Generating Set User Manual - KG320WS To KG625WS

SERVICE
KIRLOSKAR OIL ENGINE LIMITED
5
GENSET
WARRANTY
GENSET WARRANTY
This warranty is applicable for the “Kirloskar Green Power Ideas” genset manufactured
by Kirloskar Oil Engines Limited (KOEL).
Before commissioning of the Genset, please go through the contents of this warranty
section carefully
For details of the KOEL authorized service dealer for your genset, please contact either
your genset supplier or the nearest KOEL product support office.
For availing the warranty services, please ensure following:
A) Produce this warranty booklet to KOEL authorized service dealer, when

requested.
B) Carry out First installation check through KOEL authorized service
Dealer/Distributor within seven days of installation.
C) Use only recommended grade of Lube oil and ensure periodic change of oil as
per the duration mentioned in this manual.
D) Always use genuine parts like Air filter elements , Lube oil and Fuel filter
elements, Coolant that are sourced through authorized dealers / distributors of
KOEL.
E) Please maintain the proper log book for your genset. A sample of a typical log
sheet to be used is included later in this manual.
F) Any routine or breakdown maintenance should be carried out only through KOEL
authorized service dealer/distributors.
G) The performance of Genset depends on the quality of Lube oil and periodic
preventive maintenance, Use only the recommended “K-oil” lubricant that is
available with your local service dealer/Distributor.
Please provide the following details to our authorized service Dealer /Distributor.
This shall help them restore your genset at the earliest.
? Genset Model and Serial Number

? Engine serial Number
? Detailed site address
? Name of the contact person
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? Land line and cell phone numbers of the contact person

? The number of hours for which the genset has run
? The nature of complaint
6
Warranty Terms and condition
This warranty is applicable to Kirloskar Gensets with R/HA/SL 90/R1040/R1080/K
series of diesel engines.
The warranty is meant for 18 months from the date of dispatch from our factory OR
12 months from the date of commissioning OR 3000 hours of operation, whichever is
earlier.
Kirloskar Oil Engines Ltd hereby warrants that this Kirloskar Genset is free from any
defects in material, design and workmanship .
This warranty shall be limited for repairs and replacements under normal use
,regular check up and maintenance of Kirloskar Green genset as per our maintenance
schedule and purchase of the Kirloskar Green Genset through our authorized
dealer/distributor.
This warranty is the only documents 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 the genset free of cost
during the warranty period for the Kirloskar Green Genset purchased from person
other than authorized person.
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 any interest .
This Warranty is not applicable in following conditions.
1. The Kirloskar Green Genset or engine failure due to any misuse including
improper shutdown, mishandling and adjustments, negligence, over-speeding,
alteration of specification, due to accident or act of nature.
2. Kirloskar Green Genset or engine if not maintained as per the maintenance
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schedule given by Kirloskar Oil Engines Ltd.

3. If K-cool Super plus or equivalent engine coolant is not used for water cooled
Genset.
4. Damage due to improper installation of the parts , components and
accessories.
5. For the parts supplied under warranty or voluntarily at special rates or free of
charge, the warranty will be applicable only to unexpired portion of genset
warranty.
6. Damage due to use of improper lubricant or the lubricant used other than
suggested by Kirloskar Oil Engines Ltd.
7
7. Normal wear and tear of components of Kirloskar Green Genset/engine.
8. If the Genset is operated at load less than 40% of full load for long time.
9. Rubber components, O Rings, Gaskets, all electrical and electronic components.
10. If the gensets are stored for long time without preservation process explained
in the manual.
11. For resale of Kirloskar Green Genset or if the Kirloskar Green Genset purchased
is second Hand.
Any claim or obligation in connection with sale or performance of Kirloskar Green

Genset shall be subject to the jurisdiction of Pune, India.
Condition precedent to Kirloskar green Genset Warranty
The Kirloskar Green warranty Given by the Company is subjected to following condition
.Which are to be observed by the every purchaser /User of Kirloskar Green Genset, Without
which warranty claims if any will be rejected.
1. Proper Installation of the Kirloskar Green Genset as per the recommendation

given in this manual is sole responsibility of owner of Kirloskar Green Genset /
Purchaser of Genset.
2. Operation & maintenance as recommended by the company within the limits
mandated by the specifications.
3. Any defective part claimed to be returned to Kirloskar oil Engines Ltd. If such
parts are replaced by the company under Warranty. The return parts become
the property of the company. The transportation charges for same to be paid by
the customer/purchaser.
4. In case of interchange of parts between Kirloskar Green Genset / Engines shall
void the Warranty. Unauthorized repair work will make the warranty null and
void.
5. For the proprietary parts not manufactured by Kirloskar Oil Engines Ltd . such
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as Fuel Injection equipments , Batteries, Starter Electrical equipments 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 the Kirloskar engine, Kirloskar Green AC Generator and sound
proof enclosures branded as Kirloskar Green and the control panel.
To meet specific customer needs, your Genset may not contain Kirloskar Green Power
Ideas Ac generator, sound proof enclosures or control panel. If so, warranty for such
aggregates may be availed from the manufacturers of these assemblies. The seller of
the Genset will be happy to provide you the details.
8
SERVICE
9
SAFETY
INFORMATION
SAFETY INFORMATION:
Safety precautions for operation and maintenance
Daily checklist
Make a habit of checking the genset visually before operating (before the engine is started) and
after operating (after the engine has been stopped). This will help you to quickly detect fuel, coolant
or oil leaks and spot anything else unusual that has happened or is about to happen.
Refuelling
When refueling, there is a danger of fire and explosion. Do not smoke near the genset at all times.
The engine must be stopped before refueling.
Do not overfill the tank as some vacant space is necessary for the proper operation of the engine.
Do remember to close the fuel tank filler cap fully.
Only use the clean fuel recommended in the Instruction Manual. The wrong grade of fuel can cause
operating problems or cause the engine to stop. On a diesel engine, poor quality fuel may cause the
fuel injection pump to seize and the engine to overspeed with a resultant risk of damage to the
engine and personal injury.
Carbon monoxide poisoning
Operate the engine only in a well-ventilated area. If operating the engine in an enclosed space,
ensure that there is proper ventilation in order to remove exhaust gases and crankcase ventilation
emissions from the working area.
Operation
The genset must not be run in areas that contain explosive materials or gases. There are a number
of electrical and mechanical components on the genset which may cause sparking, thus dangerous
in an explosive atmosphere.
A running genset has numerous points that can pose danger to user. Be aware that the loose
clothing, hair, fingers or even a dropped tool may catch in the rotating parts of the engine and cause
serious personal injury.
Please run the genset with all the supplied guards that prevent the user from coming in contact with
hot and moving parts.
Starting authorization
The user must ensure that the genset cannot be used by unauthorized persons. The genset room
should be locked such that only the trained and authorized persons can approach the genset.
Maintenance and service knowledge
The Instruction Manual contains instructions on how to carry out general maintenance and service
operations safely and correctly. Read and understand the instructions carefully before starting work.
Service literature covering more complicated operations is available from your KOEL dealer.
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Never carry out any work on the engine if you are unsure of how it should be done. Contact your
KOEL dealer who will be glad to offer assistance.
Stop the engine
Stop the engine before opening or removing engine covers. Unless otherwise specified, all
maintenance and service must be carried out with the engine stopped.
To prevent accidental starting, remove the ignition key, turn off the power supply to the engine at the
main switches and lock them in the OFF position before starting work. Put up a warning sign in the
control position that work on the engine is being carried out. Approaching or working on an engine
that is running is a safety risk. Loose clothing, hair, fingers or a dropped tool may catch in the
rotating parts of the engine and cause serious personal injury. It is recommended that all the
servicing with the genset running be done by the service staff trained and authorized by KOEL.
10
TYPICAL
LOG SHEET
AND
INSTALLATION
REPORT
SERVICE KIRLOSKAR OIL ENGINE LIMITED
11
TYPICAL LOG SHEET
This is a sample of the parameters that have to recorded in a log book that should be
maintained with the genset. The various parameters may be modified according to the
site conditions - consult your local dealer or KOEL for guidance.
Sr No Parameters
1 Engine No
2 Date
3 Daily Use in Hours
4 Hour Meter Readings
5 Load in Kw
6 Cooling Water Temp
7 Lube oil Pressure
8 Lube Oil temperature
9 Fuel Added in Liters
10 Lube oil Added in Liters
11 Engine RPM
12 Current R Phase
13 Current Y Phase
14 Current B Phase
15 Voltage R phase
16 Voltage Y phase
17 Voltage B phase
18 Frequency in Hz
19 Power Factor
20 KWh Meter reading
21 Signature of operator
Remarks
12
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13
REPORT
TYPICAL
INSTALLATION
TYPICAL INSTALLATION REPORT
Kirloskar Oil Engines Ltd.

Genset Installation Report.
Enriching Lives
Format No.Koel/export/inst/001
Name and location of customer Name and location of Distributor
Genset Model Genset manufacturing Date/ Sr No. Details of Alternator

Make
Sr. No.
Type
Ratings
Invoice No. and Date Date of Installation
Customer contact person Phone nos.
Installation Check Points
Sr.No. Nature of Check Status Remarks

Ok Not Ok
1 Check for foundation suitability
2 Check for ventilation if the set is mounted inside
the room
3 Check for the supporting of exhaust bellows,
silencer and exhuast pipe
4 Is the Exhaust pipe is drawn out of the room?
5 Is the Exhaust pipe is provided with rain protection

cover?
6 Check for earthing resistance of earth pit
7 Check earthing of body and alternator neutral
8 Safety checks of cooling water system, lube oil
system and overspeed conducted
9 Operation Of AMF conducted and demonstrated
10 Check for availlability of fire fighting equipment
inside the room
Performance Test
Load % Testing Time Load{Amp} Voltage Frequency Lube Oil Pr Water Temp
Amps V Hz Kg/Cm2 DegC
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IDLE 5 Min
25 5min
50 5 Min
75 5 Min
100 10 Min
Remarks
Training conducted for the Customer O&M staff on routine operation and maintenance check Yes No
Genset O&M Manual copy is availlable with the customer Yes No
Genset is successfully tested and handed over to the customer for commercial operation with effect from:
Signature, Name & address of Dealer Signature and Name of customer
Head ofiice copy
14
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15
INSTALLATION
Guidelines for Installation:
? Engine inlet air must be clean and as cool as possible. Both these conditions would drastically
effect the engine life as well as the performance.
? 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 require ducting the air from outside
or from another room.
? When it does become necessary to duct air in, the air filter 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 filter.
? Ensure that hot air is positively discharged from the building by fitting a flexible
connection between the radiator and the duct.
? The size of the openings should be calculated to ensure that excessive restriction is not imposed
on the flow of cooling air. Openings should at least be as big as the radiator core area but, as a
guide, an area on 150% of the core area of the radiator should be selected.
? For weather protection, louvers should be fitted to the intake and exhaust openings. These can
be either of the fixed or movable type.
? The circuit breaker position can vary according to the requirements of the installation. It may be
mounted remote from the genset.
? The control panel could be mounted on the wall.
? The power cables may be installed from bottom through ducts or floor trenches depending on
cable routing to the genset room and terminal points at the generator.
? Openings should be provided behind the alternator for incoming cold air and directly in front of
the radiator for outgoing hot air. The cold air first passes over the alternator, then the engine,
picking up radiant heat as it passes. It then passes through the radiator and is discharged
through a duct to the outside of the genset room.
? A temperature rise of 5 to 15 Deg C (9 to 27 Deg F) in the cooling air can be expected at full
load.
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? Doors must be sized to allow access in and out for the complete generator set and major
accessories. Air inlet and outlet vents can often be made removable till the floor level to provide
easy access.
? For acoustic enclosure, ensure that the openings provided for fresh air inlet and outlet are not
blocked.
? Manually operated movable louvers may be acceptable in some cases, but they are not
acceptable for automatic standby units.
? Radiator air should not be depended on to open the louver vanes.
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INSTALLATION:
The procedure is listed for your information only. The task of installation of a genset is
expected to done by qualified, trained and competent personnel who are experienced
in the job. Please contact your local KOEL dealer or their representatives for advice
regarding the installation.
The task of the genset installation involves moving of heavy objects and use of
hazardous materials. Extreme care has to be taken to ensure safety during the
operation. Serious injury or even death can occur due to carelessness during the
genset installation.
? The genset is transported to the site in a specially designed packing case that protects
the contents from shock, weather and offers security during transit.
? Once unloaded on the site from the transport, the genset must remain inside packing
case till the last possible moment to prevent damage during handling etc.
? In case the genset is not installed immediately, ensure that the intact packing case is
protected from weather, dust and vermin during storage.
? The packing case should be opened carefully using the appropriate tools. Take care as
to not to hammer or poke the packing case as it might inadvertently damage the
internal contents.
? Apart from the genset, the packing case would also contain the documents, manuals,
tools, spare parts, accessories etc. - so please look out for these and tally them
against the packing list.
? The genset would be covered with a weather and dust protecting polythene sheet
that must be carefully removed from all the components.
? The genset’s openings such as the exhaust and air intake points would be sealed to
avoid ingress of debris - these must remain in place until the other matching systems
like exhaust pipe or the air cleaner are ready to be fitted.
? The rotating parts of the machine may be secured to prevent unintended movement
during transportation - all of these securing devices should be removed before
commissioning.
? The genset and the other heavy parts of the package would be bolted to the base of
the packing case - ensure that all such fasteners have been removed before moving te
genset out of the case.
? The genset should be carefully unloaded and shifted using appropriate devices such
as a crane or a forklift truck.
GEN
S
WITH ET
CAN
OPY
? The foundation is expected to be ready before the genset arrives so that it may be
installed at the final location in the shortest possible time.
? The supporting systems such as bulk fuel tank (if fitted), electrical cables, earth pits,
exhaust piping, civil structures etc should be ready at the time of the genset
installation.
17
Please study the correct procedures of Lifting the Genset, Foundation, Ventilation and
Air Supply System, Fuel System, Exhaust etc covered in the manual for more details.
COMMISSIONING THE ENGINE
Preparing for Operation
Before starting your engine, be sure that it is positioned on a level surface so that proper liquid
levels can be obtained. Ensure that the fuel tank is clean and filled with the recommended
diesel.
Check the engine oil.
Check the radiator coolant.
Check the battery electrolyte and charge condition.

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CAUTION
? Be sure that the Genset will be operated in a well ventilated area with all exhaust
fumes are piped away.
? Before connecting batteries, ensure that the control panel is switched off.
? Avoid prolonged inhalation of exhaust fumes as it 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.
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? Before any attempt is made to operate the machine, be sure that engine and alternator
are properly earthed.
? Local and national regulations for the grounding of gensets should be adhered to as
well as those regulations which describe the methods of connection and minimum
sizes of grounding conductors based on the size of the load cables.
Important
? Adequate grounding of the genset is necessary all types of gensets to prevent the
possibility of injury or death in the event of electrical fault.
? When filling the fuel tank, do not smoke or use an open flame in the vicinity. Also the
tank should never be filled when the Genset is operating or while the engine is hot.
Fuel spilt on the genset could ignited easily.
? Never attempt to disconnect a 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.
? The negative pole of the battery system earthed. Hence the negative connection
should be disconnected first and reconnected last.
? The cover of the control panel 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 qualified and trained technician.
Important
Always shut down the Genset and switch off circuit breaker prior to connecting or
disconnecting, loads cables. Restart only when a sound connection has been made.
INITIAL START-UP
The following procedure should be used to make initial start-up of the Genset.
These steps are critical and must be followed closely to avoid complications in
operating the Genset.
? Ensure that the machine is on a level surface so that correct volumes of liquids
(oil, fuel etc.) can be added.
? Check the engine oil and coolant levels, replenishing if necessary.

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? Fill the fuel tank with the recommended grade of diesel.
? Fill the battery with suitable electrolyte for type of batteries supplied, if not already wet
charged.
? Remove any loose items or debris in the vicinity of the genset that may inhibit
operation or could cause injury.
? The following procedure should be used when starting the Generator for the first time
or when it has been out of service for a time for maintenance purposes.
? Ensure the key switch/ control switch is turned OFF.
? Ensure the circuit breaker is switched OFF.
? Connect the batteries to the engine with correct polarity.
19
? Prime the fuel system using the hand priming pump and bleed entrapped air
from the fuel filter – see engine manual for details.
? Confirm all the control MCB's are ON. Turn the Key switch to Position ''ON'' engine
control system will be switched on.
? In the manual mode of operation, carefully crank the engine. In case the engine does
not start in the first attempt, please allow an interval of approximately 10 Seconds
between the second cranking attempt.
? In case the engine does not start even after three cranking attempts, please
investigate the cause of the failure to start and rectify.
? After the engine has been started check for any abnormal noise or vibration.
? Check for coolant leakage or high engine temperature.
? Check the control panel for indications of abnormal operation, in particular above
normal engine temperature or below normal oil pressure.
? Immediately after the engine reaching the full operating speed, the AC voltmeter
should be checked to ensure that the voltage has reached the correct operating level
on all the phases.
? The AC voltage is factory set on the Automatic Voltage Regulator (AVR) inside the
alternator and needs no further adjustment. If the voltage is incorrect, the adjustment
should only be carried out by a trained personnel.
? Voltage adjustment is done by varying the setting of a potentiometer on the AVR fitted
inside the alternator terminal box.
? The frequency of the output voltage should also be checked on the panel meter. The
frequency without the genset being loaded is approximately 52 Hz. for 50 Hz gensets
and approximately 62.4 Hz for 60 Hz gensets.
? When the generator is producing voltage, check the phase rotation of the generator by
connecting a Phase Rotation Meter to the terminals on the generator side of the circuit
breaker. (Caution: DO NOT close the circuit breaker to the load). This check should
be carried out by a qualified technician and the result noted for use later if the genset
is to be connected to an existing system.
? After the voltage and frequency checks have been made, shut the machine down by
operating the appropriate stop switch on the genset control panel.
? Restart the engine and check all the safety controls like Low Oil Pressure, High
Coolant Temperature, Low Fuel Level etc. by shorting across the appropriate switch
terminals. Depending on the logic of the panel, the engine should trip and/or create an
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alarm condition.
IMPORTANT
Always shut the genset down prior to connecting, or disconnecting, load cables. Only restart
when a sound connection has been made.
SHUTDOWN PROCEDURE
To shut down the Genset, turn off the load using the circuit breaker, and press
button the ''O'' (as per applicable) position. In case of an emergency where immediate
shut down is necessary press the emergency off push button.
20
NORMAL STARTUP PROCEDURE
(For manual operation)
The procedure for the normal starting of the genset is explained below. Please follow these
procedures strictly.
The Genset must be checked daily before starting.
FOR YOUR SAFETY ENSURE THE KEY SWITCH OR PANEL MASTER SWITCH IS
TURNED TO POSITION ‘'OFF'' WHILE CHECKING THE ENGINE.
? Make a visual check of the entire Genset. Watch for signs of leaks from the
engine. Fuel system, cooling system or lubrication seals.
? Check engine oil, water and fuel levels, replacing if necessary.
? Check the battery terminals for corrosion, cleaning where necessary.
? Check the battery electrolyte level and fill with distilled water if necessary.
? If the exhaust system has condensate traps, do open to them to drain any moisture
trapped in them. Check for evidence of exhaust leaks.
? For manual starting press the start button on genset control unit.
? The Starter Motor would then rotate and the engine would start.
? In case the engine does not rotate, please ensure that lube oil pressure switch contact
is closed when engine is at standstill, otherwise the controller would not crank the
engine.
? Starter supply will be disconnected automatically by the controller after getting supply
from AC alternator or after the oil pressure switch has opened.
? Once the engine starts, the Lube Oil Pressure gauge will show a healthy reading.
? The “Charge Failure” lamp which lights before the engine starts is extinguished once
the battery charging alternator starts generating the output current to charge the
battery. This charging activity can be seen on the DC ammeter and the DC Voltmeter
(if provided).
?
? If the weather is cold, run the genset without load for at least 2-4 minutes to warm up
he engine.
? After the engine warms up, the genset can be connected to the load by closing the
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ouput MCB/MCCB.
? After a few minutes of operation, the Coolant Temperature gauge shows an indication.
For healthy conditions, the reading should be 80 to 90 degree centigrade.

? The AC voltmeter would show the alternator output voltage.
? The Voltmeter Selector Switch could be used to view the phase to phase or phase to
neutral voltage readings.
? The AC ammeter would show the load current depending upon the connected load.
? The Ammeter Selector Switch could be used to view the currents of the three phases.
? Refer to the engine manual for specific engine maintenance requirements.
21
? If the genset is normal weather, the genset may loaded immediately by closing the
Alternator Circuit Breaker.
? However, the maximum step load that can be accepted is dependent on the operating
temperature of the Genset.
? With the Genset cold (less than 20 degrees C / 68 degrees F) a maximum step load of
50 % of the full rated output can be applied. The full load can be applied after the
engine achieves working temperature.
? If the genset is at normal operating temperature (approx 80 degrees C / 176 degrees

F) the maximum step load of 60 - 100 % can be applied immediately depending on the
type of engine.
? The above guidelines are only indicative of the genset’s performance. Please do
consult KOEL or the local representatives for the solution as per the local site
conditions.
WARNING: Always shut the Genset down prior to connecting, or disconnecting,load

cables. Only restart after a sound connection 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.
22
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23
CABLE
CHART
SELECTION
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Cable Details
Overall Diam and Type of Gland for 3- Overall Diam and Type of Gland for 3-1/2 Aluminium Cable at
Cable Size at 40deg ambient for 3-1/2 core cable
F/L Current for 3 Ph 1/2 Core Copper Cable at 40deg 40deg (Make of Gland : Comet)
Sr.
KVA Voltage Alternator Rating of Size of Rating of Size of the hole on
No. Size of Copper Type of Gland for Type of OD of
Copper Aluminum Aluminum Diameter (mm) Diameter (mm) panel and alternator
Cable(Sqmm) Copper Cable Gland Gland (mm)
1 PF. 0.8 PF. Cable (A) Cable(Sqmm) Cable (A) for gland entry
1 10 415 V 11.13 13.91 2.5 24 16.5 SCG 4 SCG 4 20 21
2 15 415 V 18.23 20.87 4 30 18 SCG 4 For Lower Rating SCG 4 20 21
For Lower Rating Copper
3 20 415 V 22.26 27.82 4 30 18 SCG 4 Copper Cables SCG 4 20 21
Cables are preffered
4 25 415 V 27.82 34.78 6 39 20 SCG 4 are preffered SCG 4 20 21
5 30 415 V 33.39 41.74 10 52 21 SCG 4 SCG 4 20 21
6 35 415 V 40.07 48.69 10 52 16 51 21 SCG 4 23 SCG 6 25 26
7 40 415 V 44.52 55.65 16 66 16 51 23 SCG 6 23 SCG 6 25 26
8 45 415 V 49.5 62.61 16 66 25 70 23 SCG 6 24 SCG 6 25 26
9 50 415 V 55.65 69.56 25 90 25 70 24 SCG 6 24 SCG 6 25 26
24
10 62.2 415 V 69.56 86.54 25 90 35 86 24 SCG 6 26 SCG 7 32 33
11 70 415 V 77.91 97.39 35 110 50 105 26 SCG 7 29 SCG 7 32 33
12 75 415 V 83.47 104.34 35 110 50 105 26 SCG 7 29 SCG 7 32 33
13 82.5 415 V 91.82 114.78 50 135 70 130 29 SCG 7 33 SCG 8 40 41
14 100 415 V 111.3 139.12 95 155 37 SCG9 40 41
15 125 415 V 139.12 173.91 120 180 41 SCG10 50 51
16 140 415 V 155.82 194.77 150 205 44 SCG11 50 51
17 160 415 V 178.08 222.60 185 240 49 SCG11 50 51
18 180 415 V 200.34 250.42 240 280 55 SCG13 63 64
19 200 415 V 222.6 278.25 240 280 55 SCG13 63 64
20 250 415 V 278.25 347.81 185*2 384 68 SCG15 75 76
21 275 415 V 302.5 382.59 185*2 384 2 hole of 49mm 2 Glands of 185 sq.mm as mentiond above
23 320 415 V 352 445.20 240*2 448 2 hole of 55mm 2 Glands of 240 sq.mm as mentiond above
* Make of the Gland is of Comet (With Brass Material)

Type : Single Compression Heavy Duty Cable Glands w ith IP 60.
Material : Brass (IS-319)
** For Ambient Temp above 45 deg, pl refer manufacture r's catalogue for the deration.
Typical Cable sizes for Three phase gensets.

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Cable Details
Overall Diam and Type of Gland for 2 Overall Diam and Type of Gland for 2 Core Aluminium Cable at
Cable Size at 40deg ambient for 2 core cable
F/L Current for 1 Ph Core Copper Cable at 40deg 40deg (Make of Gland : Comet)
SR.
KVA Voltage Alternator Rating of Size of Rating of Size of the hole on
NO. Size of Copper Type of Gland for Type of OD of
Copper Aluminium Aluminium Diameter (mm) Diameter (mm) panel and alternator
Cable(Sqmm) Copper Cable Gland Gland (mm)
1 PF. 0.8 PF. Cable (A) Cable(Sqmm) Cable (A) for gland entry
1 10 240 33.33 41.7 6 45 10 47 15 SCG 2 16 SCG 4 20 21
2 15 240 49.995 62.55 10 60 16 59 16 SCG 4 18 SCG 4 20 21
3 20 240 66.66 83.4 16 78 25 78 18 SCG 4 19 SCG 4 20 21
25
4 25 240 83.325 104.25 25 105 35 99 19.00 SCG 4 20.00 SCG 4 20.00 21
5 30 240 99.99 125.1 35 125 50 125 20 SCG 4 23 SCG 6 25 26
6 35 240 116.655 145.95 50 155 70 150 23 SCG 6 25 SCG 6 25 26
7 40 240 133.32 166.8 95 185 29 SCG 87 32 33
* Make of the Gland is of Comet (With Brass Material)

Type : Single Compression Heavy Duty Cable Glands w ith IP 60.
Material : Brass (IS-319)
** For Ambient Temp above 45 deg, pl refer manufacture r's catalogue for the deration.
Typical Cable sizes for Single phase gensets.

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26
GENSET
INDEX
1. Introduction 28
2. Description of the Genset 29
3. Selection Formula 31
4. Load Calculations 32
5. Genset Dimensions 32
6. Location of the Genset 34
7. Ventilation and Air Supply System 35
8. Foundation 39
9. Lifting the Genset 40
10. Exhaust 42
11. Fuel Systems 46
12. Fire Precautions 47
13. Electrical Connections 47
14. Earthing 48
15. Maintenance of Electrical System 52

SERVICE
16. Acoustic Canopy 55
17. Control System 57

18. Control Panels 57
19. Wiring Diagrams 65
20. Manual of DSE 704 controller 72
27
INTRODUCTION
Kirloskar Oil Engine Ltd. brings you a quality genset backed by superior engineering and over 55
years of experience.
We recommend, that for optimal performance, please follow the installation and maintenance
procedures as recommended in this manual.
The proven engine of your genset is highly reliable and fuel efficient. The matching alternator has an
optimum output waveform, a fast response to varying loads and a precise voltage regulation.
This manual is your guide to proper installation, operation and maintenance.
A well maintained genset would meet all your emergency standby or prime power needs.
SERVICE
This manual describes some simple yet essential procedures. Please follow these guidelines for the
proper installation and maintenance of your genset.
Adherence to these procedures will help to avoid preventable problems, ensuring good efficiency
and the life of your genset.
There is a trained and well equipped Kirloskar Service and Spare Parts dealer located near you.
Please do contact them, or the nearest Kirloskar area office, for any assistance. Please turn to the
end of this document for contact details of help near you.
Do study the "Trouble-Shooting" chart located in this manual to identify and overcome some
common problems.
28
Radiator Diesel Engine Air Cleaner Control Panel Alternator
Fuel Filter Anti-vibration mountings Lube Oil Filter Baseframe Fuel Filling spout
Figure 1 - Major Genset Components

NOTE: The positions of some peripherals may change in case the Genset has an acoustic
enclosure. (Example - Control Panel, Fuel filling spout, Fuel level indicator etc.)
DESCRIPTION OF THE GENSET

Figure 1 shows the major components of the genset including the alternator, the diesel engine, the
exhaust, the cooling system, and the control panel.
The engine is has a mechanical governor that maintains the engine speed within the tolerance
SERVICE
required to deliver the rated power and frequency. In case a closer tolerance is required, an
electronic governor can be offered as an option.
ENGINE
The engine of the generating set is of proven reliability and is specifically designed to operate in
conjunction with an alternator. The engine is of the heavy-duty industrial type, water cooled, 4-
stroke cycle, compression ignition and fitted with all accessories necessary to provide a reliable
power supply.
29
COOLING OF ENGINE AND ALTERNATOR
The engine cooling system comprises of a radiator, a high capacity pusher fan and a thermostat.
The radiator is used to transfer the heat from the engine to the atmosphere. The fan draws the cool
air through the radiator to help this transfer. The alternator is ventilated by an inbuilt fan.
ENGINE GOVERNOR
The primary function of the governor system is to maintain engine speed in relation to varying load
requirements. This is accomplished by the governor that senses the engine speed and maintains a
constant speed.
In case the speed drops due to an increase in the load, the governor would deliver more fuel flow to
the engine, thus maintaining the engine speed.
The same principle is applied when the load decreases. As the load is reduced, the speed
increases, and the governor delivers less fuel to maintain the rated speed.
ALTERNATOR
The genset is supplied with a robust and efficient Brushless excitation type alternator that eliminates
most of the maintenance.
The alternator output is controlled by an inbuilt Automatic Voltage Regulator (AVR). This device
allows quick building up of the output during start and keeps the output voltage within a set limit
during operation.
To suit the exact site requirements, most of the three- phase alternators have provision to vary the
connections of the internal coils and deliver a variety of voltages up to 480 Volts AC.
The genset alternator may also be of the Single phase output type. These units supply the output
through two or three lead connection offering a variety of voltages from 120-250 Volts AC.
The standard genset alternator is rated for 50 Hz output. See Alternator Section for further details of
the available connections.
SYSTEM PROTECTION
An important function of the control system is to protect the engine against faults such as high
SERVICE
temperature, low oil pressure, over speed etc. To prevent damage to the starter motor and deep
discharge of the starting battery, a crank limiting circuit is included on all automatic start sets.
A detailed explanation of these systems is included later in the manual.
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 starter motor to crank and start the engine and for
the stop solenoid.
30
The stop (or fuel) solenoid is used to cut off the fuel supply and thus stop the engine during normal
stops and during abnormal conditions. During the normal condition, the genset is stopped as it is no
longer required. A shutdown during an abnormal condition could be due to detection of an unsafe
condition – here the genset is shutdown to prevent damage to the engine, the alternator or the load.
CONTROL PANEL MOUNTING

The control panel and main circuit breaker are normally mounted on a separate base frame
mounted stand thus ensuring vibration free operation. Floor standing control panels are provided
for more complex control systems.
For acoustic enclosures, the control panel is fitted inside the enclosure. Suitable glass cover
opening is provided on the enclosure to allow the operator a clear view of the instruments.
SELECTION FORMULA
KVA / KW Rating:
The rating of the alternator is either expressed in KVA (Kilo-Volt- Ampere) or KW (Kilo Watt). The
following formulae show the relation between KVA and KW for single phase and three phase
alternators.
The relation between KW and KVA rating is:
For 3 phase alternator
KW = KVA x Power Factor or
KW = V x A x %3 x Power Factor /1000
Where:
V is the rated voltage in volts
and
A is the current in Amperes.
SERVICE
The relation between KW and KVA rating is:
For 1 phase alternator

KW = V x A x Power Factor /1000
Where:
V is the rated voltage in volts
and
A is the current in Amperes.
Normally, a generator has a designed power factor of 0.8
31
INPUT HORSE POWER REQUIREMENT
The engine used for your genset is selected on the basis of the power requirements.
The required input horse power (HP) is given by the formula:

Input HP (Metric) = KW/ 0.736 x Efficiency of the Alternator
Load Calculations
The name plate on the engine mentions the horse power (HP) that can be delivered at the Mean
Sea Level (MSL) assuming the Normal Temperature and Pressure (NTP) conditions.
However, the engine may deliver less power than the listed amount due to the various site
conditions. This is known as the Power Loss or Deration due to the site conditions.
For details of the Deration due to site conditions, please consult your genset OEM or service dealer.
Conditions that de-rate the engines are:
o
? Ambient temperature greater than 27 C
? Altitude beyond 150 meters above sea level
? Humidity in excess of 60%
? A small reduction in the rated HP is caused by the power absorbed by the
radiator fan (in case of liquid cooled engines). This loss of power is mentioned in the
engine specifications of your genset.
GENSET DIMENSIONS
The mentioned dimensions are meant only for guidance. The actual figures may differ due to
continuous process of development. Please confirm the exact size with your genset OEM or the
KOEL office nearest to you.
Prime Genset Overall canopy

Genset Power dimensions with silencer.
Engine Approx. weight (Kg)
Model Rating at Length x Width X Height (mm)
SERVICE
Model
0.8 pf (with canopy)
(kVA)
KG15AS HA294 15 1990 X 1090 X 1840 1220
KG25AS HA394 25 2730 X 1100 X 1920 1350
KG30AS HA494 30 3130 X 1100 X 1940 1440

KG35AS HA494 35 3130 X 1100 X 1940 1440
KG45AS HA494T 45 3220 X 1100 X 1940 1580
KG55AS HA694 55 3970 X 1240 X 1900 1870
KG70AS HA694T 70 3980 X 1290 X 1840 1920
Typical sizes for Air Cooled gensets with acoustic enclosure.
32
Prime Genset Overall canopy
Genset Power dimensions with silencer.
Engine Approx. weight (Kg)
Model Rating at Length x Width X Height (mm)
Model
0.8 pf (with canopy)
(kVA)
KG12.5WS RV2 12.5 2265 X 990 X 1566 1000
KG30WS1 RB33 30 2530 X 1190 X1840 1300
KG20WS1 RV3 20 2520 X 1190 X 2100 1300
KG20WS 2R1040 20 2170 X 1240 X 1895 1200
KG30WS 3R1040 30 2520 X 1190 X 2100 1260
KG40WS 4R1040 40 3350 X 1190 X 2100 1520
KG50WS 4R1190 50 3350 X 1190 X 2100 1500
KG62.5WS 4R1040T 62.5 3370 X 1900 X 2100 1930
KG82.5WS 4R1040TA 82.5 3625 X 1390 X 2250 1950
KG100WS 6R1080T 100 3940 X 1640 X 2450 2500
KG125WS 6R1080TA 125 3940 X 1640 X 2450 2700
KG140WS 6SL9088TAI 140 4625 X 1840 X 2890 3580
KG160WS 6SL9088TA 160 4625 X 1840 X 2890 3720
KG180WS 6SL1500TAI 180 4625 X 1840 X 2890 3870
KG200WS 6SL1500TA 200 4625 X 1840 X 2890 3950
KG250WS1 6SL8800TA 250 5340 X 1840 X 2450 4660
KG275WS1 6K12TA 275 5730 X 2250 X 3250 5860
KG320WS1 6K12TASrl 320 5730 X 2250 X 3250 5860
KG400WS1 8K15TA 400 5900 X 2000 X 3274 6180
KG500WS1 10K18TA 500 6235 X 2000 X 3375 6990
KG600WS1 12K22TA 600 6675 X 2000 X 3510 8200
Typical sizes for Water Cooled gensets with acoustic enclosure.
DG Capacity kVA 140 160 180 200 250
DG set without 3605 X 3606 X 3650 X 3651 X 3340 X

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acoustic: 1176 X 1176 X 1210 X 1210 X 1280 X

L(mm)xB(mm)xH(mm) 1500 1500 1600 1600 1610
Typical sizes for gensets with SL 90 engines without acoustic enclosure.

32
kVA Ratings Height
Length (mm) Width (mm)
(mm)
10 2490 940 1500

15 2490 940 1500
20 2680 940 1500
25 2680 940 1500
36 2740 1240 1625
50 2740 1240 1625
75 2990 1390 1625
125 3540 1400 1990
160 4100 1700 2025
250 4500 1640 2460
Typical sizes for rooms for gensets with acoustic enclosures.
kVA Ratings Height

Length mm) Width (mm)
(mm)
36 3100 3000 2600

50 3200 3000 2600
75 3250 3000 2600
125 3850 3000 2700
160 3850 3000 2700
250 4850 3250 2800
Typical sizes for rooms for gensets without acoustic enclosures.

33
Window
1.0 meter
minimum
cables
Rolling Shutter
1.5 meter 1.5 meter
Window
minimum minimum
Control
Panel
1.0 meter
minimum
Window
Figure 2: Typical genset room
LOCATION OF GENSET
Selecting a location for the genset is a very important part of any installation procedure.
? Always locate the genset in an area that would provide adequate ventilation and physical
protection for the unit.
? To ease the maintenance and inspection, place the genset such that movement around the
machine is easily possible.
? Generally, a space of 1.0 to 2.0 meters is required all around the genset for easy access.
? The location should be clean, dry and have good drainage capabilities.
In case the location is outdoors, the genset should be fitted with a weatherproof enclosure.
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? Ensure the space required to undertake major overhaul or service operations where
large components and the assemblies may have to be replaced.
Ensure a high degree of cleanliness as the dust and fumes could lead to a clogged radiator
?
and the consequential engine damage.
? Refer to Figure 2 for a plan of typical geset room.
34
VENTILATION AND AIR SUPPLY SYSTEM
All engines dissipate heat during operation.

? This heat is removed by the ventilation provided in the genset room.
? Failure to ventilate the genset room may overheat the engine and cause the engine to
breakdown.
? Ensure that the hot air from engine is not re-circulated but removed from the
area by the ventilation system.
? If this hot air is used by the radiator fan for cooling, the engine would overheat.
? If the hot air is used by the engine for combustion, the power output will reduce.
? As a general guideline for an engine installed in a closed room, the temperature of fresh air
passing through radiator (suction type radiator fan) should not be more than 10 deg C
above the ambient air temperature.
? Provide adequate clean openings for sufficient air circulation and ensure the
expulsion of hot air from radiator etc.
? Ensure that the space in front of the radiator is not obstructed to prevent clear ventilation of
the hot air.
? Ensure that the inlet to the air cleaner is provided with cool, fresh air.
? The room could be provided with side windows on both sides of the genset fo additional air
circulation.
? Suitable thermal insulation (lagging) should be provided on the exhaust pipes to avoid
heating of the ambient air.
? The hot air can be removed from the genset room by the use of exhaust fans.
? The natural airflow through the genset room should follow the draft of radiator fan. In case
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the natural airflow is not favorable, a wall may be constructed to prevent the radiator’s flow
being opposed. Refer Figure 3.
? Figures 4, 5 and 6 show various schemes for ventilating the genset room using fans.
? The power to drive the ventilation fans is drawn from the alternator and should be
considered while calculating the total electrical load on the genset.
35
Wind
Preferred airflow direction.
Wind
Wall to block wind from the

opposing the airflow from the radiator.
Figure 3: Natural draft through a genset room
To Silencer
Forced
fixed support Air
SERVICE
# # # #
# # # #
Vent 260
Acoustic
louvers
Figure 4: Forced draft through a genset room- example 1
36
To Silencer
Alternative
location for
forced air
fixed support
# # # #
# # # #
Window 260
Forced
Air
Figure 5: Forced draft through a genset room-example 2
To Silencer
fixed support
SERVICE
# # # #
# # # #
260
Acoustic
louvers
Figure 6: Forced draft through a genset room- example 3
37
m
0m
10
m 300 mm
0 m
30
Figure 7: Typical Foundation
300 mm PCC block

above ground level
SERVICE
100 mm PCC block
230 mm soling
Compacted Soil
(Murum)
Figure 8: Correct method of preparing the foundation
38
FOUNDATION
A reinforced concrete pad makes the best foundation. A pad with sufficient mass in proportion to the
size of the genset will provide the rigid support necessary to minimize deflection and vibration.
Typically, this should be 150 mm to 200 mm deep and have a mass at least equal to that of the
genset.
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 permitted bearing load of the support.
The bearing loads of structural steel can be obtained from Engineering Handbooks while the local
building codes would provide the permitted bearing loads for different types of soil.
A correctly designed foundation is important to a good genset installation. The absence of an
adequately foundation may lead to excessive genset vibrations resulting in radiator leaks, failure of
the auto-electrical and safety system, failure of gauges and other engine parts.
A good foundation has the following functions:

? Supports the total weight of the genset
? Maintains alignment
? Isolates the surrounding structures by absorbing the genset's vibrations
Isolation
It is advisable that the foundation of each genset rests on bedrock or solid earth completely
independent of other foundations, cement work, walls or operating platforms.
Vibration
The design of the genset is such that only minimal vibration is transmitted to the foundation. To
achieve this, anti-vibration mounts are fitted between the engine, the alternator and the baseframe.
In larger capacity gensets, the vibration isolators are mounted below the baseframe.
SERVICE
In generator rooms situated on the upper floors, special attention to vibration isolation is necessary.
Often spring type vibration isolators would be needed.
It is necessary to ensure that building structures are capable of supporting the genset, fuel storage
and accessories.
Anti-Vibration Mounting
The suitable Anti-Vibration Mountings (AVMs) are provided by KOEL with the genset. Please
ensure that the original parts are used in the event of any future replacement.
39
LIFTING THE GENSET
Make sure that your genset is unloaded at your works with a proper crane/hoist to avoid damaging
the oil sump, radiator or other genset parts.
Figure 8 shows a genset lifted with the help of a crane. The lifting belt is connected to the slots
provided around the frame of the genset. Note the frame to prevent the lifting belts coming close to
the genset.
Figure 9 shows a genset that is being moved using a forklift truck.

The general guidelines for lifting are:
? Ensure that the lifting equipment is adequately rated to lift the weight of the genset.
? Ensure that the lifting rope does not touch the parts of the genset as it would distort or
damage the various assemblies of the that are subjected to the stress while lifting.
? Ensure that the lifted genset remains steady and does not swing as it may touch other
objects or injure personnel.
? Maintain the highest standard of safety, be vigilant and cautious while lifting or moving
the genset.
CROSS MEMBER TO
PREVENT INWARD
MOVEMENT OF THE
LIFTING CABLES
SERVICE
GEN
S
WITH ET
CAN
OPY
SUITABLE LIFTING TACKLESTO BE

ARRANGED BY THE END USER.
Figure 9: Genset lifted by a crane
40
Figure 10: Genset moved using a forklift truck
41
EXHAUST
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 loss of horsepower while increasing the
engine operating temperature and the emissions.
When bends are required in an exhaust system, always make the radius at least 150% of the inside
diameter of the pipe. As most of the exhaust system designs are governed by the physical
characteristics of the building or room in which they are located, it is important that the exhaust pipe
be routed in a path offering the least amount of turns or bends to prevent an increase back pressure
greater than 50 mm of Hg (Mercury) column.
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
prevent excessive heat radiation within the room.
A metal thimble guard 300 mm in diameter slightly larger than the pipe should be installed at the
points where the piping passes through a wall or roof.
The Exhaust Outlet
The exhaust pipe outlet should be bent. This is done so that the outgoing hot exhaust gases do not
enter the power house again. Normally, the pipe outlet should be bent in the direction of the wind
and the end should be cut at an angle of about 45 degrees.
As shown in the figures 10 and 11, 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.
Figure 11: Typical Exhaust installation
42
Figure 12: Correct profile of the Exhaust outlet
The level or height at which the outlet is situated should be sufficient to prevent fumes and gases
from becoming an annoyance or potential hazard. An exhaust pressure actuated raincap is
recommended for use on vertical outlet pipes.
Type of pipe used for the exhaust system
The exhaust system should be made from black MS ERW Type (Electric Resistance Welded) pipes
rather than with galvanized water pipes. The ERW pipes have the following advantages.
BLACK MS PIPE GI PIPE

Creates less exhaust back pressure as The threaded joints and sockets create more
the welded joints offer a smooth surface. exhaust back pressure.
The seams do not fail due to the firing The seams fail frequently when subjected to
impulse and the vibration. engine vibration.
Cheaper than the GI pipe, yet easily
Costly and heavy weight.
available.
Length of the exhaust pipe

SERVICE
The total length of the exhaust pipe should not exceed 15 meters and should have a maximum of
four right angle bends. Avoid using any pipe elbows.
Increase the pipe's internal diameter by 38 mm (1.5 inch) after every 5 meter running length.
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 drain 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. The
genset should not be connected to a system accommodating more than one engines to prevent the
possibility of exhaust gas and condensation backflow which may cause permanent damage to an
idle engine.
43
Note: Health warning: Inhalation of exhaust fumes is potentially lethal. The correct installation of
exhaust systems to prevent accumulation of exhaust gas cannot be over emphasized.
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.
Inside Diameter (ID) of the exhaust pipe
Use the exhaust piping with the recommended ID (inside diameter) as mentioned in the engine
specifications. Use the Nomogram in Figure 14 as a guide for selecting the diameter of the exhaust
pipe.
Exhaust Silencer
The exhaust silencer should preferable be outside the power house to avoid excess radiation of
heat in the room. Normally, the silencer is installed horizontally.
However, if the silencer is installed vertically, do provide a rain cap to prevent water from entering
the exhaust pipe. More details of the rain cap are provided later in this document.
Expansion bellows / flexible pipes
These parts compensate for the expansion of the exhaust pipe due to heat and to provide flexibility
between genset and rigid piping during the various phases such as starting, running and stopping.
The expansion bellows and flexible pipes should be installed between exhaust piping and engine.
Exhaust Support
Provide proper support from the roof of the genset room to the exhaust system.
This would avoid the direct weight of the exhaust pipe and silencer on the exhaust manifold.
Rain Cap
A rain cover should be provided over the pipe's mouth to prevent the entry of rain water.
The rain cover should be of about 60 degrees angle. The outer diameter for the rain cover should be
approximately 5 times the pipe diameter. The cover center should be 2.5 times the pipe's diameter
away from the pipe's mouth.
Figure 13: Typical Rain Cap
44
Silencer and Exhaust Pipe
Diameter in Inches
2.0
BACK PRESSURE NOMOGRAM
2.5
Exhaust Gas Flow Back Pressure
Cubic feet per minute Î P in Hg.
(cfm) per foot 3
11000
10000
9000 2.0
8000 1.0 4
7000 0.5
6000
5000 0.1 5
4500
4000 0.05
3500 0.02
0.15 6
3000 0.01
0.0067 in. HG
2500 0.005 7
2000
(Inches Hg X 25.4 = mm Hg) 0.002
0.0015 8
0.001
(inches X 25.4 = mm)

1500 0.0005 9
(cfm X 0.472 = l/s)
0.0002 10
0.00015
0.0001
1000
900 0.00005
800
13
0.00001
600
Example:
2000 cfm = 16 X 6” dia.
thru 6 in., = 96 in. length equivalent
400 dia elbow = 8 ft of 6” pipe
=.0067 X 8 = .0536 in. Hg
300 Resistance of:
250 FLEX PIPE
200 Use 2X Equivalent

of straight pipe
ELBOWS
Straight pipe Equivalent

Length
90º Elbow = 10 X Dia. in inch/12

45º Elbow = 9 X Dia. in inch/12
Figure 14: Back pressure nomogram
45
FUEL SYSTEM
The fuel system must be capable of delivering to the engine a clean and continuous supply of fuel.
When designing a fuel system, always incorporate the requirements of Local, State, or National
Codes.
Diesel Fuel Bulk Storage (If provided)
Bulk fuel storage is the most preferable method of providing fuel supply. This method allows bulk
fuel purchases which will minimize dirt and contamination possibilities, especially when the fuel is
seldom used. The bulk storage tank (if provided) may be located either above or below the ground.
The bulk storage tank is not included in the standard scope of supply.
A vent must be installed on the main tank to relieve the air pressure created by filling the tank as
well as preventing a vacuum within tank as fuel is consumed. The tank bottom should be rounded
and placed on a 2 degree tilt to assure a concentrated settling of both water and sediments.
At the low point of the tank a drain valve should be installed to remove water that may accumulate
due to condensation.
VENT
TO DAY LEVEL GAUGE

TANK
FUEL
PUMP
STORAGE OVERFLOW
FUEL GENSET TANK AND DRAIN
FILTER (IF PROVIDED) LINE
FILLER
DAY TANK IN THE GENSET

BASE FRAME FUEL
DRAIN SHUTOFF FUEL DRAIN VALVE
VALVE / TRANSFER FOR REMOVING
SOLENOID PUMP SLUDGE
AND WATER
Figure 15:Typical Fuel System

Underground tanks must be pumped periodically to remove this water. This is best done by a tube
through the filter pipe to the low end of the tank. For these reasons it is imperative that the tank be
placed in or on stable ground. In locations with low temperature, burying the tank below the frost line
would help in avoiding seasonal settling.
Another consideration while locating the main tank is the height difference between it and the
SERVICE
auxiliary tank (day tank). The maximum vertical lift capabilities of a standard electric motor driven
fuel transfer pump is 5 meters. Do not place either tank at a level that would exceed the pump lift
capabilities. Also keep in mind the possibilities of pressure drop created by excessive horizontal
distances and bends in the pipes.
The fuel delivery line carrying fuel to the engine and the fuel return line for carrying excessive fuel
back to the tank should be of the same size. For longer runs or during operations in extremely low
ambient temperatures, increase the size of these lines to ensure adequate flow.
The fuel lines can be made of suitable material such as steel pipe or fuel line tube that will tolerate
ambient conditions. Overflow piping should be of the same material and one size larger.
46
The fuel return line should enter the tank at the top and not contain a shut-off valve. This line should
be designed with a minimum amount of bends or dips to prevent an air lock in the system. The fuel
delivery line should pick up the fuel from the point no lower than 20mm from the bottom of the tank.
If possible, locate this line at the end of the tank opposite that of the return line and at the high end
of the tank.
Flexible fuel lines should be used at a point between the tank and engine (preferably adjacent to the
genset) to avoid the potential damage that could be created by vibration.
Day Tanks
The use of Auxiliary tanks or day tanks is recommended.

All standard gensets with acoustic enclosure are provided with tank fitted in the baseframe. The day
tank should have capacity for holding sufficient fuel for 8 hours operation at 75 % load.
Filters and Traps
Clean fuel will aid in attaining maximum engine life and reliability. Primary filters are recommended
for use between the engine filters and the transfer pump. Water and sediment traps should
also be included upstream of the transfer pump. However, on border line pump installations, do not
increase fuel line restrictions to a point exceeding the capabilities of the pump.
FIRE PRECAUTIONS
When designing a genset installation the following points should be noted:
? 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.
? 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.
ELECTRICAL CONNECTIONS
Only fully qualified and experienced electrical technicians should carry out the electrical
installation work.
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. 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.
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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 nylon or 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 electrical work should be carried out in accordance with any applicable National, Local
Standards, Codes or Regulations.
47
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 genset is to run in parallel with another genset.
Loading
When planning your distribution system it is important to ensure that a balanced load is presented to
your genset. The unbalanced loading of a three phase alternator would cause damage to the
windings. A maximum unbalance of 25 % is acceptable.
Protection
The cables connecting the genset with the distribution system should be protected by means of a
circuit breaker, fuses or other means to disconnect the genset in case of overload or short circuit.
Ensure that the Load current exceeds that of the current rating of the genset.
It may be necessary to reorganize the electrical distribution system if a genset is to be connected to
an existing installation.
Power Factor
The power factor (cos Ø) of the connected load should be determined. Power factors below 0.8 will
overload the generator. The genset will provide its kilowatt rating and will operate satisfactorily from
0.8 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. The power factor problems would result in voltage instability on the generator output.
EARTHING
The Earthing should be done in accordance with applicable National, Local Code or Regulation.
Regulations vary and advice should be sought from the local supply utility as to 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
neutral to earth is the responsibility of the installation technicians.
Warning:
SERVICE
? 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 connections.
Why is Earthing necessary?
Earthing provides protection to personnel and equipment by ensuring protective control gear and
isolation of faulty circuit in following cases :
? Insulation puncture or failure.

? Accidental contact between high & low voltage lines.
? Breakdown of insulation between primary & secondary windings of a transformer.
? Lightning strike.
48
Methods Of Earthing
Following are the two most commonly used methods of earthing.
The recommended materials for the Earth Electrode are copper, copper - clad
iron, cast iron and galvanized steel.
Rod and Pipe Electrodes.
Earth Connection
Figure 16: Earthing Electrodes - Pipe type
Rod and Pipe Electrodes
Rod electrodes shall be at least 16 mm in diameter if of steel, and 12.5 mm diameter if of copper.
Pipe electrodes shall not be smaller than 38 mm internal diameter if of galvanized iron or steel and
100 mm internal diameter if made of cast iron.
SERVICE
The length of rod and pipe electrodes shall not be less than 2.5 m, which shall be driven to a
minimum depth of 2.5m. Where rock is encountered at depth of less than2.5m the electrodes may
be buried inclined to the vertical with inclination not more than 30° from the vertical.
The recommended method of installing a pipe electrode is illustrated in Figure 16 . If one electrode
fails to give the required low resistance, a number of such electrodes may be installed and
connected in parallel.
The distance between to adjacent electrodes should not be less than twice the length of the
electrodes.
49
Earth
Connection
Figure 17: Earthing Electrodes - Plate type
Plate Electrodes
Plate electrodes may be made of copper, galvanized iron or steel. The size of copper plate shall not
be less than 60 cm x 60 cm x 3.15 mm and that of iron and steel plates not less than
60cmx60cmx6.30mm. The installation of the plate electrode is shown in Figure 17.
The top edge of the plate shall be at a depth not less than 1.5m from the surface of ground.
“P”, the resistance of a plate electrode may be calculated from the formula:
r P
R= Ohms
SERVICE
4 A
Where r = resistivity of the soil in ohm-meters

2
and A = area of both sides of the plate in cm
Where the resistance of one plate electrode is not satisfactory two or more plates may be used in
parallel with a minimum distance of 8 meters between the two plates. The size of the plate too has
an effect on the resistance but there is little gain with plate area more than 1.75 m² per side.
The use of plate electrodes is recommended in generating stations and sub stations where current
carrying capacity is the prime consideration.
50
Earth Bus and Earth Wires
Round and flat sections of copper and galvanized -iron are used for earthing purposes. No earth
wire shall have cross -sectional area less than 3.0 mm² if of copper, and 6mm² if of galvanized iron,
except in portable equipment whose current carrying conductor has a less than 3.0mm². In such a
case , the earth wire shall have a cross-sectional area equal to that of the current - carrying
conductor.
The size of the main earth bus of copper can be worked out from the formula,
A = .03 I mm² for bolted or pressure joints.
where A is cross-sectional area in mm² and I is the maximum fault current.
The minimum size of copper earth bus should be nearly half the size of the corresponding current
carrying conductor, but not less than 65mm² if of copper and 200 mm² if of galvanized iron and steel.
In case of steel wire, the conductivity should be equal to that of copper. The earth wires should be
so laid that there is no danger of mechanical damage to them.
Earth -Continuity Conductor (E.C.C.)
The cross - sectional area of every separate copper E.C.C. not contained in a cable, flexible cable
or flexible cord shall not be less than one- half that of the largest current carrying conductor feeding
the circuit and in no case shall any separate earth continuity
conductor have a cross-sectional area less than 3.0 mm² if of copper and 6 mm² if of galvanized iron
or steel. It need not have a cross-sectional area greater than 65 mm² (copper) in any case.
Metal conduit pipe should normally not be used as an earth continuity conductor. Where so used, all
joints should be screwed tight for effective electrical continuity Locknuts should also be used to
safeguard against loosening.
Type of Connections
Welded, bolted and clamped joints are permissible.

All bolted and screwed connections shall be protected against corrosion.
Special care should be taken to protect connections of dissimilar metals against corrosion.
All surfaces where connections are made should be free of grease, paint, dirt or any other foreign
material.
Prohibited Connections
Water and gas pipes and members of structural steel-work shall not be used as continuity
conductor. Flexible conduit shall not be used as E.C.C. A separate earth wire should be provided
either inside or outside the flexible conduit which should be connected by means of earths clips to
the earth system at one end, and to the equipment at the other end.
Note
SERVICE
Each genset requires two separate earth pits separated by not less than 1 meter distance on any
suitable location.
Earth Pit No. 1 - Engine, Alternator, Genset base and the Control Panel.
Earth Pit No. 2 - Alternator neutral.
No separate earth pit is required for battery since the battery negative is connected to genset body.
Voltage difference between alternator neutral and earthing terminal should be less than 5 Volts AC
when the genset is running at full load.
As the earth pit depends on good conductivity, it should always be kept moist. This is achieved by
wetting with water using a suitable funnel. The user should be educated to keep the earth pit moist
as a regular maintenance practice.
51
MAINTENANCE OF THE ELECTRICAL SYSTEM:
BATTERY
Care of the battery is very critical as they are used to start the genset whenever the backup power is
required. Maintenance procedures should be carried out rigorously since the battery has to be in
perfect condition to start the diesel engine. Apart from powering the starter motor, the battery serves
as the energy source for all the electrical controls and safety devices on the engine.
Even a the slightest resistance in the starting circuit has a significant effect on the starting ability of
the engine. Therefore, the battery should be located as close as possible to the genset and the
connections should be kept tight and corrosion free.
The battery should be accessible for servicing. During charging, the battery give out fumes that are
corrosive and contain inflammable gases such as hydrogen, hence the area should be well
ventilated.
A regulated source of charging the battery is required with the genset. This may include an engine
driven battery charging alternator, a static battery charger or both. The static battery charger may be
energized from the mains supply and keeps the battery fully charged so that it may start the engine
whenever required.
The regulated source ensures that the battery is charged rapidly when it is discharged but prevents
overcharging once the voltage has recovered.
Checking Electrolyte Level:
? Remove cell caps.

? If electrolyte test elements (pegs) are available, the electrolyte level in each cell
should be high enough to wet the end of these pegs.
? An alternative method is to insert a clean wooden stick into the cell, until it touches the top
edge of lead plates.
SERVICE
Figure 18: Checking the electrolyte level

? The electrolyte should wet the stick over a length of about 10 to 15 mm.
If the electrolyte level is low, top-up with distilled water only.
?
? Replace the caps.
Checking Specific Gravity of Electrolyte:
? Check the specific gravity of electrolyte with a hydrometer, five minutes after adding distilled
water.
? Measure the specific gravity of electrolyte in the individual cells with a commercial
hydrometer.
52
? The measured values in the table below indicate the state of charge of the battery.
? Charge the battery if the reading is below the one mentioned in the following table.
Specific Gravity State of Charge

(kg/l)
Normal Tropical
Climate Climate
1.28 1.23 Fully Charged
1.20 1.12 Half Charged, suggested

to recharge.
1.12 1.08 Discharged, must recharge
immediately.
Maintenance of the Starter Motor:
? Ensure that the mounting bolts are securely fastened and all electrical connections are
clean and tight. Cables should be examined for fractures, particularly where the strands
enter the terminal lugs.
Figure 19 : Checking the starter motor brush spring
l Check the brushes. They must be renewed if worn to approximately 10 mm and 13mm
which is half of the original or to a point where springs no longer provide effective pressure.
Brushes must always be replaced in sets and with the correct grade.
l Check the brush spring balance as shown in The spring pressure should be as follows-
0.965 to 1.080kg. If the pressure is not within the above limits, renew the springs in set and
not individually.
SERVICE
l Check the commutator surface. It should be clean and entirely free from oil, any trace of
which should be removed by pressing a dry fluff free cloth against the commutator while the
armature is hand rotated.
l It the surface is dirty or badly discoloured, clean it with a strip of fine emery. Remove all
traces of dust and abrasive using compressed air.

l The starter does not require lubrication from outside, since it is equipped with porous bronze
bushes, which are pre-lubricated.
l Check the drive assembly for free movement over the shaft splines. If necessary, smear
grease over the shaft splines to enable the drive assembly to move freely.
53
Other regular electrical maintenance:
? Connections to terminals, terminal strips, plugs and sockets should be periodically

tightened. Examine the condition of the insulators, lugs, sleeves etc for cuts, abrasions,
burns, cracks etc.
? Instruments: The only regular maintenance the instruments would require is ensure that the
connections are tight and that the mounting clamps are secure. Do not change the settings
of the instruments unless trained specifically for the task.
WARNING: Always shut the Genset down prior to connecting, or disconnecting, load cables.
Restart only after a sound connection has been made.
If the generator stops at any time because of a fault, the defect should be identified and
rectified before restarting the generator.
54
ACOUSTIC CANOPY:
All gensets make sounds while they are running. These sounds can be a source of nuisance to the
surroundings and hence they are fitted with an acoustic canopy that are fitted around the working
genset.
Your genset can be supplied with the following accessories and components to reduce noise
emissions - Residential and super critical silencers, acoustic louvers and splitter vents, fan silencers
and acoustically treated enclosures.
Addition of any of the device increases the costs, complexity and price of a genset in addition of
reducing the mechanical and electrical power. These factors must be borne in mind while selecting
the sound control devices for the genset.
The local pollution control laws (such as the CPCB norms in India) may require the genset to run
inside an acoustic canopy to prevent excessive noise. Generally the noise level is controlled as per
the customer’s specifications.
The requirements for each site vary enormously and for any critical installation we recommend you
consult your dealer at an early stage. The information needed to select acoustic equipment is:
· The model and capacity of genset
· The location and overall site plan.
· The designed noise level at a fixed distance
· Environmental conditions, ambient temperature etc.
Noise emissions from diesel gensets (without acoustic treatment) are at sound pressure levels of
between 100 dB(A) and 110 dB (A) at 1m. Upto 200 KVA capacity, the typically Kirloskar Gensets
with acoustic enclosures could have a typical noise pressure level of 70 dB(A) at a distance of 7
meter from the enclosure. As mentioned before, the acoustic treatment depends on the customer’s
requirement.
Intermediate levels of treatment will prove more economic and are often satisfactory depending only
on the nature and type of installation. Sensitive areas such as hospitals etc. require more attention
than the normal commercial / industrial installation.
Figure 20 : A typical genset with acoustic canopy
55
An acoustic canopy is provided for the genset with the following characteristics:
l To reduce the noise level.

l To protect the genset against weather.
l To make the genset as a self contained assembly, thus aiding installation,
transportation and utility.
l The canopy has lockable doors to allow only authorized service personnel access to the
genset. The fuel filling spout on the canopy may also have a locking arrangement.
l The interior of the canopy would include adequate area for the service personnel to move
around the engine. The canopy could have a lamp to provide interior illumination when
required.
l The canopy has to be ventilated by exhaust fans so that the temperature inside
remain within limits. These fans are operated from the power generated from the alternator,
hence has to be considered while calculating the output of the genset.
l Adequate anti-vibration devices are placed between the genset and the canopy so that the
surface on which the assembly is installed is not affected while the engine is running.
l The canopy may contain the assemblies such as the fuel tank, control panel and the
exhaust silencer.
l Depending on the application and location, the silencer may be fitted with an additional
exhaust pipe to lead the fumes away from the genset.
l The canopy would have eyelets and slots in the frame so that it may be lifted by a crane or
a forklift truck during installation.
l The exterior of the canopy is treated with paints or finish so that it would withstand the
effects of weather and extremes of temperature.
l Care has been taken to ensure that the rain water does not enter the canopy. The canopy
has guards or grills to prevent small animals or birds entering the openings.
l The sides of the canopy are fitted with special sound absorption material.
SERVICE
l One of the sides of the canopy may contain a glass window to show the view of the control
panel while the engine is running without having to open the doors.
l An Emergency Stop push button switch is usually fitted outside the canopy to stop the
genset on an urgent basis.

l The canopy would have a cable entry point through which the power wiring is connected.
There may be a few earth points inside and on the outside of the canopy that are to be
connected to the external earth pits.
56
CONTROL SYSTEM
The Control System consists of:-
l Control Panel providing a means of starting and stopping the Generator Set, monitoring its
operation and output, and causing the engine to automatically shut down in the event of a
circuit condition arising. E.g. low oil pressure, high coolant temperature, over speed, low fuel
level etc.
l An Alternator Circuit Breaker providing a means of switching the Generator output, and
automatically disconnecting the load in event of short circuit.
l The power to operate all the control systems is derived from the engine starting
battery.
l The engine itself is fitted with devices such as:
> Various safety switches (like switches for low oil pressure, high coolant
temperature, low fuel level etc).
> Various sensors and sender (magnetic pickup for engine speed sensing, oil pressure
sender etc).
> Solenoids, Actuators and Motors to translate electrical signals into mechanical motion
(like fuel or stop solenoid, throttle actuator or a starter motor).
SERVICE
Figure 21 : A typical control panel
CONTROL PANEL:
While some parts of the controls are fitted on the genset engine, most of the elements may be fitted
inside a control panel.
There are essentially two types of controls panels:
l Manual Engine Safety panels.

l Automatic Mains Failure (AMF) panels.
57
Manual Engine Safety panel:
As is evident from the name, these panels need the user to operate the genset. The control system
automatically stops the engine if it detects an unsafe condition like high coolant temperature, low oil
pressure, engine overspeed etc.
l The heart of the panel is an electronic controller, the DSE 704. This compact unit has the
inbuilt interlocks, timers, indications, switches, inputs, relay outputs etc to avoid using
external timers and switchgear.
l Engine gauges. The engine gauges indicate the engine parameters such as oil
pressure, coolant temperature, battery voltage and fuel level. These gauges operate
proportionally based on an analogue sensor that is fitted to the oil gallery, the coolant
system or the fuel tank etc.
l Electrical Gauges: The electrical gauges indicate the three phase voltage, current or
frequency of the alternator. The voltmeter and the ammeter gauges have a switch that
selects to read between the three phases. Larger gensets may have electrical gauges with
advanced functions such as KVA, KW, PF, KVAR etc.
l Relays: The coils of the relays are driven by the controller. When energized, the relay
contacts are used to switch the heavy current required to operate the starter motor or the
stop solenoid.
l MCB (Miniature Circuit Breaker) and MCCB (Moulded Case Circuit Breaker): These protect
the electrical circuits from overloads and short circuits. They break the supply whenever the
current exceeds a set limit, thus offering protection.
l The MCB is generally used when lower currents are handled and operates on a thermal
principle. The MCBs are available in 1,2,3 and 4 pole configurations and are used in AC as
well as DC circuits.
l The MCCB is generally used when higher currents are handled and operate on thermal as
well as magnetic principles. The MCCBs are generally available in 2,3 and 4 pole
configuration and are used in the AC circuits.
l The user has to manually choose between the mains or genset supply using a changeover
switch. The user must ensure that the load is not connected to the genset during starting
and stopping of the engine.
Automatic Mains Failure (AMF) panel:

SERVICE
The AMF panels offer a high degree of automation. The AMF panel can operate completely without
user intervention.
l The AMF panel is also built around the DSE 704 electronic controller.
l The 'Line Voltage Monitor' (LVM) relay in the panel detects the presence of a healthy mains
supply and signals the controller via a relay contact.
l This controller switches a mains contactor that charges the load feeder from the mains
supply.
l If the mains supply is detected as defective (under or over voltage, phase failure etc), the
mains contactor is switched off and the genset is cranked via the starter motor.
l The starter motor is switched off automatically once the engine fires.
l Once the engine is running and the alternator is producing an output, the genset contactor
58
is switched and the load feeder is now charged from the genset supply.
l The engine safety parameters are continuously monitored by the controller and the engine
is shut down if the parameter is found to be exceeding the limits.
l While the load is being charged from the genset supply, the mains feeder is being monitored
for return back to normalcy.
l Once the mains supply is restored, the load is switched to the mains feeder by switching off
the genset contactor and switching on the mains contactor.
l The genset is run for a short period without load to cool the engine and the alternator before
being shut down.
l The system now again monitors the mains supply for operation within the set limits.
l Thus the AMF panel operates automatically without any inputs from the user.
l The panel may be fitted with audio and visual alarms to indicate various conditions.
l Many of these conditions would be also available on 'potential free' relay contacts for
remote annunciation and telemetry.
l The other features of the AMF panels are similar to the Manual panels such as the engine
and electrical gauges etc.
l In case the engine does not fire in the first attempt, the controller would try many crank
cycles to start the genset.
l If the genset does not start even at the end of many crank cycles, the controller locks out
further activity to avoid draining the battery further.
l A 'Start Failure' alarm is generated in such a condition. The user would have to reset the
panel before a fresh attempt can be made to start the genset once again.
l The AMF panel is fitted with a static charger that keeps the engine starting
battery in a healthy state. This would ensure that the battery is ready to start the genset
whenever required.
l The controller has many inbuilt timers, interlocks and logics that help to simplify the panel
wiring and reduce the complexity of the panel.
l The mains and genset contactors may be interlocked to prevent both of them from operating
at the same time.
l The coils of the contactors are fed from the supply of the same feeder i.e. the mains
contactor runs off the mains supply and the genset contactor runs off the genset supply.
l The contactors may be of 2,3 or 4 pole configuration. As the current of the Neutral is half of
the Phases, sometimes the power contactor for the three phases may have only three
poles, while the neutral is switched by a separate, smaller contactor. Often the poles of the
contactors may be wired in parallel to increase their current handling capacity.
SERVICE
l Larger AMF panels use ACBs (air circuit breakers) in place of contactors to switch the
power currents.
l MCBs, MCCBs and Fuses are used in the panel to offer protection against short circuits and
overloads. The advantages of the MCB or MCCB is that they can be reset to the original
condition while a fuse has to replaced after failing under excessive current.
l Apart from the usual fully automatic mode of operation, the AMF panel may have a Manual
mode of operation where the genset is controlled by the user. The Manual mode may offer
genset safety during operation.
l The AMF panel may also have a Bypass mode, in which the operation is controlled by the
user but there is no safety to the genset. This mode is used in case of an emergency.
59
A typical Three Phase AMF panel.
Note: The three phase AMF panel fitted in your genset may be significantly different from the
illustrated panel, however most of the components and principle of operation remain identical.
l Apart from being wired to the engine and the battery, the panel is connected to the Mains,
Genset and Load feeders.
l The logic in the panel and monitors the mains supply. If the supply is healthy then the Mains
contactor is selected, thus charging the Load feeder with supply from the Mains feeder.
l If the mains supply is found to be unhealthy, the mains contactor is de-selected and the
genset started via the panel logic.
l Once the genset is working, the genset contactor is selected to charge the Load feeder with
the genset supply.
l As the genset is running, the engine parameters are being monitored for operation within
the safe limits. In case the engine parameter is unsafe (low oil pressure, high coolant
temperature, engine overspeed etc) the panel logic shuts the engine down to prevent
damage.
l Even as the genset is running and the load is being charged from the genset feeder, the
panel monitors the mains supply for a return to normalcy.
l Once the mains is detected as normal, the load is transferred to the mains feeder and the
genset is shut down. Thus the panel operates in an automatic mode and strives to keep the
load feeder charged with a healthy supply from either the mains or the genset supply.
DC Supply Common
On Lamp Fault Lamp AMF Controller
AC
Ammeter Frequency
Meter
AC
Voltmeter
Coolant
Temperature Load On Mains
Gauge Battery Voltmeter Fuel Level Gauge Lamp
SERVICE
Load On Genset
Lamp
Oil
Pressure
Gauge
Emergency Stop
Push button
Voltmeter Ammeter Control On/Off Canopy Light

Hourmeter Switch Switch
Figure 22 : A typical AMF Panel
60
SECTION B: SL90 ENGINE
INDEX
1. Engine Numbering System 3
2. Illustrations 4
3. Engine lifting 5
4. Lube Oil 6
5. Fuel Supply System 8
6. Cooling Systems 9
7. Electrical Systems 10
8. Commissioning 11
9. Starting 13
10. Maintenance Schedule 16
11. Maintenance of Various Systems 17
12. Trouble-Shooting & Remedial Measures 34
13. Engine Preservation 42
14. Tightening Torques 43
NOTES
2
1.1 ENGINE NUMBERING SYSTEM :
1.1.1 Engine Name Plate
Engine serial number is punched on the Name Plate which is fixed on crankcase. Fig. 2.1/1 show the engine name plate.
Fig. 2.1/1
2.1.2 Engine Number

F6 . 38xx / 07 00001
Engine Serial Number
Year of manufacture
Application Code No.

30xx for 140 KVA
32xx for 160 KVA
34xx for 180 KVA
36xx for 200 KVA
38xx for 250 KVA
F6 - SL90
2.1.3 Model Designation :
There are three variants of SL 90 engines.
Engine model Capacity

6SL9088 TA SR1 140 KVA
6SL9088 TA 160 KVA
6SL1500 TA 180 KVA
6SL1500 TA 1 200 KVA
6SL8800 TA 250 KVA
3
2.2.3 Air Inlet Manifold Side
1. Air Cleaner
2. V-Belt
3. Lub. Oil filter cap
4. Charging Alternator
5. Lub Oil Header
6. Engine Mounted Control Panel
7. Gear End Foot
8. Fuel Injection Pump
9. fuel filter
10. Injector Pipe
11. Bell Housing
12. Air inlet manifold
13. Lube oil sump with drain plug
14. Lub. oil cooler
15. Cylinder Block
2.2.4 Exhaust Manifold Side
16. Engine Base Frame

17. Crankcase
18. Flywheel End Foot
19. Exhaust Manifold
20. Radiator Inlet Pipe
21. Radiator
22. CAC Inlet Pipe
23. Rocker Cover
24. Starter
25. Turbocharger
4
2.3 ENGINE LIFTING DEVICE
2.3.1 For Bare Engine
As shown in Fig. 2-3/1, before lifting a typical engine, fix the lifting hooks. The lifting hooks on the engine
are meant for lifting the bare engine only. The use of both the hooks is mandatory for safely lifting the
bare engine.
Fig.2.3/1
2.3.2 Recommended Lifting Arrangement for Base Plate Mounted Set.
Using the engine lifting hooks for lifting up of Gensets mounted on base plate could result in bending of
the studs for lifting and damage the engine/set in event of breakage. Use of a proper sling/tackle
arrangement for lifting up of such base plate mounted sets is recommended. Fig.2.3/2 shows the
recommended lifting arrangement.
Fig.2.3/2
5
2.4.1 Lubrication System
The force feed lubrication is provided by an inbuilt pump to main bearings, connecting rod big end bearings,
camshaft journals, valve gear and turbo charger bearing.
Other components like small end bearings, liners, gears are lubricated by the splash method. The oil is cleaned by
passing it through a replaceable filter element. A lube oil cooler is used to keep the temperature of the circulating oil
within limits. A relief valve, fitted on the delivery side of the pump limits the generation of the oil pressure.
The schematic diagram shows the lube oil circuit of a typical engine is as follows:
Fig.2.4/1
2.4.2 Lube Oil Pressure :-
2
Minimum recommended Lube Oil Pressure is 2 kg/cm
2
If the pressure drops below 2 kg/cm while the engine is running under loaded at 1500
RPM, the lube oil filter element/cartridge should be replaced. If the pressure continues to
remain low, please contact our authorised Service Dealer for the services of their
technicians.
2.4.3 Lube Oil consumption
Lube oil consumption varies according to engine operating conditions, but would not normally exceed
0.3% of actual fuel consumption for a Kirloskar SL90 diesel in good condition.
6
2.4.4 Lube Oil Sump Capacity
These approximate values refer to standard Oil Sump..
Oil capacity for the SL 90 in liters.
First Fill 23.5
Refill 21.0
Note :
1. First fill = Sump Capacity + Gallery Capacity + Lube oil Filter Capacity.
2. Fill the Lube Oil Filter before fitting on the engine.
3. Do not forget to fill the lube oil filter whenever you replace the filter.
4. Whenever lube. Oil filter is drained off, add as per lube oil filter capacity e.g. 0.5 lit./1.1 liter.
Extra lube Oil in the sump to maintain correct oil level.
While filling for the first time, add an additional quantity of lube oil equal to capacity of the oil filter
to the sump to maintain the correct level.
OBSERVE THE OIL LEVEL MARKS ON DIPSTICK.
2.4.5 Lube Oil Specifications :
A) Lube oils of correct viscosity and detergency grades should be used.
For detergency ‘K’ oil comply to the following specifications:-
Selection of Lubricating Oil Table
Standard For Turbocharged engines
I.S.10356:1993 E DL3 / EDL4

I.J.S. Military MIL-L 2104c/2104C plus
API CF4
CCMC D4 / D5
1) API - American Petroleum Institute.

2) CCMC - Association Of Automobile Manufacturer of Common Market.
The recommended SAE number should be used for Viscosity,

SAE J 30° C specifies the viscosity of Lube oils for each SAE Number.
The choice of the viscosity grade during winter operation should be governed by the ambient temperature
prevailing at the time of starting the engine. Oil changes as a function of ambient temperatures can be avoided
by using MULTIGRADE oils. Having an oi l with high viscosity causes starting difficulties.
The Kirloskar make K-Oil should be used for your engine. This oil meets the specification of MILC plus and SAE
20W40.
Please note that no guarantee claims would be entertained for engine damages due to use of unsuitable
engine lube oil.
7
2.5 FUEL SUPPLY SYSTEM
2.5.1 Fuel Circuit
A lift pump (feed pump) incorporated in the fuel injection pump is used to pick up the diesel from the tank. Two
stages of filters (a pre-filter and a micro paper filter) ensures the cleanliness of fuel before it is supplied to the fuel
injection pump. The schematic diagram (Fig. 2.5/1) shows the fuel circuit of the engine.
NOTE : It the fuel tank is to be installed below the fuel pump level, then the bottom level of the fuel tank should be
less than 1 meter below the feed pump inlet.
Fig.2.5/1
2.5.2 Fuel Specifications

The performance of the engine depends upon supply of clean and correct grade of fuel. The fuel injection
equipment is manufactured to very close tolerances and slightest amount of dirt in fuel can cause wear on
the injection equipment.
A) Always use clean High Speed Diesel having a sulphur content of below 1%.
In case of diesel fuel containing sulphur more than 1% the periods between oil changes should be
shortened.
The following specification are approved :-
• IS: 1460
• BS:2869-A1&A2
(In case of A2, note sulphur content)
• DIN 51601
• ASTMD 975-81:1D&2D
Winter Grade Fuel-

At low temperatures, waxing may occur and clog the fuel system, thus
causing operational troubles.
In the case of ambient temperature below 10° c, use ‘Winter Grade’ diesel
fuel, mixed with Kerosene. Proportion of Kerosene to be mixed in Diesel,
depends on the ambient temperature as shown in the graph (Fig.2.5/2).
(Maximum proportion limited to 50%) For cold starting aid see 3.4.1
PREPARE THE BLEND IN THE TANK ITSELF. FILL IN THE NECESSARY

AMOUNT OF KEROSENE FIRST, THEN ADD DIESEL FUEL.
Fig.2.5/2
8
2.5.3 Storing Fuel Oil
The storage of fuel oil is of utmost importance since many engine problems are traced to dirt in the fuel or use
of fuel that has been stored for too long a period. Store fuel in a convenient place outside the building.
It is recommended that the fuel tank should be filled in at the end of the day’s work. This keeps moisture out of
the tank.
To eliminate water from the fuel, drain out small quantity of fuel from fuel tank through a drain plug every day
before starting the engine.
2.6 COOLING SYSTEM

2.6.1 LIQUID COOLED ENGINE SYSTEM
The engine is cooled by circulating the water around the cylinders. An engine driven water pump circulates the
coolant whenever the engine is running. The cold water flows through the water jacket around the cylinders. This
hot water flows through to a radiator where the heat is transferred to the ambient air. The airflow through the
radiator is ensured by a fan. Initially, when the water is cold, a thermostat forces the water to bypass the radiator,
thus bringing the engine to the working temperature faster. Once the engine gets hot, thermostat now allows the
water to go through the radiator.
The oil cooler also uses the water circuit to exchange the heat and thus lower the temperature of the lube oil.
Fig.2.6/1
2.6.2.1 Radiator System

The cooling circuit with radiator is recommended at installation where the fresh water is available.
The Fig. 2.6/1 shows the water circuit diagram.
IMPORTANT
§ It is also necessary to ensure proper ventilation to avoid hot air re-circulation into the cooling system.
§ For any non-standard installation of radiator system (like Remote radiator mounting) please contact KOEL
OR NEAREST KOEL AREA OFFICE / KOEL authorised service dealer for necessary recommendation.
9
2.6.2.2 Coolant
In summer - Use fresh water with anti-corrosion additives for the engine cooling system. Water should be clear and free
of any corrosive chemicals formation. Water should be clear and free of any corrosive chemicals such as chloride,
sulphate and acids. We recommend to use coolant blend of soft water and the rust preventive compound as mentioned
below:
K-Cool Super : 8 cc/litre
Available with KOEL authorised parts & service dealers.
IN WINTER - Use Ethylene glycol antifreeze diluted with coolant blend as mentioned above in the following proportion
in (radiator) cooling system.
Ambient Temperature °CRatio by volume of anti freeze to cooling water blend
+5 To -5 20:80
-6 To -15 33:67
-16 To -25 40:60
below -25 50:50 (max. permissible ratio)
? Commercially available ready mixed coolants can also be used, with Antifreeze and anti-corrosion additives
after ascertaining suitability for low ambient temperature.
? Storage of engine with only fresh water in engine cooling system should be avoided at ambient temperature
below 5° C. This may cause cracks in the engine components.
? If the engine is to be transported from normal ambient areas to Low ambient areas ambient below +5° C the
complete cooling system should be drained and refilled with Antifreeze + water mixture as mentioned above.
2.7 ELECTRICAL SYSTEM
2.7.1 24 V Electrical Equipment
This system is used on SL90 series of Kirloskar Diesel Engine.

System voltage - 24V (Floating / -ve earth)
Starter - Autolek
Alternator - Autolek
Charging Ammeter - 50-0- + 50 range.
BATTERY
A) Battery Capacity Ratings
? C.I.M ( Compression ignition Motor) Rating - Minimum current at 27° C with full charged battery should sustain for 5
min. 30 sec with cell voltage of 1.33 V/cell.
• Cranking Performance Rating- It is a minimum current in amperes which fully charged battery at 27°C will sustain
for a period of 2 minutes and maintain cell voltage of 1.2V/cell or higher.
• 20 hours capacity rating-it is the capacity in ampere-hour which the fully charged battery will deliver when it is
discharged at 27°C at a constant current for 20 hour before reaching a final voltage over all of 1.75 V/cell.
2.7.2 Recommended Battery Capacity

For battery capacity at extreme low
Engine Ambient Battery Capacity in Amp-hr. (20 hr. rate)
model Temp. °C temperature i.e. below -20°C,
contact Kirloskar Oil Engines Ltd.
SL90 Above +10° 2 batteries of 12 V, 88 Amp-hr in series Pune, India.
+ 10° to -20° 2 batteries of 12 V, 120 Amp-hr in series
10
2.7.3 BATTERY CABLE
440/0.45 (70 MM ) minimum

2
Auto Cable - 65/0.3, 35 Max. Capacity

- 26/0.3 35 Max Capacity
3.1 COMMISSIONING
Before you start a new or an overhauled engine, attend to the points given below -
3.1.1 For oil filling volume, see 2.4.4 (initial fill) For oil quality grade and oil viscosity, see 2.4.6.
Fig.3.1/1
3.1.2 Fill up the fuel tank after making sure that it is properly cleaned. Use only High Speed Diesel Fuel.
See section 2.5 for fuel quality grade. In accordance with ambient temperatures, summer or winter grade diesel
fuel should be used. Never fill the fuel tank while the engine is running. Observe strict cleanliness. Do not spill
any fuel while filling.
3.1.3 Ensure that the radiator is filled to the correct level with the specified coolant and there is no
leakage. The radiator should be checked only when the engine is cold and switched off.
DO NOT open the radiator cap when the engine is hot even if it is not running.
11
B) Operate the fuel lift pump (feed pump) till fuel oil flows without air bubbles. Keep a tray to arrest the seepage of
fuel on ground. (Fig. 3.1/2).
Fig.3.1/2
C) Tighten the vent screw on the fuel filter (Fig 3.1/3)
Fig.3.1/3
D) Loosen the banjo bolt of the fuel gallery on the fuel pump and operate the lift pump till the fuel flows free of air
bubbles. Tighten the banjo bolt after the procedure (Fig. 3.1/4)
12
Fig.3.1/4
3.14 Other Preparations
? Check battery and lead connections.

? Check the cable connections at the starter, and alternator. Loose connections lead to improper contact and
damage to the terminals.
Trial run
Upon completing the preparations, run the engine for short trial period of about 10 minutes without load. Steps to
be taken during and after trial run:
- Check engine for leakages.
With engine stationary:
- Check oil level, top up with oil if necessary (see 5.1.2)
- Tighten V-belts (see 5.5)
3.15 Belts
Check that the belts are in position and the belt tension is properly adjusted. If not adjust it as described in section
5.5.
3.2 STARTING
3.2.1 Electric Starting

Before starting, make sure that no one is standing in the close vicinity of the engine or driven machine.
Ensure that the engine is unloaded during starting. The starter motor should be released as soon as the
engine fires.
After Repairs -
Make sure that all removed panels and guards have been put back into place and all tools removed from the engine.
13
With Start Push Button -
1) Do not use the starter on any occasion for more than 20 seconds at a time. Pause for a minute between two
consecutive operations.
2) Never operate the starter for more than 4 attempts continuously, otherwise battery may run down. If engine
does not start, trace the cause according to fault Diagnosis Chart.
3) On no account should the starter be operated when the engine is running, otherwise serious damage is likely to
occur to both the starter and the starter ring on flywheel.
3.3 Stopping
Never stop the engine while it is running on load. Also do not stop the engine immediately after the load has been
disconnected. Allow the engine to run without load for 2 to 3 minutes and only then stop it. To stop the engine proceed as
follows -
• The engine can be stopped by pulling the stop lever with the help of stop-linkage provided on the engine (see Fig.
3.3/1)
Fig.3.3/1
Do not release the stop lever till the engine is completely stopped.
? If the stop solenoid is fitted on the engine, press the stop push button till the engine is completely stopped.
? Charging current lamp lights up when engine has come to rest.
? Turn key anti-clockwise to ‘OFF’ position and withdraw, pilot lamp goes out.
? After stopping the engine close the ‘shut-off cock under fuel tank (if provided).
3.4 OPERATING CONDITIONS

3.4.1 Operation in Winter:
• Lube oil viscosity -
- Select viscosity (SAE grade) as governed by the ambient temperature prevailing at the time of starting the
engine, see 2.4.6
- Note shorter periods between oil changes when operating below - 10° C, see 5.1.1.
14
Diesel Fuel:
- Use winter grade fuel for operation below + 10° C, see 2.5.2
• Cold starting Aids:
- Cold starting of a Diesel engine depends among other things, on the capacity of the starter motor and that of
the battery. Since the starting equipment of the engine may differ according to its application, please consult
KOEL, about the use of cold starting aid. However, as a general guide line we are giving below the
temperature range for cold starting aid -
Up to –5°C - No cold starting aid required.
–5° to –20°C - Use flame type heater or start pilot.
Below –20°C - Use flame type heater or start pilot and hot air blower for preheating the engine oil sump,
cylinder liners etc. (contact KOEL for details)
Battery:
? Cold starting requires a good state of charge of the battery.
? Lowering the starting limit temperatures by 4-5°c is possible by raising the battery temperature to about + 20°c.
This is achieved by removing the battery and storing it in a warm room.
3.4.2 High Ambient Temperature, High Altitude

? With increasing altitude and increasing ambient temperature, the density of the air tends to decrease, which
affects the maximum power output of the engine, the exhaust gas quality, the temperature level and in extreme
cases the starting behaviour.
? Where the engines are operated at higher altitudes or higher ambient temperature, they must be derated in
accordance with the respective standards. In case of doubt concerning such engine applications, contact, your
genset supplier or KOELfor more details
?
3.5 RUNNING - IN PERIOD
3.5.1 Running -In
During the running in phase, approx 200 running hours, it is recommended to check the engine oil level twice daily.
After the running - in phase, daily checking will suffice.
3.5.2 After first 50 running hours
• Change engine oil, see 5.1.3
• Clean lube oil filter bowl & change the element / cartridge, see 5.1.4
• Retighten fasteners for lube oil sump.
• Clean fuel filter bowls & change pre-filter element/ cartridge.
• Check V - belt tension, tighten if necessary, see 5.5
• Check valve clearance, readjust if necessary, see 5.6.1
• Check engine for leakages.
• Check engine mountings, tighten if necessary. Clean fuel strainer (button filter at feed pump inlet.) see 5.2.1
• Tighten intake and exhaust manifold fastenings at cylinder heads.
During first 50 running hours, never exceed full load even for a short duration.
15
4.1 MAINTENANCE SCHEDULE -
16
5.1 MAINTENANCE OF VARIOUS SYSTEMS
5.1.1 Oil Change Intervals
• The oil change intervals depend on engine application and on quality of lube oil. Refer table below :-
• Should, within ONE YEAR, the engine run less than the hours stated in the table, the oil must be changed at least
ONCE AYEAR.
• The table is subject to the following conditions :
- For Diesel fuel max. sulphur content 0.5 % by weight.
- Prevailing ambient temperature down to -10°C.
• In the case of fuels containing more than 0.5 % to 1 % sulphur or prevailing ambient temperature below -10°C, the
intervals between oil changes are to be halved.
• In the case of fuels containing more than 1% sulphur, ask our authorised service Dealer or KOEL, PUNE.
Type of engine Oil Grade Change Oil after
SL90 K-OIL 500 hours
5.1.2 Checking Oil Level

• Stop the engine and wait for a while till oil level in the sump is settled. Ensure that engine is in horizontal position.
Fig.5.1/1
• Pull out dipstick, wipe it with a non-fraying rag and push it in as far as it will go and then withdraw again (Fig. 5.1/1).
• The film of oil left on the dipstick should extend to the upper (max) mark. If the level only reaches to the lower mark,
the oil should be topped-up without delay.
Failure to attend to oil levels may result in serious damage to the engine (piston & bearing seizure)
17
5.1.3 Changing Engine Oil
• Change engine oil at recommended intervals, See 5.1

• Position engine on level surface.
• Run engine until warm.
(lube oil temp. approx. 80°C)
• Stop the engine (Fig. 5.1/2)
Fig.5.1/2
Take care when draining off hot oil : Danger of scalding !

Collect used oil in suitable receptacle ready for proper disposal to prevent environmental pollution.
Fig.5.1/3
Place oil tray under engine.

• Unscrew oil drain plug and drain oil completely (Pig, 5.1/3)
• Refit oil drain plug with new joint washer and tighten firmly.
• Fill in fresh lube oil.
- Lube oil specifications : refer 2.4.6
- Lube oil sump capacity : refer 2.4.4
18
5.1.4 Lube Oil Filter
Following every oil change, renew lube oil filter element or spin -on filter (if fitted on engine in place of paper type lube oil
filter).
Fig.5.1/4
A) Paper element type lube oil filter :

• Unscrew the center bolt at the bottom of the center bowl and drain the oil completely
(Fig. 5.1/4).
• Clean the bowl with clean diesel oil.
• Check the condition of sealing ring, if necessary change it.
• Apply slight oil on sealing ring and replace it on its place.
• Replace new filter element in place of old one and tighten the centre bolt along with bowl until
sealing ring is evenly seated. Then tighten the centre bolt firmly.
• Check oil level, oil pressure and leakage through sealing ring, if any.
B) Spin-on type lube oil filter :
• Release lube oil filter cartridge with special tool and spin off as shown in fig. 5.1/5.
Fig.5.1/5
19
• Clean sealing surface of filter carrier (Fig.5.1/6).
• Apply light film of oil to rubber seal of new cartridge.
• Screw cartridge into place by hand until seal is evenly seated.
Fig.5.1/6
• Tighten lube oil filter cartridge firmly by giving a final half turn. (Fig-5.1/7).
• Check oil level and lube oil pressure.
• Check seal of lube oil filter cartridge for leaks.
Fig.5.1/7
Beware of hot oil. Danger of scalding !
C) Centrifuge Cleaner :
Instruction Manual
• Introduction
The Centrifuge Cleaner SCC30 cleans your engine oil continuously when your engine is running.
It separates dirt below 1 micron from engine oil thus lowers wear rate of engine components
drastically. It avoids harmful oil degradation and arrests depletion of oil additives increasing the
oil life. The Centrifuge Cleaner does not require any spare parts to be replaced and gives
consistent performance throughout engine oil.
20
• Cleaning frequency
For consistent performance, the centrifuge rotor needs to be cleaned
periodically as mentioned in this manual. It is recommended that you service the
centrifuge every 250 hours of working or at every oil change period.
The volume of dirt collected depends upon engine application, loading and
environment in which engine is working. Exact period of servicing the centrifuge
can thus vary between 200 hours of working to your oil change period. Please
follow the instructions given below for cleaning of centrifuge cleaner.
• Identification and location
The centrifuge Cleaner is located on the same manifold on which full flow oil
filter is mounted. The centrifuge can be easily identified with a dome shaped
cover bearing instruction sticker. The exact location is as shown in this
photograph.
Fig.5.1/8
Fig.5.1/9
CENTRIFUGE CLEANER
FULL FLOW FILTER

SCC30 SERVICING INSTRUCTIONS
Instructions
• It is a precision assembly, handle with care.
• Carry out servicing preferably when the engine oil is still warm.
• All threaded parts of the centrifuge require following gadgets : a 13 mm spanner, a blunt knife, a small
adjustable pliers and waste cotton for cleaning.
Servicing procedure
• Unscrew top nut with a 13 mm spanner and remove centrifuge cover. The centrifuge cover nut has a puller
arrangement so that the cover will be lifted as you unscrew the top nut.
21
Fig.5.1/10
• Hold the rotor in hand and lift rotor to remove it completely

from central shaft.
The rotor will contain about 200 ml of oil, drain oil from the
rotor.
The rotor has two bushes at its ends.
Take care while removing rotor from central shaft.
The rotor should not fall; otherwise it will damage the bushes.
Fig.5.1/11
Fig.5.1/12
• Unscrew rotor nut by holding rotor assembly in

hand. The rotor nut can be opened by hand. if it is
tight, unscrew it with light pliers. Never grip the
rotor nut tightly in clamping device like a bench
vice. It may damage the rotor body permanently.
Remove rotor cover and deflector inside. For
removing rotor cover, remove the rotor nut
completely, hold the rotor cover in hand and give a
light blow to the rotor body at the rotor nut end by
hand. The rotor body and deflector will come out
from the opposite end.
22
• After you open the rotor, you will see the collected dirt around the rotor cover on the inside. In case the
collected dirt is hard, use a blunt knife to dislodge. Clean the rotor cover and all rotors thoroughly with cotton
waste. Clean the centrifuge central shaft also.
Fig.5.1/13
? Assemble rotor in correct sequence of parts. Match the arrow marks on rotor cover and rotor.
Tighten rotor nut firmly by hand. Install the rotor on the shaft and assemble the cleaner cover.
POINTS TO CARE ABOUT CENTRIFUGE CLEANER

1. Replace rubber rings if deformation or cuts are observed. Using damaged rubber rings will result
in oil leakage and improper functioning of centrifuge cleaner.
2. While assembling the rotor, ensure that the rubber ring has taken proper seat in its place. This is
necessary for proper sealing of rotor assembly.
3. Take care with the centrifuge housing and rotor body. They are made of aluminium, thus are
susceptible to damage due to accident.
4. Always ensure that the arrow marks on rotor cover and rotor are matched after assembling the
rotor. The rotor body is dynamically balanced.
Mismatch of arrow marks on rotor cover and rotor will result in excessive vibrations of the cleaner
and part breakage.
5. The rubber ring is made of Viton rubber. Use genuine spare rubber ring only. Rubber ring of any
other material will not give desired performance.
Don’ts about centrifuge cleaner

1. Do not over tighten the top nut. Tighten just enough to prevent leakage of oil from centrifuge
cover and housing. Over tightening top nut will damage the threading in centrifuge housing and
damage the centrifuge permanently.
Use 1.2 kg-m torque for tightening of centrifuge cover.
23
2. Do not hold the rotor nut in clamping device like bench vice as shown. Extra clamping pressure on rotor nut may result in damaging the
circularity of upper bush and will result in permanent damage to rotor assembly.
3. Do not open or tamper with the valve assembly. The valve assembly is preset for opening oil pressure in engine’s oil gallery. If the setting is lost
or the valve assembly is damaged, there is risk that your engine will not get enough oil or the centrifuge will not function properly.
Consult authorised service dealer in case of any doubt.
TROUBLESHOOTING
Sr. No. Problem Probable cause Action
1. Leakage through cleaner Rectangular rubber ring damage Change rubber ring.
2. Rotor does not rotate Nozzles blocked Open rotor and clean nozzles
thoroughly.
Reassemble the cleaner.
3. Rotor does not rotate even Entry valve blocked Do not open entry valve assembly.
after cleaning nozzles It requires special tools. Contact
company representative.
4. Rotor rotates but at low Leakage of oil through rotor Open rotor and ensure that the
speed assembly rubber ring has taken proper seat
on rotor body. Then reassemble
the rotor.
5. Rotor speed very low Bushes damaged permanently Ensure that the rotor is free on
or the rotor does not turn shaft. Else replace entire rotor
assembly.
6. Rotor rotates but at Rotor filled with dirt completely Time for cleaning the rotor
low speed
7. Abnormal vibrations of Mismatch between arrow marks Open rotor and reassemble it
centrifuge cleaner on rotor cover and rotor properly.
8. Cleaner does not collect Rotor not rotating at desired See point 2 & 3.
any dirt speed Consult authorised representative.
5.2Maintenance of Fuel System

5.2.1 Cleaning Fuel Strainer
• Close fuel stop cock.
• Remove special banjo bolt situated at the bottom at the Inlet of feed pump.
• Takeout screw with strainer fitted inside banjo bolt (Fig.5.2/1). Fig.5.2/1
• Clean the strainer with clean diesel.
• Refit the strainer inside the
banjo bolt and screw in the banjo bolt using new copper washers
• Bleed the fuel system (see 3.1.5) check for leaks.
5.2.4 Fuel Filter

Cleaning the Dual Fuel Filter :
• Close fuel stop cock.
• Drain the fuel filter bowls by loosening the plug situated at the bottom of the bowls.
• Check the condition of sealing ring, if required change it.
• Complete the filter assembly and bleed the fuel system before starting the
engine, see 3.1.5
• Change over period for pre-filter insert and micro filter insert is given in
‘Routine Maintenance Schedule 4.1/4.2/4.3/4.4 as per engine type.
• For changing micro-filter insert follow the same procedure explained above.
Fig.5.2/2
24
NOTE:
1) Do not clean filter insert. Always replace the insert with new one at recommended intervals. Cleaning will
damage filter insert, reduce filtration efficiency and damage fuel injection equipment.
2) Since a filter attains the maximum efficiency only after a film of dirt is deposited on the surface of the filter insert,
avoid replacing pre-filter insert and micro-filter insert at the same time. First change pre-filter insert and then
after 250 running hours change micro-filter insert.
3) The Routine Maintenance schedule is meant to serve as a guide only for normal fuel storage and engine
operating conditions. Replacement of inserts may have to be made earlier than the recommended period.
When working on the fuel system, keep naked lights away! Do not smoke!
5.3 Maintenance of Air Cleaner System
? 5.3.1 Cleaning Intervals:

? In normal conditions, the air cleaner should be attended every 2000 hours of engine use.
? In case the genset operates in a dust laden atmosphere, the air cleaner should be attended more
frequently.
5.4.4 Dry type Air Cleaner
A) Description:
Your SL 90 Engine is fitted with a Dry type Air Cleaner. The construction of typical Dry type Air Cleaner, supplied as
optional extra, is shown below in fig, 5.4/3 and 5.4/4.
Fig.5.4/3
Fig.5.4/4
Inlet cap or pre - cleaner is supplied for the air intake, depending on the working conditions, inlet cap prevents
ingress of rain/heavy particles. Pre-cleaner separates out heavier dust particles, which are collected in the pre-
cleaner bowl, thereby extending the life of the main filter element.
Two filter elements are co - axially fitted in the air cleaner housing. The outer element is the main filter element, with
a built in cyclone separator which gives a swirling effect to incoming air, to separate out heavy dust particles by
centrifugal action.
25
This dust is collected in the end cover (which is removable). The vacuator valve at the bottom of cover helps in
expelling the accumulated dust. This is achieved by opening / closing of vacuator valve outlet due to the air flow
fluctuations inside the air cleaner.
Inner element is a ‘Safety Element’ to prevent ingress of dust into the engine, when the outer (main) element is
removed for cleaning / replacement.
B) Maintenance:
Regular check up and maintenance of the air cleaner is essential to ensure maximum protection to the engine
from the dust.
i) Daily check the connection of rubber hose and the hose clips between the manifold and the air cleaner before
starting the engine. Damaged hose/ clips nuts be replaced immediately. Any by-passing of unfiltered air
through cracks in the hose / loose hose will quickly lead to serious damage to the engine.
Since this is a dry type air cleaner, ensure that no oil or water/moisture enters the filter casing.
ii) The pre cleaner (if provided) should be cleaned, to remove the accumulated dust, after each day’s work, when
the engine is stopped. This cleaning can be done by removing the top cover of the pre cleaner.
iii) The restriction indicator, mounted on air cleaner near the hose, indicates the condition of the air cleaner
element, when the air element is in good condition, a red signal will be seen through the transparent window on
the indicator when the engine is running and will disappear when engine is stopped. However, if the element is
choked, then the red signal will remain ‘ON’ even after engine is stopped. This is an indication that the main filter
element must be removed & cleaned or replaced.
NOTE:
1) Do not clean filter insert. Always replace the insert with new one at recommended intervals. Cleaning will
damage filter insert, reduce filtration efficiency and damage fuel injection equipment.
2) Since a filter attains the maximum efficiency only after a film of dirt is deposited on the surface of the filter insert,
avoid replacing pre-filter insert and micro-filter insert at the same time. First change pre-filter insert and then
after 250 running hours change micro-filter insert.
3) The Routine Maintenance schedule is meant to serve as a guide only for normal fuel storage and engine
operating conditions. Replacement of inserts may have to be made earlier than the recommended period.
iv) Discharge the dust vacuator valve 1 by pressing apart the lips of the vacuation slot, applying pressure as
indicated by the arrows.
2) Rapping, Tapping or Pounding dust out of them is dangerous. Severe damage to the filter will result !
Fig.5.4/5
Fig.5.4/6
26
Clean the vacuation slot time to time.
? Remove any cakes of dust by pressing together the upper part of the valve.
• Make sure that vacuator valve is not damaged, if required change it. Also, check the condition of cup joint sealing,
replace if necessary.
v) Cleaning of Filter Element :
Cleaning of filter element is to be done only when a restriction indicator shows a red signal even after the engine is
stopped. For cleaning proceed as follows -
I) Loosen the mounting band of the dust cup, remove the wing nut of the element and take out the outer element
for checking and cleaning.
ii) Use a damp cloth to wipe out all excess dust in the air cleaner. (Fig 5.4/6). Similarly clean the dust from the end
cover.
Fig.5.4/6
iii) Thorough cleaning of the fitter element with compressed air is recommended. Clean the element from inside to
outside using the pressurized air pipe. (Fig 5.4/7)
1) Too much air pressure can break the filter paper and destroy the element.
(Max. Air Pressure 3.5 kg/cm )
2
Fig.5.4/7
Fig.5.4/8
iv) Carefully check new or properly cleaned element for damage before installing. Conduct a light test by passing the
light through element as shown in Fig 5.4/8. If there is any crack in the element, the light will pass through it. In
that case replace the element.
27
v) Inspect the rubber sealing ring at the end cover of the element. In case the seal is damaged, replace the filter
element. (Fig 5.4/9)
Fig.5.4/9
vi) The inner element (safety element) is not to be removed, when the main element is removed for cleaning
/ replacement. It should be replaced by a new safety element after every three changes of the main element.
Fig.5.4/10
vii) Replace the cleaned or new element in the air cleaner body and reinstall the end cover, making sure it seals
360° around the air cleaner body. Reset the restriction indicator by pressing the button at the top.
In no event use petrol (gasoline) or any hot liquid for washing the
filter element of Dry type air cleaner.
.
5.5 BELT DRIVES
5.5.1 Checking V-Belts
• Inspect V-belts over whole length for damage or cracks. Renew damaged or cracked v-belts.
•
• If necessary, re-tension V-belt, see 5.5.4.
Never check / re-tension / renew V-belts while engine is running ! Refit V-belt guard, if provided.
28
5.5.4 Re- tensioning Alternator
V-belt
• Loosen the bolts which fix the
alternator on mounting
bracket. Also, loosen the bolt
on tension adjusting lever.
• Adjust the desirable tension by
pushing the alternator
outwards with the help of bar
and tension adjusting lever.
• Re- tighten all the bolts firmly.
Fig.5.5/1
Check by pressing with the thumb

midway between the pulleys to see
whether the belt deflects inwards
by not more than 10 to 15 mm.
(Fig 5.5/2)
Fig.5.5/2
5.6 ADJUSTMENTS - VALVE

5.6.1 Checking & Adjusting Valve Clearances
The valve clearance is the requisite gap between the rocker arm toe and valve stem end. Engine performance and power output
depend on its correct setting which can be done by a skilled mechanic according to the instructions below -
Checking Valve Clearance -
• Check clearance when engine is cold. (at room temperature)
• Remove rocker cover.
• Turn crankshaft until the valves of the cylinder (on which the clearance is being checked) are “overlapping” (exhaust valve
about to close , inlet valve about to open).
• Then continue turning the crank shaft through 360° (one complete revolution).
• Insert a feeler gauge of 0.15 mm in the gap between rocker arm toe and valve for both inlet and exhaust. The valve clearance
is correct when the filler gauge can be inserted with a slight drag. Failing this, the valve clearance must be readjusted as
follows -
29
Fig.5.6/1
Fig.5.6/2
Adjusting valve clearance -

• Loosen lock nut of adjusting screw through one or two turns and adjust the screw with screw driver so that, when locknut is
re-tightened, the feeler gauge of 0.15 mm can be inserted and with drawn with slight drag. (Fig 5.6/2).
• Check the valve clearances of each of the remaining cylinders and readjust, if necessary.
• Do not change the setting of oil metering screw unless required. With hot engine running at idling, an oil flow to pad at rocker
arm must be just noticeable. An excess oil flow can lead to higher oil consumption.
5.7 MAINTENANCE OF COOLING SYSTEM

(For water cooled engines only)
Engine cooling system contains radiator, fan, water pump and temperature controller i e. thermostat. The engine control panel
consists of water temperature gauge. High water temperature stop for engine safety could be provided as an optional.
5.7.1 Radiator
Check coolant level in the radiator every day before
starting the engine Remove the radiator cap and fill
coolant through radiator neck until it spills out of
overflow pipe fitted on radiator (Fig.5.3.1). Refit the
radiator cap firmly.
• Do not open radiator cap while the engine is
running or hot. The cooling system is under
pressure. Danger of burning body skin!
• Add coolant only when the cooling system is
cold. The temperature difference between the
coolant in the engine and the coolant being added
must not exceed 50 °C.
Fig.5.3/1
30
Cleaning the radiator fins
• Clean the radiator fins after every 1000 hours. (Under very dusty conditions, this is to be done if coolant
overheating is observed).
• For cleaning, blow the pressurized air through radiator fins in the reverse direction of the flow of radiator fan
(Fig.5.3.2). Do not spill water on radiator fins.
Flushing the radiator

Flush the radiator inside after every 1000 hours or once in a year
whichever is earlier. This period is applicable for clean soft water. If the
water is hard and saline, the flushing is to be done after every 500 hours
or even earlier depending upon the type of water. In order to prevent the
rust formation use rust preventive compound.
To flush, top up the radiator with clean fresh water and run the engine on
no load till it reaches working temperature.
• While the engine is still running, open the drain cock of radiator and
allow the water to flow out. This will wash away any impurities
embedded in water passages. With engine still running, keep on
adding fresh coolant for at-least 5 minutes. Stop the engine and
Fig.5.3/2 discontinue adding fresh water. Then drain the radiator completely.
Do not use concentrated SODA LIME to clean the cooling system because it could corrode
Aluminium parts.
• Check the radiator hoses and connections. Replace the damaged hoses and tighten (he connections.
5.7.2 Thermostat
A thermostat having single or multiple element is used in the water circuit. Thermostat is provided to attain working
temperature quickly during warm-up period and maintains desired temperature of coolant during running of the
engine.
Normally thermostat does not require regular maintenance. Its operation shall be checked if sudden deviations from
the specified coolant temperature occurs. Visual inspection will reveal whether or not the element rests in its seat i.e.
whether or not close tightly (Fig.5.3.3).
Figure 5.3 3
31
5.8 MAINTENANCE OF ELECTRICAL EQUIPMENT
5.8.1 Battery
A) Checking Battery and Lead Connections :
• Keep the battery clean and dry. Use damp cloth for cleaning.
• Wash the corroded terminals (+ and -) with ammonia solution
consisting of 115 gms
(1/4 pound) of baking
soda added to one litre
(one quart) of water. Fig.5.8/1
Ensure that the cleaning solution does not enter the cell through the vent holes.
• After cleaning, flush the outside of the battery, the battery compartment and the surrounding area with clean
water. After cleaning ensure that all the vent holes are open.
• When reconnecting, ensure good contact of the terminals. Tighten clamping bolts firmly.
• Apply a film of acid-free and acid-proof grease or petroleum jelly on terminals.
B) Checking Electrolyte Level :

• Remove cell caps
• If electrolyte test elements (pegs) are provided, the level should
be high enough to wet the bottom of these.
• If no such elements are provided, the alternative method is to
insert a clean wooden
stick into the cell, until it touches the top edge of lead plates.
(Fig/ 5.7/2)
The electrolyte should wet the stick over a length of about 10 to 15
mm If the electrolyte level is low, top-up with distilled water only.
• Replace the caps. Fig.5.8/2
C) Checking Specific Gravity of Electrolyte :

Check the specific gravity of electrolyte with a hydrometer, five
minutes after adding distilled water.
• Measure the specific gravity of electrolyte in the individual cells
with a commercial hydrometer. (Fig 5.7/3)
• The measured valves (Table below) indicate the state of charge
of the battery.
• Charge the battery if the reading is below the values given in the
table.
Fig.5.8/3
Specific Gravity State of charge
(kg/l)
Normal Tropics
1.28 1.23 Fully charged
1.20 1.12 Half charged, Recharge
1.12 1.08 Discharged, Charge immediately.
• For hints on battery care in winter, see 3.4.1
32
• For hints on battery storage, read enlisted below :
1. The gases emitted by the battery are explosive! Avoid formation of sparks in vicinity of battery, keep naked
lights away !
2. Do not allow acid to come into contact with the skin or clothing ! Wear protective goggles !
3. Do not place tools on battery. Danger of short circuit!
5.8.2 Starter Motor

• Ensure that the mounting bolts are securely fastened and all electrical connections are clean and tight. Cables
should be examined for fractures, particularly where the strands enter the terminal lugs.
• Check the brushes. They must be renewed if worn to approximately 10 mm (for 2 & 3 cylinder engines, 2SM114)
and 13mm (for 4 & 6 cylinder engines, 3SM127) which is half of the original or to a point where springs no longer
provide effective pressure. Brushes must always be replaced in sets and with the correct grade.
• The spring pressure should be as follows-
1.220 to 1.580 kg (for 4 & 6 cylinder engines)
If the pressure is not within the above limits, renew the springs as a set and not individually.
• Check the commutator surface. It should be clean and entirely free from oil, any trace of which should be
removed by pressing a dry lint free cloth against the commutator while the armature is hand rotated. It the surface
is dirty or badly discoloured, clean it with a strip of fine emery. Remove all traces of dust and abrasive using
compressed air.
• The starter does not require lubrication from outside, since it is equipped with sealed type bearings on 3SM 127
type, while phosphor bronze bushes which are pre-lubricated are used for 2SM 114 starter.
• Check the drive assembly for free movement over the shaft splines. If necessary, smear grease over the shaft
splines to enable the drive assembly to move freely.
(frequency once in 3 months.)
5.8.3 Alternator
• Check the brushes. Renew the brush and spring assemblies, if the overall length of the brushes are worn to less
than 10 mm. If brushes are satisfactory but require cleaning, use a petrol moistened cloth.
• The slip ring surfaces should be clean and smooth. If slip rings are burnt and require refinishing, the surfaces
may be cleaned with a piece of very fine emery paper.
• Check bearings and renew if worn.
• Check belt tension, readjust if necessary (see 5.5.1 & 5.5.4)
• Check the battery condition, (see 5.7.1)
• Keep the alternator reasonably clean and ensure that ventilation slots or air spaces are clear and unobstructed.
Check mounting bolts for tightness.
A slack belt will rapidly wear and slip that may not drive the alternator at the required speed. Too
tight a belt will impose severe side thrust on the bearings and seriously shorten their life.
33
5.9 Additional Maintenance Jobs
5.9.1 Cleaning Exhaust Silencer
Knock out soot from exhaust silencer and clean the exhaust piping.
5.9.2 Checking of Fasteners

Check & Tighten-up the fasteners for following -
• Air intake manifold
• Exhaust manifold
• Exhaust piping
• Lube oil sump
• Front cover
• Hose clip for air cleaner
• Lube oil filter mounting
• Engine mountings
• Fuel connections
5.10 Top and Major Overhaul Periods

The top overhaul (servicing of combustion system) and Major Overhaul Periods are estimated as 3000 and 9000
running hrs. respectively. This estimation is based, provided the engine is maintained properly as per the
instructions given in this Manual.
The duration of the operating period before overhaul will depend entirely on the maintenance and service given to
the engine, quality of lube & fuel oils used, type of environment and engine load cycle. Hence, the above estimated
overhaul periods are to be referred as general guidelines.
6. TROUBLE SHOOTING AND REMEDIAL MEASURE

• Operating troubles are often due to improper operation or maintenance of the engine.
• In the event of trouble, always check whether the operating and maintenance instructions have been strictly
followed.
• An appropriate diagnosis chart is given on the next page.
• If you are unable to identify the cause of the trouble or to put it right yourself, contact our authorised Service
Dealer.
34
TROUBLE SHOOTING
Trouble Cause Solution
Engine does not start. No fuel in tank. Fill in fuel, vent fuel system.
Air in fuel system. Vent fuel system.
In sufficient speed of starter. Charge batteries.
Engine does not start at See above or the ready to start Of above, or change lamp.
temperatures below 0°C. signal lamp does not light.
Defect of series resistor solenoid Consult authorised workshop.

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

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

system. Inspect injectors.
35
Engine emits black fumes. Engine is overloaded. Reset fuel injection system,
consult workshop.
Air filter jammed. Change air filter element.
Fuel injection piping loose or Tighten fuel injection piping or

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

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

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

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

quantity engine emits black fumes. by specialised workshop.
36
Leakage of solenoid valve of cold Replace solenoid valve.
Excessively high fuel consumption

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

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

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

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

Inspect oil supply to rotor.
Heavy blowing from venting hose Excessively high oil level, Adjust oil level, consult authorised
of engine. damages of cylinder elements. workshop.
No air supply from piston or Defect of cylinder element or Consult authorised workshop.
compressor. of valve plate.
Battery charging signal lamp Defective insulation in fanned Consult authorised workshop.
alight while ignition is cable.
switched off.
37
Battery charging signal lamp does Defect of signal lamp. Replace signal lamp.
not light up when ignition is
switched on. Interruption of D* governor and Plug in connector.
generator.
Battery discharged. Change battery.
Battery charging signal lamp Broken V-belt. Replace V-belt.

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

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

connections.
Carbon brushes jam or are worn. Clean or replace brushes.
38
6.2 USEFUL TIPS FOR TURBO-CHARGERS
6.2.1
* Do not tamper with the fuel pump as it may damage the engine as well as turbo charger.
* Changes in boost pressure control of the turbo charger (where applicable) may result in reduced engine life.
* Use only the air filter recommended by the engine manufacturer.
* Use only the oil filter recommended by the engine manufacturer.
* Use only the charges air cooler (where applicable) recommended by the engine manufacturer.
* Changes in the exhaust system are not recommended.
* Use original gaskets and connecting pipes.
6.2.2 Periodical Inspection of Turbo Charger.
Application : Genset application
Inspection job : Check freeness of the rotor. Every 1200 Hours.
Clean Turbo Charger if dirt or carbon deposited on compressor &turbine wheel every 1200 hours
& 2400 hours. Renew overhaul kit every 3000 hours.
6.3 RECOMMENDATION FOR OPERATION AND MAINTENANCE

Special attention should be paid to :
1. Operation Recommendations
• Engine should not be put under full load immediately after start. We recommend the engine to be run at idling
speed for a short time (60 seconds). Warm up the engine under medium speed & load.
• After the engine has been operating at full toad for a longer period of time, we recommend a short idling time
before switching off (60 seconds).
2. Maintenance Recommendations
• Turbo chargers and boost pressure control valves do not require any maintenance.
• Engine oil has to be changed regularly.
• Maintenance work has to be carried out regularly on the oil filter and air filter systems.
• Checks have to be made on the oil, air and exhaust piping, as well as, on all other connections and seals, to
ensure that they are still tight and no damage has occurred.
• When carrying out maintenance work on the engine (e.g. adjusting valves), in most cases the piping leading from
or to the turbo charger must be removed. Close the piping opening on the turbo charger. Before fitting, clean the
piping carefully.
• When fitting the turbo charger to the engine, fill the central housing with clean oil and before fitting make
absolutely sure that all piping connected to the turbo charger is cleaned carefully.
If this advice is followed a turbo charged engine has, from our experiences the same life span as a
naturally aspirated engine.
39
6.4 DO’S AND DON’T’S FOR SATISFACTORY FUNCTIONING OF TURBOCHARGER
DO’S
* Regular change of engine oil/oil filters.
* Regular change/cleaning of air filter element.
* Check for oil pressure at engine idling condition Minimum oil pressure to be as per engine manufacture’s
recommendation during idling.
* Idle the engine for 60 seconds after starting.
* Idle the engine for 60 seconds before switching off.
* Periodic of crankcase breather is necessary to allow free flow of oil from turbo charger outlet.
* Regularly check all air, oil and exhaust connections for leaks and abnormal dust/oil/carbon build up.
DON’TS
* Don’t run the engine with low oil pressure.
* Don’t put the engine under full load immediately after starting.
* Don’t switch off the engine under full load.
* Don’t run the engine with damaged oil feed & drain pipes, pipes between air filter and turbo charger and as well as
exhaust pipes.
* Don’t open the Turbo charger yourself. Please contact the authorized dealers for any turbo charger problems.
7. INSTRUCTION MANUAL FOR ELECTRONIC GOVERNOR
LINKAGE
ACTUATOR
LEVER
GOVERNOR
ACTUATOR
FUEL PUMP STOP LEVER
Fig.6.4/1 ELECTRONIC GOVERNOR
40
Electronic Governor consists of three components.
• Electric Actuator - Connected to engine fuel pump & controls the fuel quantity delivered to the engine.
• Electronic Speed Control Unit - Compares the existing engine speed with desired speed & sends
corrective signals to the electric actuator.
• Magnetic Speed Sensor - Measures the engine speed by sending a proportional frequency signal to the
speed control unit.
The system maintains the desired speed very accurately and independent of engine load. The system offered is
highly reliable with consisting accuracy & simplicity of adjustment.
The speed control unit is factory set. It is recommended that not to disturb the settings.
SYSTEM TROUBLESHOOTING
SYSTEM IS INOPERATIVE
If the engine governing system does not function, the fault may be determined by performing the voltage tests described in
steps 1 through 6. Positive (+) and negative (-) refer to meter polarity. Should normal values be Indicated during
troubleshooting steps, then the fault may be with the actuator or the wiring to the actuator. Tests are performed with the
battery power on, engine off except where noted. See actuator publication for testing details.
Step Terminals Normal Reading Probable Cause of Abnormal Reading
1 E (+) & F (-) Battery Supply Voltage 12 or 24 VDC) 1. DC battery power not connected.
Check for blown fuse.
2. Low battery voltage.
3. Wiring error.
2. A(+) & B (-) 0-3.9 with speed trim 1. Speed trim shorted or miswired.
7.1-7.9 without speed trim 2. Defective unit.
3. C(+) & D(-) 1.0 VAC RMS min., while cranking 1. Gap between speed sensor and gear
teeth too great. Check gap.
2. Improper of defective wiring to the
speed sensor. Resistance between
C and D should be 300 to 1200 ohms.
3. Defective speed sensor.
4. E(+) & H(-) 0.8-1.5 V while cranking 1. Wiring error to actuator.

2. Defective speed control unit.
3. Defective actuator.
41
7 E N G I N E P R E S E R VAT I O N
Preservatives and Preservation procedure is recommended for engine when it is to be kept
idle ( o u t o f u s e ) f o r p r o l o n g e d p e r i o d ( m o r e t h a n 1 2 m o n t h s ) .
7.1 Recommended Preservatives
MANUFACTURER ENGINE LUBE OIL UNPAINTED FERROUS

& FUEL SYSTEM METAL PARTS
BHARAT Bharat Preserve Bharat Rustrol

PETROLEUM Oil 30 152
HINDUSTAN Autoprun T 120 Rustop 274

PETROLEUM
INDIAN OIL Servo Preserve 30 Servo RP 125

CORPORATION OR
Servo ‘RUN-N’ oil 30
CASTROL INDIA —— Rustilo DW 904

OR DW 901
VEEDOL TIDE Veedol 30/40 Veedol ruspro IT

WATER OIL CO.
7.2 Preservation Procedure

a) Using H.S.D. fuel, run the engine at approximately 70% of maximum rated speed with ‘No’ load for 5 minutes to warm
up the engine ( in case of fixed speed engines like engine for Genset, it can be run at rated speed).
b) After stopping the engine, drain lube oil from sump and refill with suitable preservative oil as mentioned above.
c) Run the engine on ‘No’ load for 3 minutes. During this time the preservative will be circulated throughout the lube oil
system of engine. Stop the engine and disconnect diesel fuel supply to fuel pump inlet. For engine speed refer point
7.2 (a).
d) Prepare a solution Diesel + Preservative Oil (5:1 ratio) in a separate tank and connect fuel line from this tank, directly
to fuel pump inlet ensuring gravity feed (by-pass fuel filter).
e) Electrically crank the engine tilt it fires and let it run for 30 seconds. During this time the diesel in fuel pump gallery and
high pressure pipes will be displaced by Diesel + Preservative Oil mixture. Stop the engine.
Engine speed during above running -
• In case of variable speed engine - 800 to 1000 rpm
• In case of fixed speed engine - Rated speed at ‘No’ load. (Genset, Pumpset etc.)
f) Close the air inlet manifold (for the air cleaner inlet) and crank the engine by starter for 5 to 10 seconds. This will
ensure coating of Diesel + Preservative oil on the combustion chamber surfaces.
g) Drain preservative oil from oil sump, reinstall drain plugs and reconnect fuel filter into the fuel pipe line.
h) Treat all unpainted external ferrous metal parts with two coats of suitable rust preventer as recommended in 7.1,
allowing sufficient time for the first coat to thoroughly dry before applying second coat.
i) All vents i.e. engine inlet pipe, exhaust pipe, air cleaner inlet, crankcase breather etc. to be carefully sealed with water
proof paper and water proof adhesive tape.
42
j) Dipstick on engine to be sealed in place, with water proof adhesive tape.
NOTE : DO NOT ROTATE CRANKSHAFT AFTER ABOVE MENTIONED OPERATIONS.
k) Loosen ‘V belts tension.
l) Battery for engine starting, if provided, should be disconnected and stored in a cool, dry place after ensuring the
electrolyte level, refill with distilled water, if necessary.
It is recommended to recharge the battery every 30 days.
m) Tag engine to indicate that it has been treated with preservatives, and should not be turned over until ready to run,
due to possible reduction of protective film. The tag should show the date of treatment and validity date.
n) It is preferable to warp the engine in polyethylene bag and store in dry shade.
Periodically inspect the engine for rust or corrosion and take corrective action if any.
o) If the engine is to be stored unused for more than 12 months, repeat the above procedure completely, after every 12
months.
7.3 Commissioning of Preserved Engine
a) Remove all the sealing tapes / papers from various openings.
b) Remove the Rust Preventive coating from those unpainted machined surfaces which are interfacing surfaces for the
driven equipment. This can be done using NC Thinner.
c) Fill recommended grade of lube oil in the oil sump till the ‘Top’ mark of the dipstick. For oil filling quantity see 2.4.4.
d) Readjust the V-belt tension after checking the condition of V-belt (s), replace, if necessary (see 5.5 ).
e) Reconnect a fully charged battery to recommended voltage and Amp-hr capacity ensuring correct polarity
connection (where applicable).
The engine is now ready for reuse. Follow the instructions given in section 3 before starting the engine.
7.2 TIGHTENING TORQUES
To prevent faulty assembly, following information on tightening of high tensile bolts is important. The bolts are to be
tightened in stages as specified in the table below. For connecting rod bolt and main bearing cap bolt use angle torque
method with the help of goniometer. The tightening angles for these two bolts are particularly important, hence Fig. 7.1
indicates the various angles can be readily obtained by comparison with a clock face.
Fig.7.1
43
Tommy bar is to be clamped in the tool slot and specified angle is to be turned with reference to the initial graduation on
outer dial of the tool or a relation of hex head of bolt can be referred.
NOTE:
1. Lubricate threads and seating face of bolt with engine oil before it is assembled.
2. Screw the bolt by hand till it is engaged upto the seating face.
3. Apply initial torque and tighten the bolts according to the angles/torques in stages as specified in the “Tightening table”.
4. In case of replacing main and big end bearings/overhaul/piston seizures, fit new bolts for main bearing cap and
connecting rod cap.
1 Nm = 0.102 kgm
= 0.74 Ib.ft.
TAPPET CLEARANCES (in cold condition only)
Engine Type Inlet Exhaust
SL 90 0.45 mm 0.40 mm
Table 8.0
44
TIGHTENING TABLE FOR BOLTS (SCREWS, NUTS)
(ANGLE TORQUE METHOD)
TIGHTENING TABLE ‘SL 90 Series’
Fastener Size Initial Tightening method

torque Torque wrench Angle of rotation
(Nm) Final torque (Goniometer)
Stage Stage Stage Stage Stage Stage
I II III II III IV
Cylinder head
bolt - Short M14 X 139 50 100 140 +10
— — —
- Long M14 X 159 50 100 140 +10
— — —
Connecting rod M 16 X 1.5 50 210+10.5 — 65° — —

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

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

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

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

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

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

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

injector fork
Table 8.1
Note:
1. Apply initial torque and tighten the bolts according to the angles / torques in stages as specified in the ‘Tightening
table.’
2. In case of replacing main and big end bearings/overhaul/piston seizures, fit new bolts for main bearing cap and
connecting rod cap.
1 Nm = 0.102 kgm
= 0.74 lb. ft.
End of Document.
45
n
®
DSEULTRA
DSE6000 Series Control Module
Document Number 057-095
Author : Anthony Manton
DSE Model 6000 Series Control and Instrumentation System Operators Manual
Deep Sea Electronics Plc

Highfield House
Hunmanby
North Yorkshire
YO14 0PH
ENGLAND
Sales Tel: +44 (0) 1723 890099

Sales Fax: +44 (0) 1723 893303
E-mail: sales@deepseaplc.com
Website: www.deepseaplc.com
DSE Model 6000 series Control and Instrumentation System Operators Manual
© Deep Sea Electronics Plc

All rights reserved. No part of this publication may be reproduced in any material form (including photocopying or storing in any
medium by electronic means or other) without the written permission of the copyright holder except in accordance with the
provisions of the Copyright, Designs and Patents Act 1988.
Applications for the copyright holder’s written permission to reproduce any part of this publication should be addressed to Deep
Sea Electronics Plc at the address above.
The DSE logo and the names DSEUltra, DSEControl, DSEPower, DSEExtra, DSEMarine and DSENet are UK registered
trademarks of Deep Sea Electronics PLC.
Any reference to trademarked product names used within this publication is owned by their respective companies.
Deep Sea Electronics Plc reserves the right to change the contents of this document without prior notice.
Amendments since last publication
Amd. No. Comments

1 Corrected configuration tables to reflect first release of module, added more detail to most sections.
2 Added detail about sleep mode (Iss 3.1)
Clarification of notation used within this publication.
Highlights an essential element of a procedure to ensure correctness.

NOTE:
Indicates a procedure or practice, which, if not strictly observed, could result in damage or
CAUTION! destruction of equipment.
Indicates a procedure or practice, which could result in injury to personnel or loss of life if not
WARNING! followed correctly.
2 Part No. 057-095 6000 Series OPERATING MANUAL ISSUE 3.1 09/03/2009 ADM
DSE Model 6000 Series Control & Instrumentation System Operators Manual
TABLE OF CONTENTS
Section Page
1 BIBLIOGRAPHY........................................................................................... 5
1.1 INSTALLATION INSTRUCTIONS ................................................................................. 5
1.2 TRAINING GUIDES ..................................................................................................... 5
1.3 MANUALS .................................................................................................................. 5
2 INTRODUCTION........................................................................................... 6
3 SPECIFICATIONS ........................................................................................ 7
3.1 PART NUMBERING .................................................................................................... 7
3.1.1 SHORT NAMES .................................................................................................... 7
3.2 TERMINAL SPECIFICATION........................................................................................ 8
3.3 POWER SUPPLY REQUIREMENTS ............................................................................ 8
3.3.1 PLANT SUPPLY INSTRUMENTATION DISPLAY..................................................... 8
3.4 GENERATOR VOLTAGE / FREQUENCY SENSING ..................................................... 8
3.5 INPUTS .................................................................................................................... 10
3.5.1 DIGITAL INPUTS ................................................................................................ 10
3.5.2 CHARGE FAIL INPUT ......................................................................................... 10
3.5.3 MAGNETIC PICKUP ........................................................................................... 10
3.6 OUTPUTS ................................................................................................................ 11
3.6.1 OUTPUTS A & B (FUEL AND START) .................................................................. 11
3.6.2 CONFIGURABLE OUTPUTS C, D, E & F .............................................................. 11
3.7 COMMUNICATION PORTS ....................................................................................... 11
3.8 COMMUNICATION PORT USAGE ............................................................................ 11
3.8.1 CAN INTERFACE ............................................................................................... 11
3.8.2 USB CONNECTION............................................................................................. 12
3.9 ACCUMULATED INSTRUMENTATION ...................................................................... 12
3.10 DIMENSIONS AND MOUNTING ............................................................................. 13
3.10.1 DIMENSIONS ..................................................................................................... 13
3.10.2 PANEL CUTOUT ................................................................................................. 13
3.10.3 WEIGHT............................................................................................................. 13
3.10.4 FIXING CLIPS .................................................................................................... 13
3.10.5 OPTIONAL SILICON SEALING GASKET ............................................................. 13
3.11 APPLICABLE STANDARDS.................................................................................... 14
3.11.1 ENCLOSURE CLASSIFICATIONS........................................................................ 15
4 INSTALLATION.......................................................................................... 17
4.1 TERMINAL DESCRIPTION ........................................................................................ 17
4.1.1 DC SUPPLY, FUEL AND START OUTPUTS ......................................................... 17
4.1.2 ANALOGUE SENSORS ....................................................................................... 18
4.1.3 MAGNETIC PICKUP ........................................................................................... 18
4.1.4 CAN ................................................................................................................... 19
4.1.5 GENERATOR / MAINS VOLTAGE SENSING........................................................ 19
4.1.6 GENERATOR CURRENT TRANSFORMERS ........................................................ 20
4.1.7 DIGITAL INPUTS ................................................................................................ 21
4.1.8 PC CONFIGURATION INTERFACE CONNECTOR................................................ 21
4.2 TYPICAL WIRING DIAGRAMS ................................................................................... 22
4.2.1 DSE 6110 AUTOSTART MODULE ....................................................................... 22
4.2.2 DSE 6120 AUTO MAIN FAILURE MODULE .......................................................... 23
Part No. 057-095 6000 Series OPERATING MANUAL ISSUE 3.1 09/03/2009 ADM 3
5 DESCRIPTION OF CONTROLS .................................................................. 24

5.1 QUICKSTART GUIDE ................................................................................................26
5.1.1 STARTING THE ENGINE .....................................................................................26
5.1.2 STOPPING THE ENGINE ....................................................................................26
5.2 GRAPHICAL DISPLAY ...............................................................................................27
5.3 VIEWING THE INSTRUMENTS ..................................................................................27
5.4 CONTROLS ..............................................................................................................28
6 OPERATION............................................................................................... 29
6.1 STOP MODE.............................................................................................................29
6.1.1 ECU OVERRIDE .................................................................................................29
6.2 AUTOMATIC MODE ..................................................................................................30
6.2.1 WAITING IN AUTO MODE ...................................................................................30
6.2.2 STARTING SEQUENCE.......................................................................................30
6.2.3 ENGINE RUNNING ..............................................................................................31
6.2.4 STOPPING SEQUENCE ......................................................................................31
6.3 MANUAL MODE ........................................................................................................32
6.3.1 WAITING IN MANUAL MODE ..............................................................................32
6.3.2 STARTING SEQUENCE.......................................................................................32
6.3.3 ENGINE RUNNING ..............................................................................................33
6.3.4 STOPPING SEQUENCE ......................................................................................33
7 MODULE DISPLAY .................................................................................... 34

7.1 BACKLIGHT..............................................................................................................34
7.2 PROTECTIONS .........................................................................................................34
7.3 WARNINGS ...............................................................................................................35
7.4 SHUTDOWN ALARMS...............................................................................................36
7.5 ELECTRICAL TRIP ALARMS .....................................................................................37
8 FRONT PANEL CONFIGURATION............................................................. 38

8.1 ACCESSING THE FRONT PANEL EDITOR (FPE) ......................................................39
8.1.1 ENTERING THE CONFIGURATION EDITOR PIN NUMBER ...................................39
8.1.2 EDITING A PARAMETER ....................................................................................40
8.2 ADJUSTABLE PARAMETERS (CONFIGURATION EDITOR) .......................................41
9 COMMISSIONING ...................................................................................... 43
9.1.1 PRE-COMMISSIONING.......................................................................................43
10 FAULT FINDING ..................................................................................... 45

11 MAINTENANCE, SPARES, REPAIR AND SERVICING............................ 47
11.1 PURCHASING ADDITIONAL CONNECTOR PLUGS FROM DSE ..............................47
11.1.1 DSE6110 ............................................................................................................47
11.1.2 DSE6120 ............................................................................................................47
11.2 PURCHASING ADDITIONAL FIXING CLIPS FROM DSE ..........................................48
11.3 PURCHASING SEALING GASKET FROM DSE .......................................................48
12 WARRANTY ............................................................................................ 49
13 DISPOSAL .............................................................................................. 49
13.1 WEEE (WASTE ELECTRICAL AND ELECTRONIC EQUIPMENT) ............................49
13.2 ROHS (RESTRICTION OF HAZARDOUS SUBSTANCES) ........................................49
1 BIBLIOGRAPHY
This document refers to and is referred to by the following DSE publications which can be obtained from the DSE
website www.deepseaplc.com
1.1 INSTALLATION INSTRUCTIONS

Installation instructions are supplied with the product in the box and are intended as a ‘quick start’ guide only.
DSE PART DESCRIPTION

053-059 6110 installation instructions
1.2 TRAINING GUIDES
Training Guides are produced to give ‘handout’ sheets on specific subjects during training sessions.

056-005 Using CTs with DSE products
056-010 Overcurrent protection
056-022 Breaker Control
056-029 Smoke Limiting
056-030 Module PIN codes
1.3 MANUALS

057-004 Electronic Engines and DSE wiring manual
057-100 6000 Series Configuration Suite manual
2 INTRODUCTION
This document details the installation and operation requirements of the DSE6000 Series modules, part of the
DSEUltra® range of products.
The manual forms part of the product and should be kept for the entire life of the product. If the product is passed or
supplied to another party, ensure that this document is passed to them for reference purposes.
This is not a controlled document. You will not be automatically informed of updates. Any future updates of this
document will be included on the DSE website at www.deepseaplc.com
The DSE 6100 series module has been designed to allow the operator to start and stop the engine/generator, and
if required, transfer the load.
The user also has the facility to view the system operating parameters via the LCD display.
The DSE 6100 module monitors the engine, indicating the operational status and fault conditions, automatically
shutting down the engine and giving a true first up fault condition of an engine failure. The LCD display indicates the
fault.
The powerful microprocessor contained within the module allows for incorporation of a range of enhanced features:
• Text based LCD display

• True RMS Voltage monitoring.
• Engine parameter monitoring.
• Fully configurable inputs for use as alarms or a range of different functions.
• Engine ECU interface to electronic engines (specify on ordering)
• Magnetic pickup interface for engine only applications (specify on ordering)
Using a PC and the 6000 series configuration software allows alteration of selected operational sequences, timers
and alarm trips.
Additionally, the module’s integral fascia configuration editor allows adjustment of this information.
A robust plastic case designed for front panel mounting houses the module. Connections are via locking plug and
sockets.
3 SPECIFICATIONS
3.1 PART NUMBERING
6110 - 001 - 01
Variant
Product type
Magnetic pickup 01
DSE 3110 6110 version
Autostart Module
CAN version 02
DSE 6110 Auto 6110
Mains Failure
(AMF) Module
Hardware revision
Revision 1 001
At the time of this document production, there have been no revisions to the module hardware.
3.1.1 SHORT NAMES
Short name Description

61xx DSE 6100 series control module
61x0-xxx-01 DSE6100 series control module (Magnetic pickup version)
61x0-xxx-02 DSE6100 series control module (CAN bus version)
3.2 TERMINAL SPECIFICATION
Connection type Two part connector.

• Male part fitted to module
• Female part supplied in module
packing case - Screw terminal,
rising clamp, no internal spring. Example showing cable entry and screw
Minimum cable size 0.5mm² (AWG 24) terminals of a 10 way connector
Maximum cable size 2.5mm² (AWG 10)
NOTE : For purchasing additional connector plugs from DSE, please see the section entitled
Maintenance, Spares, Repair and Servicing elsewhere in this document.
3.3 POWER SUPPLY REQUIREMENTS
Minimum supply voltage 8V continuous

Cranking dropouts Able to survive 0V for 50mS providing the supply was at least 10V before the
dropout and recovers to 5V afterwards.
This is more than sufficient to allow the module to operate during engine
cranking where the battery supply often falls as low as 4V (on a 12V system!)
This is achieved without the need for internal batteries or other external
requirements.
Maximum supply voltage 35V continuous (60V protection)
Reverse polarity protection -35V continuous
160mA at 24V
Maximum operating current DSE7200 / DSE7300
340mA at 12V
80mA at 24V
Maximum standby current DSE7200 / DSE7300
160mA at 12V
50mA @ 12V
Current when in Sleep Mode
32mA @ 24V
3.3.1 PLANT SUPPLY INSTRUMENTATION DISPLAY
Range 0V-70V DC (note Maximum continuous operating voltage of 35V DC)

Resolution 0.1V
Accuracy ±1% full scale (±0.7V)
3.4 GENERATOR VOLTAGE / FREQUENCY SENSING
Measurement type True RMS conversion

Sample Rate 5KHz or better
Harmonics Up to 11th or better
Input Impedance 300K Ω ph-N
Phase to Neutral 15V to 333V AC (max)
Phase to Phase 25V to 576V AC (max)
Common mode offset from Earth 100V AC (max)
Resolution 1V AC phase to neutral
2V AC phase to phase
Accuracy ±1% of full scale phase to neutral
±2% of full scale phase to phase
Minimum frequency 3.5Hz
Maximum frequency 75.0Hz
Frequency resolution 0.1Hz
Frequency accuracy ±0.2Hz
3.5 INPUTS
3.5.1 DIGITAL INPUTS
Number 6
Arrangement Contact between terminal and ground
Low level threshold 40% of DC supply voltage
High level threshold 60% of DC supply voltage
Maximum input voltage DC supply voltage positive terminal
Minimum input voltage DC supply voltage negative terminal
Contact wetting current 2.5mA @12V typical
5mA @ 24V typical
Open circuit voltage Plant supply
3.5.2 CHARGE FAIL INPUT
Minimum voltage 0V
Maximum voltage 35V (plant supply)
Resolution 0.2V
Accuracy ± 1% of max measured voltage
Excitation Active circuit constant power output
Output Power 2.5W Nominal @12V and 24V
Current at 12V 210mA
Current at 24V 105mA
3.5.3 MAGNETIC PICKUP
Type Single ended input, capacitive coupled

Minimum voltage 0.5V RMS
Max common mode voltage ±2V
Maximum voltage Clamped to ±70V by transient suppressers, dissipation not to exceed 1W.
Maximum frequency 10,000Hz
Resolution 6.25 RPM
Accuracy ±25 RPM
Flywheel teeth 10 to 500
NOTE : DSE can supply a suitable magnetic pickup device, available in two body thread lengths :
DSE Part number 020-012 - Magnetic Pickup probe 5/8 UNF 2½” thread length
DSE Part number 020-013 - Magnetic Pickup probe 5/8 UNF 4” thread length
Magnetic Pickup devices can often be ‘shared’ between two or more devices. For example, one device can often
supply the signal to both the DSE6100 series module and the engine governor. The possibility of this depends upon
the amount of current that the magnetic pickup can supply.
3.6 OUTPUTS
3.6.1 OUTPUTS A & B (FUEL AND START)
Type Fuel (A) and Start (B) outputs. Supplied from DC supply terminal 2.
Fully configurable when CAN engine is selected.
Rating 2A @ 35V
Protection Protected against over current & over temperature. Built in load dump feature.
3.6.2 CONFIGURABLE OUTPUTS C, D, E & F
Type Fully configurable, supplied from DC supply terminal 2.

Rating 2A @ 35V
Protection Protected against over current & over temperature. Built in load dump feature.
3.7 COMMUNICATION PORTS
USB Port USB2.0 Device for connection to PC running DSE configuration suite only
CAN Port Engine CAN Port
Standard implementation of ‘Slow mode’, up to 250K bits/s
Non Isolated.
Internal Termination provided (120Ω)
3.8 COMMUNICATION PORT USAGE
3.8.1 CAN INTERFACE
Modules are fitted with the CAN interface as standard and are capable of receiving
engine data from engine CAN controllers compliant with the CAN standard.
CAN enabled engine controllers monitor the engine’s operating parameters such as
engine speed, oil pressure, engine temperature (among others) in order to closely
monitor and control the engine. The industry standard communications interface (CAN)
transports data gathered by the engine controller interface. This allows generator controllers such as the DSE6100
series to access these engine parameters with no physical connection to the sensor device.
NOTE:- For further details for connections to CAN enabled engines and the functions available with
each engine type, refer to the manual Electronic Engines and DSE Wiring. Part No. 057-004
3.8.2 USB CONNECTION
The USB port is provided to give a simple means of connection between a PC and the DSE3000 series controller.
Using the DSE Configuration Suite Software, the operator is then able to control the module, starting or stopping the
generator, selecting operating modes, etc.
Additionally, the various operating parameters (such as output volts, oil pressure, etc.) of the remote generator are
available to be viewed or changed.
To connect a DSE3000 series module to a PC by USB, the following items are required:
• DSE6100 series module
• DSE configuration software

(Supplied on configuration suite software CD or available from
www.deepseaplc.com).
• USB cable Type A to Type B.

(This is the same cable as often used between a PC and a USB printer)
DSE can supply this cable if required :

PC Configuration interface lead (USB type A – type B) DSE Part No 016-125
NOTE:- The DC supply must be connected to the module for configuration by PC.
NOTE:- Refer to DSE6100 series software Manual for further details on configuring, monitoring and
control.
3.9 ACCUMULATED INSTRUMENTATION
NOTE : When an accumulated instrumentation value exceeds the maximum number as listed below, it
will reset and begin counting from zero again.
Engine hours run Maximum 99999 hrs 59 minutes (approximately 11yrs 4months)
Number of starts 1,000,000 (1 million)
The number of logged Engine Hours and Number of Starts can be set/reset using the DSE Configuration Suite PC
software. Depending upon module configuration, this may have been PIN number locked by your generator supplier.
3.10 DIMENSIONS AND MOUNTING
3.10.1 DIMENSIONS
216mm x 158mm x 42mm
(8.5” x 6.2” x 1.6”)
3.10.2 PANEL CUTOUT

182mm x 137mm
(7.2” x 5.4”)
3.10.3 WEIGHT
510g (0.51kg)
3.10.4 FIXING CLIPS

The module is held into the panel fascia using the supplied fixing clips.
• Withdraw the fixing clip screw (turn anticlockwise) until only the pointed end is protruding from the clip.
• Insert the three ‘prongs’ of the fixing clip into the slots in the side of the 6000 series module case.
• Pull the fixing clip backwards (towards the back of the module) ensuring all three prongs of the clip are
inside their allotted slots.
• Turn the fixing clip screws clockwise until they make contact with the panel fascia.
• Turn the screws a little more to secure the module into the panel fascia. Care should be taken not to over
tighten the fixing clip screws.
Fixing clip
Fixing clip fitted to

module
NOTE:- In conditions of excessive vibration, mount the panel on suitable anti-vibration mountings.
3.10.5 OPTIONAL SILICON SEALING GASKET

The optional silicon gasket provides improved sealing between the 6000 series module and the panel fascia.
The gasket is fitted to the module before installation into the panel fascia.
Take care to ensure the gasket is correctly fitted to the module to maintain the integrity of the seal.
Gasket fitted to
Sealing gasket module
3.11 APPLICABLE STANDARDS
BS 4884-1 This document conforms to BS4884-1 1992 Specification for presentation of essential
information.
BS 4884-2 This document conforms to BS4884-2 1993 Guide to content
BS 4884-3 This document conforms to BS4884-3 1993 Guide to presentation
BS EN 60068-2-1
-30°C (-22°F)
(Minimum temperature)
BS EN 60068-2-2
+70°C (158°F)
(Maximum temperature)
BS EN 60950 Safety of information technology equipment, including electrical business equipment
BS EN 61000-6-2 EMC Generic Immunity Standard (Industrial)
BS EN 61000-6-4 EMC Generic Emission Standard (Industrial)
BS EN 60529 IP65 (front of module when installed into the control panel with the optional sealing
(Degrees of protection gasket)
provided by enclosures) IP42 (front of module when installed into the control panel WITHOUT being sealed to
the panel)
UL508 12 (Front of module when installed into the control panel with the optional sealing
NEMA rating gasket).
(Approximate) 2 (Front of module when installed into the control panel WITHOUT being sealed to the
panel)
IEEE C37.2 Under the scope of IEEE 37.2, function numbers can also be used to represent
(Standard Electrical Power functions in microprocessor devices and software programs.
System Device Function The 3000 series controller is device number 11L-6000 (Multifunction device protecting
Numbers and Contact Line (generator) – 6000 series module).
Designations)
As the module is configurable by the generator OEM, the functions covered by the
module will vary. Under the module’s factory configuration, the device numbers
included within the module are :
2 – Time delay starting or closing relay

6 – Starting circuit breaker
30 – annunciator relay
42 – Running circuit breaker
54 – turning gear engaging device
62 – time delay stopping or opening relay
63 – pressure switch
74– alarm relay
81 – frequency relay
86 – lockout relay
In line with our policy of continual development, Deep Sea Electronics, reserve the right to change specification without notice.
3.11.1 ENCLOSURE CLASSIFICATIONS

IP CLASSIFICATIONS
7000 series specification under BS EN 60529 Degrees of protection provided by enclosures
IP65 (Front of module when module is installed into the control panel with the optional sealing gasket).
IP42 (front of module when module is installed into the control panel WITHOUT being sealed to the panel)
First Digit Second Digit
Protection against contact and ingress of solid objects Protection against ingress of water
0 No protection 0 No protection
1 Protected against ingress solid objects with a 1 Protection against dripping water falling vertically. No
diameter of more than 50 mm. No protection against harmful effect must be produced (vertically falling drops).
deliberate access, e.g. with a hand, but large surfaces
of the body are prevented from approach.
2 Protected against penetration by solid objects with a 2 Protection against dripping water falling vertically. There
diameter of more than 12 mm. Fingers or similar must be no harmful effect when the equipment (enclosure)
objects prevented from approach. is tilted at an angle up to 15°from its normal pos ition
(drops falling at an angle).
3 Protected against ingress of solid objects with a 3 Protection against water falling at any angle up to 60°
diameter of more than 2.5 mm. Tools, wires etc. with a from the vertical. There must be no harmful effect (spray
thickness of more than 2.5 mm are prevented from water).
approach.
4 Protected against ingress of solid objects with a 4 Protection against water splashed against the equipment
diameter of more than 1 mm. Tools, wires etc. with a (enclosure) from any direction. There must be no harmful
thickness of more than 1 mm are prevented from effect (splashing water).
approach.
5 Protected against harmful dust deposits. Ingress of 5 Protection against water projected from a nozzle against
dust is not totally prevented but the dust must not enter the equipment (enclosure) from any direction. There must
in sufficient quantity to interface with satisfactory be no harmful effect (water jet).
operation of the equipment. Complete protection
against contact.
6 Protection against ingress of dust (dust tight). 6 Protection against heavy seas or powerful water jets.
Complete protection against contact. Water must not enter the equipment (enclosure) in harmful
quantities (splashing over).
NEMA CLASSIFICATIONS
7000 series NEMA Rating (Approximate)
12 (Front of module when module is installed into the control panel with the optional sealing gasket).
2 (front of module when module is installed into the control panel WITHOUT being sealed to the panel)
NOTE: - There is no direct equivalence between IP / NEMA ratings. IP figures shown are approximate
only.
1 Provides a degree of protection against contact with the enclosure equipment and against a limited amount of falling dirt.
IP30
2 Provides a degree of protection against limited amounts of falling water and dirt.
IP31
3 Provides a degree of protection against windblown dust, rain and sleet; undamaged by the formation of ice on the enclosure.
IP64
3R Provides a degree of protection against rain and sleet:; undamaged by the formation of ice on the enclosure.
IP32
4 (X) Provides a degree of protection against splashing water, windblown dust and rain, hose directed water; undamaged by the formation
of ice on the enclosure. (Resist corrosion).
IP66
12/12K Provides a degree of protection against dust, falling dirt and dripping non corrosive liquids.
IP65
13 Provides a degree of protection against dust and spraying of water, oil and non corrosive coolants.
IP65
4 INSTALLATION
The DSE6000 Series module is designed to be mounted on the panel fascia. For dimension and mounting details,
see the section entitled Specification, Dimension and mounting elsewhere in this document.
4.1 TERMINAL DESCRIPTION
4.1.1 DC SUPPLY, FUEL AND START OUTPUTS
PIN No DESCRIPTION CABLE NOTES

SIZE
DC Plant Supply Input 2.5mm²
1
(Negative) AWG 13
(Recommended Maximum Fuse 15A anti-surge)

DC Plant Supply Input 2.5 mm²
2 Supplies the module (2A anti-surge requirement) and all output
(Positive) AWG 13
relays
1.0mm² Plant Supply Positive from terminal 2. 3 Amp rated.
3 Emergency Stop
AWG 18
4 Output A
AWG 18 Normally used for FUEL control.
5 Output B
AWG 18 Normally used for START control.
Do not connect to ground (battery negative).
2.5mm²
6 Charge fail / excite If charge alternator is not fitted, leave this terminal
AWG 13
disconnected.
1.0mm²
7 System Eartth
AWG 18
8 Output C
AWG 18 Normally used for Generator load switch control.
9 Output D
AWG 18 Normally used for Mains load switch control (DSE6120)
10 Output E
AWG 18
11 Output F
AWG 18
NOTE:- When the module is configured for operation with an electronic engine, FUEL and START
output requirements may be different. Refer to Electronic Engines and DSE Wiring for further information.
DSE Part No. 057-004.
4.1.2 ANALOGUE SENSORS

SIZE
0.5mm²
12 Sensor Common Return Return feed for sensors*
AWG 20
0.5mm²
13 Oil Pressure Input Connect to Oil pressure sensor
AWG 20
0.5mm²
14 Coolant Temperature Input Connect to Coolant Temperature sensor
AWG 20
0.5mm²
15 Flexible Sensor Input Connect to sensor
AWG 20
NOTE:- . It is VERY important that terminal 12 (sensor common) is soundly connected to an earth point
on the ENGINE BLOCK, not within the control panel, and must be a sound electrical connection to the
sensor bodies. This connection MUST NOT be used to provide an earth connection for other terminals or
devices. The simplest way to achieve this is to run a SEPERATE earth connection from the system earth
star point, to terminal 12 directly, and not use this earth for other connections.
NOTE:- . If you use PTFE insulating tape on the sensor thread when using earth return sensors, ensure
you do not insulate the entire thread, as this will prevent the sensor body from being earthed via the engine
block.
4.1.3 MAGNETIC PICKUP

SIZE
0.5mm²
16 Magnetic pickup Positive Connect to Magnetic Pickup device
AWG 20
0.5mm²
17 Magnetic pickup Negative Connect to Magnetic Pickup device
AWG 20
0.5mm²
18 Magnetic pickup screen Do not connect the other end to earth!
AWG 20
NOTE:- Magnetic Pickup interface is not fitted to the 6110-xx-00 module
NOTE:- Screened cable must be used for connecting the Magnetic Pickup, ensuring that the screen is
earthed at one end ONLY.
4.1.4 CAN

SIZE
0.5mm²
16 CAN port H Use only 120Ω CAN approved cable
AWG 20
0.5mm²
17 CAN port L Use only 120Ω CAN approved cable
AWG 20
0.5mm²
18 CAN port Common Use only 120Ω CAN approved cable
AWG 20
NOTE:- CAN interface is not fitted to the 6110-xx-01 module
NOTE:- Screened 120Ω Ω impedance cable specified for use with CAN must be used for the CAN link and
the Multiset comms link.
Ω impedance cable suitable for CAN use
DSE stock and supply Belden cable 9841 which is a high quality 120Ω
(DSE part number 016-030)
4.1.5 GENERATOR / MAINS VOLTAGE SENSING

PIN DESCRIPTION CABLE NOTES
No SIZE
1.0mm² Connect to generator L1 (U) output (AC)
19 Generator L1 (U) voltage monitoring
AWG 18 (Recommend 2A fuse)
1.0mm² Connect to generator L2 (V) output (AC)
20 Generator L2 (V) voltage monitoring
1.0mm² Connect to generator L3 (W) output (AC)
21 Generator 31 (W) voltage monitoring
1.0mm²
22 Generator Neutral (N) input Connect to generator Neutral terminal (AC)
AWG 18
1.0mm² Connect to Mains L1 (R) output (AC)
23 Mains L1 (R) voltage monitoring
1.0mm² Connect to Mains L2 (S) output (AC)
24 Mains L2 (S) voltage monitoring
1.0mm² Connect to Mains L3 (T) output (AC)
25 Mains 31 (T) voltage monitoring
1.0mm²
26 Mains Neutral (N) input Connect to Mains Neutral terminal (AC)
AWG 18
NOTE:- Terminals 23-26 are not fitted to the DSE6110.
4.1.6 GENERATOR CURRENT TRANSFORMERS
WARNING!:- Do not disconnect this plug when the CTs are carrying current. Disconnection will open
circuit the secondary of the C.T.’s and dangerous voltages may then develop. Always ensure the CTs are
not carrying current and the CTs are short circuit connected before making or breaking connections to the
module.
NOTE:- The 6100 series module has a burden of 0.5VA on the CT. Ensure the CT is rated for the
burden of the 6100 series controller, the cable length being used and any other equipment sharing the CT.
If in doubt, consult your CT supplier.
NOTE:- Take care to ensure correct polarity of the CT primary as shown below. If in doubt, check with
the CT supplier.
CT LABELLING
p1, k or K is the primary of the CT that ‘points’ towards the GENERATOR
p2, l or L is the primary of the CT that ‘points’ towards the LOAD
s1 is the secondary of the CT that connects to the DSE Module’s input for the CT measuring (I1,I2,I3)
s2 is the secondary of the CT that should be commoned with the s2 connections of all the other CTs and connected
to the CT common terminal of the DSE6100 series modules.
CT labelled as
p1, k or K To Load
To Supply CT labelled as
p2, l or L
1.0mm²
27 Generator I1 Current Transformer Connect to generator CT 1 (s1)
AWG 18
1.0mm²
AWG 18
1.0mm²
AWG 18
30 Generator Current Transformer 1.0mm²
Connect to generator CT common (s2)
31 common connection AWG 18
NOTE:- Terminals 30 and 31 are internally connected to each other.
4.1.7 DIGITAL INPUTS
PIN DESCRIPTION CABLE NOTES

No SIZE
0.5mm²
32 Configurable digital input A Switch to negative
AWG 20
0.5mm²
33 Configurable digital input B Switch to negative
AWG 20
0.5mm²
34 Configurable digital input C Switch to negative
AWG 20
0.5mm²
35 Configurable digital input D Switch to negative
AWG 20
0.5mm²
36 Configurable digital input E Switch to negative
AWG 20
0.5mm²
37 Configurable digital input F Switch to negative
AWG 20
This configuration cable is

the same as normally used
between a PC and a USB
printer.
4.1.8 PC CONFIGURATION INTERFACE CONNECTOR
DESCRIPTION CABLE NOTES

SIZE
This is a standard USB type A to
type B cable.
Socket for connection to PC with DSE 0.5mm²
Configuration Suite PC software. AWG 20
NOTE:- The USB connection cable between the PC and the 6000 series module must not be extended
beyond 5m (5yds). For distances over 5m, it is possible to use a third party USB extender. Typically, they
extend USB up to 50m (yds). The supply and support of this type of equipment is outside the scope of
Deep Sea Electronics PLC.
CAUTION!: Care must be taken not to overload the PCs USB system by connecting more than the
recommended number of USB devices to the PC. For further information, consult your PC supplier.
CAUTION!: This socket must not be used for any other purpose.
4.2 TYPICAL WIRING DIAGRAMS
4.2.1 DSE 6110 AUTOSTART MODULE
4.2.2 DSE 6120 AUTO MAIN FAILURE MODULE
5 DESCRIPTION OF CONTROLS
The following section details the function and meaning of the various controls on the module.
Display Scroll button Main status display
Common Alarm
Indicator
Info button
Start engine.
Select Stop
mode
Select Auto
mode
Select Manual Alarm
mode mute/lamp test
Select Test mode

(DSE6120 only)
Mains Available
(DSE6120 only) Generator Available
Generator On load
Mains On Load
(DSE6120 only)
5.1 QUICKSTART GUIDE
This section provides a quick start guide to the module’s operation.
5.1.1 STARTING THE ENGINE
First press Manual

mode
...Then, press the Start button

to crank the engine..
NOTE:- For further details, see the section entitled ‘OPERATION’ elsewhere in this manual.
5.1.2 STOPPING THE ENGINE
Select Stop/Reset
mode. The generator
is stopped.
NOTE:- For further details, see the section entitled ‘OPERATION’ elsewhere in this manual.
5.2 GRAPHICAL DISPLAY
- 4- line, 64 x 132 small Graphic Display with LED Backlight

- Icon and numeric display. Switch to select ‘Icon’ or ‘English’ display
- Software controlled contrast
- Mimic of Text insert / 4x indicators required via LCD
-
5.3 VIEWING THE INSTRUMENTS
It is possible to scroll to display the different pages of information by repeatedly operating the scroll button
Once selected the page will remain on the LCD display until the user selects a different page or after an extended
period of inactivity, the module will revert to the status display.
When scrolling manually, the display will automatically return to the Status page if no buttons are pressed for the
duration of the configurable LCD Page Timer.
If an alarm becomes active while viewing the status page, the display shows the Alarms page to draw the operator’s
attention to the alarm condition.
Metering: Generator Voltage, 3-phase, L-L and L-N

Generator Amps L1, L2 and L3 (On/Off selectable in software)
Generator Frequency
Mains Voltage, 3-phase, L-L and L-N
Battery Voltage
Engine hours Run
Oil Pressure Gauge
Engine Temperature Gauge
Fuel Level
Fail to Start
Indicators:
Fail to Stop
Low Oil pressure
High Engine Temperature
Under/Over-speed
Under/Over voltage – Warning, Shutdown or Electrical Trip
Emergency Stop
Failed to reach loading voltage
Failed to reach loading frequency
Charge Fail
Over Current – Warning, Shutdown or Electrical Trip
Low DC Voltage
+ AMF indications
+ CAN diagnostics
At power up, the display will display the software version, then display the default display screen,
which will display Generator Frequency.
5.4 CONTROLS
Stop / Reset
This button places the module into its Stop/Reset mode. This will clear any alarm conditions for which
the triggering criteria have been removed. If the engine is running and the module is in Stop mode, the
module will automatically instruct the changeover device to unload the generator (‘Close Generator’
becomes inactive (if used)). The fuel supply de-energises and the engine comes to a standstill.
Should a remote start signal be present while operating in this mode, a remote start will not occur.
Manual
This mode allows manual control of the generator functions. Once in Manual mode the module will
respond to the start button, start the engine, and run off load. If the engine is running off-load in
the Manual mode and a remote start signal becomes present, the module will automatically instruct
the changeover device to place the generator on load (‘Close Generator’ becomes active (if used)).
Upon removal of the remote start signal, the generator remains on load until either selection of the
‘STOP/RESET’ or ‘AUTO’ modes.
For further details, please see the more detailed description of ‘Manual operation’ elsewhere in this
manual.
Auto
This button places the module into its ‘Automatic’ mode. This mode allows the module to control the
function of the generator automatically. The module will monitor the remote start input and mains
supply status and once a start request is made, the set will be automatically started and placed on
load.
Upon removal of the starting signal, the module will automatically transfer the load from the generator
and shut the set down observing the stop delay timer and cooling timer as necessary. The module will
then await the next start event. For further details, please see the more detailed description of ‘Auto
operation’ elsewhere in this manual.
Test (DSE7220/DSE7320 only)
This button places the module into its ‘Test’ mode. This allows an on load test of the generator.
Once in Test mode the module will respond to the start button, start the engine, and run on load.
For further details, please see the more detailed description of ‘Test operation’ elsewhere in this
manual.
Start
This button is only active in STOP/RESET or MANUAL mode.
Pressing this button in manual or test mode will start the engine and run off load (manual) or on load
(test).
Pressing this button in STOP/RESET mode will turn on the CAN engine ECU (when correctly
configured and fitted to a compatible engine ECU)
Mute / Lamp Test
This button silences the audible alarm if it is sounding and illuminates all of the LEDs as a lamp test
feature/
When correctly configured and fitted to a compatible engine ECU, pressing this button in
STOP/RESET mode after pressing the START button (to power the ECU) will cancel any
“passive” alarms on the engine ECU.
SCROLL
This buttons scrolls through the instrument display pages
6 OPERATION
6.1 STOP MODE
STOP mode is activated by pressing the button.
In STOP mode, the module will remove the generator from load (if necessary) before stopping the engine if it is
already running.
If the engine does not stop when requested, the FAIL TO STOP alarm is activated (subject to the setting of the Fail
to Stop timer). To detect the engine at rest the following must occur :
• Engine speed is zero as detected by the Magnetic Pickup or CANbus ECU (depending upon module variant).
• Generator frequency must be zero.
• Oil pressure switch must be closed to indicate low oil pressure (MPU version only)
When the engine has stopped, it is possible to send configuration files to the module from DSE Configuration Suite
PC software and to enter the Front Panel Editor to change parameters.
Any latched alarms that have been cleared will be reset when STOP mode is entered.
The engine will not be started when in STOP mode. If remote start signals are given, the input is ignored until AUTO
mode is entered.
When configured to do so, When left in STOP mode for five minutes with no presses of the fascia buttons, the
module enters low power mode. To ‘wake’ the module, press the button or any other fascia control button.
Sleep mode configuration

in the DSE Configuration
Suite Software
6.1.1 ECU OVERRIDE
NOTE:- ECU Override function is only applicable to the CAN variant of the 6100 series controller.
NOTE:- Depending upon system design, the ECU may be powered or unpowered when the module is in
STOP mode. ECU override is only applicable if the ECU is unpowered when in STOP mode.
When the ECU powered down (as is normal when in STOP mode), it is not possible to read the diagnostic trouble
codes or instrumentation. Additionally, it is not possible to use the engine manufacturers’ configuration tools.
As the ECU is usually unpowered when the engine is not running, it must be turned on manually as follows :
• Select STOP mode on the DSE controller.

• Press and hold the START button to power the ECU. As the controller is in STOP mode, the engine will
not be started.
• Continue to hold the start button for as long as you need the ECU to be powered.
• The ECU will remain powered until a few seconds after the START button is released.
This is also useful if the engine manufacturer’s tools need to be connected to the engine, for instance to configure the
engine as the ECU needs to be powered up to perform this operation.
6.2 AUTOMATIC MODE
NOTE:- If a digital input configured to panel lock is active, changing module modes will not be
possible. Viewing the instruments and event logs is NOT affected by panel lock.
Activate auto mode by pressing the pushbutton. The icon is displayed to indicate Auto Mode operation if no
alarms are present.
Auto mode will allow the generator to operate fully automatically, starting and stopping as required with no user
intervention.
6.2.1 WAITING IN AUTO MODE
If a starting request is made, the starting sequence will begin.

Starting requests can be from the following sources :
• Mains failure (DSE6120 only)

• Activation of an auxiliary input that has been configured to remote start
• Activation of the inbuilt exercise scheduler.
6.2.2 STARTING SEQUENCE
To allow for ‘false’ start requests, the start delay timer begins.
Should all start requests be removed during the start delay timer, the unit will return to a stand-by state.
If a start request is still present at the end of the start delay timer, the fuel relay is energised and the engine will be
cranked.
NOTE:- If the unit has been configured for CAN, compatible ECU’s will receive the start command via
CAN.
If the engine fails to fire during this cranking attempt then the starter motor is disengaged for the crank rest duration
after which the next start attempt is made. Should this sequence continue beyond the set number of attempts, the
start sequence will be terminated and the display shows Fail to Start.
When the engine fires, the starter motor is disengaged. Speed detection is factory configured to be derived from the
main alternator output frequency but can additionally be measured from a Magnetic Pickup mounted on the flywheel
(Selected by PC using the 3000 series configuration software).
Additionally, rising oil pressure can be used to disconnect the starter motor (but cannot detect underspeed or
overspeed).
NOTE:- If the unit has been configured for CAN, speed sensing is via CAN.
After the starter motor has disengaged, the Safety On timer activates, allowing Oil Pressure, High Engine
Temperature, Under-speed, Charge Fail and any delayed Auxiliary fault inputs to stabilise without triggering the fault.
6.2.3 ENGINE RUNNING
Once the engine is running and all starting timers have expired, the animated icon is displayed.
DSE6110 - The generator will be placed on load if configured to do so.
NOTE:-The load transfer signal remains inactive until the Oil Pressure has risen. This prevents
excessive wear on the engine.
If all start requests are removed, the stopping sequence will begin.
6.2.4 STOPPING SEQUENCE
The return delay timer operates to ensure that the starting request has been permanently removed and isn’t just a
short term removal. Should another start request be made during the cooling down period, the set will return on load.
If there are no starting requests at the end of the return delay timer, the load is removed from the generator to the
mains supply and the cooling timer is initiated.
The cooling timer allows the set to run off load and cool sufficiently before being stopped. This is particularly
important where turbo chargers are fitted to the engine.
After the cooling timer has expired, the set is stopped.
6.3 MANUAL MODE
NOTE:- If a digital input configured to panel lock is active, changing module modes will not be
possible. Viewing the instruments and event logs is NOT affected by panel lock.
Manual mode allows the operator to start and stop the set manually, and if required change the state of the load
switching devices. Module mode is active when the button is pressed.
6.3.1 WAITING IN MANUAL MODE
To begin the starting sequence, press the button. If ‘protected start’ is disabled, the start sequence begins
immediately.
If ‘Protected Start’ is enabled , the icon is displayed to indicate Manual mode and the manual LED flashes. The
button must be pressed once more to begin the start sequence.
6.3.2 STARTING SEQUENCE
NOTE:- There is no start delay in this mode of operation.
The fuel relay is energised and the engine is cranked.
NOTE:- If the unit has been configured for CAN, compatible ECU’s will receive the start command via
CAN.
If the engine fails to fire during this cranking attempt then the starter motor is disengaged for the crank rest duration
after which the next start attempt is made. Should this sequence continue beyond the set number of attempts, the
start sequence will be terminated and the display shows Fail to Start.
When the engine fires, the starter motor is disengaged. Speed detection is factory configured to be derived from the
main alternator output frequency but can additionally be measured from a Magnetic Pickup mounted on the flywheel
(Selected by PC using the 3000 series configuration software).
Additionally, rising oil pressure can be used disconnect the starter motor (but cannot detect underspeed or
overspeed).
NOTE:- If the unit has been configured for CAN, speed sensing is via CAN.
After the starter motor has disengaged, the Safety On timer activates, allowing Oil Pressure, High Engine
Temperature, Under-speed, Charge Fail and any delayed Auxiliary fault inputs to stabilise without triggering the fault.
6.3.3 ENGINE RUNNING
In manual mode, the load is not transferred to the generator unless a ‘loading request’ is made.
A loading request can come from a number of sources.
• Detection of mains failure (DSE6120 only)

• Activation of an auxiliary input that has been configured to remote start on load
• Activation of the inbuilt exercise scheduler if configured for ‘on load’ runs.
NOTE:-The load transfer signal remains inactive until the Oil Pressure has risen. This prevents
excessive wear on the engine.
Once the load has been transferred to the generator, it will not be automatically removed. To manually transfer the
load back to the mains either:
• Press the auto mode button to return to automatic mode. The set will observe all auto mode start
requests and stopping timers before beginning the Auto mode stopping sequence.
•
• Press the stop button
• De-activation of an auxiliary input that has been configured to remote start on load
6.3.4 STOPPING SEQUENCE
In manual mode the set will continue to run until either :
• The stop button is pressed – The set will immediately stop

• The auto button is pressed. The set will observe all auto mode start requests and stopping timers
before beginning the Auto mode stopping sequence.
7 MODULE DISPLAY
7.1 BACKLIGHT
The backlight will be on if the unit has sufficient voltage on the power connection while the unit is turned on, unless
the unit is cranking for which the backlight will be turned off.
7.2 PROTECTIONS
When an alarm is present, the Audible Alarm will sound and the Common alarm LED if configured will illuminate.
The audible alarm can be silenced by pressing the Mute button
The LCD display will jump from the ‘Information page’ to display the Alarm Page
Number of present alarms. This is alarm 1 of a

total of 2 present alarms
Alarm 1/2
Warning The type of alarm. E.g. Shutdown or warning
Low oil pressure
The nature of alarm, eg Low oil pressure
The LCD will display multiple alarms E.g. “High Engine Temperature shutdown”, “Emergency Stop” and “Low Coolant
Warning”. These will automatically scroll round in the order that they occurred;
In the event of a warning alarm, the LCD will display the appropriate text. If a shutdown then occurs, the module will
again display the appropriate text.
Example:-
Alarm 1/2
Warning
Oil pressure Low
Alarm 2/2
Shutdown
Coolant Temperature High
7.3 WARNINGS
Warnings are non-critical alarm conditions and do not affect the operation of the generator system, they serve to
draw the operators attention to an undesirable condition.
Example
Alarm 1/1
Charge Failure
Warning
In the event of an alarm the LCD will jump to the alarms page, and scroll through all active warnings and shutdowns.
By default, warning alarms are self-resetting when the fault condition is removed. However enabling ‘all warnings are
latched’ will cause warning alarms to latch until reset manually. This is enabled using the 7000 series configuration
suite in conjunction with a compatible PC.
Display Reason
The DC supply has risen above the high volts setting level for the duration of the
Battery High Voltage high battery volts timer
The DC supply has fallen below the low volts setting level for the duration of the
Battery Low Voltage low battery volts timer
The engine ECU has detected a warning alarm and has informed the DSE
module of this situation. The exact error is also indicated on the module’s
CAN ECU Warning display.
The auxiliary charge alternator voltage is low as measured from the W/L
Charge Alternator Failure terminal.
Digital Input A-F Auxiliary inputs can be user configured and will display the message as written
by the user.
Fail To stop The module has detected a condition that indicates that the engine is running
when it has been instructed to stop.
NOTE:- ‘Fail to Stop’ could indicate a faulty oil pressure sensor - If

engine is at rest check oil sensor wiring and configuration.
Generator High Voltage Warning The generator output voltage has risen above the pre-set pre-alarm setting.
The generator output voltage has fallen below the pre-set pre-alarm setting
Generator Low Voltage Warning after the Safety On timer has expired.
The module detects that the engine coolant temperature has exceeded the high
engine temperature pre-alarm setting level after the Safety On timer has
High Coolant Temperature Warning expired.
The module detects that the engine oil pressure has fallen below the low oil
Low Oil Pressure Warning pressure pre-alarm setting level after the Safety On timer has expired.
Low Fuel Level The module detects that the fuel level is below the configured setting
GENERATOR HIGH CURRENT, if the module detects a generator output
Over Current Immediate Warning current in excess of the pre-set trip a warning alarm initiates.
Over Frequency Warning The generator output frequency has risen above the pre-set pre-alarm setting.
Over Speed Warning The engine speed has risen above the overspeed pre alarm setting
The generator output frequency has fallen below the pre-set pre-alarm setting
Under Frequency Warning after the Safety On timer has expired.
Under Speed Warning The engine speed has fallen below the underspeed pre alarm setting
7.4 SHUTDOWN ALARMS
Shutdowns are latching alarms and stop the Generator. Clear the alarm and remove the fault then press Stop/Reset
to reset the module.
Example
Alarm 1/1
Oil Pressure Low
Shutdown
NOTE:- The alarm condition must be rectified before a reset will take place. If the alarm condition
remains, it will not be possible to reset the unit (The exception to this is the Low Oil Pressure alarm and
similar ‘delayed alarms’, as the oil pressure will be low with the engine at rest).
Display Reason
The module is configured for CAN operation and does not detect data on the engine
CAN ECU Data Fail Can datalink, the engine shuts down.
The engine ECU has detected a shutdown alarm and has informed the DSE module of
CAN ECU Shutdown this situation. The exact error is also indicated on the module’s display.
Digital Input A-F Auxiliary inputs can be user configured and will display the message as written by the
user.
Emergency Stop The emergency stop button has been depressed. This a failsafe (normally closed to
battery positive) input and will immediately stop the set should the signal be removed.
Removal of the battery positive supply from the emergency stop input will also remove
DC supply from the Fuel and Start outputs of the controller.
NOTE:- The Emergency Stop Positive signal must be present otherwise the
unit will shutdown.
Fail To Start The engine has not fired after the preset number of start attempts
Generator High Voltage The generator output voltage has risen above the preset level
Shutdown
Generator Low Voltage The generator output voltage has fallen below the preset level
Shutdown
The speed signal from the magnetic pickup is not being received by the DSE
Loss of Mag. Pickup Signal controller.
The engine oil pressure has fallen below the low oil pressure trip setting level after the
Low Oil Pressure Shutdown Safety On timer has expired.
Low Fuel Level The module detects that the fuel level is below the configured setting
Oil Pressure Sender open The oil pressure sensor is detected as not being present (open circuit)
circuit
Over Frequency Shutdown The generator output frequency has risen above the preset level
Over Speed Shutdown The engine speed has exceeded the pre-set trip
NOTE:-During the start-up sequence, the overspeed trip logic can be

configured to allow an extra trip level margin. This is used to prevent nuisance
tripping on start-up - Refer to the 7000 series configuration software manual
under heading ‘Overspeed Overshoot’ for details.
Under Frequency Shutdown The generator output frequency has fallen below the preset level
The engine speed has fallen below the pre-set trip after the Safety On timer has
Under Speed Shutdown expired.
7.5 ELECTRICAL TRIP ALARMS
Electrical trips are latching and stop the Generator but in a controlled manner. On initiation of the electrical trip
condition the module will de-energise the ‘Close Generator’ Output to remove the load from the generator. Once
this has occurred the module will start the Cooling timer and allow the engine to cool off-load before shutting down
the engine. The alarm must be accepted and cleared, and the fault removed to reset the module.
Example
Alarm 1/1
Generator Current High
Electrical Trip
Electrical trips are latching alarms and stop the Generator. Remove the fault then press Stop/Reset to reset the
module.
Digital Input A-F Auxiliary inputs can be user configured and will display the message as written by the
user.
Generator phase rotation The phase rotation is measured as being different to the configured direction.
alarm
8 FRONT PANEL CONFIGURATION
This configuration mode allows the operator limited customising of the way the module operates.
Use the module’s navigation buttons to traverse the menu and make value changes to the parameters:
Next page
Edit /Accept
value
Increase value / next item

Decrease value / next item
8.1 ACCESSING THE FRONT PANEL EDITOR (FPE)
NOTE:- On 6110 modules, the (+) button is replaced with (+)
The module must be in STOP mode with the engine at rest before configuration mode can be accessed.
To enter the ‘configuration mode’ press both the INFO and STOP buttons together.
8.1.1 ENTERING THE CONFIGURATION EDITOR PIN NUMBER
If the module PIN number has been set, the PIN number request is then shown. The configuration cannot be viewed
or changed until the PIN number is correctly entered.
Enter either the ‘main’ PIN or the application PIN.
Enter pin The first * is flashing. Press (+) or (-) buttons to adjust it to the correct value for
* *** the first digit of the PIN number.
Press when the first digit is correctly entered.
The entered digit will turn back to a * to maintain security.
Enter pin The second * is now flashing. Press (+) or (-) buttons to adjust it to the correct
* * ** value for the second digit of the PIN number.
Press when the second digit is correctly entered.
Enter pin The third * is now flashing. Press (+) or (-) buttons to adjust it to the correct value
***
** * * for the third digit of the PIN number.
Press when the third digit is correctly entered.
Enter pin The fourth * is now flashing. Press (+) or (-) buttons to adjust it to the correct
****
*** * value for the fourth digit of the PIN number.
Press when the fourth digit is correctly entered.
NOTE:- When is pressed after editing the final PIN digit, the PIN is checked for validity. If the
number is not correct, the editor is automatically exited. To retry you must re-enter the editor as described
above.
If the Configuration PIN has been entered successfully (or the PIN number has not been set in the module) the first
configurable parameter is displayed :
NOTE:- To exit the front panel configuration editor at any time, press and hold the () button.
Ensure you have saved any changes you have made by pressing the button first.
NOTE:- When the editor is visible, it is automatically exited after 5 minutes of inactivity to ensure
security.
NOTE:- If the Application Menu PIN is entered, then only the Application Menu is displayed. If the Full
Configuration PIN is entered, the entire configuration menu is displayed including the Application Menu.
NOTE:- The PIN number is automatically reset when the editor is exited (manually or automatically) to
ensure security.
8.1.2 EDITING A PARAMETER
Enter the editor as described above.
Press to select the required ‘page’ as detailed below.
Press (+) to select the next parameter or (-) to select the previous parameter within the current page.
When viewing the parameter to be changed, press the () button. The value begins to flash.
Press (+) or (-) to adjust the value to the required setting.
Press () the save the current value, the value ceases flashing.
Press and hold the () button to exit the editor.

.
NOTE: - Values representing pressure will be displayed in Bar. Values representing temperature are
displayed in degrees Celsius.
NOTE: - When adjusting values in the FPE a press and hold of the increment button will cover the full
range of the item being adjusted (min to max) in under 20 seconds.
NOTE: - When the editor is visible, it is exited after 5 minutes of inactivity to ensure security.
8.2 ADJUSTABLE PARAMETERS (CONFIGURATION EDITOR)
When viewing the configuration editor, Press to select the required ‘page’ as listed below.
Front Panel Configuration Editor (Factory default settings are shown in bold italicised text)
Page Parameter as shown on display Values
PIN Pin Entry ####
DISPLAY Contrast 0% - 100% (53%)
Language English - Others
LCD Page Timer hh:mm:ss (5m)
Auto Scroll Delay 1s - 1hr (2s)
ALT CONFIG Default Config Default Config
ENGINE Oil Pressure Low Shutdown 0bar - 9.97bar (1.03bar)
Coolant Temperature High Shutdown 2ºC - 140ºC (95ºC)
Start Delay Timer 0 - 10hr (5s)
Pre Heat Timer 0 - 5m (0s)
Crank Duration Timer 0 - 1m (10s)
Crank Rest Timer 0 - 1m (10s)
Safety On Delay 0 - 1m (10s)
Smoke Limiting 0 - 15m (0s)
Smoke Limiting Off 0 - 1m (0s)
Warm Up Timer 0 -1hr (0s)
Cool Down Timer 0 - 1hr (1m)
Speed Low Shutdown Active, Inactive
Speed Low Shutdown 0RPM - 6000RPM (1270RPM)
Speed High Warning Active, Inactive
Speed High Shutdown 0RPM - 6000RPM (1740RPM)
Fail To Stop Delay 0 - 2m (30s)
Battery Voltage Low Warning Active, Inactive
Battery voltage Low Warning Delay 0 - 24hr (1m)
Battery Low Voltage 0V – 40V (10V)
Battery Voltage High Warning Active, Inactive
Battery Voltage High Warning Delay 0V - 24hr (1m)
Battery Voltage High Warning 0V – 40V (30V)
Charge Alternator Failure Warning Active, Inactive
Charge Alternator Failure Warning 0V – 39V (6V)
Charge Alternator Failure Warning Delay 0 - 24hr (5s)
Charge Alternator Failure Shutdown Active, Inactive
Charge Alternator Failure Shutdown 0V – 5.9V (4.0V)
Charge Alternator Failure Shutdown Delay 0 - 24hr (5s)
GENERATOR Voltage Low Shutdown 50V – 360V (184V)
Voltage Nominal 50V – 276V (230V)
Voltage High Shutdown 231V – 360V (277V)
Frequency Low Shutdown 0Hz - 75Hz (43Hz)
Frequency Nominal 0Hz - 75Hz (50Hz)
Frequency Low Pre Alarm 0Hz - 75Hz (45Hz)
Frequency High Pre Alarm 0Hz - 75Hz (55Hz)
Frequency High Shutdown 0Hz - 75Hz (58Hz)
Full Load Rating 5A – 6000A (500A)
Delayed Over Current Active, Inactive
Delayed Over Current 50% - 120% (100%)
AC System Single Phase, 2 Wire
3 Phase, 4 Wire
2 Phase, 3 Wire (L1 & L3)
3 Phase, 4 Wire (Delta)
2 Phase, 3 Wire (L1 & L2)
3 Phase, 3 Wire
CT Primary 5A - 6000A (600A)
Generator Transient Delay 0 - 10m (0.7s)
MAINS Voltage Low Trip 50V – 360V (184V)
Voltage Nominal 51V – 359V (230V)
Voltage High Trip 50V – 360V (276V)
Frequency Low Trip 0Hz - 75Hz (45Hz)
Frequency Nominal 1Hz - 74Hz (50Hz)
Frequency High Trip 0Hz - 75Hz (55Hz)
Mains Transient Delay 0 - 30s (2s)
Return Delay 0 - 1hr (30s)
Mains Transfer Time 0 - 10m (0.7s)
Front Panel Configuration Editor (Factory default settings are shown in bold italicised text)
Section Parameter as shown on display Values
TIMERS LCD Page Timer hh:mm:ss (5m)
Auto Scroll Delay 1s - 1hr (2s)
Start Delay Timer 0 - 10hr (5s)
Pre Heat Timer 0 - 5m (0s)
Crank Duration Timer 0 - 1m (10s)
Crank Rest Timer 0 - 1m (10s)
Safety On Delay 0 - 1m (10s)
Smoke Limiting 0 - 15m (0s)
Smoke Limiting Off 0 - 1m (0s)
Warm Up Timer 0 -1hr (0s)
Cool Down Timer 0 - 1hr (1m)
Fail To Stop Delay 0 - 2m (30s)
Battery voltage Low Warning Delay 0 - 24hr (1m)
Battery Voltage High Warning Delay 0V - 24hr (1m)
Return Delay 0 - 5hr (30s)
Generator Transient Delay 0.1s - 2m (30s)
Mains Transient Delay 0 - 30s (2s)
Mains Transfer Time 0 - 10m (0.7s)
Parameters with multiple choices use the following identification tables for the parameter values.
9 COMMISSIONING
9.1.1 PRE-COMMISSIONING
Before the system is started, it is recommended that the following checks are made:-
10.1. The unit is adequately cooled and all the wiring to the module is of a standard and rating compatible with the
system. Check all mechanical parts are fitted correctly and that all electrical connections (including earths) are
sound.
10.2. The unit DC supply is fused and connected to the battery and that it is of the correct polarity.
10.3. The Emergency Stop input is wired to an external normally closed switch connected to DC positive.
NOTE:- If Emergency Stop feature is not required, link this input to the DC Positive. The module will not
operate unless either the Emergency Stop is fitted correctly OR terminal 3 is connected to DC positive.
10.4. To check the start cycle operation, take appropriate measures to prevent the engine from starting (disable the
operation of the fuel solenoid). After a visual inspection to ensure it is safe to proceed, connect the battery
supply. Select “MANUAL” and then press “START” the unit start sequence will commence.
10.5. The starter will engage and operate for the pre-set crank period. After the starter motor has attempted to
start the engine for the pre-set number of attempts, the LCD will display ‘Failed to start. Select the
STOP/RESET position to reset the unit.
10.6. Restore the engine to operational status (reconnect the fuel solenoid). Select “MANUAL” and then press
“START”. This time the engine should start and the starter motor should disengage automatically. If not then
check that the engine is fully operational (fuel available, etc.) and that the fuel solenoid is operating. The
engine should now run up to operating speed. If not, and an alarm is present, check the alarm condition for
validity, then check input wiring. The engine should continue to run for an indefinite period. It will be possible at
this time to view the engine and alternator parameters - refer to the ‘Description of Controls’ section of this
manual.
10.7. Select “AUTO” on the front panel, the engine will run for the pre-set cooling down period, then stop. The
generator should stay in the standby mode. If not check that there is not a signal present on the Remote start
input.
10.8. Initiate an automatic start by supplying the remote start signal (if configured). The start sequence will
commence and the engine will run up to operational speed. Once the generator is available a load transfer will
take place (if configured), the Generator will accept the load. If not, check the wiring to the Generator
Contactor Coil (if used). Check the Warming timer has timed out.
10.9. Remove the remote start signal. The return sequence will begin. After the pre-set time, the generator is
unloaded. The generator will then run for the pre-set cooling down period, then shutdown into its standby
mode.
10.10. Set the module internal clock/calendar to ensure correct operation of the scheduler and event logging
functions. For details of this procedure see section entitled Front Panel Configuration – Editing the date and
time.
10.11. If, despite repeated checking of the connections between the 3000 series controller and the customer’s
system, satisfactory operation cannot be achieved, then the customer is requested to contact the factory for
further advice on:-
INTERNATIONAL TEL: +44 (0) 1723 890099

INTERNATIONAL FAX: +44 (0) 1723 893303
E-mail: Support@Deepseaplc.com
Website : www.deepseaplc.com
10 FAULT FINDING
SYMPTOM POSSIBLE REMEDY

Unit is inoperative Check the battery and wiring to the unit. Check the DC supply. Check the DC
fuse.
Read/Write configuration does not
operate
Unit shuts down Check DC supply voltage is not above 35 Volts or below 9 Volts
Check the operating temperature is not above 70°C. Check the DC fuse.
Unit locks out on Emergency Stop If no Emergency Stop Switch is fitted, ensure that a DC positive signal is
connected to the Emergency Stop input. Check emergency stop switch is
functioning correctly. Check Wiring is not open circuit.
Intermittent Magnetic Pick-up Ensure that Magnetic pick-up screen only connects to earth at one end, if
sensor fault connected at both ends, this enables the screen to act as an aerial and will pick
up random voltages. Check pickup is correct distance from the flywheel teeth.
Low oil Pressure fault operates Check engine oil pressure. Check oil pressure switch/sensor and wiring. Check
after engine has fired configured polarity (if applicable) is correct (i.e. Normally Open or Normally
Closed) or that sensor is compatible with the 3310 Module and is correctly
configured.
High engine temperature fault Check engine temperature. Check switch/sensor and wiring. Check configured
operates after engine has fired. polarity (if applicable) is correct (i.e. Normally Open or Normally Closed) or that
sensor is compatible with the 6000 series module.
Shutdown fault operates Check relevant switch and wiring of fault indicated on LCD display. Check
configuration of input.
Warning fault operates Check relevant switch and wiring of fault indicated on LCD display. Check
configuration of input.
Fail to Start is activated after pre- Check wiring of fuel solenoid. Check fuel. Check battery supply. Check battery
set number of attempts to start supply is present on the Fuel output of the module. Check the speed-sensing
signal is present on the 6000 series module inputs. Refer to engine manual.
Continuous starting of generator Check that there is no signal present on the “Remote Start” input. Check
when in AUTO configured polarity is correct.
Generator fails to start on receipt Check Start Delay timer has timed out.
of Remote Start signal.
Check signal is on “Remote Start” input. Confirm correct configuration of input
is configured to be used as “Remote Start”.
Check that the oil pressure switch or sensor is indicating low oil pressure to the
controller. Depending upon configuration, the set will not start if oil pressure is
not low.
Pre-heat inoperative Check wiring to engine heater plugs. Check battery supply. Check battery
supply is present on the Pre-heat output of module. Check pre-heat
configuration is correct.
Starter motor inoperative Check wiring to starter solenoid. Check battery supply. Check battery supply is
present on the Starter output of module. Ensure that the Emergency Stop input
is at Positive. Ensure oil pressure switch or sensor is indicating the “low oil
pressure” state to the 6000 series controller.
Engine runs but generator will not Check Warm up timer has timed out. Ensure generator load inhibit signal is not
take load present on the module inputs. Check connections to the switching device.
Note that the set will not take load in manual mode unless there is an active
remote start on load signal.
SYMPTOM POSSIBLE REMEDY

Incorrect reading on Engine Check engine is operating correctly. Check sensor and wiring.
gauges
Fail to stop alarm when engine is

at rest
Module appears to ‘revert’ to an When editing a configuration using the PC software it is vital that the
earlier configuration configuration is first ‘read’ from the controller before editing it. This edited
configuration must then be “written” back to the controller for the changes to
take effect.
When editing a configuration using the Front Panel Editor, be sure to press the
Save button to save the change before moving to another item or exiting
the Front Panel Editor.
Set will not take load Ensure the generator is available.
Check that the output configuration is correct to drive the load switch device
and that all connections are correct.
Remember that the set will not take load in manual mode unless a remote start
on load input is present.
Inaccurate generator The 3000 series controller is true RMS measuring so gives more accurate
measurements on controller display when compared with an ‘average’ meter such as an analogue panel
display meter or some lower specified digital multimeters.
Accuracy of the controller is better than 1% of full scale. Ie Gen volts full scale
is 333V ph-n so accuracy is ±3.33V (1% of 333V).
NOTE:- The above fault finding is provided as a guide check-list only. As the module can be
configured to provide a wide range of different features, always refer to the source of your module
configuration if in doubt.
11 MAINTENANCE, SPARES, REPAIR AND SERVICING

The DSE6000 Series controller is designed to be Fit and Forget. As such, there are no user serviceable parts within
the controller.
In the case of malfunction, you should contact your original equipment supplier (OEM).
11.1 PURCHASING ADDITIONAL CONNECTOR PLUGS FROM DSE
If you require additional plugs from DSE, please contact our Sales department using the part numbers below.
11.1.1 DSE6110
6110 series terminal designation Plug description Part No.

1-11 11 way 5.08mm 007-451
12-15 4 way 5.08mm 007-444
16-18 3 way 5.08mm 007-174
19-22 4 way 7.62mm 007-171
27-31 2 way 7.62mm 007-448
32-37 6 way 5.08mm 007-446
NOTE:- Terminals 23-26 are not fitted to DSE4410 controllers.
11.1.2 DSE6120
6110 series terminal designation Plug description Part No.

1-11 11 way 5.08mm 007-451
12-15 4 way 5.08mm 007-444
16-18 3 way 5.08mm 007-174
19-26 8 way 7.62mm 007-454
27-31 5way 5.08mm 007-445
32-37 6 way 5.08mm 007-446
11.2 PURCHASING ADDITIONAL FIXING CLIPS FROM DSE
Item Description Part No.
6000 series fixing clips (packet of 4) 020-294
11.3 PURCHASING SEALING GASKET FROM DSE
The optional sealing gasket is not supplied with the controller but can be purchased separately.
Item Description Part No.
6000 series silicon sealing gasket 020-389
12 WARRANTY
DSE provides limited warranty to the equipment purchaser at the point of sale. For full details of any applicable
warranty, you are referred to your original equipment supplier (OEM).
13 DISPOSAL
13.1 WEEE (WASTE ELECTRICAL AND ELECTRONIC EQUIPMENT)
Directive 2002/96/EC
If you use electrical and electronic equipment you must store, collect, treat, recycle and dispose of
WEEE separately from your other waste.
13.2 ROHS (RESTRICTION OF HAZARDOUS SUBSTANCES)
Directive 2002/95/EC:2006
To remove specified hazardous substances (Lead, Mercury, Hexavalent Chromium, Cadmium, PBB & PBDE´s)
Exemption Note: Category 9. (Monitoring & Control Instruments) as defined in Annex 1B of the WEEE directive will
be exempt from the RoHS legislation. This was confirmed in the August 2005 UK´s Department of Trade and
Industry RoHS REGULATIONS Guide (Para 11).
Despite this exemption DSE has been carefully removing all non RoHS compliant components from our supply chain
and products.
When this is completed a Lead Free & RoHS compatible manufacturing process will be phased into DSE production.
This is a process that is almost complete and is being phased through different product groups.

Generating Set User Manual - KG320WS To KG625WS

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SERVICE

KIRLOSKAR OIL ENGINE LIMITED

For availing the warranty services, please ensure following:

A) Produce this warranty booklet to KOEL authorized service dealer, when

? Genset Model and Serial Number

? Land line and cell phone numbers of the contact person

? The nature of complaint

This Warranty is not applicable in following conditions.

schedule given by Kirloskar Oil Engines Ltd.

Any claim or obligation in connection with sale or performance of Kirloskar Green

Condition precedent to Kirloskar green Genset Warranty

1. Proper Installation of the Kirloskar Green Genset as per the recommendation

as Fuel Injection equipments , Batteries, Starter Electrical equipments and

Safety precautions for operation and maintenance

Maintenance and service knowledge

Stop the engine

Kirloskar Oil Engines Ltd.

Name and location of customer Name and location of Distributor

Genset Model Genset manufacturing Date/ Sr No. Details of Alternator

Invoice No. and Date Date of Installation

Customer contact person Phone nos.

Installation Check Points

Sr.No. Nature of Check Status Remarks

5 Is the Exhaust pipe is provided with rain protection

Signature, Name & address of Dealer Signature and Name of customer

Head ofiice copy

COMMISSIONING THE ENGINE

Preparing for Operation

Check the engine oil.

Check the radiator coolant.

Check the battery electrolyte and charge condition.

? Avoid prolonged inhalation of exhaust fumes as it may result in serious illness or

? Never attempt to disconnect a load connection or perform maintenance while the

? Check the engine oil and coolant levels, replenishing if necessary.

? Fill the fuel tank with the recommended grade of diesel.

? Ensure the key switch/ control switch is turned OFF.

? Ensure the circuit breaker is switched OFF.

? Connect the batteries to the engine with correct polarity.

? Check for coolant leakage or high engine temperature.

when a sound connection has been made.

(For manual operation)

The Genset must be checked daily before starting.

? Check engine oil, water and fuel levels, replacing if necessary.

? Check the battery terminals for corrosion, cleaning where necessary.

For healthy conditions, the reading should be 80 to 90 degree centigrade.

? The AC voltmeter would show the alternator output voltage.

? Refer to the engine manual for specific engine maintenance requirements.

? If the genset is at normal operating temperature (approx 80 degrees C / 176 degrees

WARNING: Always shut the Genset down prior to connecting, or disconnecting,load

* Make of the Gland is of Comet (With Brass Material)

Typical Cable sizes for Three phase gensets.

* Make of the Gland is of Comet (With Brass Material)

Typical Cable sizes for Single phase gensets.

2. Description of the Genset 29

6. Location of the Genset 34

7. Ventilation and Air Supply System 35

9. Lifting the Genset 40

11. Fuel Systems 46

12. Fire Precautions 47

13. Electrical Connections 47

15. Maintenance of Electrical System 52

16. Acoustic Canopy 55

17. Control System 57