABOUT CENTRIFUGE CLEANER
pliers. Never grip the rotor
nut tightly in clamping device 1. Replace rubber rings if deformation or cuts are
like a bench vice. It may observed. Using damaged rubber rings will result in
damage the rotor body oil leakage and improper functioning of centrifuge
permanently. Remove rotor cleaner.
cover and deflector inside. 2. While assembling the rotor, ensure that the rubber
For removing rotor cover, ring has taken proper seat in its place. This is
remove the rotor nut necessary for proper sealing of rotor assembly.
completely, hold the rotor 3. Take care with the centrifuge housing and rotor
cover in hand and give a body. They are made of aluminium, jence are
light blow to the rotor body susceptible to damage due to accident.
at the rotor nut end by hand. 4. Always ensure that the arrow marks on rotor cover
The rotor body abd deflector and rotor are matched after assembling the rotor.
will come out from the opposite end. The rotor body is dynamically balanced.
Mismatch of arrow marks on rotor cover and rotor
will result in excessive vibrations of the cleaner and
part breakage.
5. The rubber ring is made of Viton rubber. Use genuine
spare rubber ring only. Rubber ring of any other
material will not give desired performance.
Don’ts about centrifuge cleaner
z After you open the rotor, you will see cake formed
sticky dirt mass all around the rotor cover from inside.
Remove the dirt by a blunt knife as shown. CLean the
rotor cover and all rotors thoroughly by cotton waste. 1. Do not over tighten the top nut. Tighten just enough
Clean the centrifuge central shaft also. to prevent leakage of oil from centrifuge cover and
D-41
D-5
housing. Over tightening top nut will damage theb 2. Do not hold the rotor nut in clamping device like
threading in centrifuge housing and damage the bench vice as shown. Extra clamping pressure on
centrifuge permanently. rotor nut may result in damaging the circularity of
upper bush and will result in permanent damage to
Use 1.2 kg-m torque for tightening of centrifuge
rotor assembly.
cover.
3. Do not open or tamper with the valve assembly. The
valve assembly is preset for opening oil pressure in
engine’s oil gallary. If the setting is lost or the valve
assembly is damaged, there is risk that your engine
will not get enough oil or the centrifuge will not
function properly.
Consult authorised service dealer in case of any doubt.
TROUBLESHOOTING
Sr. No. Problem Probable cause Action
1. Leakage through cleaner Rectangular rubber ring damage Change rubber ring.
2. Rotor does not rotate Nozzles blocked Open rotor and clean nozzles
thoroughly.
Reassemble the cleaner.
3. Rotor does not rotate even Entry valve blocked Do not open entry valve assembly.
after cleaning nozzles It requires special tools. Contact
company representative.
4. Rotor rotates but at low Leakage of oil through rotor Open rotor and ensure that the
speed assembly rubber ring has taken proper seat
on rotor body. Then reassemble
the rotor.
5. Rotor speed very low Bushes damaged permanently Ensure that the rotor is free on
or even rotor does not shaft. Else replace entire rotor
assembly.
6. Rotor rotates but at Rotor filled with dirt completely Time for cleaning the rotor
low speed
7. Abnormal vibrations of Mismatch between arrow marks Open rotor and reassemble it
centrifuge cleaner on rotor cover and rotor properly.
8. Cleaner does not collect Rotor not rotating at desired See point 2 & 3.
any dirt speed Consult authorised representative.
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D-4
5.2 Maintenance of Fuel z Unscrew the centre bolts and remove the bowls and
System inserts (Fig 5.2/2)
z Clean the bowls inside as well as outside with clean
5.2.1 Cleaning Fuel Strainer diesel oil.
z Close fuel stop cock. z Change pre-filter insert only. Do not change pre-filter
z Remove special insert and Micro filter insert at a time.
banjo bolt situated at the * (see Notes below)
bottom at the Inlet of feed
pump.
z Takeout screw with
strainer fitted inside banjo
bolt (Fig.5.2/1).
z Clean the strainer with
clean diesel.
z Refit the strainer inside the Fig. 5.2/1
banjo bolt and screw in the banjo bolt using new
copper washers
z Bleed the fuel system (see 3.1.5) check for leaks. Fig. 5.2/2
5.2.2 Checking Oil level in fuel pump / Governor z Check the condition of sealing ring, if required change
(Only on HA 294 engines) it.
z Slacken Oil level control plug through 3 to 4 turns to z Complete the filter assembly and bleed the fuel
drain any surplus oil + fuel mixture. system before starting the engine, see 3.1.5
(see fig 3.1/4) z Change over period for pre-filter insert and micro
filter insert is given in ‘Routine Maintenance Schedule
z If necessary, remove screw plug and fill-in fresh oil 4.1/4.2/4.3/4.4 as per engine type.
until it spills at oil level control plug.
(see fig 3.1/3) z For changing micro-filter insert follow the same
procedure explained above.
NOTE : NOTE :
At the end of 2000 running hours or when the fuel 1) Do not clean filter insert. Always replace the insert
injection pump is removed for some attention, renew with new one at recommended intervals. Cleaning
the entire oil filling. will damage filter insert, reduce filteration efficiency
and damage fuel injection equipment.
5.2.3 Cleaning Fuel Pump Breather 2) Since a filter attains the maximum efficiency only
(Only on HA 294 engines) after a film of dirt is deposited on the surface of the
z Wash the air breather of pump / governor thoroughly filter insert, avoid replacing pre-filter insert and micro-
in petrol and blow dry with compressed air. If the filter insert at the same time. First change prefilter
operating conditions are very dirty, this is to be done insert and then after 250 running hours change
during every oil change. micro-filter insert.
3) The Routine Maintenance schedule is meant to serve
5.2.4 Fuel Filter as a guide only for normal fuel storage and engine
operating conditions. Replacement of inserts may
MICO Dual Fuel Filter :
have to be made earlier than the recommended
z Close fuel stop cock. period.
z Drain the fuel filter bowls by loosening the plug When working on the fuel system, keep naked
situated at the bottom of the bowls. lights away! Do not smoke!
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D-5
5.3 Maintenance of Cooling System

5.3.1 Cleaning Intervals:
z The danger of contamination is increased due to
residues of oil and fuel on the engine. Check extra
carefully, therefore, for leakages when application
involves high dust fallout.
z More severe contamination can occur, e.g. in case of
-
- Under normal operating conditions, cleaning
intervals of 2000 running hrs are recommended.
Fig. 5.4/1
- Construction site application due to heavily dust-
laden air. 5.4.3 Cleaning the Oil - Bath Air Cleaner
5.4.1 Cleaning Intervals z Stop engine and wait about 10 minutes until the oil
Since the degree of soiling of the combustion air cleaner has run out of filter housing (1).
depends on the amount of dust in the air and the size of
filter used, the cleaning intervals cannot be laid down z Release snap clips (2) and remove oil bowl (3) to a
generally, but have to be determined from case to case. ether with filter element (4), at joint by means of screw
If dry type air cleaner is used, clean only when a need for driver if necessary. Take care not to damage rubber
air cleaner service is indicated by the air cleaner service gasket (5).
indicator. z After removing dirty oil and sludge, clean the oil bowl.
The table below gives the guide values for cleaning and
renewing oil both type air cleaner (under normal working
condition).
WORKING CONDITION INTERVAL (running hrs)
Under severe working condition and very Daily/10 hours

dusty atmosphere check, clean and
top-up oil, (if required, change the oil).
Under normal working condition, 50 hours
top-up oil. (Clean & renew oil if dust
collection in the bowl is more than 4mm)
Renew entire oil in the bowl and At the time of engine Fig. 5.4/2
service the air cleaner. oil change
z Rinse filter element (4) in diesel fuel and allow to drip-
dry thoroughly.
5.4.2 Cleaning the Pre-Cleaner
z Clean filter housing (1), if necessary.
z Clean the pre - cleaner (1).
z Release snap clips (2), empty dust collector (3) and z Inspect rubber gaskets (5) and (6), renew if necessary.
clean. (Fig. 5.4/1).
z Fill oil bowl with engine oil up to oil level mark.
Never fill dust collector z Refit oil bowl with filter element to filter housing and
(3) of ore cleaner (1). with Oil fasten snap clip;
Never rinse filter in petrol (gasoline).

Dispose off used oil in compliance with
statutory provision:
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D-4
5.4.4 Dry type Air Cleaner B) Maintenance :

A) Description : Regular check up and maintenance of the air cleaner
Construction of typical Dry type Air Cleaner, supplied as is essential to ensure maximum protection to the
optional extra, is shown below in fig, 5.4/3 and engine from the dust.
5.4/4. i) Daily check the connection of rubber hose and the
hose clips between the manifold and the air cleaner
before starting the engine. Damaged hose/ clips
nuts be replaced immediately. Any by-passing of
unfiltered air through cracks in the hose / loose hose
will quickly lead to serious damage to the engine.
Since this is a dry type air cleaner, do not fill a
single drop of oil in it. Also, protect the air
cleaner form ingress of rain / moisture.
ii) The pre cleaner (if provided) should be cleaned, to
remove the accumulated dust, after each day’s work,
when the engine is stopped. This cleaning can be
done by removing the top cover of the pre cleaner.
iii) The restriction indicator, mounted on air cleaner
near the hose, indicates the condition of the air
cleaner element, when the air element is in good
condition, a red signal will be seen through the
Fig. 5.4/3
transparent window on the indicator when the engine
is running and will disappear when engine is stopped.
However, if the element is choked, then the red signal
will remain ‘ON’ even after engine is stopped. This is
an indication that the main filter element must be
removed & cleaned or replaced.
NOTES :
1. If engine performance is poor, but restriction is still
within limits, do not change the element. The air
cleaner is probably not at fault.
Fig. 5.4/4 2. To get those extra service hours out of air cleaner
Inlet cap or pre - cleaner is supplied for the air intake, element. make sure the air inlet is away from any
depending on the working conditions, inlet cap prevents heavy dust clouds caused by operation. Also, make
ingress of rain/heavy particles. Pre-cleaner separates out sure that exhaust carbon cannot enter the air cleaner.
heavier dust particles, which are collected in the pre- iv) • Discharge the dust vacuator valve 1 by pressing
cleaner bowl, thereby extending the life of the main filter apart the lips of the vacuation slot, applying
element. pressure as indicated by the arrows.
Two filter elements are co - axially fitted in the air cleaner 2) Rapping,
housing. The outer element is the main filter element, with Tapping or
a built in cyclone separator which gives a swirling effect Pounding
to incoming air, to separate out heavy dust particles by dust out of
centrifugal action. This dust is collected in the end cover them is
(which is removable). The vacuator valve at the bottom of dangerous.
cover helps in expelling the accumulated dust. This is Severe
achieved by opening / closing of vacuator valve outlet damage to
due to the air flow fluctuations inside the air cleaner. the filter
will result!
Inner element is a ‘Safety Element’ to prevent ingress of
dust into the engine, when the outer (main) element is
removed for cleaning / replacement. Fig 5.4/5
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D-5
z Clean the vacuation slot time to time. iv) Carefully check new or properly cleaned element
z Remove any cakes of dust by pressing together for damage before installing. Conduct a light test
the upper part of the valve. by passing the light through element as shown in
Fig 5.4/8. If there is any crack in the element, the
z Make sure that vacuator valve is not damaged, if light will pass through it. In that case replace the
required change it. Also, check the condition of element.
cup joint sealing, replace if necessary.
v) Cleaning of Filter Element :
Cleaning of filter element is to be done only when a
restriction indicator shows a red signal even after the
engine is stopped. For cleaning proceed as follows-
i) Loosen the mounting band of the dust cup,
remove the wing nut of the element and take out
the outer element for checking and cleaning.
ii) Use a damp cloth to wipe out all excess dust in
the air cleaner. (Fig 5.4/6). Similarly clean the Fig. 5.4/8
dust end cover.
v) Inspect the rubber sealing ring at the end cover of the
element. In case the seal is damaged, replace the
filter element. (Fig 5.4/9)
Fig 5.4/6
Fig 5.4/9
iii) Thorough cleaning of the fitter element with vi) The inner element (safety element) is not to be
compressed air is recommended. Clean the removed, when the main element is removed for
element from inside to outside using the cleaning / replacement.
pressurised air pipe. (Fig 5.4/7) It should be replaced by a new safety element after
every three changes of the main element.
Fig 5.4/7 Fig. 5.4/10

1) Too much air pressure can break the filter vii) Replace the cleaned or new element in the air cleaner
paper and destroy the element. (Max. Air body and reinstall the end cover, making sure it seals
Pressure 3.5 kg/cm2) 360° around the air cleaner body. Reset
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D-4
the restriction indicator by pressing the button at the top. Never check / retension / renew V-belts while
engine is running ! Refit V-belt guard, if
5.4.5 Series Air Cleaners System provided.
For certain applications involving extremely dusty
environment, we recommend use of series Air Cleaner 5.5.2 Renewing Blower V-Belts
system; i.e. oil bath air cleaner in series with the dry z To renew V-belts, push belt tensioning unit (automatic
type air cleaner. belt-tensioning) (1) inwards and remove V-belt (Fig
Air for engine combustion first passes through an oil 5.5/2)
bath air cleaner and then through dry type air cleaner z Place on new V-belts.
to the engine.
As a result, major portion of the dust (especially the
heavy particles) is trapped in the oil bath air cleaner,
thereby considerably extending the life of the filter
element in the dry type air cleaner.
The sizes of the air cleaners and their relative positions
will be recommended by KOEL, for a particular application.
This is important to keep the overall airflow restriction
within limits and to avoid oil ‘carry over’ from the oil bath
air cleaner into the dry type air cleaner.
Maintenance:
Fig. 5.5/2
Follow the procedures as described earlier for oil bath air
cleaner and dry type air cleaner. 5.5.3 Checking Alarm System (for HA only)
In no event use petrol (gasoline) or any hot
z In the event of V-belt rupture, the pressure pin (1) of
liquid for washing the filter element of Dry type
V-belt failure switch (if provided on engine) is actuated
air cleaner.
by the automatic belt tension unit and an audible or
visual alarm is initiated through control panel.
5.5 BELT DRIVES
5.5.1 Checking V-Belts z Make functional test by pressing-in pin (1)
z Inspect V-belts over whole length for damage or (Fig 5.5/3)
cracks. Renew damaged or cracked v-belts.
z Check by pressing with the thumb midway between
the pulleys to see whether the belt deflects inwards
by not more than 10 to 15 mm. (Fig 5.5/1)
z If necessary retension V-belt, see 5.5.4.
Fig. 5.5/3
Never make functional test while engine is

running !
Fig. 5.5/1
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D-5
5.5.4 Retensioning Alternator V-belt

z Loosen the bolts which fix the alternator on mounting
bracket. Also, loosen the bolt on tension adjusting
lever.
z Adjust the desirable tension by pushing the alternator
outwards with the help of bar and tension adjusting
lever.
z Retighten all the bolts firmly.
Fig. 5.6/1
z Then continue turning the crank shaft through 360°
(one complete revolution).
z Insert a feeler gauge of 0.15 mm in the gap between
rocker arm toe and valve for both inlet and exhaust.
The valve clearance is correct when the filler gauge
can be inserted with a slight drag. Failing this, the
valve clearance must be readjusted as follows -
Adjusting valve clearance -
Fig. 5.5/4
z Loosen lock nut of adjusting screw through one or
5.5.5 Retensioning Blower V-Belts two turns and adjust the screw with screw driver so
z An automatic belt tension unit is used for blower V- that, when locknut is retightened, the feeler gauge of
belts. Ensure that the belt tension unit is properly 0.15 mm can be inserted and with drawn with slight
fitted and maintains desired tension. drag. (Fig 5.6/2).
z Check the valve clearances of each of the remaining
5.6 ADJUSTMENTS - VALVE cylinders and readjust, if necessary.
5.6.1 Checking & Adjusting Valve Clearances
The valve clearance is the requisite gap between the
rocker arm toe and valve stem end. Engine performance
and power output depend on its correct setting which
can be done by a skilled mechanic according to the
instructions below -
Checking Valve Clearance -

z Check clearance when engine is cold. (at room
temperature)
z Remove rocker cover.
z Turn crankshaft until the valves of the cylinder (on
which the clearance is being checked) are
“overlapping” (exhaust valve about to close , inlet
valve about to open). Fig. 5.6/2
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D-4
z Do not change the setting of oil metering screw z For cleaning, blow the pressurized air through radiator
unless required. With hot engine running at idling, an fins in the reverse direction of the flow of radiator fan
oil flow to pad at rocker arm must be just noticeable. (Fig.5.3.2). Do not spill water on radiator fins.
An excess oil flow can lead to higher oil consumption.
5.7 MAINTENANCE OF COOLING SYSTEM

(For water cooled engines only)
Engine cooling system contains radiator, fan, water
pump and temperature controller i e. thermostat. The
engine control panel consists of water temperature gauge.
High water temperature stop for engine safety could be
provided as an optional.
Figure 5.3-2 direction of air for cleaning fins

Flushing the radiator
Flush the radiator inside after every 1000 hours or once
in a year whichever is earlier. This period is applicable for
clean soft water. If the water is hard and saline, the
flushing is to be done after every 500 hours or even earlier
depending upon the type of water. In order to prevent the
rust formation use rust preventive compound.
To flush, top up the radiator with clean fresh water and
run the engine on no load till it reaches working
temperature.
z While the engine is still running, open the drain cock
of radiator and allow the water to flow out. This will
wash away any impurities embedded in water
passages. With engine still running, keep on adding
Figure 5.3-1 fresh coolant for at-least 5 minutes. Stop the engine
and discontinue adding fresh water. Then drain the
5.7.1 Radiator
radiator completely.
Check coolant level in the radiator every day before Do not use concentrated SODA LIME to
starting the engine Remove the radiator cap and fill clean the cooling system because it could
coolant through radiator neck until it spills out of overflow corrode Aluminium parts.
pipe fitted on radiator (Fig.5.3.1). Refit radiator cap firmly.
z Check the radiator hoses and connections. Replace
z Do not open radiator cap while the engine is running
the damaged hoses and tighten (he connections.
or hot. The cooling system is under pressure. Danger
of burning body skin!
5.7.2 Thermostat
z Add coolant only when the cooling system is cold. A thermostat having single element is used in the water
The temperature difference between the coolant in circuit. Thermostat is provided to attain working
the engine and the coolant being added must not temperature quickly during warm-up period and maintains
exceed 50 °C. desired temperature of coolant during running of the
z Cleaning the radiator fins engine.
z Clean the radiator fins after every 1000 hours. (Under Normally thermostat does not require regular
very dusty conditions, this is to be done if coolant maintenance. Its operation shall be checked if sudden
overheating is observed) deviations from the specified coolant temperature
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D-5
occurs. Visual inspection will reveal whether or not the z If no such elements are provided, the alternative
element rests in its seat i.e. whether or not close tightly method is to
(Fig.5.3.3). insert a clean wooden
stick into the cell, until it touches the top edge of lead
plates.
(Fig/ 5.7/2)
The electrolyte should wet the stick over a length of about

10 to 15 mm If the electrolyte level is low, top-up with
distilled water only.
z Replace the caps.
C) Checking Specific Gravity of Electrolyte :

Figure 5.3 3 the thermostat element seal
Check the specific gravity of electrolyte with a
5.8 MAINTENANCE OF ELECTRICAL EQUIPMENT hydrometer, five minutes after adding distilled water.
5.8.1 Battery z Measure the specific gravity of electrolyte in the
A) Checking Battery and individual cells with a commercial hydrometer. (Fig
Lead Connections : 5.7/3)
z Keep the battery clean z The measured valves (Table below) indicate the
and dry. Use damp cloth state of charge of the battery.
for cleaning.
z Charge the battery if the reading is below the values
z Wash the corroded given in the table.
terminals (+ and -) with
ammonia solution
consisting of 115 gms
(1/4 pound) of baking
Fig. 5.7/1
soda added to one litre
(one quart) of water.
Ensure that the cleaning solution does not enter the
cell through the vent holes.
z After cleaning, flush the outside of the battery, the
battery compartment and the surrounding area with
clean water. After cleaning ensure that all the vent
holes are open.
z When reconnecting, ensure good contact of the Fig. 5.7/3
terminals. Tighten clamping bolts firmly.
z Apply a film of acid-free and acid-proof grease or Specific Gravity State of charge
petroleum jelly on terminals. (kg/l)
B) Checking Electrolyte Normal Tropics
Level : 1.28 1.23 Fully charged
z Remove cell caps
1.20 1.12 Half charged, Recharge
z If electrolyte test
elements (pegs) are 1.12 1.08 Discharged, Charge up
provided, the level immediately.
should be high
enough to wet the z For hints on battery care in winter, see 3.4.1
bottom of these.
Fig. 5.7/2
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D-4
z For hints on battery storage, read enlisted below : z Check the drive assembly for free movement over
the shaft splines. If necessary, smear grease over the
1. The gases emitted by the battery are
shaft splines to enable the drive assembly to move
explosive! Avoid formation of sparks in vicinity
freely.
of battery, keep naked lights away !
2. Do not allow acid to come into contact with (frequency once in 3 months.)
the skin or clothing ! Wear protective goggles
! 5.8.3 Alternator
3. Do not place tools on battery. Danger of z Check the brushes. Renew the brush and spring
short circuit! assemblies, if the overall length of the brushes are
worn to less than 10 mm. If brushes are satisfactory
5.8.2 Starter Motor but require cleaning, use a petrol moistened cloth.
z Ensure that the mounting bolts are securely fastened
and all electrical connec-tions are clean and tight. z The slip ring surfaces should be clean and smooth.
Cables should be examined for fractures, particularly If slip rings are burnt and require refinishing, the
where the strands enter the terminal lugs. surfaces may be cleaned with a piece of very fine
emery paper.
z Check the brushes. They must be renewed if worn to
approxi-mately 10 mm (for 2 & 3 cylinder engines, z Check bearings and renew if worn.
2SM114) and 13mm (for 4 & 6 cylinder engines,
3SM127) which is half of the original or to a point z Check belt tension, readjust if necessary (see 5.5.1
where springs no longer provide effective pressure. & 5.5.4)
Brushes must always be replaced in sets and with the
z Check the battery condition, (see 5.7.1)
correct grade.
z Check the brush z Keep the alternator reasonably clean and ensure that
spring balance as ventilation slots or air spaces are clear and
shown in Fig.5.7/4. unobstructed. Check mounting bolts for tightness.
The spring pressure A slack belt will rapidly wear and because of
should be as follows- slip may not drive the alternator at the required
speed. Too tight a belt will impose severe side
0.965 to 1 -080kg (for thrust on the bearings and seriously shorten
2 & 3 cylinder engines) their life.
1.220 to 1.580 kg (for
4 & 6 cylinder engines) 5.9 Additional Maintenance Jobs
If the pressure is not 5.9.1 Cleaning Exhaust Silencer
within the above limits, Knock out soot from exhaust silencer and clean the
renew the springs in exhaust piping.
set and not
individually. Fig. 5.7/4 5.9.2 Checking of Fasteners
Check & Tighten-up the fasteners for following -
z Check the commutator surface. It should be clean
and entirely free from oil, any trace of which should z Air intake manifold
be removed by pressing a dry fluffless cloth against z Exhaust manifold
the commutator while the armature is hand rotated. z Exhaust piping
It the surface is dirty or badly discoloured, clean it
with a strip of fine emery. Remove all traces of dust z Lube oil sump
and abrasive using compressed air. z Front cover
z Hose clip for air cleaner
z The starter does not require lubrication from outside,
z Lube oil filter mounting
since it is equipped with sealed type bearings on
3SM 127 type, while phosphor bronze bushes which z Engine mountings
are pre-lubricated are used for 2SM 114 starter. z Fuel connections
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D-5
5.10 Top and Major Overhaul Periods 6. TROUBLE SHOOTING AND REMEDIAL MEASURE
The top overhaul (servicing of combustion system) and z Operating troubles are often due to improper
Major Overhaul Periods are estimated as 3000 and 9000 operation or maintenance of the engine.
running hrs. respectively. This estimation is based, z In the event of trouble, always check whether the
provided the engine is maintained properly as per the operating and maintenance instructions have been
instructions given in this Manual. strictly followed.
The duration of the operating period before overhaul will z An appropriate diagnosis chart is given on the next
depend entirely on the maintenance and service given to page.
the engine, quality of lube & fuel oils used, type of z If you are unable to identify the cause of the trouble
environment and engine load cycle. Hence, the above or to put it right yourself, contact our authorised
estimated overhaul periods are to be referred as general Service Dealer.
guidelines.
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D-4
TROUBLE SHOOTING
Trouble Cause Redress
Engine does not start. No fuel in tank. Fill in fuel, vent fuel system.
Air in fuel system. Vent fuel system.
In sufficient speed of starter. Charge batteries.
Engine does not start at See above or the ready to start Of above, or change lamp.
temperatures below 0°C. signal lamp does not light.
Defect of series resistor solenoid Consult authorised workshop.

valve, or flame heater plug.
Paraffin precipitation of fuel Heat up fuel pipings, Change filter.
Engine starts up but stop after Fuel tank cock closed. Open cock.
brief time.
Dirt in primary fuel cleaner or Clean or change filter cartridge
in fuel filter. respectively.
No fuel in tank, no conveyance Fill in fuel, vent fuel system,

of fuel. inspect correct operation of fuel
pump, replace if necessary, and
check safe venting of tank.
Water or dirt in fuel system. Clean fuel tank, fill in clean fuel
replace filter, and vent fuel system.
No power and misfiring of engine Interruptions of air supply or heavy Inspect, replace if necessary, or
jamming of air filter. clean.
Air in fuel system. Vent fuel system.
Fuel filter jammed. Change filter.
Starts of fuel supply missed. Reset start of fuel supply.
Defect of exhaust brake. Inspect and repair.
Engine emits white or bluish Retorted and start of fuel supply. Set correct start of fuel supply.
fumes.
Engine is still cold. Permit engine to heat up in
operation.
Miss setting of fuel injection Check start of fuel supply.

system. Inspect injectors.
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D-5
Engine emits black fumes. Engine is overloaded. Reset fuel injection system,
consult workshop.
Air filter jammed. Change air filter element.
Fuel injection piping loose or Tighten fuel injection piping or

broken replace it, respectively.
Heavy knocking of Engine. Starts of fuel supply too early. Set correct start of fuel supply.
Mis-setting of valve air gaps Adjust correct valve air gaps.
Mechanical defects of engine. Consult authorised workshop.
Engine grows excessively hot. Slipping of V-belts. Tighten or replace V-belts.
V-belts broken. Replace V-belts.
Defect of temperature governor. Emergency operation; forced

opening of valve plate.
Defect of temperature Controller. Peform electrical check of

temperature controller.
Lack of coolant. Fill in coolant.
Radiator is dirty. Clean radiator.
Mis-setting of fuel supply. Set correct engine in fuel supply.
Intake or exhaust system jammed. Redress cause of trouble.
Heavy dirt accumulation on Consult workshop.

cylinder elements.
Irregular speed of engine. Defect of speed governor. Inspect fuel injection pump and
governor.
Excessively high fuel consumption. Mis-setting of fuel injection Check fuel injection system.
system.
Leakage in fuel system. Check.
Injection of excessively great fuel Have fuel injection pump adjusted

quantity engine emits black fumes. by specialised workshop.
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D-4
Leakage of solenoid valve of cold Replace solenoid valve.

starting device.
Jammed air filter. Replace air filter.
Engine is worn. Consult authorised workshop.
Defective exhaust brake. Consult workshop.
Very low oil Pressure. Jammed paper filter cartridge. Replace paper filter cartridge.
Deficient oil level. Check and add oil.
Pressure gauge or pressure gauge Inspect and replace or tighten.

tube loose or defective.
Leakage in oil system. Check.
Improper lube oil (viscosity). Check brand of oil.
Defect of control valve for cooling Replace valve.

of pistons.
Heavy wears of bearings. Consult authorised workshop.
Increase in lube oil consumption Leakage in oil system. Inspect pipings, filters, and ducts
for tightness.
Excessively high oil level. Defect of air filter system, and

cooling of pistons, consult
authorised workshop.
No dirt deposits centrifugal filter. Rotor jams. Inspect rotor bearings,

Inspect oil supply to rotor.
Heavy blowing from venting hose Excessively high oil level, Adjust oil level, consult authorised
of engine. damages of cylinder elements. workshop.
No air supply from piston or Defect of cylinder element or Consult authorised workshop.
compressor. of valve plate.
Battery charging signal lamp Defective insulation in fanned Consult authorised workshop.
alight while ignition is cable.
switched off.
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D-5
Battery charging signal lamp does Defect of signal lamp. Replace signal lamp.
not light up when ignition is
switched on. Interruption of D* governor and Plug in connector.
generator.
Battery discharged. Change battery.
Battery charging signal lamp Broken V-belt. Replace V-belt.

alight during normal operation.
Defective alternator. Inspect or consult workshop.
Heavy boiling of battery. Defective governor, excessive Consult authorised workshop.

contact resistance of negative
polarity across brush holder and
end shield bearing of generator.
Starter does not run. Battery discharged. Charge battery.
Deficient speed of starter. Starter terminal voltage too low. Check battery cells, recharge
battery.
Oxidized or loose terminal Clean and fasten terminals.

connections.
Carbon brushes jam or are worn. Clean or replace brushes.
D-56
D-4
6.2 USEFUL TIPS FOR TURBO-CHARGERS z Checks have to be made on the oil, air and exhaust
piping, as well as, on all other connections and
6.2.1
seals, to ensure that they are still tight and no
Tampering of fuel pump and ignition system is damage has occurred.
prohibited as it may result in engine as well as
z When carrying out maintenance work on the engine
turbocharger damage.
(e.g. adjusting valves), in most cases the piping
Changes in boost pressure control of the leading from or to the turbocharger must be
turbocharger (where applicable) may result in removed. Close the piping opening on the
reduced engine life. turbocharger. Before fitting, clean the piping
Use only the air filter recommended by the engine carefully.
manufacturer. z When fitting the turbocharger to the engine, fill the
Use only the oil filter recommended by the engine central housing with clean oil and before fitting
manufacturer. make absolutely sure that all piping connected to
Use only the charges air cooler (where applicable) the turbocharger is cleaned carefully.
recommended by the engine manufacturer. If this advice is followed a turbo charged engine has,
Changes in the exhaust system are not from our experiences the same life span as a naturally
recommended. aspirated engine.
Use original gaskets and connecting pipes. 6.4 DO’S AND DON’T’S FOR SATISFACTORY
FUNCTIONING OF TURBOCHARGER
6.2.2 Periodical Inspection of Turbo Charger.
DO’S
Application : Genset application
Regular change of engine oil/oil filters.
Inspection job : Check rotar freness. Every 1200
Regular change/cleaning of air filter element.
Hours.
Clean T/C if dirt or carbon Check for oil pressure at engine idling condition
deposited on compressor & Minimum oil pressure to be as per engine
turbine wheel every 1200 hours & manufactures recommendation during idling.
2400 hours. Renew overhauler kit Idle the engine for 60 seconds after starting the
every 3000 hours. Engine.
6.3 RECOMMENDATION FOR OPERATION AND Idle the engine for 60 seconds before switching off
MAINTENANCE the engine.
Periodic cleaning of crankcase breather is
Special attention should be paid to :
necessary to allow free flow of oil from turbocharger
1. Operation Recommendations outlet.
z Engine should not be put under full load immediately Regularly check all air, oil and exhaust connections
after start. We recommend the engine to be run at for leaks and abnormal dust/oil/carbon build up.
idling speed for a short time (60 seconds). Warm up
the engine under medium speed & load. DON’TS
z After the engine has been operating at full toad for Don’t run the engine with low oil pressure.
a longer period of time, we recommend a short Don’t put the engine under full load immediately
idling time before switching off (60 seconds). after starting.
2. Maintenance Recommendations Don’t switch off the engine under full load.
z Turbochargers and boost pressure control valves Don’t run the engine with damaged oil feed & drain
do not require any maintenance. pipes, pipes between air filter and turbocharger
and as well as exhaust pipes.
z Engine oil has to be changed regularly.
Don’t open the Turbocharger yourself. Please
z Maintenance work has to be carried out regularly
contact the authorized dealers for any turbocharger
on the oil filter and air filter systems.
problems.
D-57
D-5
7. INSTRUCTION MANUAL FOR ELECTRONIC GOVERNOR
ELECTRONIC GOVERNOR
Electronoc Governor consists of three components. The system does maintains any desired speed
z Electric Actuator - Connected to engine fuel very accurately, independent of engine load. the system
pump & controls the fuel quantity delivered to the engine. offered is highly reliable with consistant accuracy &
z Electronic Speed Control Unit - Compares the simplicity of adjustment.
existing engine speed with desired speed & sends
corrective signals to the electric actuator.
The speed control unit is factory set. It is
Magnetic Speed Sensor - Measures the engine
z
recommended that not to disturb the settings.
speed by sending a proportional frequencu signal to the
speed control unit.
D-58
D-4
SYSTEM TROUBLESHOOTING
SYSTEM INOPERATIVE
If the engine governing system does not function, the fault may be determined by performing the voltage tests described
in steps 1 through 6. Positive (+) and negative (-) refer to meter polarity. Should normal values be Indicated during
troubleshooting steps, then the fault may be with the actuator or the wiring to the actuator. Tests are performed with
the battery power on, engine off except where noted. See actuator publication for testing details.
Step Terminals Normal Reading Probable Cause of Abnormal Reading
1 E (+) & F (-) Battery Supply Voltage 12 or 24 VDC) 1. DC battery power not connected.
Check for blown fuse.
2. Low battery voltage.
3. Wiring error.
2. A(+) & B (-) 0-3.9 with speed trim 1. Speed trim shorted or miswired.
7.1-7.9 without speed trim 2. Defective unit.
3. C(+) & D(-) 1.0 VAC RMS min., while cranking 1. Gap between speed sensor and gear
teeth too great. Check gap.
2. Improper of defective wiring to the
speed sensor. Resistance between
C and D should be 300 to 1200 ohms.
3. Defective speed sensor.
4. E(+) & H(-) 0.8-1.5 V while cranking 1. Wiring error to actuator.

2. Defective speed control unit.
3. Defective actuator.
D-59
D-5
7. ENGINE PRESERVATION displaced by Diesel + Preservative Oil mixture.

Preservatives and Preservation procedure is Stop the engine.
recommended for engine when it is to be kept idle Engine speed during above running -
(out of use) for prolonged period (more than 12
z In case of variable speed engine - 800 to 1000 rpm
months).
z In case of fixed speed engine - Rated speed at ‘No’
7.1 Recommended Preservatives load. (Genset, Pumpset etc.)
MANUFACTURER ENGINE LUBE OIL UNPAINTED FERROUS f) Close the air inlet manifold (for the air cleaner inlet)
& FUEL SYSTEM METAL PARTS and crank the engine by starter for 5 to 10 seconds.
(In case of purely hand start engine, it should be
BHARAT Bharat Preserve Bharat Rustrol
PETROLEUM Oil 30 152
hand cranked using the decompressor lever). This
will ensure coating of Diesel + Preservative oil on
HINDUSTAN Autoprun T 120 Rustop 274 the combustion chamber surfaces.
PETROLEUM g) Drain preservative oil from oil sump, reinstall drain
plugs and reconnect fuel filter into the fuel pipe line.
INDIAN OIL Servo Preserve 30 Servo RP 125
CORPORATION OR h) Treat all unpainted external ferrous metal parts with
Servo ‘RUN-N’ oil 30 two coats of suitable rust preventer as recommended
in 7.1, allowing sufficient time for the first coat to
CASTROL INDIA —— Rustilo DW 904 thoroughly dry before applying second coat.
OR DW 901
i) All vents i.e. engine inlet pipe, exhaust pipe, air
VEEDOL TIDE Veedol 30/40 Veedol ruspro IT cleaner inlet, crankcase breather etc. to be carefully
WATER OIL CO. sealed with water proof paper and water proof
adhesive tape.
7.2 Preservation Procedure j) Dipstick on engine to be sealed in place, with water
a) Using H.S.D. fuel, run the engine at approximately proof adhesive tape.
70% of maximum rated speed with ‘No’ load for 5 NOTE : DO NOT ROTATE CRANKSHAFT
minutes to warm up the engine ( in case of fixed AFTER ABOVE MENTIONED
speed engines like engine for Genset, it can be run OPERATIONS.
at rated speed).
k) Loosen ‘V belts tension.
b) After stopping the engine, drain lube oil from sump
and refill with suitable preservative oil as mentioned l) Battery for engine starting, if provided, should be
above. disconnected and stored in a cool, dry place after
ensuring the electrolyte level, refill with distilled
c) Run the engine on ‘No’ load for 3 minutes. During water, if necessary.
this time the preservative will be circulated
throughout the lube oil system of engine. Stop the It is recommended to recharge the battery every 30
engine and disconnect diesel fuel supply to fuel days.
pump inlet. For engine speed refer point 7.2 (a). m) Tag engine to indicate that it has been treated with
d) Prepare a solution Diesel + Preservative Oil (5:1 preservatives, and should not be turned over until
ratio) in a separate tank and connect fuel line from ready to run, due to possible reduction of protective
this tank, directly to fuel pump inlet ensuring gravity film. The tag should show the date of treatment and
feed (by-pass fuel filter). validity date.
e) Electrically crank the engine tilt it fires ( in case of n) It is preferable to warp the engine in polyethylene
purely hand start engine, hand - crank the engine bag and store in dry shade.
using decompressor lever, till it fires) and let it run
for 30 seconds. During this time the diesel in fuel Periodically inspect the engine for rust or corrosion
pump gallery and high pressure pipes will be and take corrective action if any.
D-60
D-4
o) If the engine is to be stored unused for more than c) Fill recommended grade of lub. oil in the oil sump
12 months, repeat the above procedure completely, upto the ‘Top’ mark of the dipstick. For oil filling
after every 12 months. quantity see 2.4.4.
7.3 Commissioning of Preserved Engine d) Readjust the V-belt tension after checking the
condition of V-belt (s), replace, if necessary
a) Remove all the sealing tapes / papers from various
(see 5.5 ).
openings.
e) Reconnect a fully charged battery to recommended
b) Remove the Rust Preventive coating from those
voltage and Amp-hr capacity ensuring correct
unpainted machined surfaces which are interfacing
polarity connection (where applicable).
surfaces for the driven equipment. This can be
done using NC Thinner. The engine is now ready for reuse. Follow the
instructions given in section 3 before starting the
engine.
7.2 TIGHTENING TORQUES
To prevent faulty assembly, following information on tightening of high tensile bolts is important. The bolts are to be
tightened in stages as specified in the table below. For connecting rod bolt and main bearing cap bolt use angle torque
method with the help of goniometer. The tightening angles for these two bolts are particularly important, hence Fig. 7.1
indicates the various angles can be readily obtained by comparison with a clock face.
Fig 7.1
Tommy bar is to be clamped in the tool slot and specified angle is to be turned with reference to the initial graduation
on outer dial of the tool or a relation of hex head of bolt can be referred.
NOTE :
1. Lubricate threads and seating face of bolt with engine oil before it is assembled.
2. Screw the bolt by hand till it is engaged upto the seating face.
3. Apply initial torque and tighten the bolts according to the angles/torques in stages as specified in the “Tightening
table”.
4. In case of replacing main and big end bearings/overhaul/piston seizures, fit new bolts for main bearing cap and
connecting rod cap.
1 Nm = 0.102 kgm
= 0.74 Ib.ft.
D-61
D-5
Table 8.0
TAPPET CLEARANCES (in cold condition only)

Engine Type Inlet Exhaust
HA 0.15 mm 0.15 mm
R1040 / R1080 0.25 mm 0.30 mm
SL 90 0.45 mm 0.40 mm
TIGHTENING TECHNIQUES & INSTRUCTIONS

TIGTHENING TORQUE BY ANGULAR METHOD FOR BOLTS
( SCREWS , NUTS) HA Series. - Annexure 1
Sr. No. DESCRIPTION SIZE INTIAL 1st 2nd 3rd Total REMARK
TORQ. Stage Stage Stage Angle
1 Cylinder head bolt 30 Nm 45 45 45 165 Type 12.5 quality.
2 Connecting rod bolt M12x 1.5x 55 30 Nm 30 60 - 90 Type 10.9 quality.
3 Bearing cap bolt M14x110 30 Nm 45 60 - 105 Type 10.9 quality.
4 Intermediate gear bolt M10x60 30 Nm 60 - - 60 Not applicable
5 Balance weight bolt M12x 60 30 Nm 30 30 - 60 Not applicable
6 Flywheel Bolt M10x1x35 30 Nm 30 60 - 90 Type 10.9 quality.
10 Crank Pulley Bolt M24x2x110 30 Nm 210 - - 210 Type 10.9 quality.
11 Cooling Blower bolt. M12x140 30 Nm 30 60 - 90 Type 8.8 quality.
12 Cooling Blower bolt ( HA 694) M12x180 30 Nm 30 60 - 90 Type 8.8 quality.
13 Nut for fuel injector M10x1.5 - - - - - 25 Nm
Note : In case of replacing main and big end bearings / overhaul / piston seizures, fit new bolts for main bearing cap
and connecting rod cap.
1 NM = 0.10197162 kgm
= 0.73756215 ib.ft.
D-62
D-4
Table 8.2 : TIGHTENING TORQUES FOR R1040 / R1080 ENGINE FASTENERS
Sr. Initial Tightening Method Total

No. Description Torque Angle/kgm Angle /
kgm Torque
Stage 1 Stage 2 Stage 3

1 Bolt for balance weight 3 30° 30° - 60°
(M12 X 1.75X60 mlong 10.9)
2 Bolt for Main bearing cap 3 60° 45° - 105°

(M12 14 X 2 X 128 mm long
10.9)
3 Bolt for Connecting rod 3 30° 60° - 90°

(M 12X1.5X55 mm long 10.9)
4 Bolt for crank pulley 5 25 50 73 73kgm

(M24X2 X 11 Ommlong 10.9) 5 25 48 - 45kgm
- With power take off .
- Without power take off
5 Bolt for flywheel 3 30° 60° - 90°

(M10 X 1 X 45 mm long 10.9 8kgm
6 Bolt for flywheel housing - - - - 5kgm

(M12X1.75X40 mmlong 10.9)
7 Nut for injector stud M 10 - - - - 3kgm
8 Nut for fuel pump hub M 14 - - - - 8kgm
9 Bolt for cylinder head 3 90° 75° - 165°

(12 X 1.75 X m long 12.9)
For sequence of tightening
torque refer attached sketch
10 All M8 X 1.25 screws/boIt 8.8 - - - - 2.5kgm
11 AII M10 X 1.5 screws/bolts 8.8 - - - - 3.5kgm

N.B. - For all series
z Apply initial torque & tighten the bolts according to the angles/torques in stages as specified in the tightening table
above in annexure 1,2 & 3.
z Threads & seating faces of fasteners to be cleaned & wetted with engine oil , before assembly.
z In case of replacing main or C.R.Bearings /overhaul/piston seizures , replace new bolts for main bearing caps &
connecting rod cap bolts.
z As per international standards all M8 x 1.25 screws/bolts of 8.8 quality must be applied torque of 2.5 Kgm.
z As per international standards all M10 x 1.5 screws/bolts of 10.9 quality must be applied torque of 3.5 Kgm.
1 NM = 0.10197162 kgm
= 0.73756215 ib.ft.N.B - For all series
D-63
D-5
Table 8.3 : TIGHTENING TORQUES
TIGHTENING TABLE ‘SL 90 Series’
Fastener Size Initial Tightening method

torque Torque wrench Angle of rotation
(Nm) Final torque (Goniometer)
Stage Stage Stage Stage Stage Stage

I II III II III IV
Cylinder head
bolt - Short M14 X 139 50 100 140+10 — — —
- Long M14 X 159 50 100 140+10 — — —
Connecting rod M 16 X 1.5 50 210+10.5 — 65° — —

+
bolt X 73 5°
Main bearing M16 X 150 60 270+13.5 — 45° 30° 30°

cap bolt +10°
Intermediate M14 X 1.5 — 170+10 — — — —

gear bolt X 65
Balance weight bolt M 16 X 50 — 258+8 — — — —
Flywheel bolt M16 X 45 — 240+10 — — — —
Crank pulley M20 X 1.5 — 300+10 — — — —

bolt X 65
Fly wheel M12 X 55 — 105+5 — — — —

housing bolt
Rocker support M 10 X 80 — 60+10 — — — —

bolt
Nut for exhaust M 10 — 50+10 — — — —

manifold
Nut for fuel M10 — 30+5 — — — —

injector fork
N. B.
1. Apply initial torque and tighten the bolts according to the angles / torques in stages as specified in the ‘Tightening
table.’
2. In case of replacing main and big end bearings/overhaul/piston seizures, fit new bolts for main bearing cap and
connecting rod cap.
1 Nm = 0.102 kgm
= 0.74 lb. ft.
D-64
D-4
SECTION E
INDEX
1. Alternator IIIustrations 5
2. General Information 6
3. Electrical Checks 8
4. Standard Reference condition 6
5. Do’s & Don’ts 6
6. Maintenance 6
7. Brushless - Exploded Illustrations 6
8. Brushtype - Exploded Illustrations 7
9. Part-List 8
10. Brushless - Exploded Illustrations 11
11. Brushtype - Exploded Illustrations 13
12. Patt List 23
E-3
USER MANUAL - ALTERNATOR
NOTES
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E-4
KIRLOSKAR GREEN ALTERNATORS

4 3 2 5 7
1 2 5 6
3 1 4 8
Fig. E-1 Fig. E-2
KG BRUSHLESS ALTERNATOR KG BRUSH TYPE ALTERNATOR
1 Coupling Disc. 1 DE Shield
2 DE Vent Cover 2 Slotted surround cover
3 Terminal Board and 3 Shaft
4 Terminal Box Cover 4 Fan
5 Starter Assly. 5 Eye bolt
6 Terminal box with LID
7 Excitation (CX) Unit
8 Magnet Frame (Body)

NOTE :
Depending on which alternator you have in your KGPI genset (please refer our sales office / service dealer)
you must refer the illustrations of the same shown above. Only the user serviceable parts are illustrated on the
surface of both the alternators above.
E-5
1.0 GENERAL INFORMATION z Ambient temperature Less than 40° C.

The Kirloskar Green Alternators are manufactured z Power factor 0.8 Lagging.
using the most accurate methods of design, z Speed on load I500 r.p.m.
construction and test. Their characteristics, if z Current Rated current value
properly used, ensure a continuous working and a as mentioned in the
very prolonged trouble free life. For the best use nameplate of
of Kirloskar Green Alternators. Please follow these alternator
instructions carefully. 1.5 LIMITS FOR SAFE OPERATION :
1.1 SPECIFICATIONS : z Over speed : 20% (1800 rpm for 50 Hz)
Kirloskar Green Alternators are self excited, self z Over load : 110% of rated value
regulated and supplied with Electronic Voltage for one Hr.
regulator. They comply with the following 2.0 SAFETY REQUIREMENTS :
International/Indian Standards :
Before any cleaning, lubrication or maintenance
z ISO : 9001 operation, ensure that the genset is stationary and
z BS : 5000 disconnected from the power supply.
z IS : 4722 & 13364 While stopping the gen-set,
ensure the compliance with the
z CSA : Canadian Standard
procedure for stopping prime
Association (1995) mover.
1.2 MECHANICAL FEATURES
z
z
Low Weight.
Very Compact.
The alternator, in fact has no
emergency stop, but is
controlled by the device
STOP
z Steel Body & C.I. End Shields. arranged by the installer to stop
z Life Lubricated Sealed Ball Bearings at both the prime mover.
the ends. Before installing the alternator,
z Screen Protected: IP 20 (S). arrangements must be made to
earth the machine in
z Optional: IP 21 (S), IP 23 (S) & IP 44 (S) can
compliance with any relevant
be provided.
electrical regulations. This is
z Self Ventilated. the reason why installer must
z Rotating Parts are Dynamically Balanced. make sure that the grounding
1.3 ELECTRICAL FEATURES system is in good conditions
and in compliance with the
z Single / Three Phase, 240 Volts / 415 Volts regulations of the country where
output at 50 Hz. the generators will be installed.
z Class ‘F’ Insulation.
CAUTION : THE FINAL
z Steady State Voltage Regulation of ±1%. INSTALLER IS RESPONSIBLE
z Current Compounded Self Excitation System. FOR THE INSTALLATION OF
z Lower Harmonic Content of less than 3%, at ALL THE PROTECTIONS
no load. (SECTIONING DEVICES;
z Power Factor 0.8 Lagging. PROTECTION AGAINST
DIRECT AND INDIRECT
z Phase Sequence is U-V-W when rotated
CONTACTS, OVER CURRENT
Clockwise viewing from DE side.
AND OVER VOLTAGE
1.4 NORMAL OPERATING CONDITIONS P R O T E C T I O N S ,
(AS PER IS 13364 & IS 4722) EMERGENCY STOP ETC.)
z Altitude Less than 1000 m. NECESSARY FOR THE N.B. :
E-6
MACHINE TO COMPLY WITH THE EXISTING INTER-

NATIONAL SAFETY REGULATIONS.
For handing the unpacked alternators, always use the
special eyebolts only, use
ropes having a suitable
carrying capacity and do not
lift the alternator too much No person must wear fluttering cloths (such as scarves
from the floor (max. 30 cm.) etc.) near the machine and any such garment must be
The operators in charge of the fastened with elastic bands at its ends.
installations, operation and
maintenance of the gen-sets Alternator must never and for no reason be run with
must be skilled technicians following guards removed :
who know the characteristics of the gen-sets. z Terminal box cover
z Rear cover
z Fan ventilation guard
Alternators produce heat proportional to the output.

Therefore do not touch it if you do not wear antiscorch
gloves, and after switching it off, do not touch it until it
has cooled down.
The operator must always wear work gloves and safety
shoes. In case the alternator or whole DG-SET must be Even if all machine components are protected, keep
lifted from the floor, the operators must wear a safety away from the gen-set. Do not lean or sit on the alternator
helmet. for whatever reason.
Make sure that the gen-set foundations and base frame
2.1 DANGER OF SHORT CIRCUIT
are suitable to bear the combined weight of the alternator
and prime mover. The degree of protection of the alternator is IP21. Short
circuit may occur if liquids (e.g. water etc.) are split onto
areas containing electrical parts.
2.2 STARTING AND STOPPING OPERATIONS:

All the instrumentation for starting, running and stopping
the system shall be provided by the installer.
The alternator should be securely connected and THE STARTING, RUNNING AND STOPPING
perfectly aligned with the prime mover, otherwise OPERATIONS MUST BE CARRIED OUT BY SKILLED
dangerous vibrations may occur resulting in alternator
PERSONNEL WHO HAVE READ AND UNDERSTOOD
bearing failure.
THE SAFETY INSTRUCTIONS AT THE BEGINNING OF
THIS MANUAL.
2.3 CLEANING :
Prior to approaching or touching the alternator, ensure
that it is not live and it is at room temperature; at this
stage it is possible to clean it on the out side using
The machine has been designed to ensure the rated compressed air.
output when it is installed in a room having a max.
NEVER USE LIQUIDS OR WATER FOR INSIDE
temperature of 400C and at an altitude not exceeding
CLEANING.
1000 meters; in case of deviations please make reference
to our technical leaflets.
E-7
N.B. : The alternator frame is provided with many fixing tightened.

holes so that vibration - damping may be applied in the z The control panel protection equipment is correctly
proper position to ensure the best trim of the gen-set. set.
z There is no short circuit due to wrong connections
3.0 MECHANICAL COUPLING : either / or in between the terminals of the alternator
and the power switch or breaker (this part of the
circuit is not protected by the breaker).
ALTERNATOR FOOT FIXING ON THE DE SIDE
IS ON END-SHIELD FOOT. HENCE CARE 5. SAFETY
MUST BE TAKEN WHILE CLOSING THE VENT
COVER AFTER TIGHTENING THE BOLT THAT • Basic safety precautions should always be followed to
NO MATERIAL SHOULD BE LEFT OUT eliminate fire, electric shocks or personal injuries. • Always
INSIDE, WHICH MAY CAUSE DAMAGE OF remember safety first. • Read and understand all the
FAN UNDER OPERATION. instructions. • Follow alt warnings, safety precautions
necessary during the installation, operation &
4.0 ELECTRICAL CHECKS maintenance of the alternator. • Cleaning should be
done only when the DG set is not running. • Do not use
damp cloths for cleaning. • Do not use any liquid or
4.1 CHECKING THE INSULATION aerosol cleansers. • Use only the eyebolt provided for
RESISTANCE lifting the alternator. Incorrect lifting or moving may result
If the alternator has been stored under damp in equipment damage or personal injuries. • Do not
conditions or has taken a lengthy time in shipment, the overload the cables as it may lead to fires or electric
insulation resistance should be checked. For this shocks. • Never insert any objects inside the alternator
purpose, all external connections and neutral to earth as it may lead to fires or electric shocks. • Do not spill any
link if any should be removed. A Megger of not more than liquid on the alternator. • Removing the cover of the
500 Volts D.C. should be connected between any one AC alternator while it is running will expose you to the
output terminal and the magnet frame. In case the test dangers of high voltages. • Incorrect reassembly can
reveals the insulation resistance to be less than 2.0 mega cause electric shocks when the alternator is subsequently
ohms (IR value at room temperature), identify the winding used. • Ensure that the field pole fasteners are not loose.
or the component by step by step isolation. • The earthing for body of alternator and for neutral
should always be as specified.
CAUTION: IF THE INSULATION RESISTANCE IS LESS

THAN 2 MEGA OHMS THEN THE ALTERNATOR 6.0 STANDARD REFERENCE CONDITIONS
SHOULD NOT BE OPERATED. Al-Series AC Generator is designed to perform
satisfactorily under the environmental conditions of 400
cen ambient and 1000 M altitued. However, for site
4.2 ELECTRICAL CHECKS :
conditions, please apply following deration factors.
Make sure :
z A suitable electrical protection device is fitted in the
6.1 TEMPERATURE
output circuit for safety reasons (in line with the codes
of practice in force within the country where the High ambient temperature results into excessive operating
alternator is installed) temperature of the alternator. These AC Generators are
designed for an ambient temperature of 400 C. For
z Ensure before start up that terminal nuts are properly
marine and other applications where the ambient
E-8
temperature is greater than 400 C, the alternators must be Leading pf loads cause rise in terminal voltage which may
de-rated to ensure that the actual temperature does not subsequently harm the AVR and the loads. Please refer to
exceed the spefified limits of thermal class of insulation. works in case of leading pf loads.
Outputs are normally quoted at 40 Deg. C. These outputs Note : Capacitor bank (which is normally used for PF
must be multiplied by the following factors for higher improvement) should not be left in the circuit at no
ambient temperatures. load.
TEMPERATUR DERATING FACTOR
(0C) 6.4 HUMIDITY
45 0.96 Anti-condensation heaters (SPACE HEATER)
50 0.92 High humidity results into condensation on the windings.
55 0.88 To maintain the winding temperature slightly above the
normal ambient temperature, space heaters can be
60 0.84
provide a more economic machine which still meets the
specification.
6.2 ALTITUDE
Density of air decreases with higher altitude which 7.0 GENERAL COMMENTS ON LOAD CONDITIONS:
deteriorates the heat transfer properties of air and results
7.1 It is advisable to forward a completed copy
into excess temperature rise. AC Generator rating is
specification (if available) to the works for study of the
derated for higher altitued to avoid this temperature rise.
actual requirement for which DG set is required. As a
ALTITUDES DERATING FACTOR result of such an assessment it is sometimes possible to
1,500 0.96 incorporate design changes to provide a more economic
machine which still meets the specification
2,000 0.92
7.2 There are two basic conditions to check when sizing
2,500 0.88
machines.
3,000 0.84
i. The steady state Condition.
3,500 0.80
ii. The transient condition
6.3 POWER FACTOR
Steady state condition is mainly concerned with normal
Standard AC Generators are suitable for 0.8 pf lag to UPF operation of the machine within temperature rise limits
loads. Power factor below 0.8 lag causes heating of the for specified class of insulation.
AC Generator. The Alternator output must be multiplied
The transient condition refers to terminal voltage variations
by the following factors for lower PF.
during sudden application of high current loads like
PF (LAG) DERATING FACTOR Induction motor starting etc.
0.7 0.95 It is essential thet both these conditions are checked, as
0.6 0.91 sometimes a rating sufficient for the steady state condition
0.5 0.88 is not large enough to meet motor starting or voltage dip
requirements.
0.4 0.86
0.3 0.85
0.2 0.84
0.1 0.84
0 0.84
E-9
8.0 SELECTION OF AC GENERATORS FOR 8.1.2 POWER FACTOR

DIFFERENT LOAD APPLICATIONS It is the nature of the applied load that dictates the system
DG set should be capable of supplying different types of power factor.
loads which exists at different sites. For this suitable a) Unity Power Factor : The loads which operate at or
rating AC Generators selection is very important. The very close to unity (1.0) power factor include most
different types of loads which generally exists at differnt forms of lighting, heating elements, rectifier type
site can be broadly classified in to following four types - loads.
8.1 Linear Loads b) Lagging Power Factor : For all remaining load types,
8.2 Motor Loads (Part of linear loads, considered some knowledge on their operating power factor is
separately) required. For induction motors the operating power
8.3 Non-linear Loads factor is lagging & it depends on their size and load
conditions.
8.4 Special loads
c) Leading Power Factor : For Capacitor loads the
operating power factor is leading.
8.1 LINEAR LOAD
CGL standard AC Generators are designed for 0.8 lag
Linear loads can be identified from following characteris operating power factor of the load. Also these AC
- Load impedance is always constant regardless of Generators can perform satisfactorily at any power factor
the applied voltage. in the range of 0.8 p.f. lag to unity p.f., but care should be
- The load current increases proportionately as the taken for Engine rating for pure resistive loads to operate
voltage increases and decreases as the voltage the DG set on its full capacity, For operation at lagging
decreases. power factors lower than 0.8 refer to derating factors as
per cl. 7.3
Examples of linear loads are motor, incandescent lighting
and heating loads. Under leading power factor loads these AC Generators
will not perform satisfactorily and the terminal voltage
8.1.1 SLEECTION OF ALTERNATOR FOR LINEAR
may shoot up / oscillate. Hence care should be taken to
LOADS
disconnect the power factor improvement capacitors or
To select the rating of AC Generator for linear loads, the to compensate with inductive loads such that the overall
maximum connected load and the base load which is operating power factor lies between UPF to 0.8 lag.
always connected has to be considered. In arriving at a
total load figure it is always advisable to select the
standard rating larger than that estimated, despite the 8.2 MOTOR LOADS
fact that all the loads may not be operating at the same Induction motors are most commonly used loads. During
time and hence a smaller machine could have been the starting of an induction motor, a very large current is
selected. Future operating conditions and future growth demanded from the power source, which is known as the
are very difficult to estimate. An allowance of 15% to 20% starting or locked rotor current. For sizing alternators
excess capacity designed into a set now is a small price which have to cater to motor loads, the following
to pay compared with the cost of completely new larger guidelines can be referred to.
unit that may be required to drive additional loads in a few METHOD OF STARTING STARTING CURRENT
years time.
Direct on Line (DOL) 6 to 7 Times full load current
of motor.
(lf starting current is not given
starting kVA is 7 times Hp
rating of the motor)
E-10
STAR / DELTA 2 to 2.5 times full load current 8.3.2 EFFECTS OF NON-LINEAR LOADS
of motor a) Non-liner loads generate harmonics in their current
ROTOR TRANSF waveform which in turn leads to distortion of the AC
ORMER STARTING generator waveform. Resulting in excessive heating
of magnetic cores because of heavy hysterisis and
40 % TAPPING 1.2 Times full load current of
eddy current losses.
motor
b) Odd order harmonics cause overload of neutral
60 % Tapping 4 times full load current of
conductors.
motor
c) It created problem of hunting of the terminal voltage
80 % Tapping 4.5 times full load current of
which makes paralleling of generators difficult or
motor.
impossible.
For motor applications the following information should
d) It causes damage to the power factor improvement
be furnished :
cpacitor.
a) Rating of the motor / motors.
e) Correct measurement of electrical quantities like
b) Type of motor (slip ring / squirrel cage) voltage, current etc. is difficult.
c) Method of starting f) Depending upon the degree of voltage waveform
d) Rated full load current distortion this can lead to instability of the excitation
e) Starting power factor system and impact on other loads being supplied by
the generator.
f) Any restriction on Transient Voltage Dip? (Details of
the same)
g) Frequency of starting. 8.3.3 GENERAL GUIDELINES ON DERATION FOR
NON-LINEAR LOADS
h) Base load at the time of starting induction motor.
LOADS DERATING FACTOR
i) Any other load apart from the motor loads? (Details
there of) a) Fluorescent No derating required
j) Sequence of starting of motors. b) UPS & Telecom load Non linear load should
controlled by a not exceed 90% of
8.3 NON-LINEAR LOADS 12 pluse Thyristor Alternator rating.
Advancement in the field of power electronics, brought bridge plus a filter.

different types of loads such as Reftifiler loads, Thyristor c) UPS & Telecom load Non linear load should
controlled drives, UPS, Batter Chargers etc. controlled by 6 Pluse not exceed 66% of
So care has to be taken in the sizing of the generators to Thyristor bridge Alternator rating.
ensure satisfactory performance.
plus a filter.
d) UPS & Telecom load Non linear load should
8.3.1 CHARACTERISTICS OF NON-LINEAR LOADS
controlled by 3 Pluse not exceed 66% of
a) The load current is not proportional to the
Thyristor bridge Alternator rating.
instantaneous voltage. Often the load current is not
continuous. plus a filter.
b) These are essentially electronic loads such as e) Variable speed 6 Non liner should not
Computers, UPS equipments and variable speed pulse Thyristor bridge exceed 50 % Alternator
motor drives etc. controlled drive. rating.
E-11
The above precentage figures are guidelines. There may c) Details of other types of loads existing.
be a problem with electronic load, trying to cope with
distroted waveform if distortion levels are unacceptable
8.4.2 WELDING LOADS
to the load.
Welding loads draw heavy intermittent current from the
Better sizing of machine is possible on furnishing following
AC Generator. Most of the welding loads are designed
information :
for single phase 415 V or 240 V. Welding loads stress the
a) Number of pulses of Thyrister drive : 3,6, or 12. AC Generator because of their low power factor. For
b) Level of current distortion produced by the non- selecting suitable AC Generator for these loads following
linear load. information should be furnished.
c) What is the maximum acceptable level of voltage a) kVA rating (Name plate details)
distortion the Non-linear load can accept? b) Rated power factor.
d) Operating voltage and frequency. c) Whether single phase (240v) or two phase (415 v)
e) If Non-linear load power requirement is stated in kW, d) Primary rated and transient current.
then some guidance regarding operating power
e) Details of other voltage sensitive loads if any.
factor & system efficiency is required to establish the
Alternator load.
With the information, guidance should be sought from 9. DO’S and DON’T’S
the factory regarding Alternator sizing for compatible DO’S
equipment opration. 1. Tighten the foot mounting bolts.
2. Ensure that the alternator is properly grounded.
8.4 SPECIAL LOADS 3. Ensure the tightness of the terminal bolts.
Apart From the linear and non-linear loads there are 4. Ensure the crimping of lead wires.
certain types of loads which needs consideration during
5. Check the fuse if provided.
AC Generator Selection. These are :
6. The body and neutral earthing should be perfect.
7. All protection gears should be used as required.
8.4.1 COMPUTER LOADS
8. The rating of generator should match the load.
Computer loads are very sensitive to the characteristics
such as voltage varition, frequency variation, harmonic 9. Ensure that the brushes are fully bedded
contents, voltage unbalance etc. of power supply. If centrally on the slipring.
these characteristics does not match with the stipulated 10. Check the free movement of the generator shaft
figures, malfunctioning of computers may result. Because by lifting the brushes.
of this reason selection of AC Generator for this application 11 . Check the spring pressure.
requires careful study. It is advisable to have separate
12. Check the voltage during commissioning.
DG set for computer loads.
13. Check the phase sequence during installation.
Following information should be supplied for selecting
the suitable AC Generator for this application. 14. All covers and guards should be fitted before
starting the generator.
a) Total KVA of computer load and its operating power
factor. 15. After servicing the generator, make sure the
connections are as per connection diagrams.
b) Acceptable steady state and transient state voltage
and frequency variation. 16. If the lifting of the alternator is necessary then lift
using eye bolts only as shown in the figure.
E-12
17. Maintain and operate the generator correctly. 10.0 VOLTAGE SETTING AND ROTATING SPEED :
18. Run the DG set daily for at least 5-10 minutes on The output voltage of the alternator should be
no load. checked at rated speed 1500 R.P.M.
WARNING : FOR THE ALTERNATOR
GOOD WORKING IT IS ADVISABLE NOT
TO DEVIATE FROM THE NOMINAL
VOLTAGE MORE THAN 5%
10.2 ELECTRICAL FAILURE TROUBLESHOOTING
When an electrical failure occurs, check for trouble
as explained below :
1) In order to find out if the failure has happened
in the alternator itself or in the regulation
system one has to test the alternator at no
load (at nominal speed) exciting the exciter
stator directly, using an external dc source.
When applying the voltage to the exciter stator
one has to comply with polarities : apply the
negative polarity of the auxiliary source to the
Fig. E-3
negative terminal and positive terminal to the
positive terminal of the exciter fields.
DON’T’S
Verify that :
1. Don’t operate the machine with higher current
than the nameplate current A) When feeding the winding according to
the excitation data at no load (listed in
2. Don’t operate the machine at less than 0.8 power
the table) the voltage supplied by the
factor within deration
alternator is almost the rated one
3. Don’t start the machine with load.
B) After the localization of fault, repair
4. Don’t operate the generator without the covers. properly.
5. Don’t block the air inlet and outlet of the 11. MAINTENANCE
machine.
11.1 GENERAL
6. Don’t have excessive wiring lengths at the
The machine should be completely isolated from all
application end.
electrically live wires before any electrical or rotating
7. Don’t expose the generator to moist part of it is touched. The frequency of maintenance
condition. depends largely on the site conditions. Frequent
8. Don’t use low grade cables. maintenance of approximate once a week should be
9. Don’t operate the alternator if the IR value is practiced at first and the period extended as
found to be less than 2 mega ohms. experience is gained.
10. Don’t apply capacitive loads.

12. Don’t run the machine with the field pole
fasteners loose.
E-13
11.2 CLEANING 11.4 SLIPRINGS (For Brushtype only)

The generator and excitation unit should be cleaned Satisfactory electrical operation of the generator depends
internally by blowing out with a jet of dry air and by wiping principally upon maintenance of good working condition
away any deposits of grease and carbon dust with a of the sliprings. During normal running the rings should
clean dry cloth. All fasteners especially the connectors have a dark burnished appearance without grooving or
should be inspected for tightness at less frequent intervals. uneven wear. During periodic maintenance the sliprings
11.3 BRUSHES (For Brushtype only) and the grooves between them should be cleaned. If any
signs of wear or blackening are observed the spring
The brushes should be closely examined after every 500
pressure should be checked and readjusted if required.
hours of operation to establish that they are bedded
If blackened badly, the rings should be polished by
properly and are not sticking in their holders and that the
running the machine and using a fine carborundum or
correct brush pressure is being maintained. Brushes
emery paper. This operation is to be carried out with the
should be replaced with genuine spares before they
brushes lifted.
wear down to 10mm in length. New brushes must be
bedded by placing a piece of fine carborundum cloth
between the brushes and the slipring with the abrasive If pronounced flats have developed the rings must be
side towards the brushes and high application of spring skimmed, brushes bedded and the machine cleaned out
pressure. The cloth should be drawn forward and by blowing compressed air before it is put back in to
backward under tension so that it follows the curvature of service. The brush holders should be positioned on the
the slipring. This operation should be finished by several spindle so as to let the brushes ride on the centre of the
strokes in the direction of rotation, lifting the brushes width of the sliprings.
during the return stroke. It is essential that all carbon and WARNING :
abrasive particles be removed by a jet of dry air and by
The field connections Fl & F2 should be
wiping with a clean and dry cloth. During bedding the
removed before working on the sliprings.
adjacent winding should be masked to prevent entry of
carbon dust. The pressure on each brush should be 11.5 BEARINGS
checked The bearings used in the machine are from reputed
and adjusted to 200-250gms per square cm. manufacturers and are of sealed type thus requiring no
greasing. The bearings are designed for approximately
40,000 hours of use and should be replaced after that.
Note: Emery paper or any other abrasive should never However in case high bearing noise is observed or
be used to clean bedded brushes. leakage of grease noticed it is strongly recommended
that the bearing be checked and replaced immediately to
prevent failure during running as this could cause
irreversible damage to the generator.
E-14
TROUBLE SHOOTING CHART BRUSHLESS ALTERNATORS
FAULT CAUSE REPAIR

No voltage build - up 1) Insufficient residual voltage 1) Excite the rotor using a battery
2) Improper connection 2) Correct the connection
3) Low speed 3) Reset the speed to the nominal
4) Faulty Winding 4) Check the winding resistance
and rewind if required
5) Rotating rectifier failure 5) Replace the rotating rectifier
6) Faulty AVR 6) Replace the AVR
Low no - load voltage 1) Low speed 1) Reset the speed to the nominal
2) Faulty Rotating rectifier 2) Replace the rotating rectifier
3) Faulty Winding 3) Check the winding resistance and
rewind if required
Low voltage on load 1) Low speed at full load 1) Set the rated speed of the
prime mover
2) AVR faulty 2) Change AVR
3) Faulty rotor winding 3) Check the rotor winding

resistance and if faulty, rewind it
4) Over load on alternator 4) Operate on specified load
High voltage on load 1) Capacitors on the load side 1) Disconnect the PF

improvement capacitors
2) Faulty AVR setting or 2) Correct the setting / Replace AVR
AVR is faulty
Too high 1) Excessive speed 1) Adjust the revolving speed

no - load voltage 2) Correct the setting Correct the setting
Replace AVR Replace AVR
Voltage oscillations 1) Incorrect AVR setting 1) Set the AVR stability pot
2) Thyristor load more than 2) Reduce the Thyristor load
specified limits
3) Insufficient engine flywheel
Unbalance Voltage 1) Unbalance load 1) Correct the load

2) Loose connections 2) Tighten the loose connections
3) Stator winding faulty 3) Check winding resistance &
rewind if required
E-15
TROUBLE SHOOTING CHART BRUSHLESS ALTERNATORS
FAULT CAUSE REPAIR

Excessive overheating 1) Set misalignment 1) Align the set properly
of one or both bearings 2) Bearing loose in end shield 2) Replace the faulty End shield
(temp. of bearings over housing
800C) (with or without
noise)
Excessive overheating 1) Air flow (inlet - outlet) partially 1) Check air inlet - outlets of the
of alternator frame clogged or hot air is being alternator
circulated either from alternator
or prime mover
2) Alternator operating at high 2) Set the voltage to rated value
Voltage at load
3) Alternator overloaded 3) Operate at specified load
4) Load PF less than 0.8 lag 4) correct the load power factor
Excessive vibrations Defective mounting or play in the Replace the coupling & check the
coupling alignment Reset the speed to the
nominal
Excessive vibration and 1) Three phase alternator is single 1) Check and correct the load
humming noise coming phase loaded in excess of
from the alternator acceptable limits
2) Start up with no-load : if humming 2) Rewind stator

persists - faulty alternator stator
winding
Smokes, spark or flames Short circuit in the external circuit Stop the set immediately
coming from the alternator (including wiring between alternator
and control board)
Object fallen into the machine

short circuit or flash in the stator
winding
Alternator damaged by Short circuit in external circuit Stop the gen-set immediately
a significant impact which Faulty parallel connection (out of phase)
is followed by humming Break or deterioration in the coupling
and vibration Break or twist in shaft extension
Shifting or short circuit of main field
winding
Bursting or unlocking of the fan
Diode burnt, rectifier bridge damaged
E-16
TROUBLE SHOOTING CHART BRUSHTYPE ALTERNATORS
FAULT CAUSE REPAIR

No voltage from alternator Open circuit in excitation unit Check the continuity of excitation
transformer windings
Check rectifier Connections.
Wrong field connections Check the positive terminal of the

rectifier (red wire) connected to F1
and the negative terminal (black wire)
to F2.
Open circuit in field winding Check the continuity of the field

winding, if open connected the joint
that have been broken
Loss of residual magnetism Check the residuaal voltage at the

alternator terminals. This should be
about 10 volts and balanced between
all the three lines.
Fault rectifier After charging check voltage at the

terminals F1 & F2. If there is no D. C.
Voltage replace the rectifier (if in
doubt)
Faulty surge suppressor unit Check the connections. F1 to positive

terminal (red) and F2 to negative
terminal (black)
Defective excitation capacitor Check for short circuit or open circuit

of the capacitor, if faulty replace it.
Short circuit or open curcuit Armature rewinding is necessary

in armature winding
Brushes not bedding properly Check if the brushes are sticking in

boxes or if bedding is short proper. If
the brushes are found tight in the box,
just polish the faces of the brush with
emery cloth.Check if brush holder leavers
are in locked position and the spring
pressure is even.
E-17
FAULT CAUSE REPAIR

Low or high voltage from Incorrect tappings (shunt) connected Select tappings to get correct voltage
alternator on no load if voltage and regulation are not
satisfactorily obtained.
Incorrect speed of prime mover Check the speed and adjust the
speed to 1560 rpm on no load and
1500 rpm on load
Unbalanced currents in excitation Reset the excitation unit as per the

transformer windings instructions given.
Faulty rectifier Check the rectifier unit, if current in

excitation unit windings are balanced
and if the input voltage to the rectifier
unit is unbalanced, replace the
rectifier.
Turns shorted in the field coil Check the faulty coil and replace it.
Voltage regulation is Incorrect speed of the prime mover Adjust the speed of the prime mover
unsatisfactory to correct value on no load and full
load. The speed should be 1560 rpm
on no load. On load the speed should
be uniform at 1500 rpm (Full load)
Load current are not balanced and Adjust and reduce the load.
within the rated current
Open or short circuit in capacitor Check the capacitor and replace if

necessary
Series winding of excitation unit are If voltage falls excessively low when
reserved load is applied, a possible reason is
that the series winding are reversed
Check the voltage at the terminals
and slipring unit, if there is a large
difference reconnect properly
Air gap of excitation unit transformer If the regulation is marginally outside

not correct the limits + 5% then adjustments
in air gap to be made.
Machine over loaded Check the load current with the rated
current mentioned on the nameplate.
Reduce load if necessary.
E-18
FAULT CAUSE REPAIR

Low power factor of the connected load Check power of the load.
Power factor equipment is necessary
if the power factor is lower than
rated p.f.
Over heating of alternator Over heating may be generally due to Reduce load so that allowable
excessive ambient temperature or altitude temperature are not exceeded
Re-circulation of hot air in the Avoid re-circulation by erecting

vicinity of the alternator external baffles
Blocking of inlet ventilation louvers Clean for free air intake
Misalignment Check the alignment and readjust it
Overloading of machine Check the load and current with

nameplate ratings
Over heating of bearing Low speed/frequency incorrect, Correct the speed, assemble
reassembly of worn out bearings correctly and replace the bearings
Misalignment/Loose coupling bolts Check and correct the misalignment

Tighten the coupling bolts
Over heating of armature Over loading Adjust load on the alternator
Internal short circuit Rewind the armature
Over heating of field coils Over heating of alternators Check the load current and reduce
the load of capacitors
Load power factor low Improve power factor with

connection of capacitor
Internal short circuit Replace field coils (shorted)
High vibrations Loose/Broken Coupling, Loose Tighten or replace the component

Foundation Bolts, Damaged Bearings
Misalignment Correct the alignment
E-19
E-20
PART LIST FOR SIGNLE BEARING KG BRUSHLESS AC GENERATOR
Reference Quantity Description

1 1 Stator Assembly
2 1 Rotor Assembly
3 1 Exciter Rotor
4 1 Exciter Stator
5 1 End Shield NDE
6 1 Terminal Box
7 1 NDE Bearing
9 1 End Shield DE
10 1 Slotted Surround
11 6 Disc
12 6 Shim
13 1 Pressure Plate
14 4 Lock Washer
15 1 Fan
16 1 Coupling Hub
17 2 Feet Rib
18 2 Circlip
19 3 Key
20 1 Terminal Box Top Cover
21 1 Terminal Box Front Cover
22 3 Gasket
23 3 Gland Plate
24 4 Set Insulation Washer
25 2 Terminal Bar
26 1 Automatic Voltage Regulator
27 4 Bush
28 6 Diode
29 1 set Rotating Rectifier Assembly
30 1 Locking Cup
31 4 Hex. Stud
32 6 Main Stator Output Leads
33 4 Hexagonal Head Bolt
34 2 Earthing Bolt
E-21
CONSTRUCTIONAL FEATURES OF THE KIRLOSKAR GREEN BRUSH TYPE ALTERNATORS
Fig. E-5
E-22
9.1 PARTS DESCRIPTION (Please refer Fig. C-5)
PART NO. DESCRIPTION QTY.
1 MAGNET FRAME (BODY 1
2 POLE BRICKS 4
3 FIELD COILS 1 SET
4 EYE BOLT 1
5 EARTHING SYMBOL PLATE 2
6 ROTOR 1
7 ROTOR COILS 1 SET
8 ROTOR END PLATES 2
9 SHAFT 1
10 FAN KEY 1
11 SLIPRING ASSEMBLY 1
12 BRUSH HOLDER WITH BRUSHES 4 SETS
13 FAN 1
14 EXTENSION KEY 1 NO.
15 CIRCLIP 1
16 DE BEARING CAP 1
17 DE BEARING 1
18 DE SHIELD 1
19 SLOTTED SURROUND 1
20 BRUSH HOLDER SPINDLE 4
21 NDE BEARING CAP 1
22 NDE BEARING CAP 1
23 NDE SHIELD 1
24 VENTILATION GIRDS 2
25 TERMINAL BOX WITH LID 1
26 EXCITATION (CX) UNIT 1
E-23
PART LIST
KIRLOSKAR GREEN BRUSHLESS ALTERNATOR
SR. NO. PART NO. PART DESCRIPTION KVA ( PHASE ) FRAME SIZE
1 02.804.11.0.00 AVR 15 kva to 125 kva ( 3 ph )

2 02.812.02.0.00 AVR ( Single Phase ) For single phase Alternators
3 02.804.12.0.00 Diode 15 kva to 30 kva ( 3 ph ) “160,180”
4 02.804.13.0.00 Diode 15 kva to 30 kva ( 3 ph ) “160,180”
5 02.804.14.0.00 RRA 15 kva to 30 kva ( 3 ph ) “160,180”
6 02.804.15.0.00 Exciter Rotor 15 kva to 30 kva ( 3 ph ) “160,180”
7 02.804.16.0.00 Exciter Stator 15 kva to 30 kva ( 3 ph ) “160,180”
8 04.805.11.0.00 AVR 140 kva to 250 kva ( 3ph )
9 04.805.12.0.00 Diode 35 kva to 125 kva ( 3ph ) “200,225”
10 04.805.13.0.00 Diode 35 kva to 125 kva ( 3ph ) “200,225”
11 04.805.14.0.00 RRA 35 kva to 125 kva ( 3ph ) “200,225”
12 04.805.15.0.00 Exciter Rotor 35 kva to 125 kva ( 3ph ) “200,225”
13 04.805.16.0.00 Exciter Stater 35 kva to 125 kva ( 3ph ) “200,225”
14 04.805.17.0.00 Exciter Rotor locking plate 35 kva to 125 kva ( 3ph ) “200,225”
15 02.804.18.0.00 Fan 15 kva to 30 kva ( 3 ph ) “160,180”
16 04.805.18.0.00 Fan 35 kva to 55 kva ( 3 ph ) 200
17 06.825.02.0.00 Fan 63 kva to 125 kva ( 3 ph ) 225
18 02.804.21.0.00 Terminal Block 15 kva to 30 kva ( 3 ph ) “160,180”
19 04.805.21.0.00 Terminal Block 35 kva to 55 kva ( 3 ph ) 200
20 04.805.21.0.00 Terminal Block 63 kva to 125 kva ( 3 ph ) 225
21 02.804.28.0.00 DE Adaptor SAE 2 15 kva ( 3 ph ) 160
22 2H.802.03.0.00 DE Adaptor SAE 3 20 kva to 30 kva (3 ph ) 180
23 04.805.25.0.00 DE Adaptor SAE 3 35 kva to 55 kva ( 3 ph ) 200
24 06.825.05.0.00 DE Adaptor SAE 3 63 kva to 125 kva ( 3 ph ) 225
25 02.804.24.0.00 HUB 15 kva to 30 kva ( 3 ph ) “160,180”
26 04.805.27.0.00 HUB 35 kva to 55 kva ( 3 ph ) 200
27 06.825.06.0.00 HUB 63 kva to 125 kva ( 3 ph ) 225
28 02.804.31.0.00 NDE shield 15 kva ( 3 ph ) 160
29 2H.802.06.0.00 NDE shield 20 kva to 30 kva (3 ph ) 180
30 04.805.32.0.00 NDE shield 35 kva to 55 kva ( 3 ph ) 200
31 06.825.12.0.00 NDE shield 63 kva to 125 kva ( 3 ph ) 225
32 04.804.22.0.00 Bearing 15 kva to 30 kva ( 3 ph ) “160,180”
33 04.805.22.0.00 Bearing 35 kva to 125 kva ( 3ph ) “200,225”
34 F6.819.12.0.00 AVR R-438 250 to 275 KVA 43
35 KV2.801.11.0.00 AVR R-448 320 to 600 KVA 52 AND 62
E-24
36 F6.819.02.0.00 Varistor 250 to 275 KVA 43
37 KL6.802.02.0.00 Varistor 320 to 600 KVA 52 AND 62
38 F6.819.09.0.00 Rectifier Assembly 250 to 275 KVA 43
39 KL6.802.09.0.00 Rectifier Assembly 320-500 KVA 52
40 KV2.801.08.0.00 Rectifier Assembly 600 KVA 62
41 F6.819.11.0.00 NDE Bearing 250 to 275 KVA 43
42 KL6.802.11.0.00 NDE Bearing 320 to 500 KVA 52
43 KV2.801.09.0.00 NDE Bearing 600 KVA 62
44 F6.819.06.0.00 Cooling Fan 250 to 275KVA 43
45 KL6.802.06.0.00 Cooling Fan 320 t0 500KVA 52
46 KV2.801.05.0.00 Cooling Fan 600KVA 62
47 F6.819.05.0.00 N.D.E. Bracket 250 to 275KVA 43
48 KL6.802.05.0.00 N.D.E. Bracket 320 t0 500KVA 52
49 KV2.801.04.0.00 N.D.E. Bracket 600KVA 62
50 F6.819.07.0.00 D E Cowling / D.E. Vent. Cover 250 to 275KVA 43
51 KL6.802.07.0.00 D E Cowling / D.E. Vent. Cover 320 t0 500KVA 52
52 KV2.801.06.0.00 D E Cowling / D.E. Vent. Cover 600KVA 62
53 F6.819.08.0.00 Terminal Box Cover(TOP) 250 to 275KVA 43
54 KL6.802.08.0.00 Terminal Box Cover(TOP) 320 t0 500KVA 52
55 KV2.801.07.0.00 Terminal Box Cover(TOP) 600KVA 62
56 F6.819.04.0.00 Exciter Stator 250 to 275KVA 43
57 KL6.802.04.0.00 Exciter Stator 320 t0 500KVA 52
58 KV2.801.03.0.00 Exciter Stator 600KVA 62
59 F6.819.03.0.00 Exciter Rotor 250 to 275KVA 43
60 KL6.802.03.0.00 Exciter Rotor 320 t0 500KVA 52
61 KV2.801.02.0.00 Exciter Rotor 600KVA 62
E-25
KIRLOSKAR GREEN BRUSHTYPE ALTERNATORS

1 04.801.21.0.00 Excitation wound bobbin 30 kva ( 3 phase ) 200
2 04.801.22.0.00 Excitation wound bobbin 50 kva( 3 ph) 200
3 04.801.23.0.00 Excitation wound bobbin 35 kva( 3 ph ) 200
4 04.801.24.0.00 Excitation wound bobbin 40 kva ( 3 ph) 200
5 04.801.25.0.00 Excitation wound bobbin 45 ( 3 ph ) 200
6 06.805.21.0.00 Carbon brush “63 kva to 82.5 kva (3 ph),40kva(1 ph) “ “225 , 200”
7 06.805.22.0.00 Brush holder “82.5 kva (3 ph ),40 kva ( 1ph ) “ “225 , 200”
8 06.805.23.0.00 Brush holder spindle “82.5 kva (3 ph ),40 kva ( 1 ph ) “ “225 , 200”
9 06.805.24.0.00 Slipring assembly 63/75/82.5 kva (3 ph) 225
10 06.805.25.0.00 Fan “30 to 55 kva(3ph),20/25/30/40 kva(1ph)” 200
11 06.805.26.0.00 DE shield “30 to 55 kva(3ph),20/25/30 kva(1ph)” 200
12 06.805.27.0.00 NDE shield “63 to 82.5kva (3 ph ) , 40 kva (1ph)” “225 , 200”
13 06.805.28.0.00 Excitation wound bobbin ( old) 63 kva( 3 ph ) 225
14 06.805.30.0.00 NDE shield “30 to 55kva( 3ph),20/25/30kva(1 ph)” 200
15 06.805.31.0.00 Excitation wound bobbin (new) 63 kva( 3 ph ) 225
16 06.805.32.0.00 Slipring assembly 63/75/82.5 kva ( 3 ph) 225
17 38.236.21.0.00 Excitation wound bobbin 20 kva (3 ph ) 180
18 38.236.22.0.00 Excitation wound bobbin 15 kva ( 3 ph ) 180
20 38.238.21.0.00 Carbon brush 15 to 55 kva ( 3 ph and 1 ph ) “180, 200”
21 38.238.22.0.00 Brush holder 15 to 55 kva ( 3 ph and 1 ph ) “180, 200”
22 38.238.23.0.00 Surge supressor All rating ( 3 ph and 1 ph ) All frame.
23 38.238.24.0.00 Bridge rectifier All rating ( 3 ph and 1 ph ) All frame.
24 38.238.25.0.00 Capacitor All rating ( 3 ph ) All frame.
25 38.238.26.0.00 Brush holder spindle 15 to 55 kva ( 3 ph and 1 ph ) “180, 200”
26 38.238.27.0.00 Rapid terminal block 15 kva to 82.5 kva ( 3 ph and 1 ph ) All frame.
27 38.238.28.0.00 Terminal bar 15 kva to 82.5 kva ( 3 ph and 1 ph ) All frame.
28 38.238.29.0.00 Carbon brush 15 kva ( 3 ph ) 160
29 38.238.31.0.00 Slipring assembly 15 kva to 55 kva ( 3 ph ) “180, 200”
30 38.238.32.0.00 Fan “15 kva to 25 kva(3ph),15kva(1ph)” 180
31 38.238.33.0.00 DE shield “15 kva to25kva(3ph),15 kva (1ph )” 180
32 38.238.34.0.00 NDE shield “15 kva to 25 kva (3 ph),15 kva(1ph)” 180
33 38.238.35.0.00 E- core All rating ( 3 ph and 1 ph ) All frame.
34 38.238.36.0.00 Brush holder 15 kva ( 3 ph ) 160M
35 38.238.37.0.00 Brush holder spindle 15 kva ( 3 ph ) 160M
36 38.238.38.0.00 Rapid terminal block 15 kva ( 3 ph ) 160M
E-26
37 38.238.39.0.00 Terminal bar 15 kva ( 3 ph ) 160M
38 38.238.41.0.00 Slipring assembly 15 kva ( 3 ph ) 160M
39 38.238.42.0.00 Fan 15 kva ( 3 ph ) 160M
40 38.238.43.0.00 DE shield 15 kva ( 3 ph ) 160M
41 38.238.44.0.00 NDE shield 15 kva ( 3 ph ) 160M
42 38.238.46.0.00 Excitation wound bobbin 15 kva ( 3 ph ) 160M
43 38.244.01.0.00 Capacitor 15 kva to 25 kva ( 1 ph ) “180, 200”
44 38.244.02.0.00 Capacitor 30 kva to 40 kva ( 1 ph) 200
45 38.244.03.0.00 Slipring assembly 15 kva to 25 kva ( 1 ph ) “180, 200”
47 3H.801.21.0.00 Excitation wound bobbin 25 kva ( 1 ph ) 200
50 3H.808.25.0.00 Slipring assembly 30 kva (1 ph ) 200
51 4H.814.21.0.00 Fan 63 kva to 82.5 kva (3 ph ) 225
52 4H.814.22.0.00 DE shield “63 kva (3 ph ) , 40 kva ( 1 ph)” “225 , 200”
53 4H.814.23.0.00 Excitation wound bobbin ( old ) 75 kva ( 3 ph ) 225
54 4H.814.24.0.00 DE shield (new ) 75 kva ( 3 ph ) 225
55 4H.814.25.0.00 Excitation wound bobbin (new) 75 kva ( 3 ph ) 225
56 4H.815.22.0.00 DE shield ( old ) 82.5 kva ( 3 ph ) 225
57 4H.815.23.0.00 Excitation wound bobbin ( old ) 82.5 kva ( 3 ph ) 225
58 4H.815.24.0.00 DE shield ( new ) 82.5 kva ( 3 ph ) 225
59 4H.815.25.0.00 NDE shield 82.5 kva ( 3 ph ) 225
60 4H.815.26.0.00 Excitation wound bobbin (new) 82.5 kva ( 3 ph ) 225
62 02.808.02.0.00 Slipring 15 kva ( 1 ph ) 160
63 02.808.03.0.00 Brush holder with carbon brush 15 kva ( 1 ph ) 160
64 02.808.04.0.00 Bridge Rectifier 15 kva ( 1 ph ) 160
65 02.808.05.0.00 MOV 15 kva ( 1 ph ) 160
66 02.808.06.0.00 Capacitor 15 kva ( 1 ph ) 160
67 02.808.07.0.00 Sealed Ball Bearing 15 kva ( 1 ph ) 160
E-27
NOTES
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E-28

Kirloskar DG Set Manual

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Kirloskar DG Set Manual

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Dear Customer,

 Your Name & Phone or Mobile Number.

 Engine Serial Number.

 Name of the Company.

 General Description of assistance required.

And the service will be on its way.

O FOR EMERGENCY CONTACT O

HELP DESK TOLL FREE NUMBER - 1800 233 3344

AREA OFFICE CONTACT DETAILS

KIRLOSKAR OIL ENGINES LTD.

Section A – Genset Warranty

Section B – Customer Service Package

Section C – Genset User Manual

Section D – Engine User Manual

Section F – Service Network

Each warning/most important instruction in the manual succeeds the sign .

KIRLOSKAR OIL ENGINES LTD., +91-011-23718544 (O)

KIRLOSKAR OIL ENGINES LTD., +91-0161-531372 (O)

KIRLOSKAR OIL ENGINES LTD., +91-0522-2789565 (O)

KIRLOSKAR OIL ENGINES LTD., +91-0141-2361789 (O)

GOA, GUJRAT, MAHARASHTRA, MADHYA PRADESH, & CHATISGARH

KIRLOSKAR OIL ENGINES LTD. +91-079-27480922 ( O)

KIRLOSKAR OIL ENGINES LTD., +91-0731-2531402 (O)

BIHAR JHARKHAND ORRISA WEST BENGAL AND NORTH EASTERN STATES

KIRLOSKAR OIL ENGINES LTD., +91-0674-588047 (F)

KIRLOSKAR OIL ENGINES LTD., +91-0612-2230360 (O)

KIRLOSKAR OIL ENGINES LTD.,

A. P. UPADHYE - 9881209205 RAKESH PARDESHI - 9822599877

Section B - Customer Service

Section D - Diesel Engine

Before commissioning of the genset, please go through the contents of this

3. For availing the warranty services, please ensure following :

a) Produce this warranty booklet to KOEL authorised Service Dealer, when

Please provide following details to our Authorised Service Dealer.

— Genset Model & serial No. :

— Engine serial No. :

— Detailed site address :

— Contact Person and

GENSET MODEL AND SR. NO. __________________________________________

ENGINE MODEL & SR. NO. ______________________________________________

KG ALTERNATOR SR. NO.

PANEL SR. NO. _________________________________________________________

G1 (1ST SERVICE) CHECK

G2 (2ND SERVICE) CHECK

KIRLOSKAR GREEN D.G. SET

o Locks O Kirloskar Green canopy Components supplied along

LOG SHEET (Sample for use)

Daily use in hrs.

Hour meter reading

Cooling Water Temp (°C)

Fuel added (ltr.)

Lub. oil added (cc)

Current (Amp) 3-phase

kWH meter reading if provided

Remarks - Record events of

Daily use in hrs.

Hour meter reading

Cooling Water Temp (°C)

Fuel added (ltr.)

Lub. oil added (cc)

Current (Amp) 3-phase

kWH meter reading if provided

Your Name & Phone or Mobile Number.

Engine Serial Number.

Name of the Company.

General Description of assistance required.