15 To 62.5 kVA Air Cooled PDF

CPCB II
GENSET USER MANUAL
RATING: 15 to 62.5 kVA

TYPE: AIR COOLED (HA SERIES ENGINE)
Dear Customer,
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.
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
Head, Power Generation Business
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.
FOR EMERGENCY CONTACT

In the very unlikely event of you are not receiving the prompt attention
from our eld force, following are the contact details of our Help Desk
and area e for your assistance.
HELP DESK CONTACT NUMBER - +91 880 63 344 33

HELP DESK TOLL FREE NUMBER - 1800 233 3344
KIRLOSKAR OIL ENGINES LTD.

LAXMANRAO KIRLOSKAR ROAD, KHADKI, PUNE - 411 003.
email ID - koel.helpdesk@kirloskar.com
www.koel.co.in
PREFACE
This manual deals with the Kirloskar Green Power Ideas (KGPI) genset operation. The manual also explains
components and parts which a user can service on their own. The maximum performance of the genset
largely depends on its proper maintenance and upkeep. So, please ensure proper Genset maintenance as
per the instructions and schedule given in this manual. This user manual is divided into 6 Sections. These
relate to Genset, Diesel Engine, Alternator, Warranty, Customer Service, Area Office Contacts and Check
Call Cards. Please go through a synopsis of each section.
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 commissioning
checks and maintenance checks. KOEL 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 (KG) Alternator coupled to the
diesel engine. User needs to read the safety requirements and all the “do’s & don’ts”. 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
KGPI takes care of you anywhere everywhere. And this last section contains the information (contact
details) of our zonal offices, area offices and 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 the 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.
KOEL Area Offices
Service
State Address Telephones Mobiles
Manager
Kirloskar Oil Engines Limited Anil Pandey 011-28715826 +91-
4-C/6, New Rohtak Road, 919910116895
New Delhi Opp. Liberty Cinema,
Karol Bagh,
New Delhi-110005
Kirloskar Oil Engines Limited Ravindra Kain 0161- +91-
Plot No. 12, Sherpur Chowk, 2546667/668/669 9810937556
Punjab N.P.C. Tempo, Union Street,
Near Arun Gas Godown,
Ludhiana – 141 003
Kirloskar Oil Engines Limited Varun Bali Tel :0141- 2370007 / +91-
Rajasthan Plot No. 3, Purohit Ji Ka 2370014 9829205552
Bagh, Off M. I. Road, Jaipur
– 302 001
Kirloskar Oil Engines Limited Kapil Shah/ 0522-2741440 / +91-
498/143 KA, New Faizabad Sudhir 2741441 9918000838
U.P. Road, /7678893875
Near IT College Crossing,
Lucknow – 226007
Kirloskar Oil Engines Limited Manna Arindam 033-22170858 +91-
Poonam Building, /60/61 9674003617
Flat No. 8A and 8B, 8th
West Bengal
Floor,
5/2, Russel Street,
Kolkata – 700071
Kirloskar Oil Engines Limited Mohit 0361-
29, 1st Floor,G.N.B.Road, Choudhary 2131334/2457616
Assam Pan Bazar,
Above Avery India Ltd.,
Guwahati – 781 001
Kirloskar Oil Engines Limited Santanu Das 0674- +91-
No. 178/A, Zone-B, 2588021/2588047 9778477870
Odisha Mancheswar Industrial
Estate,
Bhubaneshwar – 751010
Kirloskar Oil Engines Limited Narendra :+91-
Meena Plaza, South Kumar Roy 9031061077
Museum Road,
Bihar
Budh Marg,
Patna – 800001
Service
State Address Telephones Mobiles
Manager
Kirloskar Oil Engines Limited Kumar 0651- +91-
C/O Shri Ram Logistics Prabhakar 2301197/2211255 9771417061
Services,
Jharkhand 4P, 4th Floor, Shri Gopal
Complex,
Kutchery Road,
Ranchi – 834 001
Kirloskar Oil Engines Limited Kadhirvel 044 - 3744624/625 +91-
Nelson Towers, 1st Floor, /Bharanikumar 7299995717
2nd Wing No. 51, /9444990295
Tamil Nadu
Nelson Manickam Road,
Aminjikarai,
Chennai – 600029
Kirloskar Oil Engines Limited Vardhaman 040- +91-
D No. 5-2-220 To 222 Deepakkumar 27534197/27534176 9550500066
2nd Floor, Sri Padmavathi
Andhra Towers,
Pradesh Hyderbasti, Opp Andhra
Bank, Ranigunj,
Secunderabad – 500003
Kirloskar Oil Engines Limited Vijay T B 080-25587562/ +91-

15, Shri Laxmi Complex, 3rd 30578174 9900021100
Floor, St. Marks Road,
Karnataka
Opposite Bowring Institute,
Adjacent to India Garage,
Bangalore – 560001
Kirloskar Oil Engines Limited Shaji Mathew 0484- +91-
No. 39/2694-A1, Anugraha, 2385756/2385757 9744716767
Kerala
Panthiyil Lane, Warriam
Road, Cochin – 16
Kirloskar Oil Engines Limited Prashant Falke : 0731-3913101/11 :+91-
B-1, Radhakrishna Complex, 9826026463
10/1, Manorama Ganj,
M.P. Geeta Bhawan Square,
AB Road (Agra-Mumbai
Road),
Indore – 452 001
Kirloskar Oil Engines Limited 079-
Ground Floor, ‘D’ Block, 26929687/26929689
Gujarat Pruthvi Complex, Near
Jodhpur Char Rasta,
Ahmedabad – 380015
Kirloskar Oil Engines Limited Malay Amin/ 020- +91-
Maharashtra Laxmanrao Kirloskar Road, Rohit Patil 25810341/25815341 9922431561/
Khadki , Pune – 411003 9881495639
INDEX
Section A - Warranty
Section B - Customer Service
Section C - Genset
Section D - Diesel Engine
Section E - Alternator
Enriching Lives
Operational and Maintenance Manual:
Diesel Genset
Warranty
Important
1. This warranty is applicable for Kirloskar Green Power Ideas (KPIG) gensets
manufactured by/under license from 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 KOEL
Helpdesk.
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 (G1) at 50 hours or 30 days from date of
commissioning, whichever is earlier. Carry out second service check (G2) at
250 hours or 6 months from date of commissioning, whichever is earlier.
Thereafter carry out subsequent service checks at every 500 hours or 6
months, whichever is earlier provided KOEL Premium Oil is used in the
engine.
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 A-9.
f) Carry out all preventive maintenance and repair work of genset, through KOEL
authorised service dealers only.
g) The performance of genset depends on the quality and grade of lube oil and
periodic preventive maintenance. To ensure the genuinity of oil, KOEL has
launched the lube oil branded as K-Oil Premium. Please use K-Oil Premium
and genuine filters sourced through KOEL authorised parts and service dealer
and avail extended warranty.
A-1
-
Diesel Genset
Please provide following details to our Authorized

Service Dealer for quick restoration of your genset.
- Genset Model and Serial Number.
- Engine serial Number.
- Detailed site address
- Contact Person and Telephone/Mobile Number.
- Number of hours run till date
- Nature of failure
A-2
Diesel Genset
GENSET MODEL AND SERIAL NUMBER

_____________________________________________________
ENGINE MODEL AND SERIAL NUMBER

___________________________________________
KG ALTERNATOR SERIAL NUMBER, MAKE AND TYPE

__________________________________________
PANEL SERIAL NUMBER

__________________________________________
G1 (1ST SERVICE) CHECK CARRIED OUT ON

__________________________________________
G2 (2ND SERVICE) CHECK CARRIED OUT ON

___________________________________________
SERVICE DEALER'S STAMP AND SIGNATURE

__________________________________________
A-3
Diesel Genset
Use K- Oil Premium, 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 -
This warranty is applicable to Kirloskar Green (KG) diesel genset. The warranty is for 2 years from
the date of installation or 5000 operating hours or 30 calendar months from date of dispatch
whichever is earlier as detailed below, subject to use of Kirloskar K-Oil Premium. Kirloskar
genuine filters. K-Cool Super Plus and services sourced through KOEL authorised Service
Dealer.
For Power Generation Non Cellular Application Engines and KG
Alternator -
The warranty is for 2 years from the date of installation or 5000 operating hours or 30 calendar
months from date of dispatch whichever is earlier, subject to use of Kirloskar K-Oil Premium.
Kirloskar genuine filters. K-Cool Super Plus and services sourced through KOEL authorised
Service Dealer.Refer details in pages ahead.
Kirloskar Oil Engines Ltd. hereby warrants that this Kirloskar Green Genset is free from defects in
material, design and workmanship. This warranty shall be limited for repairs and replacement under
normal use, regular check up and maintenance of the Kirloskar Green Genset as per our
maintenance schedule and purchase and servicing of the Kirloskar Green Genset through our
authorised dealer.
This warranty is the only document given by us warranting the Kirloskar Green Genset. No other
document giving any warranty terms conflicting these contents shall be considered and entertained.
Kirloskar Oil Engines Ltd. is not liable to service, or repair of Kirloskar Green Genset free of costs
during the warranty period, for the Kirloskar Green Genset purchased from person other than an
authorised person or DG set Dealer or AGOEM of Kirloskar Oil Engines Ltd.
Kirloskar Oil Engines Ltd. is not liable for any loss or damage, direct or consequential, labour
charges or the effect of any accident resulting from defective material, faulty workmanship or
otherwise. In any case the liability of Kirloskar Oil Engines Ltd. will not exceed the Kirloskar Green
Genset price or the market value of the Kirloskar Green Genset whichever is lower and shall be
without interest.
Use K-Oil Premium for your Gensets.

For details of K-Oil Premium, please contact our Authorised Service Dealer.
A-4
Diesel Genset
This warranty does not apply for the following:

1. The Kirloskar Green Genset or engine failure due to any misuse including improper
shutdown, improper handling and adjustments, negligence, over speeding, alteration
of specification and due to accident or Act. of God.
2. Kirloskar Green Genset or engine if not maintained as per the maintenance schedule
given by Kirloskar Oil Engines Ltd.
3. If K-Cool Super Plus engine coolant is not used for liquid-cooled Genset.
4. Damage due to improper installation of the parts, components and accessories.
5. For the parts supplied under warranty or voluntarily or at special rates or free of charge,
the warranty will be applicable only to the unexpired portion of D G Set warranty.
6. Damage due to use of improper lubricant or the lubricant used other than suggested by
Kirloskar Oil Engines Ltd.
7. Normal wear and tear of the components of Kirloskar Green Genset / Engine.
8. For resale of Kirloskar Green Genset or if the Kirloskar Green Genset purchased is
second hand.
Warranty period for DG set components is as below.
For Power Generation Non Cellular Application
•Proprietary parts not manufactured by Kirloskar Oil Engines Limited like:
•Starter
•Alternator
•Fuel injection pumps
Service Dealer.
•Kirloskar Green Alternators
30 Calendar Months from Date of Despatch or 5000 operating hours or 24 calendar months from
date of installation, whichever occurs first.
•All other Electrical Components supplied along with Genset like:
•Sensors
•Switches
•Engine Safety Units
•Actuator
•Controller card A-
5
Diesel Genset
Service Dealer.
**Warranty is not applicable for fuse & charging bulb.
•Kirloskar Green canopy Components supplied along with Genset like:
•Locks •Hinges •Fuel level gauges •Exhaust fan
Service Dealer.
**Warranty is not applicable for foam,canopy door & panels, bulb, and tubes
•Kirloskar Green Control Panel Components supplied along with Genset like:
•AMF module
•Relay card / board
•LVM / GVM
•Current transformer
•Battery chargers
•Switches
•MCB
•Contactors
Service Dealer.
**Warranty is not applicable for fuse, charging bulb and contactor coil
For Power Generation Cellular Application -

•Proprietary parts not manufactured by Kirloskar Oil engines like:
•Starter
•Alternator
•Fuel injection pumps
•Battery
•Exhaust Fan
A-6
Diesel Genset
For Power Generation Cellular Application - 15 Calendar Months from Date of Dispatch or 2500
operating hours, whichever occurs first. The warranty is subject to analysiis of defect by the
respective authorised dealer of manufacturer.
•All other Electrical Components supplied along with engine like:
•Sensors
•Switches
•Engine Safety Units
•Fuel level gauge
15 Calendar Months from Date of Dispatch or 2500 operating hours, whichever occurs
first.The warranty is subject to analysis of defect by the respective authorised dealer of
manufacturer.
**Warranty is not applicable for fuse and charging bulb.
•Kirloskar Green canopy Components supplied along with Genset like:
•Locks
•Hinges
•AVM
first.The warranty is subject to analysis of defect by the respective authorised dealer
of manufacturer.
**Warranty is not applicable for foam, bulb, and tubes.
•Kirloskar Green Control Panel Components supplied along with Genset like:
•AMF module
•Relay card / board
•LVM / GVM
•Current transformer
•Battery chargers
•Switches
•MCB
•Contactors
first.The warranty is subject to analysis of defect by the respective authorised dealer of
manufacturer.
**Warranty is not applicable for fuse & charging bulb & contactor coil.
Any claim or obligation in connection with the sale or performance of Kirloskar Green Genset shall
be subject to Pune Jurisdiction.
A-7
Diesel Genset
Conditions precedent to Kirloskar Green Genset warranty.

The Kirloskar Green Genset warranty given by the company is subject to the below condition which
are to be observed by every purchaser/user of Kirloskar Green Genset, without which the warranty
claims if any will be rejected.
A. Proper installation of the Kirloskar Green Genset is the sole responsibility of

the owner of the Kirloskar Green Genset.
B. Operation & Maintenance as recommended by the company within the limits
mandated by the specifications.
C. Any defective part claimed, to be returned to Kirloskar Oil Engines Ltd., if such
part is replaced by the company under warranty, the returned part becomes
the property of the company, this transportation charges to be paid by the
customer.
D. In case of interchange of part between Kirloskar Green Gensets / Engine shall
void the warranty. Unauthorised repair work will make the warranty null and
void.
E. For the proprietary parts not manufactured by Kirloskar Oil Engines Ltd., such
as Fuel Injection Equipment, Electrical Equipment and Instruments etc. the
warranty 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.
Log Sheet
Please find a sample of Log Sheet on following sheets for your reference. You are requested to
maintain a separate log book registering the following mentioned parameters in the table.
A-8
Diesel Genset
Engine________________________ RPM_________________ HP____________
Date
Daily use in
hours
Hour meter
reading
Coolant
Temp (°C)
Pressure
(Kg/cm2) or
Lube Oil (bar)
Temp
(°C)
Fuel added
(Liters)
Lube oil
added (liters)
Engine
(RPM)
Current
(Amp) 3-
phase or 1-
phase
Voltage (V)
Frequency
(Hz)
PF & kW in
Controller
kWH meter in
Controller
Remarks -
Record
events of
maintenance
/ repairs
A-9
Diesel Genset
Engine________________________ RPM_________________ HP____________
Date
Daily use in
hours
Hour meter
reading
Coolant
Temp (°C)
Pressure
(Kg/cm2) or
Lube Oil (bar)
Temp
(°C)
Fuel added
(Liters)
Lube oil
added (liters)
Engine
(RPM)
Current
(Amp) 3-
phase or 1-
phase
Voltage (V)
Frequency
(Hz)
PF & kW in
Controller
kWH meter in
Controller
Remarks -
Record
events of
maintenance
/ repairs
A-10
Diesel Genset
Engine________________________ RPM_________________ HP____________
Date
Daily use in
hours
Hour meter
reading
Coolant
Temp (°C)
Pressure
(Kg/cm2) or
Lube Oil (bar)
Temp
(°C)
Fuel added
(Liters)
Lube oil
added (liters)
Engine
(RPM)
Current
(Amp) 3-
phase or 1-
phase
Voltage (V)
Frequency
(Hz)
PF & kW in
Controller
kWH meter in
Controller
Remarks -
Record
events of
maintenance
/ repairs
A-11
Diesel Genset
Engine________________________ RPM_________________ HP____________
Date
Daily use in
hours
Hour meter
reading
Coolant
Temp (°C)
Pressure
(Kg/cm2) or
Lube Oil (bar)
Temp
(°C)
Fuel added
(Liters)
Lube oil
added (liters)
Engine
(RPM)
Current
(Amp) 3-
phase or 1-
phase
Voltage (V)
Frequency
(Hz)
PF & kW in
Controller
kWH meter in
Controller
Remarks -
Record
events of
maintenance
/ repairs
A-12
Time FIRST SERVICE CHECK (G1) - ENGINE SIDE Date
D G Set Parameters (Within 30 days from date of commissioning or first 50 hours 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. :
P ha s e : S ingle / T hre e Type : B rus hle s s / B rus h Type F ra me :
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) :
S a fe tie s : L ow L ube O il P re s s ure – W ork ing / N ot Work ing

H igh L ube O il / W a te r Te mp – W ork ing / N ot Work ing
V B e lt F a ilure – W ork ing / N ot Work ing
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 :

t Cleaning of Air Cleaner (Dry / Oil Bath), Restriction Indicator operation. Yes / No
t Lube Oil & Oil Filter Change Yes / No
t Fuel / Filter Element Change Yes / No
t Cleaning of Radiator Cooling ns Yes / No
t 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 . - P lea s e f ill t he inf orma t ion, a s a pplic a ble. P a ge N o . 1 o f 3

1) KOEL HEAD OFFICE COPY
ALTERNATOR CHECK POINTS - DURING G1 CHECKS
S l N o. S e rvic e P oint R e m a rk
1 Alternator Checks to be carried out during stop condition for
Ma in S ta tor W inding le a ds tig htne s s a t Ma in Te rmina l. O K / NO T O K
All AV R c onne c tions tig htne s s . O K / NO T O K
O utgoing c a ble c onne c tions tig htne s s . O K / NO T O K
2 Check for Seperate Earthing connections for neutral & Genset body,
both s hould be c onne c te d to e a rth pit. O K / NO T O K
P our s uffic ie nt wa te r in to E a rth pit. DO N E / N O T DO N E
C he c k outg oing ma in c a ble c onne c tion a t te rmina l. O K / NO T O K

Observe proper lugs, crimping & glands.
3 Start the Set and observe the following parameter-
C he c k for s ta ble out put volta g e from Alte rna tor. O K / NO T O K
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 -
Ma ins c a ble tightne s s & lugs c rimping & gla nd in c ontrol pa ne l . OK / no t O K
G e ne ra tor c a ble a t c ontrol pa ne l a nd a lte rna tor te rmina l. OK / no t O K
C orre c t c a ble s iz e with c orre c t lugs . OK / no t O K
C onne c tion a re tight. ( All powe r & c ontrol c a ble ) OK / no t O K
2. C he c k the E a rth c onne c tion of c ontrol pa ne l. OK / no t O K
C he c k c ontrol pa ne l is mounte d on AV mounting or c he c k vibra tion. OK / no t O K
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
P owe r c onne c tion a t both C onta c tors a re tight. O K / no t O K
C onne c tion a t a ll fus e s or MC B a re tight. O K / no t O K
Check the proper tightness of all relays at relay base with proper relay locking clips. Ok / not OK
5. C he c k the B a tte ry volta ge a nd e ns ure tha t ba tte ry is fully c ha rge d O K / no t O K
Battery voltage
S pe c ific G ra vity of ba tte ry s olution ( re quire d 1. 270 ) O K / no t O K
Ensure all cells of battery are 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
C he c k B a tte ry te rmina l for c le a nline s s a nd tightne s s . O K / no t O K
6. Checking of electrical accessories -
C he c k a ll the ga uge s a re work ing. O K / no t O K
C he c k the e xha us t fa n work ing a nd dire c tion of fa n. O K / no t O K
C he c k s ole noid s upply is not more tha n 15-20 s e c . O K / no t O K
7. C he c k a ll the me te rs for work ing on c ontrol pa ne l work ing. O K / no t O K

8. Mains voltage ( EB Power ) -
Mains current ( EB Power ) -
9. Generator voltage -
Generator current-
10. E ns ure AU T O / MAN U L mode ope ra tion of AMF pa nne l. O K / no t O K
Site Address :
Tel. No.

Time SECOND SERVICE CHECK (G2) - ENGINE SIDE Date
( Within 6 months from commissioning 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 t Change engine lube oil. t Done

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

t Check for proper cowling ment for e ective cooling of the engine. t Done / OK
t Clean the cylinder liner & cylinder heads Clean by removing main cowling & t Done / OK
direct compressed air ow on the s, or clean with brush.
For Liquid Cooled Engines :
t Check up coolant level in radiator, compensatory tank or heat exchanger t Done / OK
& top up if required.
(For initial add Radiator coolant as recommended. Keep the 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.)
t Check whether radiator are choked. Educate customer on how to clean the t Done / OK
radiator externally.
4 t Check button of feed pump. If choked, clean it. (educate customer) Cleaned.
t Drain the water from Water Separator. Cleaned.
t C ha ng e primary and main fue l filte rs a s pe r O & M s c he dule . t Done / OK
hence not
necessary.
5 Check for all External Fasteners as per Spe ed torques. Tightened

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

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

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

S a fe tie s : L ow L ube O il P re s s ure – Work ing / N ot W ork ing
H igh L ube O il / C oola nt Te mp – Work ing / N ot W ork ing
V B e lt F a ilure – Work ing / N ot W ork ing
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 :

t Cleaning of Air Cleaner and checking of r estriction Indicator operation. Yes / No
t Lube Oil & Oil Filter Change Yes / No
t Fuel / Filter Element Change Yes / No
t Cleaning of Radiator Cooling ns Yes / No
t 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. C he c k for Abnorma l nois e during running. O K / N ot O K
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. P ut wa te r in the E a rth P it. O K / N ot O K
6. C he c k for P rope r E a rthing c onne c tions . O K / N ot O K
C he c k the tig htne s s of AV R c onne c tions . O K / N ot O K
7. Start the Set and observe the following parameter-
C he c k for s ta ble out put volta g e from Alte rna tor. O K / N ot O K
Check for Balance load. Load difference should be less than 10% of load Balance / Unbalance
in phases for 3 phase DG.
Current ( Amp ) - R- Y- B- N- phase respectively
Voltage (Volts ) - RY - YB- BR-
Power factor
8 Canopy Checks
C he c k C a nopy doors for prope r fitme nt a nd a lignme nt O K / N ot O K
C he c k C a nopy for e xte rna l & inte rna l rus ting . O K / N ot O K
C he c k C a nopy loc k s for prope r ope ra tion. O K / N ot O K
Check temperature d erence between canopy inside & outside by closing the Di rence -
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 -
Ma ins c a ble tightne s s & lugs c rimping & gla nd in c ontrol pa ne l . OK / no t O K
G e ne ra tor c a ble a t c ontrol pa ne l a nd a lte rna tor te rmina l. OK / no t O K
C orre c t c a ble s iz e with c orre c t lugs as per KOEL specifications. OK / no t O K
C onne c tion a re tight. ( All powe r & c ontrol c a ble ) OK / no t O K
2. C he c k the E a rth c onne c tion of c ontrol pa ne l. OK / no t O K
C he c k c ontrol pa ne l is mounte d on AV mounting or c he c k vibra tion. OK / no t O K
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
P owe r c onne c tion a t both C onta c tors a re tight. O K / no t O K
C onne c tion a t a ll fus e s or MC B a re tight. O K / no t O K
Check the proper tightness of all relays at relay base with proper relay locking clips
5. C he c k the B a tte ry volta ge a nd e ns ure tha t ba tte ry is fully c ha rge d O K / no t O K
Battery voltage
S pe c ific G ra vity of ba tte ry s olution ( re quire d 1. 270 ) O K / no t O K
Ensure all cells of battery are 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
C he c k B a tte ry te rmina l for c le a nline s s a nd tightne s s . Apply petroleum jelly to battery terminals. O K / no t O K
6. Checking of electrical accessories -
C he c k a ll the ga uge s a re work ing. O K / no t O K
C he c k the e xha us t fa n work ing a nd dire c tion of fa n. O K / no t O K
C he c k s ole noid s upply is not more tha n 15-20 s e c . O K / no t O K
7. Check all indicated parameters on control panel. O K / no t O K

8. Mains voltage ( EB Power ) -
Mains current ( EB Power ) -
9. Generator voltage -
Generator current-
10. E ns ure AU T O / MAN U L mode ope ra tion of AMF pa nne l. O K / no t O K
Site Address :
Tel. No.

Diesel Genset
Genset
C1. About KOEL ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ C‐1
C1.1 State‐of‐the‐art Manufacturing Setup ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ C‐1
C1.2 Design and innovation ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ C‐1
C1.3 Kirloskar Green Power Facts ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ C‐1
C1.4 Awards and Accolades ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ C‐2
C1.5 Note ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ C‐2
C2. Safety ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ C‐2
C3. Ratings Plate‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ C‐3
C4. Lifting the genset ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ C‐3
C5. Moving the Genset ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ C‐5
C6. Technical Data ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ C‐7
C6.1 Gensets with Acoustic Canopy ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ C‐7
C6.1.1 Air Cooled Gensets ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ C‐7
C7. Genset with Air‐cooled Engine ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ C‐7
C7.1 Introduction ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ C‐7
C7.2 Description Of Genset Package ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ C‐7
C7.3 Canopy ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ C‐7
C8. Engine ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ C‐8
C8.1 Cooling System ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ C‐8
C8.1.1 Air Cooled Engine ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ C‐8
C8.2 Engine Governor ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ C‐8
C8.3 Brushless Alternator ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ C‐9
C8.4 Vibration Isolation ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ C‐9
C8.5 Fuel Tank and Base Frame ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ C‐9
C8.6 Silencer and Exhaust System ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ C‐10
C8.7 Genset Circuit Breaker ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ C‐10
C8.8 System Protection ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ C‐11
C8.9 Control Panel ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ C‐11
C8.10 Control Panel Power Supply ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ C‐11
C8.11 Control Panel Mounting ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ C‐11
C9. Components of a Genset ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ C‐11
C9.1 View from Blower side ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ C‐11
C9.2 View from Starter Motor side ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ C‐14
C10. Installation ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ C‐15
C10.1 Location ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ C‐15
C10.2 Foundation‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ C‐17
C10.2.1 Features of Foundations ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ C‐18
i
Diesel Genset
C10.2.2 Soil Load Bearing Capacity ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ C‐19
C10.2.3 Calculation for Foundation Depth ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ C‐19
C10.3 Cooling and Ventilation ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ C‐19
C10.3.1 Genset installed in a room ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ C‐20
C10.3.2 Ventilation check ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ C‐20
C10.4 Air Intake Installation ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ C‐21
C10.4.1 Air Inlet ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ C‐21
C10.5 Exhaust Installation ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ C‐21
C10.5.1 Exhaust piping dimension recommendation ‐ ‐ ‐ ‐ ‐ ‐ ‐ C‐22
C10.5.2 Flexible Connections ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ C‐26
C10.6 Fire Precautions ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ C‐26
C10.7 Electrical Connection ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ C‐26
C10.7.1 Earthing/Grounding ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ C‐27
C10.7.2 Protection ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ C‐28
C10.7.3 Loading ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ C‐28
C10.7.4 Power Factor ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ C‐28
C10.8 Noise Control ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ C‐29
C10.9 Pre‐commissioning Checks ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ C‐29
C10.10 Prior to Starting ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ C‐30
C10.10.1 Warnings ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ C‐31
C10.10.2 Manual Mode (Non‐AMF) Operation ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ C‐32
C10.10.2.1 Starting the Genset ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ C‐32
C10.10.2.2 Stopping The Genset ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ C‐33
C10.11 AMF Operation ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ C‐33
C10.11.1 Activating AMF ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ C‐33
C10.12 Daily Checks ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ C‐34
C11. Battery ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ C‐35
C11.1 Battery Maintenance Schedule ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ C‐35
C11.1.1 Battery Tips ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ C‐37
C12. Optional Equipment ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ C‐38
C12.1 Battery Charger ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ C‐38
C12.2 Heater ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ C‐38
C12.2.1 Engine Heater Plug ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ C‐38
C12.2.2 Anti‐condensation Heater ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ C‐38
C12.3 Electronic Governor ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ C‐38
C13. Maintenance ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ C‐39
C13.1 Daily Maintenance ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ C‐39
C13.1.1 Maintenance every Six Months or 250 Hours ‐ ‐ ‐ ‐ ‐ ‐ ‐ C‐40
C13.1.2 Alternator Unit Cleaning ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ C‐40
C14. Control System‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ C‐40
C14.1 Control Panel ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ C‐41
ii
Diesel Genset
C14.1.1 AMF panel ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ C‐41
C14.1.2 Non‐AMF panel ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ C‐42
C15. KG EMS934 Controller ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ C‐42
C15.1 Technical Overview ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ C‐42
C15.2 Benefits ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ C‐42
C15.3 Physical Form ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ C‐43
C15.3.1 Front View ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ C‐43
C15.3.2 Rear View ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ C‐44
C15.4 Functions‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ C‐44
C15.4.1 System ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ C‐44
C15.4.2 Engine Monitoring ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ C‐45
C15.4.3 Generator Monitoring ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ C‐46
C15.4.4 System LED Indications ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ C‐46
C15.4.5 System LCD Displays ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ C‐46
C15.4.6 Engine LCD Displays ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ C‐47
C15.4.7 Genset LCD Displays ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ C‐47
C15.4.8 AC Inputs ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ C‐47
C15.4.9 Analog Inputs ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ C‐48
C15.4.10 Digital Inputs ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ C‐48
C15.4.11 Special Inputs ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ C‐48
C15.4.12 Outputs ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ C‐49
C15.4.13 Operation ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ C‐50
C15.4.14 Buttons ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ C‐50
C15.4.15 LED Lamps ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ C‐51
C15.5 Initial Power Up ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ C‐52
C15.6 Ready State ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ C‐52
C15.7 Mode Selection ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ C‐52
C15.8 Manual Mode Operation ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ C‐53
C15.8.1 To start the genset ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ C‐53
C15.8.2 To stop the genset ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ C‐54
C15.9 Display Operation ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ C‐54
C15.10 Alarms and Warnings‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ C‐58
C15.11 Alarms and Warnings‐Engine ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ C‐58
C15.12 Alarms and Warnings‐Alternator ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ C‐59
C15.13 Inputs Electrical Specification ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ C‐60
C15.14 Outputs Electrical Specification ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ C‐62
C15.15 Load Transfer and Contactor Operation ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ C‐62
C15.16 Speed Sensing ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ C‐62
C15.16.1 MPU ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ C‐63
C15.16.2 Generator ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ C‐63
C15.16.3 Battery Charging Alternator ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ C‐63
iii
Diesel Genset
C15.17 Battery Charging Alternator Excitation ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ C‐64

C15.18 Battery Voltage Monitoring and Charging Detection ‐ ‐ ‐ ‐ ‐ C‐65
C15.19 Unit General Specifications ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ C‐65
C15.20 Installation and Wiring‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ C‐67
C15.21 Trouble shooting ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ C‐69
C15.22 Error Messages ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ C‐74
C16. Circuit diagrams ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ C‐76
iv
Diesel Genset
Genset
C1. About KOEL
Incorporated in 1946, Kirloskar Oil Engines Limited (KOEL) is a part of the Kirloskar Group.
KOEL is one of the leading and largest manufacturer of diesel engines ranging from 4 HP to
800 HP and from 2,400 HP to 11,000 HP with the annual manufacturing volumes exceeding
3,20,000 engines.
Branded as 'Kirloskar,' KOEL engines are used as prime movers and are most preferred choice
when powering earthmoving and construction equipment, agro-industrial applications, material
handling equipment, marine applications and equipment used by the defense forces.
Today KOEL is one of the world's leading players in the Diesel Genset market and is committed
to offer best in its class products and services to all customers across the globe.
C1.1 State-of-the-art Manufacturing Setup
The engines are manufactured in a most eco-friendly environment in India at our Pune-Khadki,
Kolhapur- Kagal, Rajkot and Nashik Plants. The Kagal factory has both domestic and export
oriented unit.
The manufacturing plants are well equipped with most advance and high-tech machineries,
having state of the art, cutting edge technology for machining of all the critical components.
C1.2 Design and innovation
KOEL has an ultra modern Research and Engineering facility for Design, Development and up-
gradation of engines, systems, controls and canopy. A team of dedicated and experienced
professionals carry out the proactive cutting edge research to develop innovations that
delight customers in India and abroad to give KOEL the edge over competition.
C1.3 Kirloskar Green Power Facts
•Fully integrated Gensets and Power systems to meet current as well as future needs of
customers.
•Market leader with full range from 5 kVA to 625 kVA.
•Every 2nd Gen-set in the country is a Kirloskar Green Genset.
C-1
-
Diesel Genset
•Over 75,000 Gensets all over the country help to run the Indian Telecom Network.
•More than 15,000 Gensets deployed along the Indian Borders providing reliable power to the
Defence forces.
•More than 100 special containerized Genset packages, supplied for critical Defence
applications.
•Large number of satisfied customers from Manufacturing, Software, Construction,
Infrastructure sector in 320 kVA to 625 kVA range.
C1.4 Awards and Accolades
•KOEL pursues highest quality adherence for zero defect

•Rated “Most Preferred Brand” and “Customer Service Support Leadership” by Frost &
Sullivan.
•Winner of the Rated Best in Class in service by AC Nielsen.
•ISO 9001 certification for Quality Management System since 1992 by ABS QE Inc.
•ISO/TS 16949:2002 for Quality Management System since 2007 by ABS QE Inc.
•ISO 14001 certification for Environment Management System since 1999 by TUV NORD.
•OHSAS 18000:2007 certificate for Health, Safety 6k Environment since 2009 by TUV NORD.
C1.5 Note
•The information provided for this manual is subject to change without notice as we
continuously endeavor to offer the best products to our customers.
•Ensure that the use lube oil, filter filler, coolant, carbon sludge is not thrown away in open
land, gutters and landfills. This could lead to contamination of soil, rivers, streams and ground
water supplies.
•Ensure complete adherence of the local legislation rules of pollution control, electrical
installation, safety, fire hazard, waste treatment and waste disposal.
C2. Safety
KOEL encourages safety as a corporate philosophy.
•It is important that every individual of the team engaged in installation and subsequent
operation is thoroughly aware of the entire process and appreciates the criticality of each
action.
•Ensure that the tools and tackles used are of adequate capacity and are in proper working
conditions.
•Strictly follow all universal and local safety norms.
•Always remember that there are no short cuts in safety.
C-2
Diesel Genset
C3. Ratings Plate

The genset’s model and serial number are stamped on nameplate along with engine rating,
electrical ratings, and referred standards. The name plate details must be given while ordering
spares and asking for service. KOEL gensets are built by the company themselves as well as
by Genset Original Equipment Manufacturers (GOEMs), who produce under license from the
company. The gensets from KOEL or GOEMs carry different ratings plates to identify the
source of manufacture.
Manufactured by
Khadki, Pune 411 003 I www.kirloskar.com
GENSET MODEL
PRODUCT CODE
MFG. DATE/SR. NO.
NOISE LIMIT
TYPE APPROVAL
CERTIFICATE NO.
THIS PRODUCT CONFORMS TO THE
ENVIRONMENT (PROTECTION) RULES 1986.
Figure C - 1: Ratings Plate - KOEL manufacture
Manufactured by
XYZ COMPANY LTD.
XYXYXY Road, Pune 411 003. INDIA.
www.xyz.com
GENSET MODEL
PRODUCT CODE
MFG. DATE/SR. NO.
NOISE LIMIT
TYPE APPROVAL
CERTIFICATE NO.
THIS PRODUCT CONFORMS TO THE
ENVIRONMENT (PROTECTION) RULES 1986.
Under License from
Khadki, Pune 411 003 I www.kirloskar.com
Figure C - 2: Ratings Plate - GOEM manufacture
C4. Lifting the genset

The genset is a heavy object that demands great care while lifting and transporting.
C-3
Diesel Genset
•Only trained and qualified personnel should lift the genset.

•All personnel should wear personal protective gear such as safety shoes, helmets etc.
•All equipment used for lifting should be rated for handling the weight of the genset.
•Attach the sling hooks of lifting crane etc. only in the lifting eyes (holes) provided on the base.
•Attaching hooks anywhere else could permanently damage the genset.
Figure C - 3: Unloading the genset
Figure C - 4: Location and use of lifting eyes

•Use spreaders to move straps away from the body of the genset.
C-4
Diesel Genset
•The width of spreader must be greater than the genset’s width.

•Do note use chains or wire rope.
•Use slings of soft material like Nylon rope / flexible belt to avoid damage to the genset.
Figure C - 5: Use of flexible belt for lifting
Ȁ !" #$%&'(!"($)%$*+"%&,-(!
.%/"'!"&00&*+!1"'2"!*1"# !03
:0/ ";!9'!0"60!7!*%
Ȁ !" $*<&01"9/7!9!*%"
($)%$*+" /)"($)%$*+" %0&6
%0&6
80/7$1!" #$%&'(!"
0#''!0"6&1 "
%/"60!7!*%"1&9&+!"
%/",&*/62
Ȁ !"4/(! 5($)%$*+"!2!"60/7$1!1"
/*"%4!"'& !"6(&%!")/0"($)%$*+
Figure C - 6: Lifting the genset
C5. Moving the Genset
C-5
Diesel Genset
Figure C - 7: Use of lifting tackle and crane

Moving the genset to its installation location requires extreme vigilance and care.
•Only trained and qualified personnel should lift the genset.

•All personnel should wear personal protective gear such as gloves, safety shoes, helmets
etc.
•All equipment used for lifting genset should be rated for handling the weight of the genset.
• Attach the sling hooks of lifting crane etc. only in the lifting eyes (holes) provided on the
base.Use correctly rated equipment for lifting the genset.
•Use specially designed tackles with spreaders to lift genset.
•Use flexible belt to prevent damage to genset.
•Travel at a slow speed while transporting the genset,
•Ensure that the genset does not sway while moving, if required, stabilize with extra belts held
by personnel.
•Personnel should stand at the corners of genset to ensure that the moving object does not
foul any structure.
•Ensure that the moving genset does not touch any personnel.
•Ensure no personnel puts their body appendages (hands, feet) below a suspended genset at
low height or walk below a suspended genset at a higher height.
C-6
Diesel Genset
C6. Technical Data
C6.1 Gensets with Acoustic Canopy
C6.1.1 Air Cooled Gensets
Table 1: Air Cooled Gensets*
Rated Maximum Representative

Genset Engine recommended Dimensions Approx.
output at
Model Model Genset rating at [Length x Width x Weight
1500 rpm
0.8 pf Height]
(bhp) Continuous (mm) (kg)
KG1-15AS HA294 20.5 15 1772 X1185 X1818 894
KG1-25AS HA394TCI 32 25 2132 X1185 X1951 960
KG1-40AS HA494TCI 56 40 2400 X1050 X 2150 1290
KG1-62.5AS HA694TCI 83 62.5 3176 X1328 X 2061 1710
* = All ratings at Normal Temperature and Pressure (NTP) conditions.
C7. Genset with Air-cooled Engine
C7.1 Introduction
KOEL genset is carefully designed to provide optimum performance and reliability with great
economy and minimum maintenance. This genset package is a result of over 55 years of
actual site experience to deliver a comprehensive system built with advanced engineering
concepts and backed by an efficient service network.
Please read this manual to understand operation and maintenance of the genset. By following
instructions in the manual and proper care, the genset will be always ready to respond to any
emergency standby or prime power needs.
C7.2 Description Of Genset Package
Gensets consist of an alternator driven by a diesel engine. The engine has systems such as
fuel, exhaust, cooling, electrical and control. These topics are covered in detail elsewhere in
this manual.
The engine has a governor that maintains the engine speed within a set tolerance to deliver
rated power and frequency as per ISO 3046, DIN 6271 AND BS 5514. The alternator produces
output with correct voltage, optimum wave form, fast response and precise voltage regulation.
C7.3 Canopy
KOEL gensets are housed in a canopy. Use of canopy has the following advantages:
C-7
Diesel Genset
•Reduces the noise produced by genset during operation.

•Allows installation of genset outdoors without needing a shade.
•Protects the genset from weather and vermin.
•Prevents pilferage of fuel etc.
•Creates a comprehensive ‘ready to use’ package that can be easily transported to another
location.
C8. Engine
The engine of the genset has proven reliability and is specifically designed to operate in
conjunction with an alternator. The heavy duty engine is a 4-stroke, compression ignition prime
mover fitted with all accessories necessary for reliable operation.
C8.1 Cooling System
KOEL offers gensets with air cooled as well as liquid cooled engines. This manual covers only
air cooled engines. Liquid cooled engines are covered under an independent manual.
C8.1.1 Air Cooled Engine
The engine is cooled by a high capacity cooling air blower mounted on engine and driven by v-
belts off the crankshaft. The blower forces air over cylinder liners and cylinder heads to cool
engine temperature for best performance. Hot air leaving engine is routed away using air guide
ducts. For enclosed gensets, ventilation is ensured by using special fans that remove radiated
heat from engine and alternator while avoiding hot air recirculation.
All engines applications require careful attention to air flow for ensuring best performance. The
notes provided in the Installation Section of this manual offer guidelines for selecting a location
for your genset. Consult KOEL Helpdesk for optimum genset site plan and layout for your
application.
C8.2 Engine Governor
The primary function of the governor system is to maintain engine speed in relation to varied
load requirements. This is accomplished by the governor which senses engine speed and
controls the engine fuel rate, in order to maintain practically constant speed. The engine speed
governor maintains engine speed within limits regardless of the steady load. As the alternator
load increases, the engine speed is reduced.
Because the speed must remain relatively constant, the governor, sensing engine speed, will
increase fuel flow to the engine, thus adjusting horsepower to a point sufficient to maintain
engine speed and compensate for the load change. The same principle is applied when the
load decreases. As the load is reduced the speed would increase, the governor will then
reduce fuel delivery thus decreasing the horsepower to maintain the proper speed.
C-8
Diesel Genset
C8.3 Brushless Alternator
The alternator is coupled to the engine with a flexible coupling.

Brushless excitation type alternator eliminates the maintenance associated with slip rings and
brushes. The internal components of the alternator are designed so as to assure efficient and
economical operation.
The control system consists of an automatic voltage regulator (within the alternator), protective
circuits and the necessary instruments to allow you to monitor the operation of genset. On most
models current is supplied through twelve leads enabling the operator to reconnect the genset
to obtain a variety of three phase voltages up to 480 volts. Single phase units supply current
through a two or three lead connection offering a variety of voltages from 120-250V. Units can
be supplied in 50 Hz outputs. See Alternator Section for further details of connections
available.
A brushless alternator is a synchronous rotating field type unit, which produces alternating
current. This alternator unit is completely self-contained and is designed and constructed to
provided trouble free operation, ease of maintenance and long service life.
C8.4 Vibration Isolation
All gensets are fitted with anti vibration mountings which are designed to reduce vibration being
transmitted from the rotating mass of the genset to the foundation on which the genset is
mounted. Vibration isolators are selected to suit the particular duty and are fitted between the
engine, alternator feet and the base frame. On some of the models the vibration isolators are
fitted between the base frame and the foundation depending on the system requirement.
C8.5 Fuel Tank and Base Frame
The design of the base frame incorporates removable fuel tank with a capacity of
approximately 8 hours operation. The tank is provided with fittings to facilitate either manual or
automatic filling. The base frame is manufactured from heavy gauge sheet steel and welded to
form a rigid assembly.
C-9
Diesel Genset
Figure C - 8: Tank Unit

The top surface of fuel tank has a ‘tank unit’ to interface with the engine. The tank unit contains
features such as fuel level gauge, fuel level sensor, fuel level switch, fuel line connection and
return line connection.
C8.6 Silencer and Exhaust System
Exhaust silencer is provided to reduce noise emission from the engine and designed to direct
exhaust gases to areas where they will not be objectionable.
On ‘stand alone’ open gensets, the exhaust silencer is generally placed outside the Genset
room, with suitable extension piping from engine. Stainless steel expansion bellow is provided
on the engine, to facilitate the exhaust piping. For generating sets with acoustic canopy,
residential type silencer is fitted inside or outside the canopy with flange fitting at the outlet to
enable discharge of exhaust gases at desired location, through extension piping, as required.
C8.7 Genset Circuit Breaker
To protect the alternator winding, a suitably rated moulded case circuit breaker or miniature
circuit breaker (depending on the genset model) is supplied mounted in a strong fabricated
steel enclosure.
Current transformers are fitted on each of the phases on the cabling to the circuit breaker
enclosure for current measurement. In some configurations the main circuit breaker may be
incorporated in the automatic transfer panel.
C-10
Diesel Genset
C8.8 System Protection
Control system provides protection of the engine against faults such as high temperature, low
oil pressure, over speed, low fuel level or other conditions. The system also prevents damage
to the cranking motor by automatically disengaging the motor after engine starts and deep
discharge of the starting battery by avoiding cranks if engine fails to start.
C8.9 Control Panel
All control panels are mounted in welded steel enclosures equipped with a sealed hinged door
for easy access and servicing. The control panel is available in several variations to suit the
requirement of the installation.
C8.10 Control Panel Power Supply
Engine instruments and the control panel are supplied from the battery fitted to the genset. This
battery also provides power for operation of the cranking motor to start the engine and for the
stop solenoid.
C8.11 Control Panel Mounting
The control panel and main circuit breaker are normally located on a separate stand that is
mounted on the base frame or canopy to ensure vibration free running. More complex control
systems have floor standing control panels. For a genset with acoustical canopy, the control
panel is fitted inside the enclosure. Suitable glass cover opening is provided on the enclosure
to view the instruments.
C9. Components of a Genset

The following drawings show the view of genset from blower side and starter motor side. The
engine shown in image of this manual are only for illustration. Your genset may have different
appearance.
C9.1 View from Blower side
Various components are visible in this view. Only components relevant to identification, genset
operation or maintenance are listed here. More details of other details are available in the
engine section.
C-11
Diesel Genset
Ȁ%
! Ȁ
$
Ȁ
' Ȁ&
ȀȀ
( Ȁ"
Ȁ# Ȁ'
% Ȁ!
&
Ȁ
&
%
Figure C - 9: View from Blower side

1.Base Frame
This is the frame on which the genset is mounted.
2.Lifting Eye
Use the four lifting eyes spaced around the base frame to lift the genset The holes in the eye
should be used to attach a suitably rated lifting hook of a crane.
3.Canopy
This is the sound and weather proofing cover fitted over the base frame. Vents in the canopy
permit the airflow through the interiors. Access sections of genset for operation and
maintenance through lockable doors on sides.
4.Fuel Tank
Located in the base frame, this tank stores diesel fuel for the engine.
5.Fuel Filling Spout
Fill diesel in the tank through this spout, accessible only after unlocking the left hand side door.
6.Diesel Engine
Prime mover that drives the alternator.
7.Alternator
Generates AC electrical power when rotated by the engine.
C-12
Diesel Genset
8.Anti-Vibration Mount
Four Anti-Vibration Mounts help isolate the engine and alternator vibrations from reaching the
canopy.
9.Control Panel
Contains switch gear, gauges, controls and engine termination.
10.Air Cleaner
Cleans air meant for combustion of dirt and air-borne particles.
11. Air Intake
Intake for cool air from atmosphere.
12.Exhaust Silencer
Reduces noise borne in the engine exhaust.
13.Exhaust Bellows
Flexible portion to match vibrating exhaust pipe with rigidly mounted silencer.
14.Lube Oil Filler
Used to fill lube oil in the engine sump.
15.Lube Oil Filter
Cleans lube oil as it circulates through the engine.
16.Lube Oil Drain
Used for conveniently drain the lube oil from the sump during maintenance.
17.Fuel Filters
Diesel passes through two fuel filters to trap different sizes of dirt particles.
18.Blower
Cools the engine by forcing air over fins on cylinder heads.
C-13
Diesel Genset
C9.2 View from Starter Motor side
Ȁ
""
%
"&
"(
"# "Ȁ
"
! &
'
'
"
&
Figure C - 10: View from Starter Motor side

Various components are visible in this view. Only components relevant to genset operation or
maintenance are listed here. More details of other details are available in the engine section.
Several items covered in the previous section are not listed here.
1.Base Frame
This is the frame on which the genset is mounted.
2.Lifting Eye
Use the four lifting eyes spaced around the base frame to lift the genset The holes in the eye
should be used to attach a suitably rated lifting hook of a crane.
3.Canopy
This is the sound and weather proofing cover fitted over the base frame. Vents in the canopy
permit the airflow through the interiors. Access sections of genset for operation and
maintenance through lockable doors on sides.
4.Fuel Tank
Located in the base frame, this tank stores diesel fuel for the engine.
5.Diesel Engine
Prime mover that drives the alternator.
C-14
Diesel Genset
6.Alternator
Generates AC electrical power when rotated by the engine.
7.Anti-Vibration Mount
Four Anti-Vibration Mounts help isolate the engine and alternator vibrations from reaching the
canopy.
8.Control Panel
Contains switch gear, gauges, controls and engine termination.
9.Air Cleaner
Cleans air meant for combustion of dirt and air-borne particles.
10. Air Intake
Intake for cool air from atmosphere.
11.Exhaust Silencer
Reduces noise borne in the engine exhaust.
12.Blower
Cools the engine by forcing air over fins on cylinder heads.
13.Battery
Provides DC electrical energy to start the engine and operate controls.
14.Starter Motor
Rotates the crankshaft to start the engine.
15.Charging Alternator
Generates current to charge the battery when engine is running.
C10. Installation
C10.1 Location
Selecting a location for the genset is very important part of any installation procedure. Locate
the genset in an area that will provide adequate ventilation and physical protection for the unit.
Place the genset to allow easy movement all around for maintenance and replenishment of fuel
etc. Ensure 1 to 2 meters space all around the genset.
C-15
Diesel Genset
Ȁ &
!" %
!%
#" !'!
$
Ȁ &
!" %
!%
#" !'
$ !
Ȁ &
!" %
!%
#" !'!
$
Figure C - 11: Space around a genset

In case two gensets are installed next to each other, ensure a minimum of 2 meters space in
between their sides. This is to ensure easy access even if doors of both gensets are open.
Ȁ !"#"$%
!&'&!(!
Figure C - 12: Space between two gensets

•Adequate fire fighting facilities suitable for diesel, oil and electrical fires should be available at
location.
•The location should be clean, dry and have good drainage capabilities.
C-16
Diesel Genset
•The space around the gensets should be adequate to undertake major overhaul or service
operations. In some cases it may be necessary to remove major components.
•The location must allow free ventilation of inlet air and exhaust.
•Ideally the genset should be in open air. In case genset is to be mounted in side the building,
ensure proper ventilation around the genset.
•Choose the direction of placement such that natural wind helps in air flow of the genset.
•Locate the genset as near as possible to the load.
•Place the genset at one end of the site in the direction of wind to avoid dust entry into the
genset.
•In case the site’s atmosphere contains extra suspended particles like at Cement or Textile
factories, stone quarry, the genset may be placed at some distance.
• For highly dusty sites refer to the supplier representative for recommendation.
•The site selection should be complete before the genset reaches to location.
•Ensure sufficient illumination at the installation site. The interiors of acoustic canopy should
be clearly visible without help of any extra lighting.
•Provide suitable, safe access to elevated items.
•Standard tool kit (not supplied with genset) should be available easily and quickly. It should be
protected from corrosion and stored in a dry place.
•If spares are supplied along with the equipment, they should be protected from corrosion and
stored in a dry place.
•While designing the layout, provision should be made for:
-Proper laying of cables.
-Free access to fuel lines and filters.
-Sufficient space in front of the breather vent.
-Space for draining of coolant and lub oil.
-Adequate oil storage space.
-Space for safe storage of spares.
C10.2 Foundation
The foundation provides a leveled platform to seat and seal the Genset.
•Supports 1.5 times of the total dead weight of the single genset and 2 times of the total dead
weight for multiple gensets.
•Support the dynamic load of genset while in running. For dynamic load of the genset, please
refer to manual or contact the supplier.
•Isolate the surrounding structures by absorbing the vibration of genset while running.
C-17
Diesel Genset
C10.2.1 Features of Foundations
•Provide a reinforced concrete foundation for the genset. Do not install acoustic canopy on
loose sand or clay.
•The foundation should have sufficient mass in proportion to the size of the genset to provide
the rigid support necessary for minimizing deflection and vibration.
•Before easing the genset on the foundation, ensure that no hard material such as stones or
steel objects remain on the mounting surface as this may damage fuel tank at the bottom.
•Design the foundation while considering safe load bearing capacity of soil.
•The length and breadth of foundation should be at least 150-300 mm more on each side than
length and breadth of the acoustic canopy.
•Ensure sufficient space for personnel to walk all around the foundation.
•Check the level of foundation diagonally as well as across length for even flatness.
•In case surface is rough, lay nitrile rubber strips, 15mm thick and equal to the width of the
base frame, under the genset, along the periphery of the base frame.
•It is recommended to raise foundation height about 150 to 200 mm above ground level, to
helps maintain cleanliness and avoid flooding.
•Ensure that concrete is completely set and cured before positioning the canopy.
•Consult a qualified structural engineer when seismic events are in consideration.
•The foundation may be located on soil, structural steel, building floors etc., provided the total
weight of the foundation and genset package does not exceed the allowable bearing load of
the support.
•Allowable bearing loads of structural steel can be obtained from Engineering Handbooks
while local building codes will provide the allowable bearing loads for different types of soil.
C-18
Diesel Genset
C10.2.2 Soil Load Bearing Capacity
Table 2: Soil Load Bearing Capacity
Nature of the load bearing material Safe bearing capacity kg/sq. meter
Hard rock granite 2,44,100-9.76.400
Medium rock shell 97,600- 1.46.400
Hard pan 78.100-97.600
Soft rock 48,800 58.600
Hard clay 39.000 - 48.800
Gravel and coarse sand 39.000 - 48.800
Loose, medium coarse and compact fine sand 29.300-39.000
Medium clay 19.500 39.000
Loose fine sand 9.750 - 39.500
Soft clay 9,750
C10.2.3 Calculation for Foundation Depth
1.5  W
Depth = --------------------------------------
2400  B  L
Where:
• Foundation Depth is in Meters

•W = Total wet weight of Genset in Kgs.
•2400 = Density of concrete (Kg/cubic meter)
•B= Foundation width in meters
•L= Foundation length in meters
C10.3 Cooling and Ventilation
In case of air-cooled engines, a v-belt driven blower draws in cool and fresh air from
atmosphere.
•The blower’s draft passes over fins on the cylinders and cylinder head to cool the engine.
•If the engine is fitted with an intercooler, part of the cool air from blower passes through the
intercooler to reduce temperature and increase density of turbo-charger’s output.
•The alternator has a shaft-mounted ventilation fan to circulate cool air through its interiors.
•The hot air is channeled out of the canopy through special ducts.to avoid recirculation.
•The exhaust should flow in the direction of cooling airflow.
C-19
Diesel Genset
Figure C - 13: Airflow through genset

•A temperature rise of 5-15 oC (9-27 oF) in the cooling air can be expected at full load.
•The radiated heat given off by the engine, generator and exhaust piping can result in a
temperature high enough to adversely affect operation and performance of the genset.
•Locate the genset in a room or area that will provide or allow sufficient ventilation to remove
this heat as well as radiated heat from the engine. If possible, provide exhaust fans to drive
hot air outside.
•If acoustic canopy is placed in an enclosed place, ensure that it is well ventilated and exhaust
gases are driven out of the enclosure.
•It may be necessary to add a flexible connection between the canopy and building ventilation
to ensure positively discharged of hot air from building. Consult KOEL for dimensions and
design of ventilation system of gensets fitted in buildings.
•For weather protection, louvers should be fitted to the intake and exhaust openings. These
can be either of the fixed or movable type.
•Manually operated movable louvers may be acceptable in some cases, but they are not
acceptable for automatic standby units.
•The cooling airflow should not be depended upon to open/close the louver vanes.
•Ensure that the exhaust releases in the direction of wind flow.
C10.3.1 Genset installed in a room
For basement installations, forced ventilation through air ducts is required. Contact supplier
representative for recommendation of values of air required and fan flows for various gensets
rated at 1500 rpm. Ensure the exhaust piping has lagging inside the room and silencer is fitted
outside the room.
C10.3.2 Ventilation check
Maximum allowed temperature rise above ambient in genset canopy air intake is 7°C.
C-20
Diesel Genset
•Measure the ambient air temperature outside the canopy in shade.

•Measure the temperature inside the canopy near air cleaner inlet of engine.
•Calculate temperature difference between canopy temperature and ambient i.e. delta T.
•It may be necessary to measure actual airflow using an anemometer.
C10.4 Air Intake Installation
C10.4.1 Air Inlet
•Engine inlet air must be clean, dry and as cool as possible. These conditions will drastically
effect both engine life and performance.
•Air temperature near air cleaner should not be more than 5°C above ambient. Sufficient
window openings are required to maintain air inlet temperature within the limit.
•Normally the inlet can be taken from the area surrounding the installation site. However, in
some cases the condition of the air surrounding the machine may warrant ducting the air from
outside or another room.
•When it does become necessary to duct air in, the air cleaner should remain mounted to the
engine as opposed to a remote mounting (such as on a roof or in another room). This will
eliminate the possibility of dirt leaking through the duct work upstream of the air cleaner.
C10.5 Exhaust Installation
The exhaust system is used to direct exhaust gases to non-confined areas and reduce the
noise to tolerable levels. When designing a system the main objective is to minimize back
pressure. Excessive back pressure in an exhaust system will create horsepower loss and
increase the engine operating temperature, and emissions.
•Exhaust pipe outside the canopy should be lagged with aluminum sheet cladding. Typical
thickness of lagging - 50mm.
•If exhaust pipe length is more than 7 meter, add additional flexible bellows.
• Higher back pressure in exhaust system than specified limit will lead to:
-Higher fuel consumption
-Poor performance
-Engine component failure due to higher exhaust temperature
-Reduced engine life
C-21
Diesel Genset
 
Figure C - 14: ERW and GI pipes

•Use of 'B class' MS ERW pipes or prefabricated stainless steel pipe and long bend elbows is
recommended for exhaust piping.
•Never use galvanized water pipes (GI pipes) for exhaust piping as they are heavy and costly.
C10.5.1 Exhaust piping dimension recommendation
•A maximum of 4 bends is acceptable in the exhaust pipe.

•Increase the pipe diameter by approximately 12.2 mm (0.5 inch) after every 5 meters length
above silencer.
•Curve the pipe. Do not use right angle bends.
C-22
Diesel Genset
Figure C - 15: Use Curved Pipe for Exhaust
Figure C - 16: Do not use Angle Pipe for Exhaust

•Provide a rain cap to avoid entry of rain water into the engine. Add a slope to the horizontal
run of the exhaust piping downwards, away from engine to the condensate trap. Silencer
should be installed with drain plug at bottom.
Figure C - 17: Raincap
C-23
Diesel Genset
•If the exhaust pipe cannot be bent at 90 degree, provide a rain cap over the pipe’s mouth, as
shown. In such case, the distance between exhaust pipe end, and the rain cap should be
higher than at least twice the diameter of the pipe.
Figure C - 18: Raincap on straight Exhaust Pipe

•Fit a loose grill over the end of the exhaust to prevent birds or small animals entering the pipe.
•For installations in the basement or inside a room, the exhaust piping should be directed
outside through the wall or the ceiling.
•For installations in populated areas, direct the exhaust above roof height of adjacent
buildings, as per statutory requirements.
•When bends are required in an exhaust system, always make the radius at least 150% of the
inside diameter of the pipe.
•As most exhaust system designs are governed by the physical characteristics of the building
or room in which they are located, it is of the utmost importance that the exhaust pipe be
routed in a path offering the least amount of turns or bends so not to increase back pressure
more than 50 mm of Mercury Column.
•Generating sets with acoustic canopy are provided with exhaust outlets having connecting
flanges. Exhaust gases from the outlet can be routed away to desired location.
•For up to 3 meter distance exhaust pipe size same as provided on the outlet can be used. For
longer lengths total exhaust system assessment should be done by competent person.
•In no case, exhaust back pressure should exceed 50 mm of Mercury Column when measured
at exhaust manifold of engine, at rated load.
•Be sure that all pipes are well supported and that springs or other dampers are used at points
of high vibration.
•Due to the heat radiation of the exhaust pipes it is recommended that all pipes be located at
least 250 mm from any combustible material.
•Wrapping the exhaust pipes with high temperature insulation or installing fitted insulated
sections will aid in preventing excessive heat radiation within the room.
C-24
Diesel Genset
•At points where the piping passes through a wall or roof, a metal thimble guard 300 mm in
diameter slightly larger than the pipe should be installed.
•Bevel the end of the pipe at a 30 - 45 degree angle. Should the pipe end be horizontal, bevel
the pipe from the top back to the bottom. This will not only reduce the noise levels at the outlet
but will also minimize entrance of precipitation on horizontal pipes.
2)'3.454/( "
&4)'6!4+/
+*"74/&
Ȁ ! "#$%"&'()'' "
*)+, "-+!!+, "
./& "0%"&'()'' "
.! "!+1
Figure C - 19: End of Exhaust Pipe

•The level or height at which the outlet is situated should be sufficient to prevent fumes and
odours from becoming an annoyance or potential hazard. Also, an exhaust pressure actuated
raincap is recommended for use on vertical outlet pipes.
•Any long horizontal or vertical piping should include water legs and drain traps at their lowest
points so that water does not reach either the silencer or the engine. It is also recommended
that a slight slope downward from the silencer to the water leg or rain trap be added to assure
the proper removal of water.
•By locating the silencer as close to the engine as possible you will be able to minimize the
noise level in the exhaust piping.
•Each genset installation should have it’s own exhaust system and should not be connected to
a system accommodating more than one genset as the possibility of exhaust gas and
condensation back-flow may cause permanent damage to an idle engine.
Health Warning
•Inhalation of exhaust fumes is potentially lethal.
•The correct installation of exhaust systems to prevent accumulation of exhaust gas cannot be
overemphasized.
•Additionally, prolonged exposure to engine exhaust noise can be damaging to hearing.
•A genset should never be operated without a fully installed exhaust system and all personnel
in close vicinity should wear ear protection.
C-25
Diesel Genset
C10.5.2 Flexible Connections
The exhaust piping should be connected via a flexible joint located on the engine exhaust
outlet.
This connection serves three purposes.
-It relieves some of the weight of the exhaust piping from the engine.
-It isolates the exhaust system from vibration.
-It allows for some movement of either the genset or exhaust system components.
Long piping runs should be divided into sections separated by additional flexible connections.
This will also compensate for the expansion and contraction of the piping itself due to
temperature change. Any insulation material used for a flexible connection should allow for the
expansion and contraction of the connections, due to temperature changes.
C10.6 Fire Precautions
Note the following points when designing a genset installation:

•The room should be designed so that there is an easy escape route for operating personnel in
the event of fire within the room.
•A recommended type of fire extinguisher or fire extinguishing system should be provided to
fight the fire.
•Personnel manning the genset should be trained in identifying and fighting various types of
fires.
•Gravity operated fire valves operated by fusible links, mounted above the engine, can be
installed in the fuel lines.
•The room should be kept clean and free from accumulated rubbish which can be a fire
hazard.
C10.7 Electrical Connection
Only fully qualified and experienced electrical technicians should be allowed to carry out
electrical installation work.
Warning: Never attempt to work on live wiring. Always stop the genset and open
the circuit breaker on the load cables before working on the alternator or it’s
connectors. Disable starting of engine while working on genset.
•All electrical work should be carried out in accordance with any applicable National, Local
Standards, Codes or Regulations.
•The electrical connection to the genset should be made with flexible cable to prevent the
transmission of vibration and possible damage to the alternator or circuit breaker terminals.
C-26
Diesel Genset
•If it is not convenient to use flexible cable throughout then a link box can be installed close to
the set with a flexible connection between it and the set.
•The cable may be laid in a duct or on cable tray. When bending cable reference must be
made to the recommended minimum bending radius. No rigid connection should be made
between the set and the cable support system, eg, cable tray.
•When single core cables are used the gland plates must be of non-ferrous material, eg,
aluminum, brass or a non- metallic material such as teflon.
•The cable must be suitable for the voltage being used and adequately sized to carry the rated
current with allowances made for ambient temperature, method of installation, proximity of
other cables, etc.
•All connections should be carefully checked for integrity. Phase rotation must be checked for
compatibility with the installation. This is vitally important when connection is made to an auto
transfer switch, or if the machine is to be paralleled.
C10.7.1 Earthing/Grounding
Earthing/Grounding should be done in accordance with applicable National, Local Code or

Regulation. These regulations vary and advice should be sought from the local supply utility to
comply with their requirements. The factory connects the frame of the alternator to the frame of
the genset therefore the complete mass of the genset is at the same potential. The connection
if required of the generator winding star point / neutral to earth is the responsibility of the
installation technicians.
Figure C - 20: Typical Earth Pit

•Any leakages in current will be earthed through the shortest route in the link.
•The size of the link used for the main earth connection should be adequate size as shown in
table.
Table 3: Recommended Size of Earthing Conductor
Genset Rating Recommended Earth Strip /Cable
5-82.5 kVA 8 SWG - Copper
C-27
Diesel Genset
Table 3: Recommended Size of Earthing Conductor (Continued)
Genset Rating Recommended Earth Strip /Cable
100-250 kVA 25x3mm CU / 25x6mm GI
320 - 500 kVA 50x6mm CU / 50x6mm GI 2 runs
625 - 750 kVA 50x6mm CU / 50x6mm GI 2 runs
•The generating set and all associated equipment must be earthed before the set is put into
operation.
•4 earth pits are required as per Indian electricity rule / local electricity regulations.
•2 earthing pits for genset / control panel body.
•2 earthing pits for neutral,
•Check the Resistance between 2 earth pits.
•Earthing in Rocks and Rocky area to done using grounding Transformers / Zig Zag
Transformers or Use soil conditioning agents - Marconite conductive aggregate and bentonite
moisture retaining clay on Earth electrode back fill.
•Each earth pit to be separated by five times of its depth.
•Earthing resistance must be less than 3 ohms.
C10.7.2 Protection
The cables connecting the genset with the distribution system should be protected by means of
a circuit breaker or fuses to disconnect the output in case of overload or short circuit.
C10.7.3 Loading
When planning the distribution system it is important to ensure that the genset has a balanced
load. Loading one phase excessively as compared to other two phases this will cause
overheating in the alternator windings, imbalance in the phase to phase voltage output and
possible damage to sensitive 3 phase equipment connected to the system. Ensure that no
phase current exceeds that of the current rating of the genset.
Reorganizing an electrical distribution system may be necessary if a genset is to be connected
to an existing installation.
C10.7.4 Power Factor
Determine the power factor (cos phi) of the connected loads while ordering the genset. Power
factors below 0.8 will overload the generator. The genset will provide its kilowatt rating and will
operate satisfactorily from 0.8 to unity power factor. Particular attention must be given to
installation with automatic or manual power factor correction equipment to ensure that a
leading power factor is not present under any conditions. This will lead to voltage instability on
the generator output and may result in damaging overvoltages.
C-28
Diesel Genset
C10.8 Noise Control
The genset is available with accessories and components that reduce noise emissions. These
include residential and super critical silencers, acoustic louvers, splitter vents, fan silencers
and acoustically treated canopies.
The requirements for each site vary enormously and for any critical installation KOEL
recommends a consultation with the dealer at an early stage. The information needed to select
acoustic equipment is:
•The model and capacity of genset

•The designed noise level at a fixed distance, normally 1m or 7m.
• Environmental conditions, ambient temperature etc.
•The location and overall site plan.
Noise emissions from diesel gensets (without acoustic treatment) are at sound pressure levels
of between 100 dB(A) and 110 dB (A) at 1m. Kirloskar Gensets with acoustic canopies have a
typical noise pressure level of 75 dB(A) or less (average) at a distance of 1 meter from the
canopy.
Intermediate levels of treatment will prove more economic and are often satisfactory depending
only on the nature and type of installation. Hospital Care Areas will require more attention than
the normal commercial / industrial installation.
C10.9 Pre-commissioning Checks
Pre - commissioning checks will be conducted by the supplier’s commissioning team.

•Before starting the DG set, ensure that it is positioned on a level surface so that proper liquid
levels can be obtained. This is especially important for mobile or vehicle mounted gensets.
•Ensure that the top of the canopy does not accumulate rain water. If the foundations are
absolutely flat, a 1o slope is built into the design of canopy to ensure drainage of water.
•Hardware:
-Open the doors of the genset on both sides and check the tightness of all the fixing
hardware of the various systems.
-Tighten, if found loose.
-Check all hardware on engine- alternator coupling, mountings, fan and radiator mounting.
•Hose check:
-Check proper fitting of Fuel hose. Air hose and Exhaust hose.
•Bellow alignment:
-Check correct alignment of the expansion joint or bellow on the exhaust line.
•Leakage:
-Check for damage on the canopy and for openings on canopy roof which might lead to
water and sound leakage.
C-29
Diesel Genset
-Repair the damages (if any) and close the openings.

•Power cables:
-Check the proper termination power cables are terminated properly and are without
damage.
•Control cables:
-Check that the control cables are terminated properly and are without damage.
•Lube Oil level:
-Check that the lube oil is filled up to marked level.
•Coolant level check (for liquid-cooled engines):
-For filling coolant do not step on or climb on engine its components.
-A ladder is provided for the easy accessibility of radiator cap for filling the coolant.
-Ensure proper coolant level in the compensation tank.
•Battery:
-Ensure that the battery used is of correct rating and is connected with the right polarity.
•Cable routing:
-Check whether the power and the control cables are properly routed and secured with
cable ties.
•Cleanliness:
-Ensure that the inside and outside of the genset is dry and clean.
-Remove stains with diesel oil and clean up any oil spillage mark on the floor of the
canopy.
-Ensure that no debris is left inside the canopy which could clog moving parts or become a
fire hazard.
C10.10 Prior to Starting
•Study and familiarize the aspects of genset.

•Get trained by the seller or authorized service dealer before starting the generator.
•Maintain a log book to record all electrical and mechanical parameters with starts and stop
timing.
•Carefully follow all the instructions mentioned in the Pre-commissioning checks.
•Check the Lube oil level, Coolant level and Fuel level. Top up if necessary.
•Check that the restriction indicator of the air cleaner is in the healthy zone.
•Ensure that the load change over switch or the breaker is in off position.
C-30
Diesel Genset
C10.10.1 Warnings
•Please read, understand and comply with the following warnings to avoid fire hazard and
damage to the genset.
•Prolonged inhalation of exhaust fumes may result in serious illness or death.
•Prolonged exposure to the noise levels of a diesel engine can impair hearing unless proper
ear protection is worn.Check levels of engine oil, radiator coolant, battery electrolyte and fuel.
Top up as necessary.
•Ensure that the Genset is operated in a well ventilated area with all exhaust fumes piped
away.
•In case the controller fails to start the engine, investigate the reasons before trying to restart.
Checks during commissioning.
•Always shut the genset prior to connecting, or disconnecting, load cables. Only restart after
proper connections has been made.
•If at any time the generator stops because of a fault, the fault should be rectified before trying
to restart the generator.
•Before connecting batteries, ensure control panel is switched off.
•Before starting the genset, ensure that engine and alternator are earthed correctly.
•Adhere to the local and national regulations for the grounding of gensets.
•Confirm following of regulations that describe methods of connection and minimum sizes of
grounding conductors based on the size of the load cables.
•Adequate grounding of the genset is necessary for both stationary and wheel mounted units
to prevent the possibility of injury or death in the event of electrical fault.
•Do not smoke or use naked flame in vicinity when filling the fuel tank.
•Fill the fuel tank only when Genset is switched off and the engine is cold.
•Spilled or vaporized fuel ignites easily.
•Do not connect or disconnect load connection or perform maintenance while the Genset is in
operation.
•To avoid an accidental start of the engine, always disconnect the battery when performing
major operations.
•As the battery system is negative earth, disconnect negative connection first and reconnect
negative connection last.
•The door of the control panel and alternator connections should not be removed while the
genset is in operation. The cover, when removed, exposes live electrical connections.
•Maintenance on the control panel should only be carried out by a trained and qualified
personnel.
C-31
Diesel Genset
•Always shut down the genset and switch off circuit breaker prior to connecting, or
disconnecting load cables. Restart only after making firm connections.
C10.10.2 Manual Mode (Non-AMF) Operation
C10.10.2.1 Starting the Genset
•In this mode, the user starts and stops the engine. The user also transfers the load from
mains to genset and back, as required.
•Before starting, ensure load is disconnected from genset. Ensure people and material/tools
are clear of the engine.
•Check if Manual Mode is selected on the EMS 934 controller by the lit state of lamp on the top
left of the MAN button. If not, operate MAN button once and verify the lighting of the lamp.
MAN
•To start the engine operate the Manual Start button once.
I
•The controller will initiate cranking to start the engine. If the engine fails to start, the controller
will try again. If the engine does not start despite several attempts, the controller indicates a
Start Failure condition and inhibit further cranking. See Controller section for more details.
•After engine starts:
-Check for any leakages.
-Allow engine to idle for 3 minutes and then start connecting load in steps.
-Check engine parameters like Oil pressure, coolant temperature and battery changing
rate at regular intervals, while the genset is in operation.
-Maintain log book.
-Check for exhaust smoke.
-Check for any abnormal sounds.
-Check for alternator parameters, like voltage, ampere, kW and Power Factor on all
phases.
-During commissioning, cross check the meter readings with a calibrated multimeter or
clamp - on meter.
-Ensure that the load is balanced in all phases and within rated output of the genset.
-Check that all engine and alternator parameters on the controller are working.
C-32
Diesel Genset
C10.10.2.2 Stopping The Genset
•Disconnect the load from the genset.
0
•Operate the Stop Button once. STOP
•The controller will keep the engine running for several seconds due to a Cool down timer for
ventilating the engine and alternator.
•After engine stops, check for any leakages.
•Top up fuel tank.
•Close the canopy securely.
•Switch off the Control Panel.
C10.11 AMF Operation
•Unlike Manual Mode operation, AMF (Automatic Mains Failure) panel is active all the time.
•If mains supply is in limits, the panel connects that feeder to load through mains contactors.
•If mains supply is out of limits (or failed), the AMF panel deselect the mains supply and starts
the genset.
•Once the genset is running, the AMF panel connects the load to alternator through the genset
contactors.
•While the genset feeds the load, the AMF panel monitors mains supply for a return back to
normalcy.
•Once the mains supply restores, the genset transfers load back to mains feeder and shuts the
genset after elapsing of cool down timing.
•AMF panel also monitors engine safety parameters for genset.
C10.11.1 Activating AMF
•Before activating, ensure people and material/tools are clear of the engine. Ensure that no
mishap could occur once the load is charged from either mains or genset supplies.
•Check if Auto Mode is selected on the EMS 934 controller by the lit state of lamp on the top
left of the AUTO button. If not, operate AUTO button once and verify the lighting of the lamp.
AUTO
AUTO
C-33
Diesel Genset
•Now the controller will automatically decide the operation of engine and selection of supply
(mains or genset).
•Switch on panel and all circuit breakers. Ensure that the load is connected to mains supply.
•Switch off mains supply, the controller will start the engine and transfer load to genset supply.
•While engine is running, check engine parameters like Oil pressure, coolant temperature and
battery changing rate at regular intervals.
•Maintain log book.
•Check for exhaust smoke.
•Check for any abnormal sounds.
•Check for alternator parameters, like voltage, ampere, kW and Power Factor on all phases.
•During commissioning, cross check the meter readings with a calibrated multimeter or clamp
- on meter.
•Ensure that the load is balanced in all phases and within rated output of the genset.
•Check that all engine and alternator parameters indications on the controller are working.
•Reconnect mains supply, the controller will transfer load back to mains supply and stop
engine after a cool time timer delay.
•Ensure battery charger inside panel working when load is on mains by observing rising
battery terminal voltage.
•At any time of genset operation operate STOP button to stop the engine including the delay of
0
cool down time. STOP
•In case genset is to be stopped immediately, use the Emergency Stop switch on the panel
and canopy. This is not recommended unless there is a situation that demands the engine to
stop immediately.
C10.12 Daily Checks
Perform these checks daily before starting. If the genset runs infrequently except for standby
duties, these checks may be performed at a weekly interval.
•Visually check entire genset. Watch for potential leaks of fuel, coolant and lubrication oil.
seals.
•Check the alternator for obstructions in the cooling air ventilation screens.
•Check the alternator and control box for accumulation of dirt and dust.
•Clean any dirt/dust accumulations to avoid electrical hazard and cooling problems.
•Check the air cleaner. Clean or replace if necessary.
C-34
Diesel Genset
•Check the fuel level.

•Check the engine coolant level.
•Check the engine oil level.
•Ensure no obstruction to the radiator/cooling air flow.
•Check the condition of the fan, alternator belts and their tension.
•Check hose condition and connections.
•Check battery terminals for corrosion.
•Check the battery electrolyte level, top-up with distilled water if necessary.
•Refer to the engine maintenance section for specific engine maintenance requirements.
•Replace and secure all parts removed for inspection and maintenance before starting the
genset.
•Drain condensate traps in the exhaust system, if fitted.
•Check for exhaust leaks.
•Check for any abnormal noise or vibration.
•Check for fluid leakage or high temperature.
•Dispose of any unnecessary items in the vicinity of genset that may inhibit operation or
represent cause of potential injury.
•Check the control panel for readings within set limits.
C11. Battery
Resistance in starting circuit has a significant effect on the cranking of the engine. Locate the
batteries as close as possible to the genset.
The batteries should be accessible for easy servicing. Maintenance procedures should be
carried out rigorously since the batteries have to be in perfect condition to start the diesel
engine.
Note: Batteries emit inflammable gas. Do not smoke or create sparks or naked flames adjacent
to batteries.
C11.1 Battery Maintenance Schedule
Table 4: Battery Maintenance Schedule
Checking
No. Description Result
Frequency
1. Check battery electrolyte level after Monthly Electrolyte level to match MAX line on
removing the vent caps battery. Don’t cross over MAX line
C-35
Diesel Genset
Table 4: Battery Maintenance Schedule (Continued)
2. In case of low level, top up the same As & when Top up the level up to MAX by DM
with Battery Grade DM Water only ( found Water only
Don’t use Acid )
3. Keep battery terminals sufficient tight Monthly Clean & Dust / corrosion free terminal
& clean & Dry joints
4. Don’t hammer on terminals while As required Terminals should be gently tighten

fitment with clamps
5 Always ensure the vent plugs are Monthly Vent holes on plugs are clean & vent
Clean & hold tightly on battery top plugs are always in intact position on
cover battery top
6. Clean the battery top cover by wet Monthly Clean & dust free battery top
cloth& Dry it with dry cloth
7. Avoid any physical short circuit As required No short circuit / Accident hazards
between the battery terminals while
checking / Maintaining the batteries
8. Ensure proper fitment of battery in Monthly Battery fit properly in battery box /
cradle cradle
9. Don’t use the battery for other than Every day Good battery life
Engine cranking
11. In case of DG Set remains Idle ( As required Good battery life

without operation ) for more than 3
weeks, please ensure followings :-
• Remove Negative cable of
battery.
• Ensure battery in adequate
charged condition before
removal.
• In case of low charge, remove
battery and use external charger
to raise charge to correct level.
12. In case of any battery problem, report As required Fast decision on battery claim & less
immediately to KOEL Service resolution time
Department
C-36
Diesel Genset
C11.1.1 Battery Tips
Follow the tips to get the maximum life from your battery.
•The top of the battery must be kept clean and dry.

•Vaseline should be applied to cable clamps and terminals, Never apply
grease.
•Terminal corrosion dirt and moisture cause loss of power and make the battery weak.
•Battery open circuit voltage checked regularly and recorded in the service record.
•A faulty electrical system will damage the battery.
•The charging voltage setting measured across the battery terminals shall be maintained at
14.00+ 0.20 volts for 12V System and 28.0 V + 0.4 Volts for 24Vsystem.
•The recommended Specific Gravity of a fully charged battery is 1.270+ 0.005 at 27 oC. Take
immediate corrective action if case of any deviation.
•Electrolyte level must always be maintained in line with the bottom of the vent hole In case of
any drop in the electrolyte level, add pure distilled water. NEVER ADD ACID!
•. Keep battery away from places near fire as hydrogen gas generated from the battery may
cause fire and explosion.
•Shorting the battery terminals with a wire etc. will lead to fire and explosion.
•To prevent potential of harm, keep battery away from the reach of children and personnel who
do not have knowledge of battery.
•Wear the protection goggle and hand gloves while I handling the battery, since battery water
may cause blindness and severe burns.
•Do not add excess distilled water above the barrel level. Excess flow may cause damage and
burns.
•Do not drop and shake the battery, as it may cause injuries/damages.
•Care should be taken while handling the battery, as sulphuric acid may cause blindness and
severe burns.
•If battery water gets in the eyes, flush eyes thoroughly with clean water and seek medical
attention.
•When battery water gets in mouth, rinse immediately with plenty of water and seek medical
attention.
•When battery water gets into contact with skin, wash thoroughly with soap and water and
seek medical attention.
•IT IS STRONGLY RECOMMENDED TO NOT USE BATTERY ADDITIVES OR DOPES.
•Social Responsibility and Govt of India Notification:
-Lead acid batteries contain Lead and Sulphuric Acid, which are highly toxic and extremely
hazardous to health and environment
C-37
Diesel Genset
-Lead poisoning affects the Central Nervous System, causing irreversible retardation and
subsequent death.
-As per the notification of the Govt of India, "It shall be the responsibility of the consumer to
ensure that used batteries are not disposed off in any manner other than depositing with
the dealer, manufacturer or at the designated collection centers”.
-It is mandatory for our authorized dealers to accept a used battery and provide
corresponding rebate on purchase of a new battery
•Please note that violations of these guidelines may lead to legal action and prosecution by
Government Authorities
C12. Optional Equipment
C12.1 Battery Charger
A mains powered battery charger is recommended for gensets meant for Non-AMF standby
duty. This is especially important if the genset does not run often. The battery charger will
ensure that the battery is kept in the peak condition for quickly starting the genset when
required. The battery charger has automatic charge control, thus avoiding overcharging of the
battery.
In case of AMF genset, a mains powered battery charger is usually built in the panel.
C12.2 Heater
C12.2.1 Engine Heater Plug
To ease cold weather starting, a 12 VDC heater plug is fitted to the inlet manifold. This heater
plug is energized for a preset interval before cranking the engine. The passage of electrical
current through the heater plug heats the device and the air inside the inlet manifold. The 12
VDC supply to the heater plug should be switched off during cranking to ensure maximum
battery capacity for the starter motor. Ensure that the heater plug is not energized when the
engine is running.
C12.2.2 Anti-condensation Heater
Alternators are offered with heaters to prevent condensation, These heaters are fitted to the
alternator stator winding. These operate at a relatively low temperature and do not require a
thermostat. These heaters should be switched off when the genset is running. An external AC
power supply is required to power these heaters.
C12.3 Electronic Governor
Genset engines are available with Electronic Governors to closely regulate engine speeds and
therefore output frequency. Electronic Governor is recommended for gensets powering critical
loads and also when two or more gensets are required to run in synchronisation.
C-38
Diesel Genset
C13. Maintenance
A good maintenance programme is essential for long genset life. Please find a program that
should keep your machine in top running condition. Also included in this programme are
routine maintenance operations required for the engine and alternator (see Engine
Maintenance and Alternator Maintenance Sections).
It is good practice to have all of the maintenance and service operations performed by trained
personnel familiar with genset maintenance. This, along with a good service records system,
should aid in developing an efficient maintenance program. The service records of each genset
should include information such as complete nameplate data with model and serial numbers,
all drawing and wiring diagrams, spare parts stock lists, as well as a service schedule and a
copy of this manual. These records will allow quick reference and may help to diagnose a
problem in the future.
C13.1 Daily Maintenance
Perform this maintenance before every start up. If the genset is used for standby applications
with little running, these procedures may be required after longer periods like every weekly.
to weekly.
•Make a visual check of the entire genset. Watch for signs of potential leaks from the engine
fuel system, cooling system or lubrication seals.
•Check the alternator for obstructions in the cooling air ventilation screens.
•Check the alternator and control box for heavy accumulation of dust and dirt. Clean any
heavy accumulations as electrical hazards, as well as cooling problems could arise.
•Check the air cleaner. Clean or replace if necessary.
•Check the fuel level.
•Check the engine coolant level (in case of liquid cooled engines).
•Be sure that the radiator air flow or blower air flow is not obstructed.
•Check the condition of the blower, fan and alternator belts and their tension.
•Check all hose connections and hose conditions.
•Check the engine oil level.Maintain the level at ‘H’ mark, top up if level is low.
•Check the battery terminals for corrosion.
•Check the battery electrolyte level and fill with distilled water if necessary.
•Ensure cleanliness around genset. Dispose of any unnecessary items in the vicinity of the
genset that may inhibit operation or represent cause of potential injury.
•Refer to the engine maintenance section for specific engine maintenance requirements.
•Start the genset after all checks have been made.
•Drain condensate traps in the exhaust system, if so equipped, and check for exhaust leaks.
•Check for any abnormal noise or vibration.
•Check for leakage of air, fuel, oil or coolant.
C-39
Diesel Genset
•Check the control panel for indications of abnormal operation.
C13.1.1 Maintenance every Six Months or 250 Hours
•Repeat the daily maintenance checks.

•Check all safety devices by electrically simulating a fault to ensure that all systems will
function properly in the event of a fault.
•Clean all battery cap vents.
•Start the genset and observe the readings for all parameters are within limits.
•Tighten all exhaust connections.
•Tighten all electrical connections.
•Check and adjust belt tension of Blower assembly. Replace belt if not in good condition.
•Do external cleaning of Charge Air Cooler fins and coiling.
•Refer to the engine maintenance section, for further details.
C13.1.2 Alternator Unit Cleaning
The alternator unit should be cleaned inside and out on a regular basis. The frequency of such
cleaning depends on the environmental conditions of the operating site. The following
procedure should be applied when cleaning is necessary:-
•Disconnect all power.
•Wipe dust, oil, water or any other liquids from the external surfaces of the alternator unit. All of
these materials can work their way into the windings and may cause overheating or insulation
breakdown.
•Remove these same materials from the ventilation screens around the circumferences of the
unit. Do not permit such material to accumulate on these screens as this will obstruct air flow.
Such debris is best removed with a vacuum cleaner to avoid redepositing of these materials
on other parts of the equipment.
•DO NOT USE COMPRESSED AIR, STEAM OR A HIGH PRESSURE WATER CLEANER.
•Use a vacuum cleaner to clean the windings of the alternator unit. This will remove dust from
the coils that cannot be reached with a wiping cloth.
C14. Control System

Most diesel gensets work fully or partially without continuous human supervision. This
necessitates an electrical and electronic control system that ensures safe operation for the
genset all the time.
The Control System has several design objectives, some or all of which may be present on a
particular genset:
C-40
Diesel Genset
• Means of starting and stopping the Generator Set on user’s command.

•Detect various conditions like failure of mains or restoration of main for starting or stopping
genset automatically.
•Monitor and display engine and genset parameters.
•Compare engine and genset parameters against set levels to ensure operation within safe
limits.
•If the parameters deviate from the set levels, generate alarms to warn the operator.
•If the parameters exceed another set of levels, automatically trip (shut down) the genset to
protect the installation, load and personnel.
•Typical conditions for alarm and trip condition are low oil pressure, high coolant temperature,
over speed, under speed, low coolant level, low fuel level etc.
C14.1 Control Panel
The genset are provided with a control panel with the following typical components:
•Electronic unit that provide logic to control genset,

•Gauges for displaying engine and genset parameters.
•Termination for sensor wires from engine.
•Termination for solenoid and relay outputs to engine.
•Termination for alternator incoming supply.
•Termination for load.
•Fuses and circuit breakers
•Alternator Circuit Breaker for connecting the generator output to load and automatically
disconnecting the load in case of overload or short circuit.
•Mains and Genset contactors.
•Battery charger.
C14.1.1 AMF panel
Auto Mains Failure (AMF) panel contains electronic logic for automating genset operation
including transferring power from mains to genset and vice-versa without human intervention.
AMF logic performs the following functions:
•Senses mains supply parameters for operation within set parameters.

•If mains supply is acceptable, the AMF logic selects the mains contactor and the load is
charged from mains feeder.
•If the mains supply goes out of set parameter limits, the AMF logic deselects the mains
contactor and starts the genset.
C-41
Diesel Genset
•Once the genset is running and the parameters are within set limits, the AMF logic selects
genset contactor to charge load from genset feeder.
•AMF logic displays the engine and electrical parameters while the genset is running.
•The AMF logic monitors genset safety to ensure operation within limits
•The AMF logic also monitors mains feeder for a return back to normalcy.
•Once mains restores, the AMF logic deselects the genset contactor and selects the mains
contactor to charge load from mains feeder.
•The AMF logic shuts the genset down in the prescribed sequence and restarts the monitoring
of mains feeder for operation within safe limits.
•The AMF logic offer several timers that add delays necessary for correct operation.
C14.1.2 Non-AMF panel
Non-AMF panel provides basic genset safety and display functions. The task of starting,
stopping of genset as well as selecting between mains and genset feeder is done by the
operator.
C15. KG EMS934 Controller

This electronic controller provides all the logic for AMF and Non-AMF panels, for single phase
as well as three phase gensets.
C15.1 Technical Overview
The EMS934V0/V1 is an integrated Engine and AC controller for small gensets.

The unit incorporates both manually and autostart initiated start and stop sequencing, monitors
engine and alternator operating parameters and provides both engine and alternator
protection, in a single integrated package.
The genset operating parameters are shown by scrolling screens on a backlit 128 x 64 dot
Graphics LCD. Alarms and warning are also shown on the LCD and supplemented by an alarm
LED and Hooter output.
The unit provides comprehensive monitoring of the engine and generator operating parameters
and provides automatic shutdown of the genset in the event of damaging conditions. In
addition to the usual engine safety protections the unit monitors coolant level, fuel level,
canopy temperature and generator loading to provide even more comprehensive protection.
The unit incorporates a Stop Alarm Log (10 events) to give the field service engineer the
operational alarm history for easier diagnostics.
In the factory environment, the unit is configured by cloning through a PC system. Field specific
parameters can be adjusted by using the front panel buttons and an inbuilt menu system.
C15.2 Benefits
• Reduces system cost:
C-42
Diesel Genset
• Integrates engine gauges and AC metering into one unit.
• Minimizes control panel wiring offering reduced material and labour costs.
• Reduces warranty costs by providing comprehensive engine and generator protection and a
maintenance due timer.
• Flexible, as the unit can be customized by PC cloning with application codes for individual genset
model characteristics and fitment.
C15.3 Physical Form
C15.3.1 Front View
Figure C - 21: Front View of Controller
C-43
Diesel Genset
C15.3.2 Rear View
Figure C - 22: Rear View of Controller

NOTE : For J3 connectors read J3-1, J3-3 & J3-5
C15.4 Functions
C15.4.1 System
Table 5: System
Function Description
Protection Shutdown Automatic preventative engine and genset shutdown in the event of
abnormal operating conditions with optional configuration parameters
and clear LCD status messages
Manual Start In response to the front panel pushbutton performs a fully sequenced
engine start with optional configuration parameters and clear LCD
status messages
Manual Stop In response to the front panel pushbutton performs a fully sequenced
engine stop with optional configuration parameters and clear LCD
status messages
Auto Start In response to a digital input performs a fully sequenced engine start
with optional configuration parameters and clear LCD status
messages
C-44
Diesel Genset
Table 5: System (Continued)
Auto Stop In response to a digital input performs a fully sequenced engine cool
down then stop with optional configuration parameters and clear LCD
status messages
Emergency Stop In response to a digital input performs a fully sequenced engine stop
with optional configuration parameters and clear LCD status
messages.
C15.4.2 Engine Monitoring
Table 6: Engine Monitoring
Over / Under Speed Monitors engine speed with optional configuration parameters and
clear LCD status messages this ensures the engine speed remains
within configured limits. Exceeding these limits will result in automatic
engine shutdown to prevent damage.
Lubrication Oil Pressure Monitors engine oil pressure with optional configuration parameters
and clear LCD status messages this ensures the oil pressure
remains within configured limits. Exceeding these limits will result in
automatic engine shutdown to prevent damage.
Engine Temperature Monitors engine temperature with optional configuration parameters

and clear LCD status messages this ensures the engine temperature
remains within configured limits. Exceeding these limits will result in
automatic engine shutdown to prevent damage.
Battery Voltage Monitors engine battery voltage with optional configuration

parameters and clear LCD status messages this ensures the battery
voltage remains within configured limits.
Battery Charging Monitors engine battery charging status and clear LCD status
messages this ensures the battery is charged when the engine is
running.
Radiator Water Level Monitors engine radiator liquid minimum level with clear LCD status
messages this ensures the radiator liquid level remains sufficient.
Low liquid will result in automatic engine shutdown to prevent
damage.
Fuel Level Monitors engine fuel level with clear LCD status messages. Low fuel
level will result in automatic engine shutdown to prevent damage.
Canopy Temperature Monitors an engine canopy temperature switch with clear LCD status
messages. This function will result in automatic engine shutdown to
prevent damage.
Running Hours Records engine run hours with clear LCD status messages.
C-45
Diesel Genset
C15.4.3 Generator Monitoring
Table 7: Generator Monitoring
AC Phase Voltage Monitors Genset 1, 2 or 3 phases of AC voltage with optional

configuration parameters and clear LCD status messages.
AC Phase Current Monitors Genset 1, 2 or 3 phases of AC current with optional

configuration parameters and clear LCD status messages. Uses
externally fitted 5A CTs.
AC Phase Frequency Monitors Genset phase 1 of AC Frequency with optional

AC Phase Reversal Monitors Genset AC for Phase reversal with optional configuration
parameters and clear LCD status messages.
AC Loading Monitors AC load as a percentage of full load with optional

configuration parameters.
C15.4.4 System LED Indications
Table 8: System LED Indications
Alarm Red LED indication of system alarm.
C15.4.5 System LCD Displays
Table 9: System LCD Displays
Setup menu System configuration menus
Start Up Clear step-by-step start up sequencing messages
Shutdown Clear step-by-step shutdown sequencing messages
Transfer Clear step-by-step load transfer messages
C-46
Diesel Genset
C15.4.6 Engine LCD Displays
Table 10: Engine LCD Displays
Low oil pressure Engine oil pressure low
High engine Engine temperature high

temperature
Low coolant level Radiator liquid level low
Low fuel level Engine fuel level low
Battery Voltage Engine Battery Voltage and Droop voltage at last cranking cycle.
C15.4.7 Genset LCD Displays
Table 11: Genset LCD Displays
Phase Voltages Phase 1, 2 and 3 Voltages Line to Neutral and Line to Line.
Phase Currents Phase 1,2 and 3 Currents
Phase Frequencies Phase 1
AC Power Metering Monitors AC power output (KW, KVA, KVAR, PF. KWH) with optional
C15.4.8 AC Inputs
Table 12: AC Inputs
3 Phase Genset AC Genset AC voltages.

Voltage 0 - 300V AC RMS
3 Phase Genset Current Genset AC currents via external 5A CTs.

0 - 5 Amp input
C-47
Diesel Genset
C15.4.9 Analog Inputs
Table 13: Analog Inputs
Lubrication Oil Pressure Engine oil pressure sensor. (LOP).

Current limited excitation for resistance sensing.
Engine Temperature Engine coolant temperature sensor (Air or liquid).

Fuel Level Engine fuel level sensor.

Analog 1 Yet to be defined

C15.4.10 Digital Inputs
Table 14: Digital Inputs
Auto Start / Stop Input Auto start switch.
Emergency Stop Input Emergency stop switch.

Close to 0VDC to activate.
Oil Switch Input Oil pressure switch (LLOP)

Canopy Temperature Canopy temperature switch (HCT).

Digital Input 1 User defined Input. Default option = V Belt switch.

Digital Input 2 User defined input. Default = Not Used.

C15.4.11 Special Inputs
Table 15: Special Inputs
Battery Voltage Internal measurement of incoming DC supply.
Excitation Voltage Internal measurement of battery charging alternator excitation

voltage.
C-48
Diesel Genset
Table 15: Special Inputs (Continued)
Low Water Level Oscillating, AC coupled, Zero net current flow.
C15.4.12 Outputs
Table 16: Outputs
Excitation Output Battery charging alternator excitation control (WL)

Current controlled pulse
Fuel Output Fuel relay coil control.

Open drain 300mA overload protected
Crank Output Crank relay coil control.

Open drain 300 mA overload protected
Output 1 User Selectable options

Default = Contactor A
Preheat
Output 2 Fuel Pullin
Default = Contactor B Contactor A
Output 3 Contactor B
Default = Preheat Sounder
Start Warning
Output 4 Open drain 300mA overload protected
Default = Off
C-49
Diesel Genset
C15.4.13 Operation
For Front Layout - Refer to Figure on page C43.
C15.4.14 Buttons
Table 17: Buttons
Button Function Description
Manual Stop button / Menu Control
0
• Used to initiate generator manual stop sequence
• LED blinks during the stopping sequence
• Used as system menu previous menu
STOP • Used to select Off mode, when the engine is in standby
• Used to clear alarms when the Genset was stopped for an alarm
Manual mode button

• Used to select manual mode.
• Allows genset to be started only with start button press
• LED indicates manual mode is active
MAN
Auto mode button / Menu Control
• Used to select auto mode
AUTO
• Allows genset to be started only with Auto start input activation
• LED indicates auto mode is active
AUTO • Used as system menu next or value down button
Test mode button
T
• Used to select Test mode
• Allows the genset to be started manually without changing the
contactors
TEST • LED indicates test mode is active
Manual Start button / Menu Control
I •
•
Used to initiate generator manual start or test sequence
Used as system menu next and to accept value changes
C-50
Diesel Genset
Table 17: Buttons (Continued)
Button Function Description
Screen Scroll button / Menu Control

• Used to scroll LCD display to next screen
• Used to initiate menu system
Alarm Acknowledge / Menu Control

ALARM • Used to silence the sounder when the system is in alarm or has
an active warning. Self resetting if enabled
• LED indicates warnings and alarms.
ACK/RESET • Used as menu system previous and value up button
C15.4.15 LED Lamps
Table 18: LED Lamps
LED lamp Function Description
Alarm LED
• Indicates warnings and alarm
A LA RM • Warnings are indicated by 1 blink per second
• Alarms are indicated by 4 blinks per second
Low oil pressure LED (LOP)

• Indicates low oil pressure warnings and alarms
LOW OIL
PRESSUR E
• Warnings are indicated by 1 blink per second
• Alarm is on solid
High Engine Temperature LED

H IGH ENGINE
TEMPERATU RE • Warnings are indicated by 1 blink per second
Battery Charging LED

• Blinking indicates under voltage, over voltage and charge failure
BATTERY
C HAR GI NG
• On solid indicates no excitation while the engine is running
• Off indicates battery charging condition is OK
C-51
Diesel Genset
Table 18: LED Lamps (Continued)
LED lamp Function Description
Under / over speed LED

U ND ER /OVER
SPEED • Warnings are indicated by 2 blinks per second
Low Fuel Level LED

LOW FUEL
LEVEL
• Warning is indicated by 2 blinks per second
Genset Running LED

G ENSET • Indicates the genset is running.
R UN NIN G
• Blinks to indicate the genset is starting
C15.5 Initial Power Up
On power up, the unit displays the Kirloskar logo, and turns on LEDs for a lamp test.
The unit then displays the Serial number, Application Code and Firmware version.
After the initialization process is complete, the unit enters the mode selected in the setup menu
and changes to READY.
C15.6 Ready State
When the unit is in READY all measuring systems and display systems are turned on. The unit
remains on for 1 minute and if the genset is not started in that time the unit goes into sleep
mode to conserve battery power. In this mode the unit wakes periodically to check for any
unusual conditions and if it finds none it goes back to sleep, otherwise it alarms accordingly.
Any activity on the buttons immediately wakes the unit and the appropriate action is taken.
In this state the engine and generator parameters are as expected for a stationary genset. If
the conditions are not as expected, an appropriate warning or alarm is displayed on the LCD.
C15.7 Mode Selection
The unit may be operated in Auto, Manual, Test or Stop modes. The mode is selected by
pressing the appropriate mode button. The mode is indicated on the LCD and the LED
associated with the mode buttons.
•The engine can be stopped with the Stop button in MANUAL, AUTO or TEST modes.
•In MANUAL mode the unit responds only to the manual push button and may control A and B
contactors if these options have been enabled.
C-52
Diesel Genset
•In the AUTO mode, the unit responds to the autostart input or Remote Starts and controls A
and B contactors.
•In TEST mode the engine responds only to the manual start button and runs for a preset test
time if configured. Contactors are not controlled.
•In STOP mode the unit will enter low power mode, which turns off all LED's and sensor
checking and will not start the genset.
-To enter STOP mode, press the Manual Stop button when the unit is showing READY in
the manual mode.
-To exit STOP mode, press any button.
C15.8 Manual Mode Operation
C15.8.1 To start the genset
When the display is showing READY, press the start button momentarily to start the genset.
Any warning or alarm conditions must be cleared before the genset can be started.
The unit will perform the starting sequence as follows:
• PREHEAT.
•If PREHEAT is selected then the PREHEAT Output will activate for the time specified.
• FUEL-ON.
•If ETR (Energise To Run) fuel control is configured, the unit will control the fuel output and
display FUEL ON and the proceeds to the CRANK state. If the Fuel Pull-in is configured it will
be on for the first second of this sequence.
•For ETS (Energise To Stop) the sequence does not activate the output \and proceeds to the
CRANK sequence after a short delay.
• CRANK.
•The crank output is activated and the display shows 'Cranking' with a count down time.
•The crank output is deactivated when the unit has detected a speed signal above the crank
disconnect speed specified in the settings. If selected, the crank will also terminate on
achieving oil pressure or Battery charging alternator excitation has been achieved. This
provides a secondary crank disconnect function to avoid over-cranking.
•If the genset does not start, the LCD will show STOPPING, control the Fuel and Crank outputs
accordingly, and return to READY. No retries are done.
•If the unit looses power due to battery voltage droop during cranking, and the engine fires,
then on regaining adequate battery voltage, the unit will continue to allow the engine to run.
• RUN UP.
•When the engine starts, the display shows RUN UP with a count down in seconds. This
allows the engine measurement system to stabilise. Over speed and loss of speed signal are
the only parameters checked during RUN UP.
• WARM UP
C-53
Diesel Genset
•The display shows WARMUP with a countdown time. This allows the engine to stabilise at full
speed before going on load. Oil pressure and Over-speed are monitored.
• RUNNING
•The display shows RUNNING. Operating parameters are scrolled onto the display.
•Engine temperature alarms have a hold-off period and will not prematurely cause engine
shutdown if the engine has been previously run and has a high temperature.
C15.8.2 To stop the genset
Push the stop button briefly.

The unit will perform a stopping sequence as follows:
• COOLDOWN
•The display will show COOLDOWN with a count down time.
•The B contactor (if configured) is opened immediately and after a short delay contactor A (if
selected) is closed.
•On expiry of the cool down timer the sequence continues to stop the engine.
•The cool down timer can be set to zero in the menu system to skip this sequence step.
•To truncate the cool down timer press the stop button again.
•The set can be returned to the running sequence by pressing the start button. The contactors
return to place the genset on load again.
• STOPPING
•The display will show STOPPING with a countdown time.
•If ETR fuel control has been selected the Fuel output will be deactivated.
•If ETS fuel control has been selected then the Fuel output will be activated for the Max Fuel
Time or until the engine stops. The stopping process will retry if the engine fails to stop the
first time. Between stopping retries the Fuel output is deactivated for a short time to help
overcome any jamming.
•The fuel output is controlled until the engine stops rotating and oil pressure decays. If the Oil
Pressure has not decayed by the end of the 'Max Fuel Time', the fuel output is deactivated
and the controller raises the alarm FAILED TO STOP. The speed must remain at zero and the
oil pressure must be below the alarm set point for the 'Stop Time' before the engine is
considered stopped.
• READY
•The engine has stopped and is ready to start again as required.
C15.9 Display Operation
• When the genset is ready
C-54
Diesel Genset
• When the genset is running

When the genset is starting and stopping, the display shows the state of the sequence together
with the time remaining before the next state will commence.
Once the genset is fully running or if the genset is stopped and in 'READY', the running
parameters are displayed. This includes generator and engine parameters simultaneously on
separate displays. The unit sequentially scrolls through screens as shown below:
Table 19: Display when genset is running
Display Explanation
Splash Screen 1
Only shown at Power up
Splash Screen 2
Product Identification
Software Version
KOEL Serial Number
KOEL Application Code ID
Sequence Status
Engine Speed in RPM
C-55
Diesel Genset
Table 19: Display when genset is running (Continued)
Display Explanation
Oil Pressure
Engine Temperature
liquid or Air
Genset Battery Voltage Status
Fuel Status
Engine Running Hours

Total Engine Starts
Genset Voltages
Line to Neutral
Line to Line
Genset Amps and Hz
C-56
Diesel Genset
Table 19: Display when genset is running (Continued)
Display Explanation
Genset KW and KVAR
Genset KVAR and Power Factor
Genset Power Total
Genset Average
Genset KWHours
Contactor Status
Any active warnings are shown here.

They are NOT interleaved with the measurement screens.
This is an example alarm screen
After this, the display returns to the first sequence screen.
C-57
Diesel Genset
C15.10 Alarms and Warnings
In the event of abnormal operating conditions the unit will issue a warning of an impending
alarm, then an alarm if a failure is detected. The genset is then shut down. The LCD shows an
appropriate message indicating the nature of the condition. To draw operator attention to the
condition the flashing general alarm LED is used.
In most cases, Warnings do not stop the genset and are self resetting. Alarms will normally
stop the genset and require the operator to clear the alarm by pressing the Stop or Hooter
button. The genset can not be started if an alarm exists.
•Warnings are indicated by slow flashing of the alarm LED and displaying the appropriate
message on the LCD as follows.
•Alarms are indicated by fast flashing of the ALARM LED and displaying the appropriate
message on the LCD.
C15.11 Alarms and Warnings-Engine
Table 20: Alarms and Warnings-Engine
Message Function description
Oil Pressure Low The oil pressure went below the alarm setpoint while running.
Check oil level and replenish. Check for blocked oil filter.
Engine Temp High The Engine / Coolant temperature went above the alarm setpoint
Coolant Temp High while the genset was running.
Check for over loading. Check cooling air flows, Check coolant level.
Canopy Temp High The Canopy Temperature switch was activated.

Check cooling air flows. Check for overloading.
Fuel Level Low The Fuel Level is below the alarm setpoint.
The engine is stopped to prevent air and dirt infiltration to the engine.
Replenish the fuel.
Fuel Loss The Fuel Level is unexpectedly going down while the genset is not
running
Battery Voltage High The battery voltage went above the setpoint.
High battery voltage usually indicates that the battery charging
alternator has failed and it is producing a voltage which might
damage the battery, control relays or the controller.
Engine shutdown is recommended to minimise the risk of damage
and fire.
Under Speed The engine was running below the under speed setpoint.
Check for overloading. Check fuel system.
Over Speed The engine was running above the setpoint.

Check governor system. Check power takeoff couplings.
Hirev Alarm The speed signal indicates the engine is grossly over speed.
Check Governor system.
C-58
Diesel Genset
Table 20: Alarms and Warnings-Engine (Continued)
Coolant Level Low The radiator liquid level is below the required level.
The liquid level needs topping up.
Start Fail The engine has failed to start.

Check Fuel supply, check battery condition, check air cleaners.
Stop Fail The engine has failed to stop.

Check stop solenoid, check rack operation.
Belt Broken Bbelt break detector has been activated.Check the belts.
Oil-P Fault The Oil Pressure sensor system is not functioning as expected.
Check oil pressure sensor and associated wiring.
Eng-T Fault The Engine Temperature Sensor is not functioning as expected.

Check engine temperature sensor and associated wiring.
Fuel-L Fault The Fuel Level Sensor is not functioning as expected.

Check the Fuel Level Sensor and associated wiring.
Speed Fault The Speed Sensing system is not working as expected.

Check the associated speed sensor wiring and external influences
such as poorly operating battery chargers and poorly filtered UPS
systems connect to the load.
Speed Detected Speed signal is unexpectedly present.

Check the associated speed sensor wiring and external influences
such as poorly operating battery chargers and poorly filtered UPS
systems connected to the load.
Check electrical safety earthing systems. Check associated
communications networks are isolated and not part of an unexpected
earth loop.
Oil Detected Oil Pressure is unexpectedly present.

Check the Oil Pressure Sensors and associated wiring.
Check the Oil filter system is not blocked.
Check the engine is not running with a failed speed sensing system.
E-S Lock-out The emergency stop input has been activated. Deactivate the
emergency stop input, then press the stop button to clear this alarm.
C15.12 Alarms and Warnings-Alternator
Table 21: Alarms and Warnings-Alternator
AGF Phase Reversal The generator has a phase reversal or the wiring is incorrect
AGF Loss V1 Volts Voltage on Alternator Phase V1 was lost
C-59
Diesel Genset
Table 21: Alarms and Warnings-Alternator (Continued)
AGF Low V1 Volts Voltage on Alternator Phase V1 is Low
AGF High V1 Volts Voltage on Alternator Phase V1 is High
AGF High Frequency Alternator frequency is high
AGF Low Frequency Alternator frequency is low
AGF Phase Reversal The generator has a phase reversal or the wiring is incorrect
AGF High Frequency Alternator frequency is high
AGF Low Frequency Alternator frequency is low
C15.13 Inputs Electrical Specification
Table 22: Inputs Electrical Specification
Input Type Comment
Nominal 12VDC or 24VDC or Station Battery

Battery + Volts Power Supply
Range 6-36VDC
0V Common Power 0VDC, Common
Suitable for either resistive or switch C.O.F

Fuel Level Sensor Analog/Digital
senders
Coolant Temperature Suitable for either resistive or switch C.O.F.

Analog/Digital
Sensor senders
C-60
Diesel Genset
Table 22: Inputs Electrical Specification (Continued)
Input Type Comment
Canopy Temperature Digital Suitable for switch input. Connect to 0V = Active
Suitable for either resistive or switch senders.

Oil Pressure Sensor Analog
Optionally for protection or display only.
Low Water Level Special Open Circuit = No liquid present
Autostart Digital Suitable for switch input. Connect to 0V = Active
Emergency Stop Digital Suitable for switch input. Connect to 0V = Active
Oil Pressure Switch Digital Used for backup Oil Pressure protection.
Digital Input 1 Digital Suitable for switch input. Connect to 0V = Active
Digital Input 2 Digital Suitable for switch input. Connect to 0V = Active
Excitation Internal High Impedance input
Battery Voltage Internal High Impedance
Generator Phase 1 Volts

GL1 Voltage
Max 350VRMS

GL2 Voltage
Max 350VRMS

GL3 Voltage
Max 350VRMS
Generator Neutral
GN Voltage
Max 350VRMS
Phase 1 Amps CT Loop

I1 Amps
Max 5A peak

I2 Amps
Max 5A peak

I3 Amps
Max 5A peak
I Com Common CT connection for S1 terminals.
Speed A magnetic pickup input 3V - 70V peak at

>500 to 10KHz
SPA Voltage
Speed A Battery Alternator input 2V to 70V peak
at 20Hz to 1KHz
Speed B magnetic pickup input 3V - 70V peak at

>500 to 0KHz
SPB Voltage
Speed B Battery Alternator input. Connect to
common
SPCom Voltage Speed Common 0VDC
C-61
Diesel Genset
C15.14 Outputs Electrical Specification
Table 23: 8.Outputs Electrical Specification
Output Type Comment
Excitation Current 200mA burst mode pulsed current controlled output.
Fuel Solenoid Open Drain 300mA Open Drain protected coil drive. Max
36VDC. This output is used to maintain the fuel
solenoid activated for running or stopping duty.
Crank Open Drain This output is used to control the crank relay coil.
The crank relay should be sized for the crank
contactor current. It is recommended that the crank
relay is located in the wiring loom near to the starter
motor. This position removes the need for high
current wiring to the control box and thus leads to
lower cost.
Output 1 to Output 4 Open Drain 300mA Open Drain protected coil drive. Max
36VDC. This output is used to switch the load from
the mains.
C15.15 Load Transfer and Contactor Operation
The unit provides for both Mains and Generator contactor control even though in many
applications this function will not be used, instead an MCB is used to switch the generator to
and from the load. Contactor outputs are controlled in both Manual and Auto operating modes.
The Mains contactor output can be setup to deactivate the Mains contactor in several ways
-"Immediately when the start button is pressed or the autostart input is activated.
-"A short delay after the start request
-"When the genset is running and able to take load.
The Generator contactor output will activate only after the Mains contactor has opened and
only when the genset able to take load. The timing is controlled by the XFR DELAY
configuration setting.
If the genset was started by activating the Autostart input, then deactivating the input will move
the sequence to the "Run On" sequence then to the"Cool Down" sequence. During cool down
the Generator contactor output is deactivated and after a delay the Mains Contactor output is
controlled to re-activate the Mains contactor.
C15.16 Speed Sensing
The unit can obtain speed information from one of four sources.
C-62
Diesel Genset
-Magnetic pickup unit (MPU)

-Generator output 50/60Hz if used for genset control (internally connected from GL1)
-Battery charging alternator
C15.16.1 MPU
The magnetic pickup unit counts teeth on the flywheel and is mounted in the bell housing. It is
important to ensure the gap between the MPU face and the teeth is 1mm to 2mm, as this
distance greatly affects the output of the MPU. The unit requires a minimum of 3VRMS at low
speed to ensure proper crank disconnect. Setup requires calculating the number pulses per 10
revolutions and the calculated number is then entered into the menu system "Cal Value".
Calculate: Number of Teeth x 10 = Speed Pulses Per 10 Revolutions.

Eg: 125 teeth x 10 = 1250.
Enter the number 1250.
C15.16.2 Generator
If the unit is used in a genset application the speed source can be the generator 50/60 Hz
output and is connected internally within the unit from the AC input connectors. AC should NOT
be connected directly to the speed MPU / Magneto input. For correct crank disconnect the
generator must be providing a detectable output at low speed and therefore the voltage at 300
RPM must be greater than 40VRMS. This can be affected by the AVR and must be confirmed
to provide suitable signals and timing for proper crank disconnect.
For setup the number of pulses per 10 revolutions must be calculated and entered into the
menu system "Cal Value". The generator output frequency and standard RPM must be known.
Calculate Speed Calibration value as follows:

Cal Value = (Freq x 600) / RPM.
Eg: (50Hz x 600) / 1500 = 20
C15.16.3 Battery Charging Alternator
A low cost speed source can be derived from the battery-charging alternator if fitted. It
unfortunately is also the most troublesome, and not recommended for reliable and repeatable
long-term service. The difficulties arise from the in-exact relationship of alternator output
frequency and engine RPM. As a result of slippage and variable mechanical coupling both
calibration and long-term stability are compromised.
The ratio of crank pulley to alternator pulley is indeterminate, as it depends very significantly on
where the coupling belt rides in the V grove. Belt tension plays a very significant role, as does
belt wear and instantaneous belt loading.
C-63
Diesel Genset
Immediately after starting an engine the alternator is required to re-charge the partially
discharged battery. The loading on the alternator is very high and belt slippage is common as is
belt set low in the V groove. The output frequency may be lower than expected. If speed
calibration is performed at this time, the speed representation will be too low and subsequently
as the load reduces on the alternator, the engine speed will appear to erroneously increase.
The battery charging alternator output frequency and current RPM must be known. This is
achieved by independently running the engine, and measuring the battery charging alternator
frequency on the W (sometimes D+) terminal. Excitation must also be provided to ensure self-
excitation and an adequate output signal. Some small variation in reported speed may result
but this can be calibrated out later during engine commissioning. For setup the number of
pulses per 10 revolutions must be calculated and entered into the menu system "Cal Value".
Calculate Speed Calibration value as follows:

Cal Value = (Freq x 600) / RPM.
Eg: (257Hz x 600) / 1500 = 102.8.
C15.17 Battery Charging Alternator Excitation
The battery charging alternator excitation system is implemented using a burst mode pulse
system. This ensures reliable self-excitation while managing current consumption during
standby, heat dissipation during fault conditions, and pulsing the battery-charging alternator
prior to cranking for improved speed signal output.
During standby and Ready, the alternator excitation is pulsed once per minute to maintain
some level of residual magnetism in the alternator but still maintaining minimum power
consumption. On receiving a start signal, the unit pulses the alternator excitation input with a
burst of 200mA pulses.
The pulse width is dependent on the battery voltage. This pulse burst establishes a definite
magnetic field in the battery-charging alternator prior to cranking. This ensures a significant
speed-sensing signal is generated for crank disconnect sensing.
The alternator excitation is turned off and the engine is cranked without the usual alternator
burden loading the cranking process. This aids easier starting. When the engine has fired and
is running, more 200mA pulse bursts are applied. Given the alternator is rotating at more than
the 3000RPM the alternator will achieve self-excitation.
If self-excitation is not achieved this process will repeat for a few seconds before the excitation
failed warning is given.
C-64
Diesel Genset
Alternator excitation may also be used as a secondary crank disconnect signal for the case
where the speed signal has failed immediately the engine starts to run. This feature can be
disabled if not required by setting "Excite Dis" to NO.
For systems where a battery-charging alternator is not fitted, turning off the excitation warning
will disable the excitation system.
C15.18 Battery Voltage Monitoring and Charging Detection
A battery is considered charged if (assuming a 12V system. x2 for 24V) its terminal voltage is
above 13.1Volts. Typically a fully charged battery has a terminal voltage of 13.6V, above this
and the battery is being overcharged. During cranking the large discharge current will reduce
the battery terminal voltage below 12.5V and the battery cannot increase the terminal voltage
again without the assistance of a charger. This sequence provides a useful mechanism to
determine if a battery is being actively charged.
Many applications have a current meter to show charging current. Such meters provide very
limited value as a good battery will recover its terminal voltage very quickly and then be
maintained with a very low level of trickle current. This trickle current is usually too small a
percentage of the current meters range to provide any useful information.
The unit constantly measures the battery terminal voltage and can detect proper charging and
discharging performance. Voltage readings are taken and compared against an inbuilt voltage
profile. If the battery terminal voltage falls outside the critical voltages for each action then a
battery warning is indicated.
During standby, and particularly where an on line charger is not available, monitoring the health
of the battery is vital. The unit regularly wakes and measures the battery voltage, if it falls below
the set point a warning is issued to ensure the operator is aware of the need for battery
recharging.
C15.19 Unit General Specifications
Table 24: Unit General Specifications
Feature Specification
Overall Dimensions 180 x 126 x 51mm
Mounting Hole 155 x 117mm
IP rating IP56 front, IP20 rear
Supply Voltage 8 V to 36V DC

Nominal Automotive
Operating Temperature -20 to +70°C
C-65
Diesel Genset
Table 24: Unit General Specifications (Continued)
Storage Temperature -20 to +70°C
Relative Humidity 95% non condensing
Supply Current Standby < 10mA

Running 70mA
AC Voltage Range L-N = 350VRMS.
AC Frequency Range 40 - 70Hz
CT current range 0 - 5A + 25% Overload
Overall Accuracy Class 1
Digital Output Rating Open Drain Relay Coil Driver. 300mA 32VDC max.
Short Circuit protected.
Digital Input Rating Opto-coupler isolated.

Whetting current 10mA at 12 V DC.
DC input protection for +/- 30V DC
Transient Protected.
Analog Input Rating Current limited outputs approximately 15mA or less as required by
sensors.
Short circuit and reverse voltage protected.
Input Reference 0V Common
Displayed Speed Range 0 - 4000 RPM
Engine Hours 0 - 99999.9 Hours
Kilo Watt Hours 0 - 999999.9 KWH
Oil Pressure Sensor Switch: Close on fault

Type Resistive 0 to 90, 10 to 180 Ohms, User Curve
Oil Pressure Ranges 5.0, 7.5, 10 Bar
Engine Temperature Switch: Close on fault

Sensor Type Resistive (NTC)
Engine Temperature VDO 150ºC, User Curve

Ranges
Canopy Temperature Switch: Close on fault

Sensor Type
Fuel Level Sensor Type Switch: Close on fault

Resistive: 10 to 180 Ohms, User Curve
Battery Volts 8 to 36 Volts

Measurement
Set-up and Adjustment All features may be adjusted using set-up buttons and LCD menu or
via a PC Windows based utility
Terminations Amp DUAC / Molex Mini Fit JNR
C-66
Diesel Genset
Table 24: Unit General Specifications (Continued)
Testing Environmental Tests: IEC68 Part2

EMC Compliance: EN50081-1, EN50081-2, IEC6100-4-3
Electrical Safety AS 3100 and AS 3260
C15.20 Installation and Wiring
The unit is fitted with 2, 3, 6 and 14 way Molex Minifit or equivalent socket connectors for which
mating plugs can be selected from the Amp PE, or TPK range.
The unit is also fitted with 4 way Mate-N-Lok or equivalent socket connectors for which mating
plugs supplied by Tyco Electronics or equivalent can be used.
The majority of unit wiring is low current for which 0.75mm2 wire is sufficient. This excludes the
CT wires (i1, i2 and i3) for which 1.5mm2 wire should be used.
NB: The unit is a complex electronic device and caution should be taken to ensure correct
wiring before power is applied.
C-67
Diesel Genset
Figure C - 23: Rear View for wiring
Table 25: Connector Detail
Connector Assignment Connection Information
J7: Data Port

Programming and Auxiliary Unit data port.
NB: Connect ONLY manufacturer approved equipment to this

port
J1: DC Power Supply

Pin Connection
1
1 Common -ve. (Note 1)
2 2 Battery +ve. (Note 2)
J4: Speed Input Pin Connection
1 2 3 1 Speed Input A
2 Speed Input B
3 Speed Common
J6: Alternator AC Input
1
Pin Connection
2 1 Alternator AC Phase 1 (Red)
2 Alternator AC Phase 2 (Yellow)
3 Alternator AC Phase 3 (Blue)
3 4 Alternator AC Neutral
J3: Input / Output

Pin Connection
J3-1 1 Output 1
2 Output 2
3 Output 3
J3-3 4 Output 4
5 Input 1
J3-5 6 Input 2
C-68
Diesel Genset
Table 25: Connector Detail (Continued)
Connector Assignment Connection Information
J2: Engine Pin Connection
1 Charger WL
J2-1 2 Fuel Relay
3 Crank Relay
J2-3 4 Fault Relay
5 HCT (High Canopy Temperature) switch
J2-5 6 LLOP (Low Oil Pressure) switch
7 LOP (Oil Pressure) Resistive Sensor
J2-7 8 Coolant Temperature Resistive Sensor
9 Fuel Level Resistive Sensor
J2-9 10 liquid Level
11 Auto Start
J2-11 12 Emergency Stop
13 Analog 1 (To be defined)
J2-13 14 Not Used
CT1, CT2 & CT3
CT Com CTR
CT Use
1 Phase 1 Current (Red) (Note 3)
2 Phase 2 Current (Yellow) (Note 3)
3 Phase 3 Current (Blue) (Note 3)
4 CT Common - Connect L2 of all CTs to here
CTY CTB
Notes:
1.This connection must be made directly to the engine crankcase for lowest electrical noise.
This connection must not have currents other than the controller currents flowing and must be
used exclusively for the controller.
2.This connection must be made directly to the positive terminal of the battery for best
performance. Do not make this connection to the positive terminal on the Starting Motor.
3.Wire must be passed through the CT in the direction of the arrow.
NB: The unit is a complex electronic device and caution should be taken to ensure correct
wiring before power is applied.
C15.21 Trouble shooting
The unit displays the following messages when an alarm occurs. Alarms shut down the engine,
set the alarm output and flash the alarm indicator. The alarm indications can be cleared after
C-69
Diesel Genset
the genset has stopped, by pressing the stop button. The hooter can be silenced with the
Hooter Button. .
Table 26: Trouble shooting
Message Cause
Low Oil Pressure Oil pressure has not reached the Oil Alarm set point (Oil Alarm) at
the end of the run up time or has dropped below this value when the
engine is running.
Check:
• Engine oil level

• Cleanliness of oil filters
• Wiring between sender/switch and panel
• Function of sender/switch
Low Fuel Level Fuel level is less than the minimum value set point.
Check:
• Fuel level in tank

C-70
Diesel Genset
Table 26: Trouble shooting (Continued)
Message Cause
High Engine Temp High Engine or liquid Temperature.

Engine temperature has exceeded the high temperature set point.
The temperature icon turns on. Either message may also be shown
depending on temperature system setup.
Check:
For Air Cooled Engine:
• Blower operation.
• Obstruction to cold air intake and hot air exhaust
• V Belt status and tension.
• Overloading of engine.
• Clogging of cooling surfaces.
• Closing of engine cowls,
For liquid Cooled Engine:
• Coolant level in header and radiator.

Caution: Open radiator cap only when engine has
stopped and is cold. Never open radiator pressure cap
when engine is hot, even if it is not running.
• Obstruction to cooling airflow for liquid as well as air cooled
engines.
• Radiator fan function.
• Clogging of radiator cores.
• Coolant leaks causing reduction in quantity
High Canopy Temp Canopy temperature switch was activated.
Check:
• Is the canopy interior temperature really hot? Investigate and

correct the reasons.
C-71
Diesel Genset
Message Cause
Low Water Level For liquid cooled engines only:
liquid Level has gone below the level sensor.
Check:

Under speed Engine speed has dropped below the under speed set point.
Check:
• Overloading of engine
• Wrong setting of fuel pump
• Wrong setting of governor
• Friction in the engine
• Faulty speed sensor or wrong setting of sensor
Over speed Engine speed has exceeded over speed set point.
Check:
• Engine running free of load

High Rev Engine has exceeded safe operating speed.
Check:
• Engine running free of load

C-72
Diesel Genset
Message Cause
No Speed Signal Engine has lost speed signals while running.
Check
• Wiring between sender and panel

• Function of sender
• Wrong setting of sender
Start Failure The engine has failed to start.
Check
• No fuel in tank
• Clogged air cleaner
• No compression
• Wrong setting of pump
• Weak battery
• Faulty starter motor
• Faulty or loose wiring to motor
• Stop solenoid or governor stuck at ‘no fuel’ position
Stop Failure The engine has failed to stop.
Check
• Faulty stop solenoid or governor

• Faulty or unadjusted linkage between stop solenoid or governor
and fuel pump
• Faulty wiring to stop solenoid or governor
• Faulty setting of governor
• Dirt in injectors
E-S Lock out The emergency stop input has stopped the engine.
Check
• Emergency switch active on the canopy or panel? If yes, verify

the reason for operation and reset the panel.
• Wiring between switch and panel
• Function of switch
C-73
Diesel Genset
Message Cause
Oil Pressure Flt The unit has detected that the Oil Pressure sender has become open
circuit. Normally this indicates a faulty sender or broken wiring. This
will only shut down when the Oil System is set to Sender.
Check:
• Oil level in sump

• Clogged oil filter
Engine Temp Flt The unit has detected that the engine temperature has not risen to 50
degrees within the first 5 minutes of running or the temperature
sensor has shorted to common. Normally this indicates a faulty
temperature sender or broken wiring.
Check:

• Obstruction to cooling airflow for liquid as well as air cooled
engines.
• Radiator fan function.
• Clogging of radiator cores.
C15.22 Error Messages
The following warning messages indicate potential problems. When a warning occurs, the
message associated with the warning is displayed. Warnings clear automatically when the
warning condition is cleared.
Table 27: Error Messages
Message Cause
No Excitation Excitation voltage is low when engine is running. This indicates a

probable charging fault or the alternator belt has broken.
C-74
Diesel Genset
Table 27: Error Messages (Continued)
Message Cause
Low Charge Volts Battery Voltage is below the charging voltage setpoint when the
engine is running. Indicates that the alternator is not charging the
battery.
Under Voltage Battery Voltage is below the low battery setpoint.
Over Voltage Battery Voltage is above the high battery volts setpoint. This may be
due to a faulty regulator or battery charger.
Oil Lock Out The unit has detected that the oil pressure is above the oil pressure
alarm set point with the engine not running. This warning prevents
the engine from attempting to crank with the engine potentially
running. This may be due to a faulty oil sender or a very tight engine.
This warning is disabled if Oil Pressure Check before Cranking is set
to Off.
Tacho Lock Out The unit has detected that a speed signal is present with the engine
not running. This warning prevents the engine from attempting to
crank with the engine potentially running. This warning can
sometimes be caused by ripple generated by mains powered battery
chargers.
Excite Lock Out The unit has detected that Excitation is present with the engine not
running. This warning prevents the engine from attempting to crank
with the engine potentially running. This warning can sometimes be
caused by ripple generated by mains powered battery chargers.
AutoStart On The unit has detected an Autostart signal when not in auto mode,
indicating the engine needs to be started in Auto mode.
Low Oil Pressure The Oil Pressure has dropped below the Oil Pressure Warning set
point while the engine is running. The Oil Pressure Icon is lit.
High Engine Temp Engine/liquid temperature has exceeded the high temperature
High Water Temp warning set point after the Temperature monitoring delay has
expired.
High Canopy Temp Canopy Temperature was activated after the Temperature monitoring
delay has expired.
Low Fuel Level Fuel level is less than the warning set point.
Fuel Level Flt The unit has detected that the fuel sender is open circuit. This is only
a warning, and will not shut down the engine
No Speed Signal A speed signal could not be detected after the engine had started
C-75
Diesel Genset
Table 27: Error Messages (Continued)
Message Cause
Maintenance The time since the last maintenance has exceeded the maintenance
time. The alarm output is not activated for this warning. The warning
ALARM
is cleared by pressing and holding the ACK/RESET button for 30

seconds. If the engine maintenance is carried out prior to the timer
ALARM
expiring, pressing the ACK/RESET button for 60 seconds will reset the
timer.
C16. Circuit diagrams

The following section contains drawings of AMF and NON-AMF panels offered with KOEL
gensets of the specified range.
C16.1 Non AMF panels
Three Non-AMF panel circuit diagrams are included in the manual:
Description with drawing number
•03.327.21.0_CNTRL PWR DWG _ Standard 1PH (2 sheets): This single-phase panel uses
a KG 934 controller with the following features:
-To start and stop the genset depending on the status of an external ‘Autostart’ input.
-Monitor engine and genset safety.
-Display engine and genset parameters.
-The KG 934 unit has relays to drive main and genset contactors.
-This panel is meant for gensets with a single phase alternator.
•03.326.21.0CNTRL & PWR DWG _ 3PH (2 sheets): This panel is similar to the earlier panel
but is meant for gensets with a three phase alternator.
•4H.1684.22.0_GENSET CONTROL POWER DWG 3PH[1] (2 sheets): This three - phase

panel includes all features of earlier panels and an electronic governor. This governor
controls engine speed with precision for powering sensitive loads. The electronic governor
also permits synchronization of two or more gensets to share load.
C-76
Diesel Genset
Engine - HA series
D1. Model ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ D‐1
D1.1 Rating plate ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ D‐1
D1.2 Rating Plate Location ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ D‐2
D1.3 Cylinder Numbering ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ D‐2
D1.4 Direct Injection ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ D‐3
D2. General ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ D‐3
D2.1 Your engine needs ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ D‐3
D2.2 Service and Maintenance‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ D‐3
D2.3 Maintenance and Repairs‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ D‐3
D2.4 Safety ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ D‐4
D3. Engine Illustrations ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ D‐5
D3.1 HA294 G1, Service Side ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ D‐5
D3.1.1 HA294 G1, Exhaust Side ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ D‐6
D3.1.2 HA394 TCI G1, Service Side ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ D‐7
D3.1.3 HA394 TCI G1, Exhaust Side ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ D‐8
D3.1.4 HA494 TCI G1, Service Side ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ D‐9
D3.1.5 HA494 TCI G1, Exhaust Side ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ D‐10
D3.1.6 HA694 TCI G1, Service Side ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ D‐11
D3.1.7 HA694 TCI G1, Exhaust Side ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ D‐12
D3.2 Lube Oil System ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ D‐13
D3.2.1 HA294 G1 NA ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ D‐13
D3.2.2 HA694 TC ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ D‐14
D3.3 Engine Fuel System ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ D‐15
D3.4 Fuel Pump ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ D‐15
D3.4.1 In‐line Fuel Pump ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ D‐15
D3.4.1.1 Rotary Fuel Pump ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ D‐16
D3.5 Engine Cooling System ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ D‐17
D3.6 Air System ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ D‐17
D3.6.1 Dry type Air Cleaner ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ D‐18
D3.7 Exhaust System ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ D‐19
D4. Engine Operation ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ D‐21
D4.1 Commissioning ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ D‐21
D4.1.1 Filling Engine Oil ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ D‐21
D4.1.2 Adding Fuel ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ D‐21
D4.1.3 Fuel System Ventilation ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ D‐21
D4.1.3.1 For In‐line Fuel Injection Pump ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ D‐21
D4.1.3.2 For Rotary Fuel Pump ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ D‐22
D4.1.4 Other Preparations ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ D‐22
D4.1.5 Additional Maintenance Work ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ D‐23
i
Diesel Genset
D4.2 Starting ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ D‐23
D4.2.1 Before Starting ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ D‐23
D4.2.2 Starting without Engine Heater ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ D‐24
D4.2.2.1 Starting the Engine ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ D‐24
D4.2.2.2 Stopping The Genset ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ D‐25
D4.2.3 Starting with Engine Heater ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ D‐25
D4.2.3.1 Starting the Engine ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ D‐25
D4.2.3.2 Stopping the Engine ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ D‐25
D4.3 Electrical System ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ D‐25
D4.3.1 Electrical Equipment ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ D‐26
D4.3.2 Battery Cable ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ D‐26
D4.3.3 Recommended Battery Capacity ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ D‐26
D4.4 Monitoring System ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ D‐26
D4.4.1 Engine Lube Oil Pressure ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ D‐26
D4.4.2 Engine Oil Temperature ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ D‐26
D4.4.3 V‐Belt Failure Switch ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ D‐27
D4.4.4 High Cylinder Head Temperature Switch ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ D‐27
D4.5 Operating Conditions ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ D‐27
D4.5.1 Winter Operation ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ D‐27
D4.5.2 High Ambient Temperatures and High Altitude ‐ ‐ ‐ ‐ ‐ ‐ D‐28
D5. Operating Media ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ D‐28
D5.1 Lube Oil ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ D‐28
D5.1.1 Quality Grade ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ D‐28
D5.1.2 Viscosity ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ D‐28
D5.2 Fuel ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ D‐29
D5.2.1 Quality Grade ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ D‐29
D5.2.2 Winter Grade Fuel ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ D‐29
D6. Routine Maintenance‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ D‐31
D6.1 Maintenance Schedule ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ D‐31
D6.1.1 Log of Maintenance Work ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ D‐32
D7. Service & Maintenance ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ D‐33
D7.1 Lubrication system ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ D‐33
D7.1.1 Oil Change Intervals ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ D‐33
D7.1.2 Checking Oil Level ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ D‐34
D7.1.3 Changing Engine Oil ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ D‐35
D7.1.4 Changing Oil Filter Element ‐ Spin On Type ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ D‐36
D7.2 Fuel system ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ D‐37
D7.2.1 Changing Fuel Filter ‐ Spin On Type ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ D‐37
D7.2.2 Changing Fuel Filter ‐ Element Type ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ D‐38
D7.2.3 Fuel Strainer ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ D‐39
D7.3 Cooling System ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ D‐40
ii
Diesel Genset
D7.3.1 Cleaning Intervals ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ D‐40
D7.4 Combustion Air Filter ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ D‐41
D7.4.1 Air Cleaner Service Intervals ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ D‐41
D7.4.2 Dry Type Air Cleaner ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ D‐41
D7.5 Belt Drives‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ D‐43
D7.5.1 Checking V‐Belts ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ D‐43
D7.5.2 Replacing Fan V‐ Belt ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ D‐44
D7.5.3 Tensioning Alternator Belt ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ D‐44
D7.5.4 Changing Alternator Belt ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ D‐45
D7.5.5 V‐belt Failure Warning System ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ D‐45
D7.5.6 Visual Inspection of V‐Belts ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ D‐46
D7.5.7 Re‐tensioning of Alternator Belt ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ D‐46
D7.6 Adjustments‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ D‐46
D7.6.1 Checking Valve Clearance ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ D‐46
D7.6.2 Adjusting Valve Clearance ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ D‐47
D7.7 Accessories ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ D‐48
D7.7.1 Checking Battery and Cable Connectors ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ D‐48
D7.7.2 Checking Electrolyte Level ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ D‐48
D7.7.3 Checking Electrolyte Density ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ D‐49
D7.7.4 Lifting Tackle ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ D‐50
D7.8 Engine Cleaning ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ D‐50
D7.8.1 Cleaning the engine with Compressed Air ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ D‐50
D7.8.2 Cleaning the engine with Cold Cleaning Agent ‐ ‐ ‐ ‐ ‐ ‐ ‐ D‐51
D7.8.3 Cleaning the engine with High Pressure Steam Jet ‐ ‐ ‐ ‐ ‐ D‐52
D8. Faults, Causes & Remedies ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ D‐52
D9. Engine Preservation ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ D‐54
D9.1 About Preservation ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ D‐54
D9.2 Preserving Engine ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ D‐54
D9.3 Commissioning Preserved Engine ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ D‐55
D10. Technical Specifications ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ D‐55
D10.1 Engine Specifications for CPCB II ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ D‐55
D10.2 Power Output for CPCB II ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ D‐56
D10.3 Torque Wrench Setting ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ D‐57
iii
Diesel Genset
HA series Diesel Engine

D1. Model
D1.1 Rating plate
The engine model and engine serial number are stamped on nameplate along with engine
rating, rpm and referred standard. The name plate details must be given while ordering spares
and asking for service.
Figure D - 1: Engine Rating Plate
D-1
-
Diesel Genset
D1.2 Rating Plate Location
The name plate is fixed on engine crankcase as shown in the figure.
Figure D - 2: Location of ratings plate
D1.3 Cylinder Numbering
The engine in the illustration is from the HA family, The engine in your genset may be different
from the one shown in the image.
Figure D - 3: Cylinder Numbering
D-2
Diesel Genset
D1.4 Direct Injection
Engines are with direct fuel injection to deliver high performance and meet pollution
regulations.
Figure D - 4: Direct Injection
D2. General
D2.1 Your engine needs
•Clean high speed diesel oil.

•Lubricating oil of specified quality and viscosity grade.
•KOEL recommends use of K-Oil Premium.
•Fresh air for combustion of fuel, for cooling of engine and genset.
•Genuine spare parts for its maintenance.
D2.2 Service and Maintenance
•Sound service and maintenance practices will ensure that the engine continues to meet your
requirements.
•Recommended preventive maintenance at regular intervals must be observed. The service
and maintenance work should be carried out conscientiously.
•Special care should be taken under abnormally demanding operating conditions.
D2.3 Maintenance and Repairs
•Shut down the engine before carrying out maintenance or repair work.
D-3
Diesel Genset
•When the work is complete, be sure to install safety devices that may have been removed.
•If you have to work on a running engine, ensure that all clothing is tight fitting and cannot
entrap the moving parts.
•Observe all industrial safety regulations when engine are operating in enclosed spaces or
underground.
•Please contact your KOEL dealer for spare parts enquiry. Use only genuine spare parts.
D2.4 Safety
• All Safety instructions (for both engine and operator) in this manual are designed by the
accompanying symbol. Please follow them carefully.

•The attention of operating personnel should be drawn to these instructions.
•General safety and accident prevention regulations laid down by law must also be observed.
D-4
Diesel Genset
D3. Engine Illustrations
D3.1 HA294 G1, Service Side
Figure D - 5: HA294 G1 NA Service Side
Table 1: HA294 G1, Service Side
Number Item
1 Cooling blower
2 Lifting hook
3 Fuel injection pump
4 Flywheel housing
5 Crank pulley
6 Oil filler neck/ cap
7 Lube oil sump
8 Lube oil filter
9 Fuel filter
10 Air cowling
11 V-belt
12 Feed pump
13 Lube oil drain plug
D-5
Diesel Genset
D3.1.1 HA294 G1, Exhaust Side
Figure D - 6: HA294 G1 NA Exhaust Side
Table 2: HA294 G1, Exhaust Side
Number Item
15 Charging Alternator
16 Starter
17 Crankcase
18 Crankcase breather
19 Flywheel
20 Rocker cover
21 Air intake manifold
22 Exhaust manifold
D-6
Diesel Genset
D3.1.2 HA394 TCI G1, Service Side
Figure D - 7: HA394 TCI G1 Service Side
Table 3: HA394 TCI G1 Service Side
Number Item
1 Cooling blower
2 Lifting hook
4 Flywheel housing
5 Crank pulley
6 Belt tensioning unit
8 Lube oil sump
9 Lube oil filter
10 Fuel filter
11 Air cowling
12 V-belt
13 Feed pump
D-7
Diesel Genset
D3.1.3 HA394 TCI G1, Exhaust Side
Figure D - 8: HA394 TCI G1 Exhaust Side
Table 4: HA394 TCI G1 Exhaust Side
Number Item
16 Starter
17 Crankcase
19 Flywheel
20 Rocker cover
22 Exhaust manifold
23 Turbocharger
24 Intercooler
D-8
Diesel Genset
Number Item
1 Cooling blower
2 Lifting hook
4 Flywheel housing
5 Crank pulley
8 Lube oil sump
9 Lube oil filter
10 Fuel filter
11 Air cowling
12 V-belt
13 Feed pump
D-9
Diesel Genset
Number Item
16 Starter
17 Crankcase
19 Flywheel
20 Rocker cover
22 Exhaust manifold
23 Turbocharger
24 Intercooler
D-10
Diesel Genset
Number Item
1 Cooling blower
2 Lifting hook
4 Flywheel housing
5 Crank pulley
8 Lube oil sump
9 Lube oil filter
10 Fuel filter
11 Air cowling
12 V-belt
13 Feed pump
D-11
Diesel Genset
Number Item
16 Starter
17 Crankcase
19 Flywheel
20 Rocker cover
22 Exhaust manifold
23 Turbocharger
24 Intercooler
D-12
Diesel Genset
D3.2 Lube Oil System
D3.2.1 HA294 G1 NA
Figure D - 13: Lube Oil System HA294 G1 NA
Table 9: Lube Oil System HA294 G1 NA
Number Item Number Item
1 Lube Oil Sump 12 Camshaft Bearing
2 Suction Pipe 13 Push Rod
3 Lube Oil Pump 14 Rocker Arm Bearing
4 Pressure Relief Valve 15 Metering Plug
5 Delivery Pipe 16 Push Rod Cover Tube
Lube Oil Cooler Tappet with groove for pulse fed

6 17
rocker arm lubrication
Lube Oil Filter Restrictor ( for lubrication of

7 18
gears)
8 Relief Valve (not shown) 19 Spray Nozzle for Piston Cooling
9 Oil Gallery 20 Connection for Pressure Gauge
10 Main Bearing 21 Oil Pressure Gauge
Large End Bearing Fuel Pump Connected to Lube

11 22
Oil Circuit
D-13
Diesel Genset
D3.2.2 HA694 TC
Figure D - 14: Lube Oil System HA694 TC
Table 10: Lube Oil System HA694 TC
1 Oil Sump 13 Camshaft Bearing
Suction Pipe Tappet with groove for pulse

2 14
fed rocker arm lubrication
3 Oil Pump 15 Push Rod
4 Pressure Valve 16 Rocker Arm Bearing
5 Delivery Pipe 17 Metering Plug
6 Pipe to Oil Cooler 18 Push Rod and Cover Tube
7 Oil cooler plate type 19 Restrictor Hole
8 Lube Oil Filter 20 Nozzle for Piston Cooling
9 Safety Valve 21 Oil Pipe to Turbocharger
10 Oil Gallery 22 Oil return Pipe
11 Main Bearing 23 Oil Pressure Gauge
12 Big-End Bearing
D-14
Diesel Genset
D3.3 Engine Fuel System
Figure D - 15: Fuel System for In-line Fuel Pump
Table 11: Fuel System
1 Fuel tank 7 Fuel Injector
Fuel pipe - tank to fuel Leak-off pipe

2 8
pump
3 Fuel feed pump 9 Fuel overflow line
4 Fuel filter 10 Overflow valve
5 Injection pump 11 Fuel return line to tank
Fuel injection pipe A Clearance; keep as far

6 apart as possible.
(Minimum of 200 mm)
D3.4 Fuel Pump
Depending on the type of engine, the fuel pump may be In-line or Rotary type.
D3.4.1 In-line Fuel Pump
Fuel is supplied to In-line Fuel by an in built feed pump. A set of fuel filters ensures the supply
of clean fuel to the In-Line fuel pump. The pump creates a high pressure stream of diesel that
is led to the individual engine cylinders through high pressure pipes. The pump has a Stopping
Lever that helps stop the engine when required. The pump also has an Accelerating Lever that
sets the engine speed.
D-15
Diesel Genset
Figure D - 16: In- line Fuel Pump
D3.4.1.1 Rotary Fuel Pump
Some engines are fitted with Rotary Fuel Pump. Fuel is supplied to the Rotary fuel pump by a
fuel lift pump (feed pump) a spin-on fuel filter ensures the supply of clean fuel to the rotary fuel
pump.
Figure D - 17: Rotary Fuel Pump
The schematic diagram below shows the fuel circuit of the engine.If fuel tank is installed below
fuel pump level, then the bottom level of fuel tank should be less than 1 meter below the feed
pump inlet. Fuel pipe from fuel tank to feed pump should be of 9mm I.D.
D-16
Diesel Genset
Figure D - 18: Parts of Rotary Fuel Pump
D3.5 Engine Cooling System
Air cooling for the engine is achieved by quiet, highly efficient and integral axial blower that has
sufficient reserve capacity to cope up with high ambient temperatures. The blower is driven by
the engine crankshaft pulley through V-belts. The V-belts tension is maintained by belt
tensioning unit.
Air flow from the blower is directed on the liners and cylinder heads by detachable sheet metal
lower & upper cowlings.
Figure D - 19: Cooling Air Flow
D3.6 Air System
Engine requires fresh, clean, cool, and sufficient quantity of air to burn the fuel and deliver
satisfactory performance. Use of clean air avoids unnecessary wear and tear of engine
component. Your engine may look different from the ones illustrated in this manual.
D-17
Diesel Genset
Ȁ !") *%
(! Ȁ !"#$*(%"
6 &$ 3+*7
Ȁ-! "2- %*(%"
3!+4"
Ȁ !"#$%&
'( , -!.+/0 &!1(!
"
Ȁ !"#$*(%"%
+"
, -!.+/0 &!1(! #$%(!/++*(!
5-/ %
#$%
(!/++*(!
, -!.+/0 &!1(!
Figure D - 20: Air Inlet System

Depending on the type of engine, an Air System consist of Air Cleaner or Air Filter, various
Hoses, Turbocharger, Intercooler and Air Inlet Manifold. A simple engine uses basic natural
aspiration while more complex and powerful engines have Turbocharger and/or Intercooler.
•The Air Intake draws in cool air from the atmosphere.

•The air is then cleaned in the Air Filter which separates heavier particles in air by a swirling
action.
•Subsequently, a fine paper element inside the AIr Filter screens the smaller particles from the
air.
•This clean air gets compressed by the Turbocharger. The compression of air also raises its
temperature, which is detrimental to the performance of engine.
•This compressed but hot air is cooled by the Intercooler which is a variety of heat exchanger.
•The Intercooler receives a cooling draft of air from the blower. The cooled and compressed air
from the output of Intercooler enables the engine to deliver maximum output over a variety of
altitudes.
D3.6.1 Dry type Air Cleaner
Figure shows the construction of dry type air cleaner used on HA series engines. Dry type Air
Filters are used in heavy duty engines. The filtration efficiency of Dry type air cleaner is 98.9 -
99.9%. Generally two elements are used in this type of air cleaner - Main element & Safety
element.
Restriction indicator is provided for all dry type air cleaners. Cleaning of filter element is
required when restriction indicator shows red signal even after engine has stopped.
D-18
Diesel Genset
Figure D - 21: Dry Type Air Filter
Figure D - 22: Parts of Air Filter
D3.7 Exhaust System
The Exhaust System is necessary to direct exhaust gases to non confined areas and reduce
the noise level to tolerable level. Exhaust system should exert minimum back pressure on
engine. Exhaust back pressure should be restricted to less than 50 mm of Hg.
Exhaust system consist of exhaust manifold, adaptor & exhaust silencer. Exhaust piping
should be lagged to avoid injury to operating personnel. Total length of exhaust pipe should not
D-19
Diesel Genset
exceed 15 meters and should have maximum of four right angle bends. Avoid using elbows.
Increase pipe I.D. by 1.5” after every 5 meter length of exhaust pipe. Expansion bellows &
flexible pipes should be installed between engine and exhaust piping.
The exhaust pipe outlet should be bent so that outgoing exhaust gases are not recirculated.
The exhaust pipe outlet should be bent in the direction of wind and the end should be cut at an
angle of 45 degrees.There should be rain trap to avoid rain water entry. If rain cap is used the
distance between exhaust pipe and rain cap should be 2.5 times diameter of exhaust pipe.
Figure D - 23: Exhaust System

The figure shows HA694 Engine with exhaust outlet facing downwards. Exhaust silencer is
mounted separately on the equipment and connected to exhaust manifold by flexible piping.
D-20
Diesel Genset
D4. Engine Operation
D4.1 Commissioning
D4.1.1 Filling Engine Oil
Figure D - 24: Engine Oil Filler

Engines are delivered with first fill oil.
D4.1.2 Adding Fuel
Never fill the tank while the engine is running. Observe cleanliness and do not spill any
fuel.
Figure D - 25: Use High Speed Diesel

Use only High speed diesel fuel. For fuel specifications refer D5.2.
D4.1.3 Fuel System Ventilation
D4.1.3.1 For In-line Fuel Injection Pump
•Loosen overflow valve 1 on the fuel pump.

•Loosen hand pump 2 of the fuel feed pump at the knurled grip by unscrewing it.
D-21
Diesel Genset
•Operate the hand pump till fuel flow without air bubble at overflow valve.
•Tighten the overflow valve while fuel is flowing simultaneously operating the hand pump.
•Tighten the hand pump at knurled grip.
•Refer image Figure D - 26:.
Figure D - 26: Fuel System Ventilation for In-line FIP
D4.1.3.2 For Rotary Fuel Pump
Ȁ ! "#$%&
'$(( ! )*+$(
Figure D - 27: Ventilating a Rotary Fuel Pump

The Rotary Fuel pump gets clean fuel through a feed pump and a spin-on fuel filter.
•Loosen Overflow Connection on the fuel pump.
•Operate the hand pump on top of fuel filter till fuel flow without air bubble through the overflow
connection.
•Tighten the overflow connection while operating the hand pump leading to a fuel flow. This will
avoid air entrapment in the fuel system.
D4.1.4 Other Preparations
•Check battery and lead connections.
D-22
Diesel Genset
•Also check cable connection at the starter and alternator end for tightness.
•Remove engine lifting tackle.
•Trial run
-After completing the engine preparations run the engine for about 10-15 min. at no load.
-While engine is running check lube oil pressure (3.5 to 4.5 kg/cm2) and lube oil
temperature is within limits.
•During and after trial run
•After trial run and engine stationary
-Check oil level, refer D7.1.2.
-if required top up oil, refer D4.1.1.
-Re-tension V-belts, refer D7.5.
•Running in
-During running in period- about 50 running hours, check oil level twice a day.
-After running in, checking oil level once a day will be sufficient.
D4.1.5 Additional Maintenance Work
The following maintenance should be carried out after 50 operating hours;

•Change lube oil refer D7.1.3.
•Change oil filter element /cartridge, refer D7.1.4.
•Change fuel filter element / cartridge, refer D7.2.1.
•Check V-belts and re-tension if necessary, refer D7.5.
•Check the engine for any leakages.
D4.2 Starting
D4.2.1 Before Starting
Before starting, make sure that nobody is standing in the immediate vicinity of the
engine or driven machine.
After repair work;

Check that all guards have been replaced and all tools have been removed from
the engine.
When starting with Engine Heater Plug, do not use any other starter substance (e. g. injection
with start pilot).
Caution: If the speed regulator has been removed for any reason, the engine must
not be started under any circumstances. Disconnect the battery.
D-23
Diesel Genset
D4.2.2 Starting without Engine Heater
D4.2.2.1 Starting the Engine
•The user starts and stops the engine through the EMS 934 controller.
•Before starting, ensure completion of genset’s daily maintenance.
•Ensure that load is disconnected from genset. Ensure people and material/tools are clear of
the engine.
•Check if Manual Mode is selected on the EMS 934 controller by the lit state of lamp on the top
left of the MAN button. If not, operate MAN button once and verify the lighting of the lamp.
MAN
•To start the engine operate the Manual Start button once.
I
•The controller will initiate cranking to start the engine. If the engine fails to start, the controller
will try again. If the engine does not start despite several attempts, the controller indicates a
Start Failure condition and inhibit further cranking. See Controller section for more details.
•After engine starts:
-Allow engine to run for 3 minutes, ensure all parameters within limits and then start
connecting load in steps.
-Check engine parameters like Oil pressure, coolant temperature and battery changing
rate at regular intervals, while the genset is in operation.
-Maintain log book.
-Check for exhaust smoke.
-Check for any abnormal sounds.
-Check for alternator parameters, like voltage, ampere, kW and Power Factor on all
phases.
-During commissioning, cross check the meter readings with a calibrated multimeter or
clamp - on meter.
-Ensure that the load is balanced in all phases and within rated output of the genset.
-Check that all engine and alternator parameters on the controller are working.
D-24
Diesel Genset
D4.2.2.2 Stopping The Genset
•Disconnect the load from the genset.
0
•Operate the Stop Button once. STOP
•The controller will keep the engine running for several seconds due to a Cool down timer for
ventilating the engine and alternator.
•After engine stops, check for any leakages.
•Top up fuel tank.
•Note fuel consumed for hours operated.
•Check oil level 30 minutes after stopping. If low, top up and note the oil consumption.
•Close the canopy securely.
•Switch off the Control
If the engine does not start in first attempt wait a minute then try again. if the engine does not
start after two attempts, refer to the Diagnosis Chart D8.
Where possible, disengage the engine from any driven equipment. Do not start the engine if it
is separated from load for any reason or if engine speed regulator has been removed for any
reason.
D4.2.3 Starting with Engine Heater
The procedure for stating the engine with Engine Heater is similar to procedure as in Starting
without Engine Heater.
D4.2.3.1 Starting the Engine
After starting is initiated, through Manual Start button

I , the controller first activates the
Engine Heater for a preset time. Then the controller goes to the normal start sequence as
mentioned in D4.2.2.1.
D4.2.3.2 Stopping the Engine
The sequence for stopping the engine is same as mentioned in D4.2.2.2.
D4.3 Electrical System
Standard engines are equipped with 12V, negative earth electrical starting system.
D-25
Diesel Genset
D4.3.1 Electrical Equipment
Table 12: Electrical Equipment for R series
12 V Electrical system
12V DC, 35 Amp
Alternator 12V DC, 55 Amp
12V DC, 65 Amp
12V DC, 2.0 KW
Starter 12V DC, 2.7 KW
12V DC, 3.0 KW
D4.3.2 Battery Cable
Battery Cable (Copper) = 35mm2
D4.3.3 Recommended Battery Capacity
Table 13: Battery Capacity
Genset with
Recommended Battery
Air Cooled Engine Series
HA2, HA3, HA4 12 V, 88 AH
HA6 12 V, 130 AH
D4.4 Monitoring System
D4.4.1 Engine Lube Oil Pressure
The display of EMS 934 controller indicates lube oil pressure of engine. If the pressure drops
below the set value, the controller will stop the engine automatically. During running, the
pressure must be above minimum as indicated in D10.1.
D4.4.2 Engine Oil Temperature
The display of EMS 934 controller indicates the lube oil temperature. If the temperature goes
beyond the set value, the controller will stop the engine automatically. Refer diagnosis chart
(Refer D8.) for the cause of high oil temperature.
D-26
Diesel Genset
D4.4.3 V-Belt Failure Switch
HA294 G1NA, HA394TCI G1, HA 494 TCI and HA /694 TCI are provide with a V-Belt Failure
Switch. If the V - Belt fails, lever of automatic belt tension actuates an electrical switch to trigger
the controller and stop the engine to prevent engine overheating.
Figure D - 28: Belt Failure Switch
D4.4.4 High Cylinder Head Temperature Switch
HA294 G1 engines have a High Cylinder Head Temperature Switch that detects high cylinder
head temperatures (Set point 175 ± 5 oC) and stop the engine via the controller. This protects
the engine in case of belt failure.
D4.5 Operating Conditions
D4.5.1 Winter Operation
•Lube Oil Viscosity

-Select the oil viscosity (SAE grade) according to the ambient temperature when the
engine is started, see D5.2.1.
-Increase oil change frequency when operating below -10°C, see D7.1.1.
•Diesel Fuel
-Use winter- grade diesel fuel operation below 0°C, see D5.2.2.
•Additional Maintenance Work
-Drain the sludge from the fuel tank once a week. (Unscrew the drain plug.)
-If necessary, allow the oil in the oil bath air cleaner and the engine oil to settle at the
ambient temperature while checking oil level.
-Below -20°C after removing the starter if necessary, smear the ring gear on the flywheel
via the pinion bore from time to time with cold resistant grease.
•Cold- Start Aid
-At low temperatures the genset can be offered Engine Heater.
•Battery.
-Efficient cold starting requires a healthy battery, see D7.7.1.
-The starting limit temperatures can be lowered by 4-5°C by heating the battery up to
about +20°C (to do so, remove the battery and store in a warm place.)
D-27
Diesel Genset
Figure D - 29: Focus for Winter Operation
D4.5.2 High Ambient Temperatures and High Altitude
•As the altitude and ambient temperature rise, the density of air tends to decrease, which
affects the maximum power output of the engine, the exhaust gas quality and in extreme
cases the starting behavior.
•The engine can be used for operating conditions other than NTP conditions: (Temp. - 27 oC,
Relative Humidity 60% and 100 meters above sea level ) however power output will have to
be derated accordingly.
•In case of doubts about engine operation under severe conditions, refer to your dealer /
equipment supplier whether engine has been derated for power to enhance service life,
reliability and exhaust gas quality. Consult KOEL Service for more details.
D5. Operating Media
D5.1 Lube Oil
D5.1.1 Quality Grade
K-Oil Premium lube oil is recommended to use in the engine. It has the correct viscosity and
detergency grades for the best all round performance..
Warranty is applicable on use of ‘K-Oil Premium’ engine oil only.
D5.1.2 Viscosity
Multi-grade oil should be used. As the viscosity of lube oil is dependent on temperature. the
choice of SAE grade should be governed by the ambient temperature prevailing at the engine
operating site.
D-28
Diesel Genset
Figure D - 30: Temperature versus Oil Viscosity

Optimum operating behavior will be attained if you take the accompanying oil viscosity diagram
as a guide Should be temperature fall temporarily below the limits of the SAE grade selected,
cold starting may be affected but the engine will not be damaged.
In order to keep wear to a minimum, do not exceed application limits for extended period of
time.
D5.2 Fuel
D5.2.1 Quality Grade
The commercially available diesel fuel with sulphur content less than 0.05% be used. If sulphur
content is higher, then oil change period should be halved. The following specifications /
standards are approved
•IS 1460 : 2005
•ASTM D975 - 88 :1-D & 2-D
D5.2.2 Winter Grade Fuel
Waxing may occur at low temperatures clogging the fuel system and reducing engine
efficiency. If the ambient temperature is less than 0 deg. C. Winter grade fuel ( suitable down to
- 20deg.cel. ) should be used. This fuel is usually available from filling stations well in advance
of the cold months.
•At temperatures below -20deg C. kerosene should be added to the diesel fuel. The relevant
percentages are given in the diagram at the right.
D-29
Diesel Genset
If summer grade diesel fuel must be used at temperatures below 0 deg.C, up to 60% kerosene
can be added (see diagram).
Figure D - 31: Temperature versus Fuel Type
Table 14: Legend for Temperature vs. Fuel Type
Type Explanation
I Summer diesel fuel
II Winter diesel fuel
A Outside temperature
B Percentage of kerosene to be added
Diesel fuels must never be mixed with petrol.
Mix in tank only. Fill with the appropriate amount of kerosene first, then the diesel fuel.
D-30
Diesel Genset
D6. Routine Maintenance
D6.1 Maintenance Schedule
Table 15: Maintenance Schedule for HA series engines
Operating Hours
Refer
Job
Section
Daily 250 500 750 1000 5000 9000
* Oil level in engine D7.1.2
* o Air Cleaner - oil bath
* o Air Cleaner - dry type D3.6.1
* Battery & lead connections D7.7.1
+ Cooling system D7.3
o Engine lube oil D7.1.1
o Lube oil filter element / cartridge D7.1.4
* Fuel strainer D7.2.3

Major Overhaul
* o
Top Overhaul
V - Belt Tension
V - Belt D7.5
Fuel filter insert - pre-filter element / D7.2.1

x o cartridge
Fuel filter insert - micro filter element / D7.2.2

o o cartridge
* Fasteners D10.3
* Starter & Alternator
* Valve clearance D7.6.1
* Injector
* Safety system D7.5.5
* Engine Heater D4.2.3
D-31
Diesel Genset
Table 15: Maintenance Schedule for HA series engines (Continued)
Operating Hours
Refer
Job
Section
Daily 250 500 750 1000 5000 9000
* = Checking Recommended, o = Change, + = Clean,

X = Fuel Filter Insert Change only for HA2/HA3 engines.
-Change the lube oil every 250 hours, if using lubricant other than K-Oil Premium.
-Above maintenance schedule is applicable for Standard Operating Conditions.
D6.1.1 Log of Maintenance Work
Table 16: Maintenance Log
Hours Date Remark Signature / Stamp
50
250
500
750
1000
1250
1500
1750
2000
2250
2500
2750
3000
3250
3500
3750
4000
4250
4500
D-32
Diesel Genset
Table 16: Maintenance Log (Continued)
Hours Date Remark Signature / Stamp
4750
5000
5250
5500
5750
6000
6250
6500
6750
7000
7250
7500
7750
8000
8250
8500
8750
9000
D7. Service & Maintenance
D7.1 Lubrication system
D7.1.1 Oil Change Intervals
•The oil change intervals are dependent on engine application and operating environment.
Refer subsequent table below.
.
Table 17: Oil Change Interval
Engine Operating Conditions - Normal Duty
Naturally Aspirated, Turbocharged and Every 500 hours or 6 months.

Turbocharged Aftercooled
•If the engine runs fewer hours than stated in the table, oil should be changed at least once in
a year.
D-33
Diesel Genset
•The oil change period in table refer to following operating conditions: Ambient temperature
down to -10deg.C. sulphur content less than 0.05%
•If the sulphur content is above 0.05% to 1% or operating temperature is below -10deg.C. then
oil change intervals should be halved.
•If case fuel containing more than 1% sulphur, contact KOEL Service.
Recommended lube oil change period is applicable in only case when using K-Oil
Premium in the engine, sourced from KOEL Service Dealer.
Change the lube oil every 250 hours, if using lubricant other than K-Oil Premium.
.
D7.1.2 Checking Oil Level
•Ensure engine is horizontal.

•Stop the engine if running, wait for 30 minutes.
•Remove the oil dipstick.
•Wipe the dipstick with clean, non-fibrous cloth.
•Insert the dipstick to the stop and remove again.
•Check oil level, it should be between Max.and Min. mark.
•If required top up to Max. mark.
Figure D - 32: Markings on Oil Dipstick
Oil level should never be below Minimum mark. Oil level should not exceed Maximum
mark.
D-34
Diesel Genset
D7.1.3 Changing Engine Oil
Figure D - 33: Oil Temperature

•Ensure that the engine or vehicle is on a level surface.
•Start the engine at idle.
•Allow the engine warm up.
•Achieve Lube oil temperature of approximately 80 oC.

•Switch off the engine.
Figure D - 34: Oil Draining

•Place oil tray under the engine.
•Unscrew drain plug.
•Drain oil.
•Fit oil drain plug, with the new gasket and tighten firmly.
•Fill with lube oil.
-For grade / viscosity.Refer D5.1.2.
-For quantity, Refer D5.1.1
•Confirm correct oil level. Refer D7.1.2
Take care when draining hot oil. Danger of scalds! Do not let used oil run into the soil
but collect it in a container ready for proper disposal.
D-35
Diesel Genset
D7.1.4 Changing Oil Filter Element - Spin On Type
Figure D - 35: Removing Oil Filter Cartridge

•Remove the filter cartridge by rotating it anti-clockwise with commercial tool.
•Collect dripping oil in a tray.
•Destroy the removed cartridge.
Figure D - 36: Fitting new Oil Filter Cartridge

•Clean sealing surface of filter carrier rim.
•Apply light film of oil to the rubber seal of new cartridge.
•Assemble the new cartridge by rotating it clockwise.
•Sealing gasket of cartridge be hand tight.
D-36
Diesel Genset
Figure D - 37: Tightening new Oil Filter Cartridge

•Tighten the oil filter cartridge with another half - turn using commercial tool.
•Check oil level, see D7.1.2.
•Check oil pressure, see D4.4.1
•Check cartridge seal for leaks, see D7.1.4.
Beware of burns from hot oil.
D7.2 Fuel system
D7.2.1 Changing Fuel Filter - Spin On Type
Figure D - 38: Removing Fuel Filter

•Remove the cartridge by rotating in anti-clockwise using commercial tool.
•Collect dripping fuel in a tray.
•Destroy the removed cartridge.
D-37
Diesel Genset
Figure D - 39: Fitting new Fuel Filter Cartridge

•Clean the sealing surface of filter.
•Apply light film of oil or diesel fuel to the rubber gasket of the new fuel filter cartridge.
•Screw in the new cartridge finger tight against the gasket.
Figure D - 40: Tightening new Fuel Filter Cartridge

•Tighten the fuel filter cartridge with a final half turn using commercial tool.
•Open fuel stopcock.
•Check for leaks.
•Fuel system bleeding is not required.
Keep naked flames away when working on they fuel system. Do not smoke while
working with fuel system.
D7.2.2 Changing Fuel Filter - Element Type
•Close fuel valve.

•Unscrew the plug at bottom of bowls and collect the fuel in tray.
D-38
Diesel Genset
•Unscrew the center bolt of bowls and remove bowls and fuel inserts.
•Clean the bowl with diesel.
•Change Pre-filter insert only. Do not change Pre-filter insert & Micro filter insert at a time.
•Discard the removed insert.
Figure D - 41: Changing Fuel Filter - Element Type

•Check the condition of sealing ring, change if required.
•Assemble the bowls and tighten centre bolts firmly.
•Bleed the fuel system before starting engine.
•For changing Micro filter insert follow the same procedure.
Do not clean fuel filter inserts. Always replace the insert with new one at recommended
intervals.
D7.2.3 Fuel Strainer
Figure D - 42: Fuel Strainer

•Remove banjo bolt at inlet of feed pump.
D-39
Diesel Genset
•Unscrew the strainer fitted inside the banjo bolt.

•Clean the fuel strainer in fuel & blow it with compressed air. Replace if necessary.
•Refit the fuel strainer in banjo bolt.
•Refit the banjo bolt to feed pump with new copper washer.
•Bleed the fuel system.
No naked flames when working on the fuel system. Do not smoke in the vicinity.
D7.3 Cooling System
D7.3.1 Cleaning Intervals
•The amount of contamination in the cooling system depends on the engine application.
•Oil or fuel leakages on the engine increase the risk of contamination. Be careful and avoid
leakage when engine is used in dusty environment.
•Serious contamination can occur, for example - on construction sites where there is a high
level of air - borne dust. - in harvesting application where there are high concentrations of
chaff and chopped straw in the vicinity of the machine.
•Because applications vary, cleaning intervals have to be determined from case to case.
•The cleaning intervals given in the table below can be used as a guide.
Table 18: Cleaning Intervals
Recommended
Inspection
and Engine application
Clearing
Intervals
Operating Hours
2000 Ships, Gensets in enclosed areas, pumps
1000 Vehicles on reinforced highways
500 Tractors, fork-lift trucks, mobile electrical units.
250 Vehicles on construction sites and on roads with loose surfaces, construction
machinery, compressors, mining equipment.
125 Agricultural machinery, tractor used for harvesting purpose.
D-40
Diesel Genset
D7.4 Combustion Air Filter
D7.4.1 Air Cleaner Service Intervals
Figure D - 43: Restriction Indicator

•The soiling of air cleaner depends on the dust in air, operating environment and size of air
cleaner used.
•Cyclone type pre-cleaner is recommended in dusty environment.
•Cleaning intervals will have to be determined from case to case.
•If dry-type air cleaners are used, it should be cleaned only in accordance with the restriction
indicator.
•Air cleaner servicing is needed when the red flag is visible on the restriction indicator and
coincides with level indicated.
•After completing the service work, reset the red flag by operating the button on the indicator.
D7.4.2 Dry Type Air Cleaner
Figure D - 44: Cleaning Dust Ejector Valve

•Empty dust ejector valve by pressing apart lips of discharge slot as indicated.
•Clean discharge slot from time to time.
•Remove any caked dirt by pressing together the upper section of the valve.
•Inspect the dust ejector valve, replace if necessary.
D-41
Diesel Genset
Figure D - 45: Filter Element

•Loosen the mounting clamp of dust cup / top cover assembly.
•Take out the element for cleaning.
•Use damp cloth to wipe out dust in the air cleaner.
Figure D - 46: Cleaning Filter Element

•Clean the element by dry compressed air (air pressure 3 kg/cm2 maximum).
•Blow the air from inside to outside for cleaning the element.
•Replace main element after two cleaning intervals.
•Replace outer element at least once in a year.
Never clean air cleaner with petrol.
Figure D - 47: Checking Element with Light Test

•Check cleaned/new element for damage before installing.
•Check for cracks by passing a light through element.
D-42
Diesel Genset
•Any crack in the element will show up due to leakage of light.

•Replace element if found cracked.
Figure D - 48: Checking Sealing Ring

•Check rubber sealing ring for damage.
•Replace if necessary.
•Inner / Safety Element element should be replaced after every two changes of outer element.
•Repeat same procedure as outer element while replacing inner element.
Never clean the inner element, always replace it.
D7.5 Belt Drives
•Inspect complete belt for damage, refer section D7.5.1

•Replace damaged V-belts.
•After installing new, belts, run engine for 15 minutes, then check belt tension as mentioned in
section D7.5.3.
Check tension and change belts only when engine is at standstill. Refit belt guard, if
provided. When new V-belts are fitted, check the belt tension after 15 minutes running time.
D7.5.1 Checking V-Belts
Figure D - 49: V-Belts
D-43
Diesel Genset
D7.5.2 Replacing Fan V- Belt
Figure D - 50: Replacing Fan V- Belt

•To replace V-belts, press in tension unit using a commercial tool and remove the old V-belts.
•Fit new V-belts.
D7.5.3 Tensioning Alternator Belt
Figure D - 51: Tensioning Alternator Belt

•Loosen bolts which fix alternator on mounting bracket. Also loosen bolts of tension adjusting
lever.
•Pull out alternator until correct belt tension is achieved.
•Retighten all bolts firmly.
Check/ tension/ replace V-belts only when the engine is at a standstill. Replace V-belt
cover before restarting the engine.
D-44
Diesel Genset
D7.5.4 Changing Alternator Belt
Figure D - 52: Changing Alternator Belt

•Remove fan V-belts as described in D7.5.2.
•Loosen alternator mounting bolts.
•Push alternator inwards.
•Remove old V-belt and replace with new belt.
•Pull alternator out until desired belt tension is achieved.
•Retighten alternator mounting. bolts.
•Fit fan V-belts covers.
Retighten new V-belts after 15 minutes running time
D7.5.5 V-belt Failure Warning System
Figure D - 53: V-belt Failure Warning System

•If the V-belts fails, the Failure Warning System actives an electrical switch.
•This switch initiates a warning or shutdown through the engine’s safety system.
•* To do a functional check, press switch actuator and simulate V-Belt failure.
Check belt only when the engine is at a standstill.
D-45
Diesel Genset
D7.5.6 Visual Inspection of V-Belts
Figure D - 54: Cracked V belt

Check V belts (Blower and Alternator) for cracks and wear along entire length. Replace belt if
excessive wear and cracks are observed. Replace belt if any other abnormalities like cords
coming loose or fraying of belt exteriors.
Figure D - 55: Excessive wear of V belt
D7.5.7 Re-tensioning of Alternator Belt
Figure D - 56: Belt Tensioning Device

Appropriate belt tensioning device should be used to measure the belt tension.
Belt tension should be between 60 to 50 Hz (190 to 130N). If the belt tension value of
falls below 50 Hz, (130N) Re-tension to 60±2 Hz (190±20N). Applicable for HA air cooled
engines series only.
D7.6 Adjustments
D7.6.1 Checking Valve Clearance
•Check and adjust valve clearance when engine is in cold condition.
D-46
Diesel Genset
•Remove the rocker cover.

•Turn crankshaft until the valves of cylinder (on which clearance is being checked) are
overlapping.
•Then turn the engine by 360 degree.
•Check valve clearance between rocker arm toe and valve stem with feeler gauge.
•Feeler gauge of 0.15mm should pass with slight resistance. Failing this, adjust valve
clearance. Refer D7.6.1. For permissible valve clearance, see D10.1.
Figure D - 57: Checking Valve Clearance
D7.6.2 Adjusting Valve Clearance
Figure D - 58: Adjusting Valve Clearance

•Loosen lock nut of adjusting screw.
•Use screw driver to loosen setscrew so that feeler gauge of 0.15mm can be inserted and
removed with slight resistance.
•Tighten the lock nut.
•Check and adjust valve clearance on all remaining cylinders.
•Reassemble rocker cover. (use new gasket if needed).
D-47
Diesel Genset
D7.7 Accessories
D7.7.1 Checking Battery and Cable Connectors
Figure D - 59: Battery and Terminations

•Keep the battery clean and dry.
•Ensure the cable terminals tightly fitted on the battery posts.
•Secure the battery firmly on the cradle.
•Ensure battery earth. Use rubber or wooden strip between battery & cradle.
•Clean the terminals (+ve and -ve) and clamps with ammonia solution. Mix in the ratio of 115
grams of ammonia for 1 litre of water.
•Apply petroleum jelly / vaseline on terminals & posts. Never apply grease.
•Ensure good contacts of terminals.
D7.7.2 Checking Electrolyte Level
Figure D - 60: Removing Battery Vent Caps

•Remove cell caps.
•Top up only with distilled water.
•Maintain level corresponding to the maximum level.
•Do not add Acid.
D-48
Diesel Genset
•Keep vent plugs tightly closed.

•Ensure the holes in battery caps are open. Choked vent holes could lead to bursting of the
battery.
D7.7.3 Checking Electrolyte Density
Figure D - 61: Checking Electrolyte Density

•Check the specific gravity of individual cell with hydrometer.
•Check specific gravity if battery has been topped up with distilled water. Check 5 minutes
after topping up.
•The measured values indicate state of charge of battery.
•Charge the battery if necessary.
•Avoid measuring specific gravity when battery is warm.
Table 19: Specific Gravity of a Battery
Specific Gravity (kg/1) State of Charge
Normal Tropics
1.28 1.23 Fully charged
1.20 1.12 Half charged, Recharge
1.12 1.08 Discharged, Charge up immediately.
-The gases emitted by the battery are explosive!

-Keep spark and naked flames away from the battery.
-Do not allow battery acid to come into contact with skin or clothing.
-Wear protective goggles.
-Do not rest tools on the battery
D-49
Diesel Genset
D7.7.4 Lifting Tackle
Figure D - 62: Lifting Tackle

•Always use proper lifting tackle when transporting and lifting the engine.
•After transportation / lifting engine, remove lifting tackle before starting the engine.
Figure D - 63: Do not lift without tackle
Use only the correct lifting tackle.
D7.8 Engine Cleaning
D7.8.1 Cleaning the engine with Compressed Air
•Stop the engine.

•Release the cowling clamps and remove cowling.
•Remove baffle on exhaust side.
•Cover electrical / electronic components. (Starter, alternator, stop solenoid etc.)
•Blow the compressed air through the engine starting from exhaust side.
•Be careful with cooling fins and cooler.
•Remove dirt blown inside engine compartment.
D-50
Diesel Genset
•Reassemble the cowling.
Figure D - 64: Cleaning the Engine with Compressed Air
D7.8.2 Cleaning the engine with Cold Cleaning Agent
Figure D - 65: Cleaning the Engine with Cold Cleaning Agent

•Stop the engine.
•Cover inlet & exhaust ports.
•Spray the engine with cold cleaning agent and allow it to soak for 10 minutes.
•Clean the engine with pressurized water jet. Repeat the process if necessary.
•Blow the engine with compressed air to remove water.
D-51
Diesel Genset
D7.8.3 Cleaning the engine with High Pressure Steam Jet
Figure D - 66: Cleaning the Engine with High Pressure Steam Jet
•Stop the engine.
•Cover inlet and exhaust ports.
•Clean the engine with steam jet. (Steam pressure - 60 bar and temperature 90 deg.C)
•Loosen pipe connection 1.
•Rotate engine with starter, key switch in START position.
•Fuel must be emitted at loosened pipe connect ion.
•Otherwise have the system, solenoid 3, checked by a specialist.
Test stage 3:
•Loosen pipe connection 1.
•Remove flame glow plug 2 and reconnect pipe.
•Rotate engine with starter, key switch in START position.
•Fuel must be emitted at flame glow plug 2, replace plug 2 if necessary
•Use heat resistant sealant when fitting flame glow plug 2.
•Refit flame glow plug 2 on fuel line.
•Keep away from rotating parts.
Collect any leaked fuel and dispose off as per approved environmental policy.
D8. Faults, Causes & Remedies

Most common faults and solutions are listed in the diagnosis chart on next page..
D-52
time
wear
speed
starting
constant
Complaints
Diesel knock
Bearing wear
Engine overheat
Mechanical knock
Excessive vibration
Engine lacks power
Engine will not start
Engine fails to rotate
Low lube oil pressure
Breaking of valve springs

Excessive oil consumption
Excessive smoke at no load
Excessive fuel consumption

Mixing of diesel with lube oil
Excessive smoke at full load
Engine has starting difficulty
Engine gives out blue smoke
Battery runs down frequently

Engine gives out white smoke
Engine speed does not remain
Engine does not reach governed

Engine misfires during operation
Engine rotates very slowly during

Excessive liner & piston ring wear
Engine starts but stops after some
Excessive fuel injection equipment

Excessive valve & valve guide wear
•
•
•
•
•
•
•
•
•
Dust entry in air inlet system

•
•
•
•
•
•
•
•
•
•
•
•
Dirty / clogged air cleaner

•
•
•
•
High exhaust back pressure

Derating due to altitude
System
Air /Exhaust
• •
• • •
Derating due to temperature

•
No fuel
•
•
•
•
•
•
•
• •
Poor quality of fuel

•
•
Air in the fuel line

•
•
•
• •
Choked fuel line

•
•
External / Internal fuel leakage

•
•
• • • •
Choked fuel injector holes

•
• •
•
• •
• •
• • •
Damaged or dribbling nozzle

Loose HR pipe connections
Fuel System
•
•
•
Dirty / Choked fuel filter

•
• •
• • •
• • •
Control lever settings wrong

•
•
•
•
•
•
•
•
Faulty fuel pump
•
•
• •
• •
• •
Water mixed with fuel

•
•
•
•
•
•
Wrong grade of lube oil used

•
Dirty / Choked suction tube strainer

Lube oil dilution
•
•
•
Dirty / Clogged lube oil filter
•
Clogged oil passage

•
Excessive oil in the sump

• •
External / internal leakages
Lubricating System
•
•
•
Faulty oil pump
Radiator fins choked
• •
• •
Loose V - Belt
• • •
Air leakages through radiator &
System
Cooling
•
•
No coolant in radiator/Coolant level
• •
•
•
• •
• •
• Engine overloading
•
•
•
•
•
Engine used after a long time
•
•
•
•
•
•
Wrongly adjusted valve clearances

Maint.
• •
•
•
•
• •
• •
Operation
Prolonged oil change period

•
Blown cylinder head gasket
• •
• •
Valve leakages
•
•
•
• • •
•
• • •
• •
Broken / worn out piston rings
Excessive end play in crankshaft
• • •
•
•
•
•
•
• • •
• • •
•
•
Worn out cylinder liner & piston
Incorrect bearing clearances
• •
• •
• •
• •
•
•
Damaged main & connecting rod
•
•
•
•
• • •
Worn out valves & valve guides
•
•
•
Incorrect valve & fuel timing
• •
• •
• •
•
•
• •
• •
Injector needs adjustment
•
•
•
•
•
•
Engine seized
Faulty governor setting
Mechanical System
•
•
• •
• •
•
• •
•
One or more cylinders not working
Loose mounting bolts
• •
• •
Loose flywheel / wrong alignment
•
•
•
•
•
•
•
•
•
•
Engine needs overhauling
Fuel pump rack stuck in stop
Battery run down / under rated
Faulty starter
• • •
• • •
• • •
• • • •
Battery of wrong capacity
System
•
•
•
•
Electrical
Loose or dislodged wiring
Diesel Genset
D9. Engine Preservation
D9.1 About Preservation
If the engine is to remain idle for an extended period of time, it is necessary to take protective
measures to prevent rust formation. The preservative measures described here will protect the
engine up to 12 months.
Table 20: Recommended Preservatives for Lube and Fuel system
Manufacturer Brand
Indian Oil Corp. Servo Preserve 30
Bharat Petroleum Bharat Preserve Oil 30
Hindustan Petroleum Autoprun T120
Veedol Tide Oil Co. Veedol 30/40
Table 21: Recommended Preservatives for External Surfaces
Manufacturer Brand
Indian Oil Corp. Servo RP 125
Bharat Petroleum Bharat Rustrol 152
Hindustan Petroleum Rustop 274
Veedol Tide Oil Co. Veedol Ruspro IT
Castrol India Rustilo DW-904 or DW-901
Recommended cleansing agent to remove preservatives when recommissioning engine : NC

Thinner.
D9.2 Preserving Engine
•Clean the engine preferably using thinner and compressed air.

•Run the engine until warm and stop.
•Drain the lube oil.
•Fill the engine with preservative oil.
•Clean the oil bath air cleaner, fill oil bowl with preservative oil.
•Drain the fuel tank.
•Prepare mixture of Diesel + Preservative, ratio 5 :1. Refill the fuel tank with mixture.
•Run the engine for 5 minutes at low speed / fix speed engine at No Load.
•Stop the engine.
•Turn the engine manually several times to preserve the cylinders and combustion chamber.
D-54
Diesel Genset
• While rotating with starter, stop lever of fuel pump to be in stop condition.
•Drain the preservative oil from engine
•Drain the Diesel + Preservative oil from fuel tank.
•Remove the V-belts.
•External unpainted surfaces to be treated with rust preventive oil
•Plug all the openings, vents of the engine.
•Disconnect the battery and store it in a safe place.
•Cover the engine with polyethylene bag if possible.
•Procedure to be repeated if engine is to be stored for more than 12 months.
D9.3 Commissioning Preserved Engine
•Remove plugs, tapes from inlet port, exhaust port and vent.
•Remove the rust preventive coating from all external surfaces.
•Install V- belts.Retension belts after brief operation if required.
•Set the engine in operation. Refer D4.1.
D10. Technical Specifications
D10.1 Engine Specifications for CPCB II
Table 22: Engine Specifications
HA394TCI HA494TCI HA694TCI

Sr No Specification Unit HA294 G1
G1 G1 G1
1 Number of Cylinder 2 3 4 6
Cylinder
2 Vertical In-line
arrangement
3 Bore mm 100
4 Stroke mm 120
5 Total displacement cc 1885 2827 3770 5655
6 Compression ratio 17:1
7 Working Cycle 4-Stroke Diesel Engine
8 Combustion System Direct Injection
9 Direction of rotation Counter-clockwise, looking from flywheel end
Starting
10 Electric start
arrangement
11 Firing order 1-2 1-3-2 1-3-4-2 1-5-3-6-2-4
D-55
Diesel Genset
Table 22: Engine Specifications (Continued)
HA394TCI HA494TCI HA694TCI

Sr No Specification Unit HA294 G1
G1 G1 G1
12 Power Refer 9.2.1 / 9.2.2
13 Speed Refer 9.2.1 / 9.2.2
14 Lubrication Forced feed Gerotor pump
15 SAE Oil K-OIL PREMIUM SAE 15 W 40 CI4
Lube Oil oC
16 90-125
temperature
Minimum Oil
17
Pressure at idle kg/cm2 1.5
Minimum Oil
18 Pressure at rated kg/cm2 3.0 to 4.5
Speed
Sump Capacity-w/o
19 Liter 5 8 11 13.5
Lube filter
20 Sump + Lube filter Liter 6.5 9 12.5 15.5
Valve clearance in
21 mm 0.15
cold condition
Injector Opening
22
Pressure kg/cm2 260 ± 10
23 Fuel timing degrees 8±1 °BTDC 8.5±1.5 °BTDC
24 Bumping Clearance mm 0.8-0.9
25 Dry weight of engine Kg 243 300 370 450
Dry engine weight

26 with flywheel and Kg 338 370 440 520
housing
D10.2 Power Output for CPCB II
Table 23: Power Output
Engine Model Speed Continuous Power As Per Iso 3046
Rating
RPM
KW BHP
HA294 G1 1500 15.1 20.5
HA394TCI G1 1500 23.5 32
HA494TCI G1 1500 41.2 56
D-56
Diesel Genset
Footnotes:
1.Total angle torque 165 degree for cylinder head with steel gasket.
2.During replacement of piston, piston rings and bearings it is recommended to change main
bearing cap bolts, connecting rod cap bolts and cylinder head bolts.
D-58
Diesel Genset
Kirloskar Green AC Alternator

E1. General ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ E‐1
E1.1 Introduction ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ E‐1
E1.2 Standards ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ E‐1
E1.3 Enclosures and Mounting ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ E‐1
E2. Design of AC Generator ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ E‐1
E2.1 Stator ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ E‐1
E2.2 Rotor‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ E‐2
E2.3 Exciter Stator ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ E‐2
E2.4 Exciter Rotor‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ E‐2
E2.5 Rotating Rectifier Assembly‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ E‐2
E2.6 Impregnation ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ E‐2
E2.7 Balancing ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ E‐2
E2.8 Terminal Box‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ E‐3
E2.9 Bearings ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ E‐3
E2.10 Ventilation ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ E‐3
E2.11 Earthing ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ E‐3
E2.12 Space Heater ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ E‐3
E2.13 Voltage Regulator ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ E‐3
E2.14 Optional Accessories‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ E‐4
E3. Operating Principle ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ E‐4
E3.1 Standard Brushless AC Generator‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ E‐4
E3.2 Brushless AC Generator with PMG ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ E‐5
E3.3 Advantages Of PMG Excitation System: ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ E‐5
E4. Kirloskar Green (KG) AC Generators ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ E‐6
E4.1 Electrical Performance ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ E‐6
E4.2 Process‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ E‐6
E5. Automatic Voltage Regulator ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ E‐7
E5.1 Features ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ E‐7
E5.2 AVR Models ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ E‐7
E6. Derating Factors ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ E‐8
E6.1 Temperature‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ E‐8
E6.2 Altitude ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ E‐8
E6.3 Power Factor ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ E‐9
E7. Selection of AC Generators ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ E‐9
E7.1 Linear Loads ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ E‐9
E7.2 Linear Loads ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ E‐10
E7.3 Power Factor ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ E‐10
i
Diesel Genset
E7.4 Motor Loads‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ E‐10
E7.5 Non Linear Loads ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ E‐11
E7.6 Characteristics of Non Linear Loads ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ E‐11
E7.7 Effects Of Non Linear Loads‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ E‐11
E7.8 Deration for Non Linear Loads ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ E‐11
ii
Diesel Genset
Brushless A C Generators
E1. General
E1.1 Introduction
Kirloskar Green (KG) Brushless AC Generators are of salient pole, revolving field, brushless,
horizontally foot mounted, and single/double bearing type. These AC Generators are available
with and without PMG generators Standard Voltage of operation i.e., 415/460 V at 50/60 Hz for
3Ø and 230/240 V at 50/60 Hz for 1Ø.
E1.2 Standards
The Kirloskar Green (KG) AC Generators generally comply with various national and
international standards such as IS: 4722, IS: 13364, BS: 5000 Part3 and IEC 6034-1 (34-1)
and specifications mutually agreed upon at the time of order.
E1.3 Enclosures and Mounting
The AC Generators have degree of protection of IP 23 with B15(SB)/B3(DB) type of Mounting.

Other types of protection and mounting can also be offered on request.
Figure E - 1: Alternator Designation
E2. Design of AC Generator
E2.1 Stator
Stator of the AC Generator is made of high quality, low loss high permeability steel stamping
built rigidly to with stand all types of forces due to static, dynamic and transient loading
conditions. The armature coils are made up of enameled high conductivity copper wires with
E-1
-
Diesel Genset
class ‘H’ insulation, 2/3 pitch winding to eliminate triple and its multiple harmonics in the
generated output voltage. Windings are subjected to vacuum pressure impregnation for better
consolidation and the overhangs are provided with epoxy gel coating to protect against ingress
of dust, moisture and others. The winding leads themselves form the output terminals directly
from the armature without any joints on the overhang. All the 6/12 leads are brought out
sleeved and terminated with suitable crimping sockets.
E2.2 Rotor
The main rotor is made of low loss high permeability steel stamping, built directly on to the
shaft, which is then wound with field coils using high conductivity enameled copper for Class
‘H’ insulation. A set of completely interconnected damper winding cage is provided in the rotor
for compensation for any unbalance and during transient condition. Coil support blocks are
provided for adequate supporting of the coils from high centrifugal forces.
E2.3 Exciter Stator
Exciter stator built up of high quality laminated steel stampings carries the field coils mounted
on the Non- Driving End shield of the machine. The coils are made up of high conductivity
enameled copper with class ‘H’ insulation. The coils are firmly supported by suitable epoxy
wedges inserted in between the pole shoes.
E2.4 Exciter Rotor
Exciter rotor built up of thin laminations in the form of riveted core carries three phase armature
windings and is mounted on to the shaft. The winding is made of high conductivity enabled
copper with class ‘H’ Insulation. The output winding leads are terminated at the rotating rectifier
assembly.
E2.5 Rotating Rectifier Assembly
Rotating Rectifier Assembly is a three-phase bridge rectifier mounted on two Aluminum heat
sinks. Provisions are made in the rectifier assembly for connecting the main rotor leads and
surge suppressor provided to protect the diodes from surge voltages.
E2.6 Impregnation
All the windings are impregnated with Class ‘H’ resin and taken through the temperature curing
cycle to form a rigid winding. The overhangs are protected with a coat of epoxy gel application
against ingress of dust, moisture and others particles.
E2.7 Balancing
All generators rotors are dynamically balanced to better than Grade 2.5 (BS 6861: Part 1) for
minimum vibration in operation.
E-2
Diesel Genset
E2.8 Terminal Box
The sheet metal/cast Aluminum terminal box having ample space is fixed on the top of the NDE
end shield. 6/12 output terminals are terminated. It is possible to terminate the customer cables
on either side, depending on the customer’s choice. The Voltage Regulator is also mounted
inside the terminal box and terminated.
E2.9 Bearings
Two nos. of anti-friction double shielded ball bearings are provided one each at NDE and DE in
double bearing machine and only one at NDE in case of Single/double Bearing machine.
Adequate care is taken in the design of the Single/double Bearing machine to accommodate
for possible axial differences in the close coupling system.
E2.10 Ventilation
The AC Generators are self-cooled. The centrifugal Aluminum/Steel fan fitted on the shaft at
the driving end of the rotor draws the fresh air through the opening provided at the NDE cover
and discharges through ventilating ducts provided in the DE End Shield in double bearing
machines and adaptor in Single Bearing machines. The method of cooling is IC 01 as per
IS:6362.
E2.11 Earthing
Two earthling screws provided on the feet ribs are used for grounding of the AC Generator.
E2.12 Space Heater
Two space heaters (optional) suitable for 230 V / 24 V, single phase/ DC are provided on each
overhang of the main stator winding of AC Generator on request.
E2.13 Voltage Regulator
Automatic Voltage Regulator provided is compact, high performance encapsulated unit

mounted inside the terminal box. This unit senses the voltage between lines and controls the
generator output voltage automatically to be with in the specified regulation band. AVR consists
of separate potentiometers for adjusting the voltage, stability, frequency roll off and quadrature
droop adjustment (Optional).
The following are the features of the AVR.
•Build up from a very low residual voltage -about 2.5 V (L-N).

•Voltage regulation within +/- 0.8%of pre-set value.
•Fast response to the load changes.
•Remote V-trim pot for voltage adjustment up to ± 10%of nominal terminal voltage.
E- 3
Diesel Genset
•QDC pot for Quadrature droop adjustment during parallel operation (Optional).
•Stability pot for adjustment of the response.
•Frequency-Roll-Off pot to set the frequency range.
•Over excitation limit pot to set the excitation limit
E2.14 Optional Accessories
These optional accessories are provided on the customer requirement. These are basically for
the protection of the machine while working on the extreme conditions. The following
accessories are provided.
•Winding temperature detectors (RTD/Thermistor).

•Bearing temperature detectors (BTD).
•Current transformers for differential protection.
•Permanent magnet generator.
•Auxiliary winding facility.
•Filters for dusty environment.
•Filters for harmonics.
E3. Operating Principle
E3.1 Standard Brushless AC Generator
1.In this generator there is a separate source to AVR from a small permanent magnet A.C.
generator mounted on the same shaft as the main machine. Refer Figure E - 2 on page 5.
2.The permanent magnet produces an output voltage that is only dependent on speed and is
independent of load conditions. This constant output voltage is fed to the exciter field winding
through the AVR.
3.By comparing the main output ‘sensed’ voltage with the ‘set reference’ voltage, the AVR
decides on the proportion of permanent magnet machine output to rectify and feed to the exciter
field.
4.The exciter rotor output would then increase, established a strong main field and therefore a
marked increase in main output voltage.
5.The AVR senses and compares voltages and adjusts exciter field excitation until desired
output voltage is developed. In this way the main stator voltage is progressively built up until the
‘sensed’ voltage is the same as the ‘set reference’ voltage.
E-4
Diesel Genset
Figure E - 2: Standard Alternator
E3.2 Brushless AC Generator with PMG
PMG = Permanent Magnet Generator
Figure E - 3: PMG Alternator
E3.3 Advantages Of PMG Excitation System:
E- 5
Diesel Genset
•Better motor starting characteristics with lower transient voltage dips.

•Better co-ordination with relay under sustained short circuit condition.
•Since the Power to AVR is supplied from the PMG, isolation from AC Generator output
terminals, harmonic currents from the load are prevented from passing to the AVR. This
reduces output voltage distortion.
•The process of initial voltage build up is very positive in this system, as residual magnetism is
no longer continually depended upon.
E4. Kirloskar Green (KG) AC Generators
E4.1 Electrical Performance
1.AVR used on the machine is of proven design, reliability and performance. These are unique
encapsulated against moisture, sand, salt, humidity and corrosive atmosphere ensuring trouble
free operations under the most demanding conditions. The voltage regulation offered is +/-
0.8%.
•Transient voltage dips are lower.
•Wave-form distortion on no-load is less than 1.8%. Total harmonic distortion and the
telephonic interference is less than 4% in distorting balanced linear load.
•All stators are wound to 2/3rd pitch, which along with PMG excitation system as optional and
2 line sensed as standard AVR and 3 line sensing as optional to provide better system
performance.
•Damper winding on poles ensure smooth parallel operation with similar and dissimilar
machines and with the grid. Power factor controller is recommended when balancing with
gird.
•Liberally rated diode used in rotating rectifier assembly ensures high reliability.
•The rotating diodes are protected by a surge suppresser which has the ability to chop the
transients.
•Short Circuit Current with stand capability is up to 3 times the rated current for 3 seconds.
•Excellent motor starting capacity 2.5 times rated kVA.
E4.2 Process
•Gel coat application is a standard feature which enhances the mechanical strength of the
winding overhang and ensures trouble free performance in humid and corrosive atmosphere.
•Burr free stamping pack construction and file free winding results in excellent quality of
winding and also better machine life.
•Hammer free assembly and sealed bearing increase bearing life.
•Dynamically balanced rotor to minimize vibration.
E-6
Diesel Genset
Table 23: Power Output (Continued)
Engine Model Speed Continuous Power As Per Iso 3046
HA694TCI G1 1500 61 83
D10.3 Torque Wrench Setting
Table 24: Torque Wrench Setting
Total
Remark
Description Size Initial Torque Tightening Angle In Degree Angle
Nm (kgm) 1st 2nd 3rd 4th

Stage Stage Stage Stage
Cylinder M12x1. See

30 (3.1) 45 45 45 30 165
Head Bolt 75x211 Footnote 1
Connecting M12x1.
30 (3.1) 60 30 .... .... 90
Rod Bolt 5x55
Bearing Cap M14x1 See

30 (3.1) 60 45 .... .... 105
Bolt 10 Footnote 2
Intermediate M10x6
30 (3.1) 60 .... .... .... 60
Gear Bolt 0
Balance M12x6
30 (3.1) 30 30 .... .... 60
Weight Bolt 0
Crank M24x2 Left Hand

50 (5.1) 210 .... .... .... 210
Pulley x110 Threads
Cooling
Blower Bolt M12x1
30 (3.1) .... .... .... .... 90
(HA294 G1/ 40
394/494)
Cooling
M12x1
Blower Bolt 30 (3.1) 90
80
(HA694)
M 10
Flywheel x1x
30 (3.1) 30 60 90
Bolt 35/40/
45/50
25-30Nm
Fuel Injector M 10
- - - (2.5-3.1
Nut x1.5
kgm)
Footnotes on next page.
D-57
Diesel Genset
E5. Automatic Voltage Regulator

Kirloskar Green (KG) regulators are in wide range for wide application. Our regulators have the
following specifications.
•Encapsulated components for weather protection.
•Compact and rugged construction.
•Solid state.
•Fast response to the load changes.
•Build up from a very low residual voltage – about 2.5 V (L-N)
E5.1 Features
•Voltage adjustment: The V trimmer is provided in the AVR for voltage adjustment up to +/-
10% of rated voltage.
•Stability Adjustment: The AVR include stability circuit to provide the good steady state and
transient performance of the generator.
•Under frequency Roll off (UFRO): The AVR incorporates an under speed protect circuit which
gives a Volts/ Hz characteristics when the generator speed falls below a presentable value
the red LED gives indication that the UFRO circuit is operating.
•Droop Adjustment: Generator intended for parallel operation are fitted with a quadrature
droop CT. CT is connected to Q1, Q2 on the AVR with ratios of rated current: 5Amps, 1%
accuracy, 5/2.5 VA burden.
•Accessory Input: for 250 kVA and above AC Generators
•An analog input (A1& A2 is provided to connect to the DC current source device. It is
designed to accept DC signal up to +/- 4.5 Volts.
E5.2 AVR Models
Table 1: AVR Models
Number Parameter TAVR -20 TAVR -30 TAVR -18 (PMG) DSR
1 Voltage adjustment Yes Yes Yes Yes
Stability Yes Yes Yes Yes

2
adjustment
Under frequency No Yes Yes Yes

3
roll off adjustment
Remote voltage Yes Yes Yes Yes

4
adjustment
Over Excitation Yes Yes Yes Yes

5
adjustment
Accessory ( DC No Yes No Yes

6
input)
E- 7
Diesel Genset
Table 1: AVR Models

Number Parameter TAVR -20 TAVR -30 TAVR -18 (PMG) DSR
7 Quadrature Droop No Yes Yes Yes

Sense Loss Yes Yes Yes No
8
indication
Over excitation Yes Yes Yes No
9
indication
Under frequency Yes Yes Yes Yes

10
roll off
Frequency roll of Yes Yes Yes Yes
11
indicator
12 Used on frames KG 164 - 254 KG 284 - 354 KG 284 - 354 KG3-28-32-34
13 Ratings 5 - 200 kVA 250 - 750 kVA 250 - 750 kVA 5 - 160 kVA
E6. Derating Factors
E6.1 Temperature
These AC Generators are designed for an ambient temperature of 40°C. For other applications
where the ambient temperature is greater than 40°C, the AC Generators must be de-rated to
ensure that the actual temperature does not exceed the specified limit.
Outputs are normally quoted at 40°C. These outputs must be multiplied by the following factors
for higher ambient temperatures.
Table 2: Derating for Temperature
TEMPERATURE (°C) MULTIPLIER
45 0.97
50 0.94
55 0.91
60 0.88
E6.2 Altitude
Above 1000 m the effectiveness of the air is reduced sufficiently to make de-rating necessary.
For altitudes above 1000 m outputs must be multiplied by the following factors.
Table 3: Derating for Altitude
Altitudes Multiplier
1500 0.97
2000 0.94
E-8
Diesel Genset
Table 3: Derating for Altitude
Altitudes Multiplier
2500 0.91
3000 0.88
3500 0.85
4000 0.82
E6.3 Power Factor
Standard AC Generators are suitable for 0.8 pf lag to UPF loads. Power factor below 0.8 lag
causes heating of the AC Generator. The A C Generator output must be multiplied by the
following factors for lower PF.
Table 4: Multiplier for Power Factor
P.f(Lag) Multiplier
0.7 0.95
0.6 0.91
0.5 0.88
0.4 0.86
0.3 0.85
0.2 0.84
0.1 0.84
0.0 0.84
Leading pf loads cause rise in terminal voltage which may subsequently harm the AVR and the
loads. Please refer to works in case of leading pf loads.
E7. Selection of AC Generators

This section deals with selection of AC Generators to suit various loads.
The different types of load encountered by an AC Generators can be broadly classified as

a) Linear Loads.
b) Motor Loads (part of linear loads, considered separately).
c) Non-linear Loads.
E7.1 Linear Loads
•Constant load impedance regardless of applied voltage.
E- 9
Diesel Genset
•he load current increases proportionately as the voltage increases and decreases as the
voltage decreases.
Examples of linear loads are motor, incandescent lamp and heating loads.
E7.2 Linear Loads
To select the rating of AC Generator for linear loads the maximum connected load and the
base load which is always connected has to be considered. In arriving at a total load figure is
always wise to select the standard rating larger than that estimated. This despite the fact that
all the loads may not be operating at the same time hence a smaller machine could have been
selected. Future operating conditions and future growth are very difficult to estimate. An
allowance of 15% to 20% excess capacity designed into a set now is a small price to pay
compared with the cost of completely new larger unit that may be required to drive additional
loads in a few years time.
E7.3 Power Factor
It is the nature of the applied load that dictates the system power factor.
1.The loads which operate at or very close to unity (1.0) power factor include most forms of
lighting, all heating elements, rectifier and thyristor type loads & all domestic loads which are
fractional hp motors (washing machine, refrigerator, etc.).
2.For all remaining load types, some knowledge of operating power factor is required, which for
motors depends a great deal on their size and power rating.
Kirloskar Green (KG) A C Generators perform satisfactorily at any power factor in the range of
0.8 p.f lag to unity. For p.f operation at leading low power factor Please refer back to works.
E7.4 Motor Loads
During the starting of an induction motor, a very large current is demanded from the power
source, which is known as the starting or locked rotor current. For better sizing of AC
Generators, the following guidelines can be referred to.
Table 5: Motor Loads
Method Of Starting Current Starting Current as I rated times full load
Direct On Line 6-7
Star Delta 3-3.5
Rotor Resistance 1.5-2
Auto Transformer: At 40% Tapping 1.1
At 60% Tapping 2.5
At 80% Tapping 4.5
E - 10
Diesel Genset
For motor applications the following information should be furnished:
a) Rating of the motor/ motors.

b) Type of the motor (slip ring / squirrel cage).
c) Method of starting.
d) Rated full load current.
e) Starting power factor.
f) Any restriction on Transient Voltage Dip? (Details of the same).
g) Frequency at starting.
h) Base load at the time of starting induction motor.
i) Any other load apart from the motor loads? (Details there of).
j) Sequence of starting of motors.
E7.5 Non Linear Loads
Over a period of time the loads applied to AC generators have become more complex and
more care has to be exercised in the sizing of the generators to ensure satisfactory
performance.
E7.6 Characteristics of Non Linear Loads
a) A non linear load is one in which the load current is not proportional to the instantaneous
voltage. Often the load current is not continuous.
b) These are essentially electronic loads such as computers, UPS equipments and variable
speed motor drives.
E7.7 Effects Of Non Linear Loads
a) Non linear loads generate harmonics in their current waveform which in turn leads to
distortion of the AC generator waveform. Depending upon the degree of voltage waveform
distortion this can lead to instability of the excitation systems and impact on other loads being
supplied by the generator.
b) Odd order harmonics cause heating of neutral conductors.
E7.8 Deration for Non Linear Loads
The above percentage figures are guidelines. There may be a problem with electronic load,
trying to cope with distorted waveform if distortion levels are unacceptable to the load.
Table 6: Non Linear Loads
Loads Derating Factors
Fluorescent lighting load No derate required.
UPS & Telecom load controlled by a 12 Non linear load should not exceed 90% of AC Generator
pulse Thyristor bridge plus a filter. rating
E- 11
Diesel Genset
Table 6: Non Linear Loads
Loads Derating Factors
UPS & Telecom load controlled by 6 pulse Non linear load should not exceed 60% of AC Generator
Thyristor Bridge plus a filter. rating
UPS & Telecom load controlled by3 pulse Non linear should not exceed 50% of AC Generator rating.
thyristor bridge pulse a filter
Variable speed 6 pulse thyristor Non linear load should not exceed 35% of AC
controlled drive. Generator rating
Better sizing of machine is possible on furnishing following information:

a) Number of pulses of Thyristor drive: 3, 6, or 12.
b) Level of harmonic distortion produced by the non-linear load.
c) What is the maximum acceptable level of voltage distortion the Non-linear load can accept?
d) Operating voltage and frequency.
e) If Non-linear load power requirement is stated in kW, then some guidance regarding
operating power factor & system efficiency is required to establish the AC Generator load.
With the information, guidance should be sought from the factory regarding AC Generator
sizing for compatible equipment operation.
E - 12
HELP DESK CONTACT NUMBER - +91 880 63 344 33
HELP DESK TOLL FREE NUMBER - 1800 233 3344
email ID - koel.helpdesk@kirloskar.com Drawing: 02.083.14.0.00
www.koel.co.in

15 To 62.5 kVA Air Cooled PDF

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

15 To 62.5 kVA Air Cooled PDF

Uploaded by

Copyright:

Available Formats

CPCB II

GENSET USER MANUAL

RATING: 15 to 62.5 kVA

Ideas diesel generating sets.

For Kirloskar Oil Engines Ltd.,

Head, Power Generation Business

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.

FOR EMERGENCY CONTACT

HELP DESK CONTACT NUMBER - +91 880 63 344 33

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 Limited Vijay T B 080-25587562/ +91-

Section B - Customer Service

Section D - Diesel Engine

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 Authorized

- Genset Model and Serial Number.

- Engine serial Number.

- Detailed site address

- Contact Person and Telephone/Mobile Number.

- Number of hours run till date

GENSET MODEL AND SERIAL NUMBER

ENGINE MODEL AND SERIAL NUMBER

KG ALTERNATOR SERIAL NUMBER, MAKE AND TYPE

PANEL SERIAL NUMBER

G1 (1ST SERVICE) CHECK CARRIED OUT ON

G2 (2ND SERVICE) CHECK CARRIED OUT ON

SERVICE DEALER'S STAMP AND SIGNATURE

KIRLOSKAR GREEN D.G. SET WARRANTY

For Power Generation Non-Cellular Application Engines -

For Power Generation Non Cellular Application Engines and KG

Use K-Oil Premium for your Gensets.

This warranty does not apply for the following:

Warranty period for DG set components is as below.

For Power Generation Non Cellular Application

•Proprietary parts not manufactured by Kirloskar Oil Engines Limited like:

•Kirloskar Green Alternators

•All other Electrical Components supplied along with Genset like:

•Kirloskar Green canopy Components supplied along with Genset like:

•Locks •Hinges •Fuel level gauges •Exhaust fan

For Power Generation Cellular Application -

•All other Electrical Components supplied along with engine like:

•Kirloskar Green canopy Components supplied along with Genset like:

Conditions precedent to Kirloskar Green Genset warranty.

A. Proper installation of the Kirloskar Green Genset is the sole responsibility of

To meet specific customer needs, your Genset may not contain

Engine________________________ RPM_________________ HP____________

Engine________________________ RPM_________________ HP____________

Engine________________________ RPM_________________ HP____________

Engine________________________ RPM_________________ HP____________

Ambient temp. (air temp. near air-cleaner element) :

S a fe tie s : L ow L ube O il P re s s ure – W ork ing / N ot Work ing

Overall Performance of DG Set OK / Not OK.

Engine________________ RPM_ HP____

Engine________________ RPM_ HP____

Engine________________ RPM_ HP____

Engine________________ RPM_ HP____