OWNER’S MANUAL

Mahindra & Mahindra Ltd.,

Mahindra Powerol Business, Powerol Building, Gate No. 2, Akurli Road, Kandivali (E),
Mumbai – 400101, Phone: 022 – 6648 3051, Website: www.mahindrapowerol.com

MP/CC/18/OM-5KVA-RIL/01 Dec’14
 Foreword
Congratulations on becoming a proud owner of Mahindra Genset.

We welcome you to the Mahindra family, which is one amongst the top business houses in India. Mahindra &
Mahindra Ltd. is into manufacturing of Cars, Tractors, Engines, Steel and other engineering products, besides
the company is also in diverse businesses like Construction & Software.

From the year 2001, we started a new business of Gensets under the brand name of Powerol. These Gensets
are powered by the engines which are already time tested and accepted as fuel efficient and durable in Tractor
market.

This user manual has been prepared keeping in mind the need of the operators. If you need more technical
information feel free to contact us.

The Technical details mentioned in this manual are subject to change depending upon company
requirements/norms.

We are sure Powerol Gensets will serve you well for years if you follow the maintenance schedule prescribed
in this manual.
Important note:

The information contained within this publication is given with our best intensions and are believed to be
correct at the time of going to the press.
Our policy is one of continued development and we reserve the right to amend any technical information
with or without prior notice.
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WARRANTY POLICY
1. Mahindra & Mahindra Ltd. (herein after called Company) warrants to the retail purchaser for the Engine manufactured
by Company, that the company’s Authorized Dealer/Distributor (Mahindra Authorized Genset & Industrial Engine Center -
MAGIEC) will repair or replace any part thereof subject to limitations specified herein below, found to be defective in
materials or workmanship in the Company’s opinion, Within 1 year from the date of commissioning or sale or 1200 hours
of operation, whichever occurs earlier.

2. This warranty is limited to delivery to the purchaser, free at the Mahindra Authorized Genset & Industrial Engine Center -
MAGIEC setup or it’s workshop, of the part or parts whether new or repaired, in exchange for those acknowledge by the
company to be defective.

3. The warranty shall not apply to and cover items like Gaskets (other than cylinder head gasket), fasteners (except main
bearing cap bolts etc.) and those part like oil, filters etc. which are replaced during scheduled maintenance.

4. The company desires and expects that the purchaser shall make a thorough examination of the company’s products
before purchasing. The MAGIEC of the company’s product are in no way the legal agents of the company and have no right
or authority to give any other warranty, assume any obligation on its behalf, or to bind the company in any way.

5. For the purpose of this warranty, the term “Product” means and includes only new Engines manufactured by or for the
company to the Company’s designs and drawings by OEM / company itself, sold by Sales dealer / OEM / company itself
and commissioned by the company’s Authorized Service Dealer (MAGIEC)..

6. The company’s responsibility is limited to the terms of this warranty and it shall not be answerable for personal injuries
or consequential or resulting liability, damage or loss arising from any defects.
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7. This warranty shall not apply to:

a) Defects/damage caused by normal wear and tear.
b) Accidents, misuse or neglect, or the defects in any products which have been altered outside the company’s works or
which have been let out on hire.
c) The identification marks of which have been altered or removed.
d) Loaded beyond the recommended power ratings.
e) Misapplication, not as per recommended specifications and condition of use.
f) If the engine is not used properly or for any other purpose for which it is not meant for.
g) If the engine is exposed during running condition to the conditions beyond operating norms like excess heat,
temperature, improper installation etc.
h) Improper mounting and coupling of driven units.
i) Use of spurious / non-genuine (not purchased from Authorized Powerol Service Dealer) parts and non recommended
lubricants.
j) If regular service, (as per company recommendation) is not carried out through MAGIECs.
k) Any failure due to non-use of set for long time and without preservation.
l) Failure due to improper Operation and maintenance (not recommended by company)
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8. The company’s liability under this warranty is dependent upon the strict observance by the purchaser, of the following
provisions:-
a) The purchaser at the time of installation shall sign, complete and return the installation form
b) Installation of the set to be done as per norms specified by the company.
c) Mahindra Authorized Genset and Industrial Engine Centre (MAGIEC) will do the commissioning re-check and warranty
of engine will start ONLY after the commissioning.
d) The commissioning report has to be signed by Purchaser and MAGIEC representative.
e) Any pending jobs mentioned in commissioning report has to be complete by Purchaser (if it in his / her scope) within
the time specified in report to avail the warranty benefits. d) Under all operating conditions adequate quantity of air
will be supplied.
f) Repairs and replacement will be performed by the MAGIECs only, following delivery of the product by the purchaser
to the distributor’s place of business, or on the site of commissioning.
g) This warranty shall not apply if the product or any part thereof is repaired or altered otherwise in accordance with our
standard repair procedure or by any person other than our MAGIEC or their branch distributor or their service centres
in any way.
h) The purchaser shall at all time in the operation of the engine use only those brands of oils, lubricants and parts,
officially approved in writing by the company.
i) The judgment of the Company or its MAGIECs in all cases of claims shall be final and conclusive and the purchaser
agrees to accept its decisions on all questions as to defects and to exchange of part or parts. After the expiration of six
days from the dispatch of notification of the Company’s or its MAGIECs decision, the part or parts submitted may be
scrapped or returned carriage forward by the company or its MAGIEC.
j) Claims arising from this warranty will be recognized only if they are notified in writing to our
k) MAGIEC concerned or to us without delay, after the defect has been ascertained.
l) We reserve the right to make changes in design or introduce any improvement or add any part on products at any
time without incurring any obligation to install the same on products previously sold.
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9. The use on the engine of replacement parts not manufactured or supplied by the company will invalidate this Warranty.

10. The above warranty is in lieu of all other warranties expressed or implied, and no person, agent or representative of the
company is authorized to give any other warranties on the Company’s behalf or to assume for it any other liability in
connection, with the above products.

11. All proceedings relating to any dispute arising between the company and the purchaser on the liability of the company
under this warranty shall be decided in civil courts having jurisdiction in Greater Mumbai only.

LABOUR FREE SERVICE

The company offers three labour free services to the customers. Labour free services will be provided at 50 hours, 250
hours and 500 hour.

Parts and fuel used during the course of these services will be charged.
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Table of contents
1. Specifications .................................................................................................................................. 1
2. Safety Precautions .......................................................................................................................... 2
3. Know your Genset ........................................................................................................................... 5
3.1 Location ................................................................................................................................... 5
3.2 Grouting .................................................................................................................................. 6
3.3 Earthing ................................................................................................................................... 7
3.4 Emergency Switch ................................................................................................................... 8
4. Control Panel................................................................................................................................. 10
5. Preparing the engine for work ...................................................................................................... 16
6. Preventive Maintenance ............................................................................................................... 17
6.1 Service Schedule ................................................................................................................... 17
6.2 Oil and Oil Filter .................................................................................................................... 18
6.3 Fuel Filter & diesel filling ....................................................................................................... 20
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6.4 Air Cleaner............................................................................................................................. 22

7. Troubleshooting ............................................................................................................................ 23
8. Contact Details .............................................................................................................................. 23
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1. Specifications

Engine: Genset:
Make LOMBARDINI 15 LD 440 Model MM1105SI-FEMTO1
Power (kW) 6.1 Rating (KVA) 5
Bore 86MM No. of Phase One
Stroke 76MM Control Panel ECP with DSE 4520
RPM 3000 Size (L X W X H) - (mm) 1080 x 700 x865
Cooling Air Cooled Fuel Tank Capacity 80
Aspiration Natural (Ltr.)
No. Of Cylinders 1 Approximate Weight 225
Displacement (cc) 442 (kg)
Governing Class A2 Alternator:
Starting System 12 V DC Make MeccAlte
Battery (Ah) 35 Voltage (Volts) 230
SFC (g/kWh) 245 Phase Single
Oil Capacity (Litre) 1.5 Frequency (Hz) 50

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2. Safety Precautions
There are WARNING and DANGER stickers pasted in the Genset indicating Hot surface, Hot exhaust
gas and Electric shock hazard to avoid any personal injury. However, Common sense, caution and
care must be taken when operating or cleaning the Genset.

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Safety instructions:

 DO NOT run engine indoors or in an area with poor ventilation unless exhaust hoses are used. Diesel
Engine exhaust contains carbon monoxide; a deadly, odourless and colourless gas which, if inhaled,
Can cause nausea, fainting or death.

 DO NOT fill fuel tank near an open flame, while smoking, or while engine is running.

 DO NOT touch or lean against hot exhaust pipes or engine cylinders.

 DO NOT clean Air Filter with gasoline or other types of low flash point solvents.

 DO NOT operate the unit without a functional exhaust system. Prolonged exposure to higher sound
levels can cause permanent hearing loss. Wear hearing protection when working around a running
engine without soundproof enclosure.

 Keep hands, feet and loose clothing away from moving parts on the generator and engine.

 Keep area around exhaust pipes and air ducts free of debris to reduce the chance of an accidental fire.

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 Batteries contain sulphuric acid which can cause severe injury or death. Sulphuric acid can cause eye
Damage, burn flesh or eat holes in clothing. Protective eye wear and clothing are necessary when
working on or around the battery. Always disconnect the NEGATIVE (-) battery cable from the
corresponding terminal before performing any service on the engine or other components.

 This unit uses high voltage circuits capable of causing serious injury or death. Only a qualified
electrician should troubleshoot or repair electrical problems occurring in this equipment.

 Before servicing the generator, make sure engine OFF and the negative terminal on the battery is
disconnected. NEVER perform even routine service (oil/filter changes, cleaning, etc.) unless all
electrical components are shut down.

 NEVER wash the unit with any high pressure hoses or power washers.

 ALWAYS use extreme caution when servicing this unit in damp conditions. Do not service the unit if
your skin or clothing is wet.

 Do not allow water to collect around the base of the unit.

 ALWAYS connect the unit to a good earthen ground before use.

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3. Know your Genset
3.1 Location

Ensure that the Genset is placed on a levelled surface.

Put the Genset in proper location. Inlet air and outlet air should be free of obstruction.

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3.2 Grouting
The Genset must be grouted to the Foundation. Four
grouting points are provided for this purpose.

Nut
Plain Washer
Spring Washer

Grouting Bolt FOUNDATION

Hardware specifications for Grouting

Hex Bolt M10 x 75 – 4 no.s
Grouting point
Plain Washer M10 – 4 no.s
Spring Washer M10 – 4 no.s
Nut M10 – 4 no.s

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3.3 Earthing
Earthing point
This Genset must be earthed using at least one
out of the two earthing points provided in the
Genset.

The earthing points are provided on Right Hand

Side and on the Left Hand Side.

[Looking from the Control Panel side.]

Use standard copper wire for earthing. Tighten

the nut against the earthing wire. The other end
of this wire should be connected to a copper or
brass earthing plate that driven into the earth.
Earthing point
Earthing codes can vary by location. Contact a
local electrician for information on grounding
regulations in your area.

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3.4 Emergency Switch

In case of emergency, the Genset can be immediately stopped by pressing the Emergency Switch.

Do not forget to reset the switch. Otherwise, the Genset will not start.

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3.5 Fuel Drain Arrangement

Diesel tanks naturally accumulate

water, solids and sludge resulting
in degradation of fuel. Therefore
periodic cleaning of diesel tank is
recommended.

A Fuel Drain Plug is provided in

this Genset for this purpose.

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4. Control Panel

Control Panel Side (Front Control Panel with DSE 4520 Controller
View)

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BUTTON & LED IDENTIFICATION – DSE 4520

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Running In Manual Mode

To run the Generator in Manual mode, first the Manual/Start Mode button should be pressed.
If ‘protected start’ is disabled, the start sequence begins immediately. (* The ‘protected start’ can
be selected or de-selected via DSE Configuration Suite Software.)

If ‘Protected Start’ is enabled, the Waiting in Manual Mode icon is displayed and the LED above
the Manual/Start Mode button flashes to indicate Waiting in Manual Mode.

The Manual/Start Mode button must be pressed once more to begin the start sequence.

As soon as the oil pressure and voltage builds up, the Generators is ready to take load.

This is displayed by the Engine Running icon/animation . To stop the Generator first disconnect
the load and then press the Stop button .

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Viewing the Parameters

To enter the navigation menu, press both (up) and (down) buttons simultaneously, the
navigation menu is then displayed. Now various instrument pages can be browsed.

Main navigation menu and cycling through the menus

To select the required icon, press the (up) button to cycle right or the (down) button to
cycle left until the desired instrumentation section is reached. Once the desired icon is at the top,

press the Auto Mode button to enter that instrumentation section.

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Power Circuit Drawing

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Control Circuit Drawing

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5. Preparing the engine for work
Before starting the engine for the first time, please ensure the following checks:

Check the lubricating oil level. Check with dipstick, oil level must be upto the maximum mark of the
dipstick.

Fill the diesel tank from the fuel filling neck. Use a funnel to pour diesel. Securely tighten the fuel
filling cap after filling and immediately wipe up any spilled diesel with a dry cloth.

NOTE:
 Never use a mixture of kerosene and diesel.
 Never use contaminated diesel.
 Avoid getting dirt or water in the fuel tank.

After filling up the diesel tank, remove air from diesel line and fuel filter by priming the Feed Pump.

Connect the battery with correct polarity.

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6. Preventive Maintenance
6.1 Service Schedule
Labour Free Paid Service
Work Description
50 Hrs 250 hrs 500 Hrs 750 Hrs 1000 Hrs 1250 Hrs
LUB OIL FILTER Replace Replace Replace Replace Replace Replace
ELEMENT FUEL FILTER PRIMARY Replace Replace Replace Replace Replace Replace
FUEL FILTER ASSEMBLY SECONDARY Replace Replace Replace Replace Replace Replace
Air Filter Cartridge Clean Clean Replace Clean Clean Replace
LUBE OIL (VALVOLINE POWERGEN @ 2LT) Replace Replace Replace Replace Replace Replace
Valve Setting - - Check - Check -
Injector setting - - Check - Check -
Air cleaner connection / hose Check Check Check Check Check Check
Fuel tank sediments Drain Drain Drain Drain Drain Drain
Fuel tank breather Check Check Check Check Check Check
Feed pump filter Clean Clean Clean Clean Clean Clean
Fuel pump oil Check Check Check Check Check Check
Fuel Leakage Check Check Check Check Check Check
All Electrical OE item & harness Check Check Check Check Check Check
Battery Electrolyte level Check Check Check Check Check Check
Battery terminal Clean Clean Clean Clean Clean Clean
Battery Vent Clean Clean Clean Clean Clean Clean

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6.2 Oil and Oil Filter
Check engine oil level with the Dip Stick. Oil level should be at
high mark. If found low, please top up. Dip Stick

While replacing the oil filter do not damage the ‘O’ Rings,
replace ‘O’ Rings if damaged.

Oil Filter ‘O’ Ring

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To drain the oil, remove the drain plug.

Top up oil, use Mahindra recommended Powergen

Excel oil (API CH4/SJ SAE 15W40).

Drain Plug

Oil filling

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6.3 Fuel Filter & diesel filling

To remove the filter, loosen the centre bolt and

replace the filter cartridge.

To remove the Primary Filter Element, loosen the

centre bolt. Primary Fuel
Replace the Secondary Filter Assembly. Filter

Clean the Feed Pump filter.

Feed Pump Filter Secondary

Fuel Filter

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Fill the diesel tank from the fuel filling neck. Use a Diesel filling
funnel to pour diesel.

Securely tighten the fuel filling cap after filling and

immediately wipe up any spilled diesel with a dry cloth.

NOTE:
 Never use a mixture of kerosene and diesel.
 Never use contaminated diesel.
 Avoid getting dirt or water in the fuel tank.

After filling diesel, always remove air from the fuel lines
by priming the Feed Pump.

Priming the Feed Pump

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6.4 Air Cleaner

Clean the cartridge from inside to outside using a Air Filter Element
blower.

Please note: Air Cleaner element cleaning and

replacement frequency may increase if the Genset is
used in dusty atmosphere.

Clean inside of the Air Cleaner body using a dry cloth.

Remove the Dust Unloader, clean it and refit.

Dust Unloader
Air Cleaner Body

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7. Troubleshooting

Engine not starting: High/Low RPM:

 Check Emergency Stop button.  Check engine RPM
 Check the diesel level. Fuel level fault:
 Check for air lock in the diesel line.  Check the float unit connection.
 Check battery connection/voltage. Oil pressure low:
 Check stop solenoid.
 Check oil level, LLOP switch
 Check starter motor.
No speed:
Charging fault:
 Check alternator connection with
 Check battery connection/battery
controller
voltage/battery charger.
 Check AC output
Oil pressure lock out:  If no output, check alternator brush
 Check LLOP connection  If brush ok, check AVR connection
Oil temperature high/high engine
temperature:
 Check Oil Temperature Sensor.
 Check blower/ air inlet and outlet.

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8. Contact Details
HEAD OFFICE WEST
Mahindra & Mahindra Ltd., Powerol Business, Mahindra & Mahindra Ltd, Farm Equipment Sector
Powerol Building, Gate No. 2, Akurli Road, Misem Tower, 19/2, Plot No.15, Off Karve Road,
Kandivali (E), Mumbai – 400 101, India Near Sharda Centre, Erandwane, Pune - 411 004
Visit us at: mahindrapowerol.com
Tel: 020 - 25409100

NORTH SOUTH
Mahindra & Mahindra Ltd., Mahindra Towers, Mahindra & Mahindra Ltd. Farm Equipment Sector
2nd Floor, No. 2A, Bhikaji Cama Place Mahindra Tower, Door No. 17/18, 1st Floor
New Delhi – 110 066 Pattullos Road, Chennai 600 002

Tel : 011‐4122 0326 / 0327 Tel: 044-2857 1075

EAST
Mahindra & Mahindra Ltd.
7, Kyd Street, 3rd Floor, Kolkata – 700 016

Tel: 033‐2845 0855 / 2246 9067

/ 2239 2605

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