User and Maintenance Manual For Generating Sets: K44 - APM303

User and maintenance manual
for generating sets
K44 - APM303
33504485502NE_5
K44
Engine ref. KDI2504TM-40
Alternator ref. KH00602T
Performance class G3
GENERAL CHARACTERISTICS
Frequency (Hz) 50 Hz
Voltage (V) 400/230
Standard Control Panel APM303
Optional control panel APM403
POWER
ESP PRP
Voltage Standby Amps
kWe kVA kWe kVA
415/240 35 44 32 40 61
DESCRIPTIVE
400/230 35 44 32 40 64
Mechanic governor
380/220 35 44 32 40 67
Mechanically welded chassis with antivibration
suspension
Main line circuit breaker DIMENSIONS COMPACT VERSION
Radiator for core temperature of 48/50°C max with Length (mm) 1700
mechanical fan
Width (mm) 896
Protective grille for fan and rotating parts (CE option)
9 dB(A) silencer supplied separately Height (mm) 1200
Charger DC starting battery with electrolyte Dry weight (kg) 618
12 V charge alternator and starter Tank capacity (L) 100
Delivered with oil and coolant -30°C
Manual for use and installation
DIMENSIONS SOUNDPROOFED VERSION
Type soundproofing M137
POWER DEFINITION
PRP : Prime Power is available for an unlimited number of annual
Length (mm) 2100
operating hours in variable load applications, in accordance with ISO Width (mm) 938
8528-1. ESP : The standby power rating is applicable for supplying
emergency power in variable load applications in accordance with ISO Height (mm) 1285
8528-1. Overload is not allowed.
Dry weight (kg) 806
TERMS OF USE
According to the standard, the nominal power assigned by the genset is
Tank capacity (L) 100
given for 25°C Air Intlet Temperature, of a barometric pressure of 100 Acoustic pressure level @1m in dB(A) 76
kPA (100 m A.S.L), and 30 % relative humidity. For particular conditions
in your installation, refer to the derating table. Sound power level guaranteed (Lwa) 91
ASSOCIATED UNCERTAINTY Acoustic pressure level @7m in dB(A) 63
For the generating sets used indoor, where the acoustic pressure levels
depends on the installation conditions, it is not possible to specify the
ambient noise level in the exploitation and maintenance instructions .
You will also find in our exploitation and maintenance instructions a
warning concerning the air noise dangers and the need to implement
appropriated preventive measures.
23/01/2019
K44
ENGINE CHARACTERISTICS
GENERAL ENGINE DATA EXHAUST

Engine brand KOHLER DIESEL Exhaust gas temperature @ ESP 50Hz (°C) 530
Engine ref. KDI2504TM-40 Exhaust gas flow @ ESP 50Hz (L/s) 117
Air inlet system Turbo Max. exhaust back pressure (mm H2O) 800
Cylinders configuration L
Number of cylinders 4 FUEL
Displacement (L) 2.48 Consumption @ 100% load ESP (L/h) 10.60
Charge Air coolant Consumption @ 100% PRP load (L/h) 9.40
Bore (mm) x Stroke (mm) 88 x 102 Consumption @ 75% PRP load (L/h) 7.10
Compression ratio 18.5 : 1 Consumption @ 50% PRP load (L/h) 4.90
Speed (RPM) 1500 Maximum fuel pump flow (L/h) 55
Pistons speed (m/s) 5.10
Maximum stand-by power at rated
41
RPM (kW) OIL
Frequency regulation, steady state (%) Oil system capacity including filters (L) 11.50
BMEP @ PRP 50 Hz (bar) 12 Min. oil pressure (bar) 0.70
Governor type Mechanical Max. oil pressure (bar)
Oil consumption 100% ESP (L/h) 0.21
COOLING SYSTEM Oil sump capacity (L)
Radiator & Engine capacity (L) 9.10
HEAT BALANCE
Heat rejection to exhaust (kW)
Fan power (kW) 1.10 Radiated heat to ambiant (kW) 7
Fan air flow w/o restriction (m3/s) 2 Heat rejection to coolant HT (kW) 30
Available restriction on air flow (mm
20
H2O)
Type of coolant Glycol-Ethylene AIR INTAKE
Max. intake restriction (mm H2O)
Intake air flow (L/s)
EMISSIONS
Emission PM (g/kW.h) 0.60
Emission CO (g/kW.h) 5.50
Emission HC+NOx (g/kWh) 0
Emission HC (g/kW.h)
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K44
ALTERNATOR CHARACTERISTICS
GENERAL DATA OTHER DATA

Alternator ref. KH00602T Continuous Nominal Rating 40°C (kVA) 40
Number of Phase Three phase Standby Rating 27°C (kVA) 45
Power factor (Cos Phi) 0.80 Efficiencies 100% of load (%) 88.90
Altitude (m) 0 à 1000 Air flow (m3/s) 0.10
Overspeed (rpm) 2250 Short circuit ratio (Kcc) 0.4240
Number of pole 4 Direct axis synchro reactance unsaturated (Xd) (%) 281
Capacity for maintaining short circuit at Quadra axis synchro reactance unsaturated (Xq) (%) 143
Yes
3 ln for 10 s
Open circuit time constant (T'do) (ms) 944
Insulation class H
Direct axis transcient reactance saturated (X'd) (%) 14.80
T° class (H/125°), continuous 40°C H / 125°K
Short circuit transcient time constant (T'd) (ms) 50
T° class (H/163°C), standby 27°C H / 163°K
Direct axis subtranscient reactance saturated (X''d)
%regulation_avr% #regulation_avr# 7.40
(%)
Total Harmonic Distortion in no-load Subtranscient time constant (T"d) (ms) 5
<3.5
DHT (%) Quadra axis subtranscient reactance saturated (X"q)
Total Harmonic Distortion, on linear load 10.60
<5 (%)
DHT (%)
Subtranscient time constant (T"q) (ms) 5
Wave form : NEMA=TIF <50
Zero sequence reactance unsaturated (Xo) (%) 0.60
Wave form : CEI=FHT <2
Negative sequence reactance saturated (X2) (%) 9.02
Number of bearing Single Bearing
Armature time constant (Ta) (ms) 8
Coupling Direct
No load excitation current (io) (A) 0.56
Voltage regulation at established rating
0.50 Full load excitation current (ic) (A) 2.19
(+/- %)
Recovery time (Delta U = 20% 500 Full load excitation voltage (uc) (V) 32.10
transcient) (ms)
Engine start (Delta U = 20% perm. or 30% trans.)
Indication of protection IP 23 98.53
(kVA)
Technology Brushless Transcient dip (4/4 load) - PF : 0,8 AR (%) 13
No load losses (W) 888.22
Heat rejection (W) 3955.16
Unbalanced load acceptance ratio (%) 100
DIMENSIONS
Dimensions soundproofed version Dimensions DW compact version
Type soundproofing M137 Type soundproofing
Length (mm) 2100 Length (mm) 2074
Width (mm) 938 Width (mm) 932
Height (mm) 1285 Height (mm) 1401
Dry weight (kg) 806 Dry weight (kg) 827
Tank capacity (L) 100 Tank capacity (L) 240
Acoustic pressure level @1m in dB(A) 76 Acoustic pressure level @1m in dB(A)
Sound power level guaranteed (Lwa) 91 Sound power level guaranteed (Lwa)
Acoustic pressure level @7m in dB(A) 63 Acoustic pressure level @7m in dB(A)
Dimensions DW soundproofed version Dimensions DW 48h soundproofed version
Type soundproofing M137-DW Type soundproofing M137-DW48
Length (mm) 2100 Length (mm) 2100
Width (mm) 932 Width (mm) 932
Height (mm) 1486 Height (mm) 1539
Dry weight (kg) 1015 %PdnetE_5% 1022
Tank capacity (L) 240 Tank capacity (L) 470
Acoustic pressure level @1m in dB(A) 76 Acoustic pressure level @1m in dB(A) 75
Sound power level guaranteed (Lwa) 91 Sound power level guaranteed (Lwa) 91
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Acoustic pressure level @7m in dB(A) 64 Acoustic pressure level @7m in dB(A) 63
23/01/2019
K44
CONTROL PANEL
APM303, comprehensive and simple APM403, basic generating set and power plant
control
The APM403 is a versatile control unit which allows

operation in manual or automatic mode
Measurements : voltage and current
kW/kWh/kVA power meters
The APM303 is a versatile unit which can be operated in Standard specifications: Voltmeter, Frequency meter.
manual or automatic mode. It offers the following features: Optional : Battery ammeter.
Measurements: J1939 CAN ECU engine control
phase-to-neutral and phase-to-phase voltages, fuel level Alarms and faults: Oil pressure, Coolant temperature,
(In option : active power currents, effective power, power Overspeed, Start-up failure, alternator min/max, Emergency
factors, Kw/h energy meter, oil pressure and coolant stop button.
temperature levels) Engine parameters: Fuel level, hour counter, battery
Supervision: voltage.
Modbus RTU communication on RS485 Optional (standard at 24V): Oil pressure, water temperature.
Reports: Event log/ Management of the last 300 genset events.
(In option : 2 configurable reports) Mains and genset protection
Safety features: Clock management
Overspeed, oil pressure,coolant temperatures, minimum USB connections, USB Host and PC,
and maximum voltage, minimum and maximum frequency Communications : RS485 INTERFACE
(Maximum active power P<66kVA) ModBUS protocol /SNMP
Traceability: Optional : Ethernet, GPRS, remote control, 3G, 4G,
Stack of 12 stored events Websupervisor, SMS, E-mails
For further information, please refer to the data sheet for the
APM303.
23/01/2019
General and safety manual
Generating set
GENERAL – SAFETY – INSTALLATION
IZIDOC-1311_EN
2017/07/17 33532000201_6_1
MGS_ 33532000201_6_1
CONTENTS
1 Preface........................................................................................................................................................................................ 4
1.1 Description of the documentation for generating sets ........................................................................................................ 4
1.2 General recommendations ................................................................................................................................................. 5
2 Safety instructions ....................................................................................................................................................................... 6
2.1 Meaning of the pictograms on the generating set............................................................................................................... 6
2.2 General guidelines ............................................................................................................................................................. 7
2.3 Risks relating to handling phases ....................................................................................................................................... 9
2.4 Risk of electrocution ........................................................................................................................................................... 9
2.4.1 Safety precautions in case of electrical shock................................................................................................................ 9
2.5 Risk of fire, burns and explosions..................................................................................................................................... 10
2.6 Risks relating to exhaust gases and Risks related ........................................................................................................... 11
2.7 Risks relating to noise ...................................................................................................................................................... 12
2.8 Guidelines for protecting the environment ........................................................................................................................ 12
3 General description of the equipment ....................................................................................................................................... 13
3.1 Identification plates........................................................................................................................................................... 13
3.1.1 Identifying sets ............................................................................................................................................................. 13
3.1.2 Location of plates on generating sets with and without an enclosure .......................................................................... 14
3.1.3 Location of plates on containerised generating sets .................................................................................................... 14
3.1.4 Identifying generating set components ........................................................................................................................ 15
3.2 Fixed generating set ......................................................................................................................................................... 16
3.2.1 Generating set without protective cover ....................................................................................................................... 16
3.2.2 Generating set with protective cover ............................................................................................................................ 17
3.3 Mobile generating set ....................................................................................................................................................... 18
3.3.1 Generating set without trailer ....................................................................................................................................... 18
3.3.2 Trailer-mounted generating set .................................................................................................................................... 19
3.3.3 Lighting column ............................................................................................................................................................ 19
3.4 Containerised generating set ........................................................................................................................................... 20
3.4.1 ISO 20 and ISO 40 containers ..................................................................................................................................... 21
3.4.2 CPU 20 and CPU 40 containers .................................................................................................................................. 22
3.4.3 CIR 20 containers ........................................................................................................................................................ 23
3.4.4 Trailer-mounted container ............................................................................................................................................ 23
3.5 Technical characteristics and operation of additional equipment (if so equipped) ............................................................ 24
3.5.1 Built-in fluid retention container (option) ....................................................................................................................... 24
3.5.2 REN-RAB automatic oil auxiliary adjuster .................................................................................................................... 25
3.5.2.1 Technical specifications ........................................................................................................................................... 25
3.5.2.2 Operation ................................................................................................................................................................. 25
3.5.3 JAPY manual pump ..................................................................................................................................................... 26
3.5.4 JAPY electric pump ...................................................................................................................................................... 27
3.5.5 Shut-off valve ............................................................................................................................................................... 28
3.5.6 Battery charger ............................................................................................................................................................ 28
3.5.6.1 BC0512.................................................................................................................................................................... 29
3.5.6.2 BC0524.................................................................................................................................................................... 31
3.5.6.3 BC1012.................................................................................................................................................................... 33
3.5.6.4 BC1024.................................................................................................................................................................... 35
3.5.6.5 BC2024.................................................................................................................................................................... 37
4 Handling .................................................................................................................................................................................... 39
4.1 Unloading the equipment ................................................................................................................................................. 40
4.2 Moving the equipment using slings .................................................................................................................................. 40
4.2.1 Display of lifting points ................................................................................................................................................. 41
4.3 Moving the equipment using a forklift truck ...................................................................................................................... 42
4.3.1 Handling generating sets with and without an enclosure ............................................................................................. 42
4.3.2 Handling containerised generating sets ....................................................................................................................... 42
4.4 Moving the equipment using a mobile winch .................................................................................................................... 43
4.5 Moving equipment by rollers or dolly systems .................................................................................................................. 43
5 Transporting and storing the generating set.............................................................................................................................. 44
5.1 Preparing for transport ..................................................................................................................................................... 44
5.2 Road transport.................................................................................................................................................................. 44
5.2.1 ADR regulations concerning the transport of dangerous materials .............................................................................. 44
5.2.2 Generating sets with and without an enclosure............................................................................................................ 45
5.2.3 Containerised generating sets ..................................................................................................................................... 46
5.3 Rail transport .................................................................................................................................................................... 47
5.3.2 Containerised generating sets ..................................................................................................................................... 47
5.4 Shipping ........................................................................................................................................................................... 47
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5.4.2 Containerised generating sets ...................................................................................................................................... 47
5.4.3 Accessories and spare parts ........................................................................................................................................ 47
5.5 Air transport ...................................................................................................................................................................... 47
5.6 Generating sets on trailers ................................................................................................................................................ 48
5.6.1 Safety instructions ........................................................................................................................................................ 48
5.6.2 Description.................................................................................................................................................................... 48
5.6.2.1 Weight characteristics .............................................................................................................................................. 48
5.6.2.2 Hitches ..................................................................................................................................................................... 48
5.6.2.3 Signalling.................................................................................................................................................................. 49
5.6.2.4 Limits ........................................................................................................................................................................ 49
5.6.3 Use ............................................................................................................................................................................... 50
5.6.3.1 Verifications prior to hitching .................................................................................................................................... 51
5.6.3.2 Hitching a trailer equipped with a hitching ring ......................................................................................................... 51
5.6.3.3 Hitching a trailer equipped with a coupling head (ball) ............................................................................................. 52
5.6.3.3.1 Coupling ......................................................................................................................................................... 52
5.6.3.3.2 Wear indicator (on certain models) ................................................................................................................. 53
5.6.3.4 Operation ................................................................................................................................................................. 53
5.6.3.5 Uncoupling ............................................................................................................................................................... 53
5.6.4 Technical information.................................................................................................................................................... 54
5.6.4.1 General specifications .............................................................................................................................................. 54
5.6.4.2 Wheels and tyres...................................................................................................................................................... 55
5.6.4.3 Fastening the generating set on the trailer ............................................................................................................... 55
5.6.4.4 Connection of electric harnesses ............................................................................................................................. 55
5.6.4.5 Maintenance schedule ............................................................................................................................................. 56
5.6.4.6 Troubleshooting tables ............................................................................................................................................. 57
6 Installation ................................................................................................................................................................................. 58
6.1 General instructions, prerequisites for all installations ...................................................................................................... 58
6.1.1 Determining the installation location ............................................................................................................................. 58
6.1.2 Creating the base for the generating set....................................................................................................................... 59
6.1.3 Fuel management ......................................................................................................................................................... 60
6.1.3.1 Reminder of applicable regulations .......................................................................................................................... 60
6.1.3.2 Description of the installation ................................................................................................................................... 61
6.1.4 Limiting noise pollution ................................................................................................................................................. 62
6.1.5 Install the additional equipment .................................................................................................................................... 62
6.1.6 Protect against surges .................................................................................................................................................. 62
6.2 Generating sets without enclosures, installation in a room ............................................................................................... 63
6.2.1 Introduction ................................................................................................................................................................... 63
6.2.2 Selecting the type of premises ...................................................................................................................................... 64
6.2.3 Determining the dimensions and layout of the premises .............................................................................................. 64
6.2.4 Opening the premises for access and ventilation ......................................................................................................... 65
6.2.5 Preparing a lifting system ............................................................................................................................................. 65
6.2.6 Soundproofing the premises ......................................................................................................................................... 66
6.2.6.1 Reminder of applicable regulations: Acoustics ......................................................................................................... 66
6.2.7 Defining the exhaust circuit........................................................................................................................................... 67
6.2.7.1 Reminder of applicable regulations: exhaust emissions ........................................................................................... 67
6.2.8 Cooling ......................................................................................................................................................................... 75
6.3 Generating sets with enclosure and containers, outdoor installation ................................................................................ 76
6.3.1 Ensuring correct ventilation .......................................................................................................................................... 76
6.3.2 Guaranteeing a correct exhaust system ....................................................................................................................... 77
6.4 Mobile generating sets ...................................................................................................................................................... 78
6.4.1 Trailer-mounted generating set ..................................................................................................................................... 78
7 Installation ................................................................................................................................................................................. 79
7.1 Electrically connecting a generating set ............................................................................................................................ 79
7.1.1 Low-voltage installation ................................................................................................................................................ 80
7.1.1.1 Low-voltage wiring.................................................................................................................................................... 80
7.1.1.2 Low-voltage earthing system .................................................................................................................................... 82
7.1.1.2.1 TT system ....................................................................................................................................................... 83
7.1.1.2.2 TNS system .................................................................................................................................................... 83
7.1.1.2.3 IT system ........................................................................................................................................................ 84
7.1.2 High-voltage installation................................................................................................................................................ 85
7.1.2.1 High-voltage installation ........................................................................................................................................... 85
7.1.2.2 High-voltage earthing system ................................................................................................................................... 86
7.2 Fuels, lubricants and coolants........................................................................................................................................... 87
7.2.1 Fuel specifications ........................................................................................................................................................ 87
7.2.2 Lubricant specifications ................................................................................................................................................ 90
7.2.3 Coolant specifications ................................................................................................................................................... 93
7.3 Inspect the generating set installation, commissioning ..................................................................................................... 94
7.3.1 Settings of the cooling tower temperature regulator and variator ................................................................................. 95
7.4 Preparing for operation of the generating set .................................................................................................................... 96
7.5 Checking the generating set before startup ...................................................................................................................... 96
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7.6 Starting the generating set ............................................................................................................................................... 97
7.6.1 Generating sets equipped with a preheating boiler ...................................................................................................... 97
7.6.2 Starting......................................................................................................................................................................... 97
7.7 Checking the generating set after startup ......................................................................................................................... 97
7.8 Operation ......................................................................................................................................................................... 98
7.8.1 Avoid operation without load or underloaded ............................................................................................................... 98
7.8.2 Take the necessary safety measures during operation ................................................................................................ 98
7.9 Switching the generating set off ....................................................................................................................................... 98
8 Maintenance ............................................................................................................................................................................. 99
8.1 Maintenance plans ........................................................................................................................................................... 99
8.1.1 Develop an adapted maintenance plan ...................................................................................................................... 100
8.2 Testing generating sets .................................................................................................................................................. 103
8.3 Cleaning a generating set .............................................................................................................................................. 104
8.3.1 Cleaning a generating set with an enclosure ............................................................................................................. 104
8.3.1.1 Cleaning frequency ................................................................................................................................................ 104
8.3.1.2 Cleaning procedure ............................................................................................................................................... 104
8.3.2 Cleaning a containerised generating set .................................................................................................................... 107
8.3.2.1 Cleaning frequency ................................................................................................................................................ 107
8.3.2.2 Cleaning procedure ............................................................................................................................................... 107
8.4 General principles for maintaining the circuits ................................................................................................................ 110
8.4.1 Oil circuit .................................................................................................................................................................... 110
8.4.1.1 Oil sampling ........................................................................................................................................................... 110
8.4.1.2 Draining and replacing the oil filter ........................................................................................................................ 112
8.4.2 Fuel circuit.................................................................................................................................................................. 113
8.4.2.1 Fuel pre-filters........................................................................................................................................................ 113
8.4.2.1.1 Pre-filter maintenance .................................................................................................................................. 114
8.4.2.1.2 Bleeding ....................................................................................................................................................... 114
8.4.2.1.3 Filter replacement ........................................................................................................................................ 114
8.4.2.2 Draining the fuel system ........................................................................................................................................ 115
8.4.3 Cooling system .......................................................................................................................................................... 116
8.4.3.1 Drainage schedule ................................................................................................................................................. 116
8.4.3.2 Coolant sampling ................................................................................................................................................... 116
8.4.3.3 Draining ................................................................................................................................................................. 117
8.4.3.4 First fill ................................................................................................................................................................... 118
8.4.3.5 Sealing test and addition ....................................................................................................................................... 118
8.5 Air filter ........................................................................................................................................................................... 119
8.5.1 Air filter for dusty atmospheres .................................................................................................................................. 119
8.6 Hoses ............................................................................................................................................................................. 121
8.7 Starter batteries .............................................................................................................................................................. 122
8.7.1 Checking the electrolyte level .................................................................................................................................... 122
8.7.2 Checking the voltage/acid density.............................................................................................................................. 122
8.7.3 Connecting/disconnecting the battery ........................................................................................................................ 123
8.7.4 Charging the battery .................................................................................................................................................. 123
8.7.5 Cleaning the battery ................................................................................................................................................... 123
8.8 Air coolers ...................................................................................................................................................................... 124
8.9 Maintenance of additional equipment ............................................................................................................................. 126
8.9.1 Exhaust mufflers ........................................................................................................................................................ 126
8.9.2 JAPY manual pump ................................................................................................................................................... 126
9 Storage/Removal from storage ............................................................................................................................................... 128
10 Rapid identification of minor malfunctions ............................................................................................................................... 129
10.1 Generating set verifications ............................................................................................................................................ 129
10.2 Starter batteries .............................................................................................................................................................. 130
10.3 JAPY manual pump........................................................................................................................................................ 131
10.4 JAPY electric pump ........................................................................................................................................................ 131
11 Glossary .................................................................................................................................................................................. 132
12 Table of illustrations ................................................................................................................................................................ 138
MGS_186_EN _17/07/2017 15:01 33532000201_6_1 Section_0 _CONTENTS 3

1 Preface
1.1 Description of the documentation for generating sets
The documentation supplied with the generating sets defines all operating and maintenance operations for the generating set or
power station, as well as instructions for the safety and protection of people and equipment. This reference documentation is designed
to help you become familiar with the equipment, operate and maintain it, and conduct daily and periodic servicing. It consists of the
following elements:
- The instructions and safety regulations to be respected for the protection of persons,
- The generation set's technical specifications (data sheet),
- The general recommendations containing, among other things:
 the transport and handling indications,
 the general rules for installing generating sets,
 general instructions for preparing generating sets prior to their commissioning,
 the specifications for fuel, lubricants and coolants to be used,
 special maintenance instructions,
 maintenance specifications and/or instructions for certain optional equipment.
- The operating instructions for the control unit (if equipped),
- The operating and maintenance manual for the engine fitted to the generating set*,
- The maintenance manual for the alternator fitted to the generating set*,
- The electrical diagrams (separate document or included in the documentation, as the case may be).
The information and references contained in the manuals are taken from technical data available at the time of print (the photos
shown in our manuals are not legally binding). In line with our policy of continually improving the quality of our products, this information
may be amended without warning.
* The reference documents for the engines and alternators fitted to the generating sets consist of engine operating and maintenance
manuals (provided by the manufacturer) and alternator operating and maintenance manuals (also provided by the manufacturer).
Certain operating and maintenance manuals of the engines powering the generating sets have control units and indicate the engine
start-up and shut-down procedures: as our generating sets are equipped with specific control units, only the information provided in
the documentation of the control units equipping our generating sets are to be taken into consideration.
In addition, depending on the manufacturing criteria of the generating sets, some engines may be fitted with specific electrical wiring
different from that described in the engine documentation.
In this manual, the warning messages are used in the following manner:
Immediate danger.
Indicates an imminent danger which may result in death or serious injury. Failure to follow the instruction
shown may pose serious risks to the health and life of those concerned.
DANGER
Potential danger.
Indicates a dangerous situation if the warning is not heeded. Failure to follow the instruction indicated may
cause minor injuries to those concerned or damage to equipment.
IMPORTANT
The left and right sides can be seen from the back of the generating set (the radiator is at the front). Abbreviations and terms defined
in the glossary and references to figures and chapters are shown in italics.
4 Section 1 Preface 33532000201_6_1 MGS_186_EN _17/07/2017 15:01

1.2 General recommendations
Carefully read the entire generating set operating and maintenance manual and safety instructions. It is essential that the instructions,
safety regulations and current legislation be respected.
If you have any doubts regarding the instructions or recommended operations, please contact your nearest agent. Our dealers are
highly qualified and can answer all of your questions. They can also supply spare parts and other services. They also have trained
staff to carry out preventive and corrective maintenance on generating sets and even ensure their complete overhaul.
All operations not specified in the generating set's documentation are prohibited; no settings are to be modified if not expressly
stipulated in the documentation. Ensure that all operations are carried out by personnel who have received appropriate training. Never
let other people use the generating set without having given them all the necessary instructions beforehand. Never let a child touch
the generating set, even when not in operation.
In all cases, respect the local regulations currently in place concerning the use of generating sets.
MGS_186_EN _17/07/2017 15:01 33532000201_6_1 Section_1 _Preface 5

2 Safety instructions
2.1 Meaning of the pictograms on the generating set
Reading the manual

Warning: general for the equipment is Important:
Diesel fuel. Filling with oil. Filling with coolant.
danger. compulsory. electrical dangers.
Important: Important:
Important:
rotating or moving danger, automatic Draining fuel. Draining oil. Draining coolant.
high temperature.
parts. start.
Important: Draining the

Important: External fuel Retention container
explosive Earth. retention
corrosive materials. connections. high level.
materials, risk of container.
explosion.
Water spray Flammable products,

prohibited, jet Naked flames and naked flames and Fill up with coolant
washing smoking prohibited. Inspection flap. before preheating.
smoking prohibited Fuel supply
prohibited. selection valve.
Danger: Important:
Consult the Sight and hearing Do not open the Open the doors
Sight protection Battery isolating
information protection doors when the before starting
compulsory. switch.
guide. compulsory. generating set is the generating
operating. set.
Lifting point Forklift required for Class 3 danger: Transport bracket,

required. lifting. flammable liquid. to be removed
Lashing: Point for passing through
before installation.
transport straps and anchorages for
generating sets.
6 Section 2 Safety instructions 33532000201_6_1 MGS_186_EN _17/07/2017 15:01

2.2 General guidelines
Installing the equipment

The installer of the equipment must create a document describing any modifications made to the equipment during installation.
Using the equipment

- Before starting any operations on the equipment:
o Nominate an operations manager.
o The role of the operations manager is to monitor, either directly or indirectly, any operations performed on the equipment
and to ensure that the safety and operating instructions are respected.
o The operations manager should read and understand all the documentation supplied with the equipment.
- Information for personnel:

o Regularly reiterate the safety and operating instructions to the operating personnel.
o Contact your dealer if you have any questions regarding the equipment and any training requests for personnel.
o Make the manufacturer's instructions available to the users (if possible on site).
- Protection for individuals and equipment:

o Wear suitable clothing.
o Move away from equipment in operation.
o Ensure that persons who are not authorised to intervene as well as animals are kept away from the equipment. Observe
this guideline regardless of whether the equipment is in operation or stopped.
o Protect the equipment from any fluid splashes and bad weather.
o Before starting the equipment, refit the enclosures and close all the access doors.
o Before starting the engine, check that the air filter is present and the correct extraction circuit for the exhaust gas.
o Respect the current regulations relating to fuel use.
o Under no circumstances use seawater or any other corrosive or electrolytic product in the cooling circuit.
o Adjust the equipment according to the manufacturer's prescriptions.
o Check that the equipment operates correctly.
o Engage the parking brake when the equipment is installed on the operating site on its trailer. When chocking the trailer
on a slope, ensure that there is nobody in the path of the trailer.
Maintaining the equipment

- Personnel skills:
o Ensure that the maintenance operations are performed on the equipment by appropriately trained personnel.
- Personnel protection:
o Wear suitable clothing and protective goggles.
o Remove any personal belongings that may hinder the operation: watch, bracelet, etc.
o Fit a panel over the controls of the equipment to prevent any attempt to start.
o Disconnect the battery (and pneumatic starter if fitted) before beginning any maintenance operation.
o Handle the equipment according to best practices, using techniques which do not endanger the personnel.
o It is essential to wear gloves when detecting leaks.
o Regularly check that the safety devices are operating correctly.
MGS_186_EN _17/07/2017 15:01 33532000201_6_1 Section_2 _Safety instructions 7

- Equipment protection:
o Use tools in good condition and suited to the work to be done. Ensure you have understood the instructions before
beginning any operation.
o Respect the maintenance table and its recommendations. In dusty or unfavourable conditions, certain maintenance
intervals will need to be reduced.
o Check that the spare parts fitted on the equipment are supplied only by the dealer.
o Handle the equipment according to best practices, using techniques which do not risk damaging the equipment.
o Replace any safety pictograms that are missing or illegible on the equipment.
Note: the mounting bolts on the protective devices of the rotating parts are captive bolts equipped with retaining washers.
Also, in order to ensure the integrity of this assembly, it is prohibited to use electric or pneumatic screwdrivers to undo
these mounting bolts.
- Cleaning the equipment:

o Clean off any trace of oil, fuel or coolant using a clean cloth.
o Use only approved cleaning solvents.ing products and methods that are strictly prohibited:
 petrol or other flammable substances;
 soapy solution containing chlorine or ammonia;
 high pressure cleaner.
- Additional instruction:
o If necessary, contact the dealer for the following reasons:
 answers to any questions relating to the equipment;
 training requests for personnel;
 supplying the relevant documentation for maintenance operations;
 supplying spare parts;
 corrective or preventive maintenance operations.
Operating site
- Maintenance:
o Clean the entire operating site regularly with suitable cleaning materials.
o The presence of dangerous or combustible materials inside premises must be limited to the operating requirements.
- Access:
o Prohibit free access to persons who are not part of the establishment, except for those designated by the user.
- Respecting the environment:

o Drain and dispose of engine oil in a specially provided container (fuel distributors can collect your used oil).
o Burning of waste in the open air is prohibited.
o Remove waste water, sludge and other waste in a specialised processing centre.

2.3 Risks relating to handling phases
HANDLING PHASES - RISK OF DROPPING
DANGER
- Select the appropriate handling equipment and apparatus according to the type of equipment being handled. Check that
there is sufficient handling capacity.
- Check that the handling equipment and apparatus are in good operating condition.
- Respect the handling instructions described in the present documentation and the pictograms displayed on the equipment
to be handled.
- Be sure never to stand under the load being handled.
Note: the lifting rings provided on the equipment are designed to handle the generating set alone. If additional equipment is fitted to
the generating set, a study should be conducted in order to define the centre of gravity of the assembly and to check the correct
mechanical performance of the structure and its lifting rings.
2.4 Risk of electrocution
ELECTRICAL EQUIPMENT - RISK OF ELECTRIC SHOCKS
DANGER
- Read the manufacturer's identification plate carefully. The values for voltage, power, current and frequency are shown.
Check that these values match the installation being supplied.
- The electrical connections must be made in accordance with current standards and regulations in the country of use and the
neutral system sold.
- Ask a qualified electrician to intervene when there are specific cases requiring equipment to be connected to an existing
electrical network.
- Disconnect the power to the equipment (equipment voltage, battery voltage and network voltage) before any installation or
maintenance operation is performed.
- Connect the equipment wires by respecting the wiring diagram supplied by the manufacturer.
- Always handle the equipment with dry hands and feet.
- Take all the necessary precautions to avoid touching stripped cables or disconnected connectors.
- Use and maintain the cables in good condition, well insulated and connected correctly and securely.
- Only replace equipment that provides protection against electric shock with identical equipment (specifications and nominal
values).
- Only use flexible durable cables with a rubber covering, which conform to ECI 245-4, or equivalent cables.
- Refit the protective plates (blanking covers) after each maintenance operation.
Note: The electrical equipment supplied with the equipment complies with standard NF C15.100 (France), or with the standards of
the countries in question.
2.4.1 Safety precautions in case of electrical shock
In the event of an electric shock, observe the following instructions:
1. Avoid direct contact both with the live conductor and the victim's body.
2. Shut off the power immediately and activate the emergency stop for the equipment concerned. Note:
the live wire may be cut with an axe. Take extreme care to avoid the electric arc that will be generated
by this.
3. If it is impossible to access the equipment: move the victim away from the live conductor using a dry
piece of wood, dry clothing or other non-conducting material.
4. Move the victim away from any situations where there is a danger of death.
5. Contact the emergency services.
6. If breathing has stopped, begin artificial respiration at once.
7. In the event of cardiac arrest, carry out cardiac massage.

2.5 Risk of fire, burns and explosions
FUELS / FLAMMABLE PRODUCTS / PRESSURIZED

FLUID
- RISK OF BURNS -
- RISK OF FIRE -
DANGER - RISK OF EXPLOSION -
1. Before starting the equipment, move any flammable or explosive products away (petrol, oil, cloth, etc.).
2. It is prohibited to put combustible materials on the hot parts of the equipment (for example: exhaust pipe).
3. Avoid any contact with the hot parts of the equipment (for example: exhaust pipe).
4. Use appropriate ventilation to allow the equipment to cool correctly.
5. Wait for the engine to stop and cool down completely before removing the radiator cap.
6. Wait for the equipment to stop and cool down completely before covering the equipment (if necessary).
7. Depressurize the air, oil and cooling circuits before removing or disconnecting all the fittings, pipes or connected components.
When installing the equipment on a vehicle or other mobile equipment, a study must be conducted beforehand in
order to take into account the various specific uses of the generating set.
IMPORTANT
Fuels
- Respect current local regulations regarding the equipment and fuel used (petrol, diesel and
gas).
- Top up the engine with fuel when the engine has stopped (except for equipment with an
automatic filling system).
- Smoking, using a flame or producing sparks are forbidden while the fuel tank is being filled.
- Use protection suitable against fires and explosions.
- Pipes must be replaced as soon as their condition demands it.
Oils
1. Check that the system is no longer pressurized before carrying out any procedures.
2. Avoid contact with hot oil.
3. Wait for the engine to stop and cool down completely before topping up the oil.
4. Before starting the engine, refit the oil filler cap.
5. It is prohibited to cover the generating set with a fine layer of oil for anti-rust protection.
Battery
Smoking, using a flame or producing sparks are forbidden close to batteries (particularly when the batteries are being charged).
Supply gas (concerns generating sets running on gas) :

- Request the user technical notes and LPG or NG safety data sheets from your gas supplier.
- For any operation on a gas installation, ask a recognized specialist to intervene.
- Gas supply procedures must be carried out in the open air (outside) in accordance with local regulations, in an area well
away from fires, people or animals.
- Check the sealing of the gas supply circuit using soapy water with the circuit pressurized, or using a leak detector.
- It is forbidden to smoke, bring flames near or create sparks when the tank is being filled, and near to the generating set.

2.6 Risks relating to exhaust gases and Risks related
EXHAUST GAS - TOXIC PRODUCTS - TOXIC RISK
DANGER
Exhaust gas
- Use suitable ventilation to release the exhaust gas outside and prevent it from accumulating.
- Respect current local regulations regarding the equipment and fuel used (petrol, diesel and gas).
- Periodically examine the burnt gas exhaust.
- Pipes must be replaced as soon as their condition demands it.
Note: the carbon monoxide present in the exhaust gas may lead to death by inhalation if the concentration levels in the atmosphere
are too high.
Corrosion inhibitor in the coolant (contains alkali)

- Read the instructions on the packaging.
- Keep the product out of the reach of children.
- Do not swallow it.
- Avoid prolonged or repeated contact with the skin.
- Never allow contact with the eyes.
In the event of contact with the eyes:
1. Rinse immediately with plenty of water for at least 15 minutes.
2. Consult a doctor immediately.
In the event of contact with the skin:
1. Wash thoroughly with water and soap.
Fuels and oils

- Do not swallow it.
- Ensure proper ventilation.
- Use a suitable protective mask.
Battery electrolyte
- Avoid all contact with the skin and eyes.
- Wear suitable protective goggles and clothing and strong alkali-resistant gloves
for handling the electrolyte.
If splashes get into the eyes:

1. Rinse immediately with running water and/or a 10% diluted boric acid solution.

2.7 Risks relating to noise
HIGH SOUND LEVEL - RISK OF HEARING LOSS
DANGER
- Always use suitable ear defenders when working in close proximity to a generating set which is in operation.
- The sound pressure level measured at 1 m is indicated on the generating set's nameplate.
Note: For generating sets operating indoors, for which the ambient noise levels are dependent upon the installation conditions, it is
not possible to specify these ambient noise levels in the operating instructions. As prolonged exposure to high sound pressure levels
can cause permanent damage to hearing, acoustic measurements must be performed after installation in order to determine the
sound pressure level and, if necessary, to implement the appropriate preventive measures.
2.8 Guidelines for protecting the environment

Oil, fuel and coolant are very toxic products for the environment and for people's health: they should never be tipped over or allowed
to run into the ground (collect fluids in suitable containers and take them to a waste collection point). Once the generating set is no
longer being used (end of product life), take it to a waste collection point. To prevent the risk of fire, allow a broad clearance around
the generating set (risk of sparks). To reduce noise disturbance, as far as possible, prevent sound from reverberating through walls
or buildings (the noise will be amplified).

3 General description of the equipment
There are 3 main types of generating set:

- Fixed generating set:
 without a protective cover;
 with a protective cover.
- Mobile generating set:
 without a trailer;
 with a trailer;
 lighting column.
- Generating set in a container:
 without a trailer;
 with a trailer.
Note: mobile generating sets always have protection (cover or container).
3.1 Identification plates
3.1.1 Identifying sets
Generating sets and their components are identified by means of identification plates.
The precise rules for identifying each major component (engine, alternator, etc.) are set out in each manufacturer's documentation
contained in the appendices of this manual. 16
1
3
17
2
14
12 10 11 7 15
13 9 8
5 4 18
1 - Generating set
2 - Manufacturer name 9 - Maximum ambient temperature for the rated power (°C)
3 - Model 10 - Rated frequency (Hz)
4 - Serial number 11 - Generating set rotation speed (RPM)
5 - Year of manufacture 12- Rated voltage (V)
6 - Rated output (kVA and kW) according to the ISO 8528-1 13 - Rated current (A)
standard 14 - Weight (kg)
PRP: main power 15 - CE marking
ESP: emergency power 16 - Non CE standard marking (e.g.: EAC)
7 - Rated power factor 17 - Sound pressure
8 - Maximum altitude of the site above sea level (m) for the 18 - Sound power
rated power
Figure 1 : Example of a generating set identification plate
MGS_186_EN _17/07/2017 15:01 33532000201_6_1 Section_3 _General description of the equipment 13

3.1.2 Location of plates on generating sets with and without an enclosure
The identification plate for generating sets with and without protective covers is affixed to the lower section of the base frame.
Identification plate
Figure 2: Position of the identification plate for generating sets with and without protective covers
3.1.3 Location of plates on containerised generating sets
The identification plate for containers is affixed by the emergency stop.
Identification plate
Figure 3: Position of the identification plate for generating sets in a container
14 Section 3 General description of the equipment 33532000201_6_1 MGS_186_EN _17/07/2017 15:01

3.1.4 Identifying generating set components
Figure 4: Examples of engine identification plates
Figure 5: Examples of alternator identification plates
Figure 6: Example of an electrical cabinet identification plate

3.2 Fixed generating set
3.2.1 Generating set without protective cover
5 2
12
11
10
Figure 7: General description of a generating set without a protective cover
1 Air filter 5 Engine 9 Frame

2 Alternator 6 Protective grille for rotating parts 10 Identification plate
3 Damper studs 7 Control unit 11 Circuit breaker
4 Starter battery 8 Radiator 12 Console

3.2.2 Generating set with protective cover
1
2
6
3
15
8
14
13
10
12
11
Figure 8: General description of a generating set with a protective cover
1 Lifting ring 6 Engine 11 Frame

2 Air filter 7 Protective grille for rotating parts 12 Identification plate
3 Alternator 8 Exhaust 13 Circuit breaker
4 Damper studs 9 Radiator 14 Console
5 Starter battery 10 Protective cover 15 Control unit

3.3 Mobile generating set
3.3.1 Generating set without trailer
1
2
14
7
13
6 10
12
16
15 11
Figure 9: General description of a generating set with a protective cover
1 Lifting ring 6 Engine 11 Frame

2 Air filter 7 Protective grille for rotating parts 12 Identification plate
3 Alternator 8 Exhaust 13 Circuit breaker
4 Damper studs 9 Radiator 14 Control unit
5 Starter battery 10 Protective cover 15 Forklift pockets
16 Tow bar

3.3.2 Trailer-mounted generating set
All mobile generating sets are available on a trailer.
Figure 10: Example of a mobile generating set on a trailer
3.3.3 Lighting column
Lights
Column
Generating set with a

protective cover
Trailer
Figure 11: Example of a lighting column

3.4 Containerised generating set
The CONTENERGY® concept offers 3 types of containers:

- ISO 20 and 40 containers,
- CIR 20 container, and
- CPU 20 and 40 containers.
These commercial* designations are used to identify ISO standard container sizes:
ISO
Standardisation 20 feet 40 feet
1CC 1CCC 1AAA

6.058 m x 2.438 m x 2.591 m 6.058 m x 2.438 m x 2.896 m 12.192 m x 2.438 m x 2.896 m
C.S.C. approval:
C.S.C. - ISO20 ‘HC’ ISO40 ‘HC’
C.S.C. CPU20 - CPU40
- CIR20 ‘Dry’ CIR20 ‘HC’ -
The term ‘HC’ makes reference to “High Cube” containers which are high-capacity and have a greater height. The term ‘Dry’
designates standard height containers.
*ISO (making reference to ISO dimensions) - CIR ("Conteneur Industriel et Rental", Industrial and Rental Container) - CPU
(Containerised Power Unit)

3.4.1 ISO 20 and ISO 40 containers
ISO 20 and ISO 40 20' and 40' containers comply with the ISO/TC104 standards and are CSC1 certified, i.e. authorised for shipping.
Silencer
Console
AIPR
Sound trap
Soundproofed
Radiator air inlet grille
Figure 12: Example of an ISO 20 container
Fuel tank
Silencer
Sound trap
Soundproofed
air inlet grille
AIPR
Radiator
Figure 13: Example of an ISO 40 container
1 CSC: Container Safety Convention

3.4.2 CPU 20 and CPU 40 containers
CPU 20 and CPU 40 containers are compact generating sets designed for low noise level and exceptional accessibility. The
dimensions and ISO corners of these models allow ISO transport and handling equipment to be used.
Radiator cores Muffler Console
Air inlet grille
Figure 14: Example of a CPU 20 container
Sound traps
Air inlet grille

Radiator
Figure 15: Example of a CPU 40 container

3.4.3 CIR 20 containers
CIR 20 containers (not C.S.C. certified) are built based on ISO 20 containers (compliant with ISO/TC104 on request).
These low noise level containers are well-suited to mobile and rental applications.
NOTE: The non-retention zone must be in the open air: do not plug the side drainage openings.
Radiator
Muffler
Soundproof air
inlet grille
Tank Drainage hole
Non-retention zone
Figure 16: Example of a CIR 20 container
3.4.4 Trailer-mounted container
All container generating sets (20' and 40') are available on a trailer.
Figure 17: Example of a container on a trailer

3.5 Technical characteristics and operation of additional equipment (if so equipped)
3.5.1 Built-in fluid retention container (option)
Any outflow of the fluid contained in the generating sets (fuel, oil and coolant) will be collected in a retention container if the generating
set is fitted with this option.
The containers have a capacity which allows 110% of the fluids contained in the generating set fitted with this option to be collected.
Three different fittings are available:
Fitting 1: Fluid retention container Fitting 2: Offset fluid retention container Fitting 3: Offset fluid retention container
integrated into the tank frame underneath the generating set frame integrated into the frame and tank
Figure 18: Integrated fluid retention container
Note: generating sets equipped with the option corresponding to fitting 3 (see Figure: Integrated fluid retention container) are also
equipped with a high level indicator in the retention container.
In all cases, the retention containers must be regularly checked to ensure they contain no fluid (fuel, oil and coolant, or rainwater or
condensation). If necessary, drain the containers either via the drain port or using the drain pump (for containers fitted with this pump).
Drain the fluids from the retention container into a designated container.
It is prohibited to perform this drain procedure on the ground.
IMPORTANT

3.5.2 REN-RAB automatic oil auxiliary adjuster
The REN regulator type RAB 101 -70 is an oil level regulator for all engine power ratings. It keeps the oil level in the crankcase
correct. Set to "engine running" oil level, it regulates the level in line with consumption.
3.5.2.1 Technical specifications
Most models have a low level alarm or stop threshold to inform the user about insufficient oil supply, a drop in the crankcase oil level
or potential overfilling.
An integrated oil level threshold triggers an alarm or stops the engine and warns the user that there is an insufficient oil supply, whilst
the engine continues to consume.
Figure 19: General view of the regulator
3.5.2.2 Operation
When the crankcase oil level drops, the float drops and opens the valve.
The open valve allows oil to flow through from the tank to the crankcase via the regulator.
When the desired level is reached in the crankcase, the regulator float rises which causes the valve to close and stops the flow.
The valve has been designed to be self-cleaning and cannot clog.
A 3 mm hole in the regulator is large enough to allow the oil sump to be topped up.
Oil supply
TOP
Float
action
Separation of
unit LR857
BOTTOM
Low level
contacts
Figure 20: Simplified diagram of valve action

3.5.3 JAPY manual pump
The pump is designed to transfer : water, diesel oil, certain solvents
Type Use Exploded view Reference key

Water
Diesel
EP
Oil
Coolant
1. Lever
Water 2. Cap
Diesel 3. Piston + valves + pins
BP Oil 4. Seat + valves + pins
Coolant 5. Body
Seawater 6. Fittings and seals
7. Felt seal + O-ring + fittings
8. Packing gland + ring + packing
Non-flammable
HL
solvents
Diesel
HV
Oil 1. Lever
3. Piston + valves + pins
4. Seat + valves + pins
5. Body
6. Fittings and seals
8. Cap
EZ Diesel
The maximum pressure in the body of the pump should not exceed 10bars. Normal use of the pump should not require any major
effort by the operator during pumping.
In case of major difficulty using the lever during pumping, do not force it, and check to make sure there are no foreign bodies in the
suction circuit, drain the pump. If the difficulties persist, contact one of our agents.
The hourly flow rates are given at the indicated double stroke rate and for a full range of movement of the lever, 1 metre suction, 1
metre discharge, free flow.
Suction capacity is independent of the size of the pump. A size 0 pump and a size 5 pump have the same suction capacity. These
pumps can achieve 7 meters of suction with cold water, at sea level, and with a foot flap. It is advisable to check installation conditions
for suction : Ø of pipe and length.
Size Flow in m3/h Rate Ø openings TDH in m

0 0.9 80 1/2 " 30
1 1.3 80 3/4 " 22
2 2 80 1" 15
3 2.7 70 1 " 1/4 11
5 5 70 1 " 1/2 6
The presence of air in the circuit limits the suction capacity of the pump. To avoid any air ingress, all joints must be perfectly sealed
and the piping must have no cracks or porosity.
Figure 21: JAPY manual pump

3.5.4 JAPY electric pump
Technical data:
- Max. flow rate 35 L/min

- Max pressure: 20m liquid column
- Max. suction head 5 m
- Rotation speed: 2800 rpm
- Fitted with a by-pass
- Operation with discharge cut-off 2 to 3 minutes maximum
- IP 55 protection.
Electrical data:
- Power: 0.37 kW
- Engine made for continuous work
- JEV 10/658 single phase 50 Hz: 220 V – 2.4 A – 240 V – 2.1 A

- JEV 10/658 single phase 60 Hz: 208 V – 3.7 A – 277 V – 3.3 A
- JEV 11/661 three phase 50 Hz: 380 V – 0.8 A – 415 V – 1 A

- JEV 11/661 three phase 50 Hz: 200 V – 1.5 A – 240 V – 1.6 A Figure 22: JAPY JEV Electric pump
- JEV 11/661 three phase 60 Hz: 380 V – 0.9 A – 480 V – 1.4 A

- JEV 11/661 three phase 50 Hz: 208 V – 1.8 A – 240 V – 2 A
The engines are not flame proof.

Use JAPY electric pumps only in areas where there are no inflammable vapours.
DANGER
Usable fluids
- Water, fuel, diesel & light oil

- Maximum viscosity of 10 cSt at atmospheric temperature.
Prohibited fluids
Fluids Corresponding dangers

Petrol Fire, explosion
Flammable fluids with PM below 55 degrees C Fire, explosion
Water Oxidation of the pump
Liquid foods Pollution of the fluids
Liquids with viscosity > 10 cSt Engine overloaded
Corrosive chemical fluids Corrosion of the pump
Solvents Damage to linings and joints
Never let the pump run idle.

Before operating, close the valve or the spray pump.
The bypass will allow the pump to operate with the pump outlet closed for a limited period of time.
IMPORTANT

3.5.5 Shut-off valve
Damper valves are safety components which close automatically and are reset manually.
SHUT-OFF VALVE
Wear gloves and take care operating the damper valves: risk of injury.
DANGER
All models are equipped with a resetting system comprising:

- either a hexagon shape for a spanner,
- or a lever for direct activation.
To reset:
1. Hold the lever or position the spanner on the hexagon shape (we recommend using a ring spanner for improved ergonomics).
2. Slowly but firmly, turn in the direction indicated below until it is possible to feel it lock into place.
3. Gradually release the pressure: the valve should remain open.
Generating set R66 Generating set R350 Generating set R550
Model "B" Model "N" Model "F" Model "E"
Lever
19 hexagon 17 hexagon Lever or 19 or 22 hexagon
depending on model
Figure 23: Damper valve models
3.5.6 Battery charger
Battery chargers are charging modules for emergency electrical supplies, adapted to equipment and systems with inrush currents:
relays, motors, solenoid valves, automata, audible warning devices, etc. and their constant monitoring, signalling, inspection and
control circuits or designed to charge accumulator batteries.
These charger modules associated with batteries comprise battery charger assemblies which make each system safe in the event of
mains supply faults.
They permanently supply the equipment (monitoring, signalling, inspection and control) and ensure that the batteries are maintained.

3.5.6.1 BC0512
Features
DC voltage 12 V
Rated current 5A
Current range 0~5A
Rated power 60 W
Ripple & Noise (max.) 120mVp-p
Voltage adj. Range 12 ~ 15 V
OUTPUT
Line regulation (+/-) 1.0%
Load regulation (+/-) 1.0%
Setup, rise time 500ms, 30ms/230VAC 500ms, 30ms/115VAC at full load
Hold up time (typ.) 50ms/230VAC 20ms/115VAC at full load
Please adjust output voltage required with the potentiometer according to
Information
the battery charger
Voltage range 85 ~ 264VAC 120 ~ 370VDC
Frequency range 47 ~ 63Hz
Efficiency (typ.) 86%
INPUT
AC current (typ.) 1.8A/115VAC 1A/230VAC
Inrush current (typ.) Cold start 30A/115VAC 60A/230VAC
Leakage current <1mA / 240VAC
105 ~ 150% rated output power
Overload Protection type: constant current limiting recovers automatically after fault
PROTECTION condition is removed
15.6 ~ 18V
Over voltage
Protection type : shut down o/p voltage, re-power on to recover
FUNCTIONS Fault relay contact Relay contact ratings (max.) 30V/1A resistive Contact closed = fault
Working temp. (-)20 ~ (+)70°C (refer to output load derating curve)
Working humidity 20 ~ 90% RH non condensing
Storage temp, humidity (-)40 ~ (+)85°C, 10 ~ 95% RH
ENVIRONMENT
Temp. Coefficient (+/-)0.03%/°C (0 ~ 50°C)
Component: 10 ~ 500Hz, 2G 10min./1cycle, period for 60min. each along
Vibration
X, Y, Z axes ; Mounting: Compliance with IEC60068-2-6
Safety standards UL508, UL60950-1, TUV EN60950-1 approved
Withstand voltage I/P-O/P:3KVAC I/P-FG:1.5KVAC O/P-FG:0.5KVAC
Isolation resistance I/P-O/P, I/P-FG, O/P-FG:>100M Ohm / 500VDC / 25°C / 70% RH
SAFETY
& EMC Emi conduction & radiation Compliance with EN55011, EN55022 (CISPR22), EN61204-3 Class B
Harmonic current Compliance with EN61000-3-2,-3
Compliance with EN61000-4-2, 3, 4, 5, 6, 8, 11, ENV50204, EN55024,
Protections EMS
EN61000-6-2, EN61204-3, heavy industry level, criteria A
MTBF 299.2Khrs min MIL-HDBK-217F (25°C)
OTHERS Dimension 40 x 90 x 100mm (W x H x D)
Packing 0.33kg; 42pcs/14.8kg/0,82CUFT
All parameters NOT specially mentioned are measured at 230VAC input, rated load and 25°C of ambient
temperature.
Ripple & noise are measured at 20MHz of bandwidth by using a 12" twisted pair wire terminated with a 0.1µF
& 47% µF parallel capacitor.
NOTES
The power supply is considered a component which will be installed into a final equipment. The final
equipment must be re-confirmed that it still meets EMC directives
Length of set up time is measured at cold first start. Turning ON/OFF the power supply very quick may lead
to increase of the set up time.

Mechanical specification
Unit: mm
Block diagram
Derating curve Battery connection
Output derating VS Input voltage (VAC)

3.5.6.2 BC0524
Features
DC voltage 24 V
Rated current 5A
Current range 0~5A
Rated power 120 W
OUTPUT
2000ms, 70ms, 50ms/400VAC
Setup, rise, hold up time
2000ms, 70ms, 10ms/230VAC at full load
Please adjust output voltage required with the potentiometer according to the
Information
battery charger type before the commissioning
Efficiency (typ.) 91% / 400V
INPUT
AC current (typ.) 0.55A/400VAC 1.2A/230VAC
Inrush current (typ.) Cold start 50A
Leakage current <3.5mA / 530VAC
Overload Protection type: constant current limiting, recovers automatically after fault
condition is removed.
31 ~ 37V
PROTECTION Over voltage
110°C (+/-)5°C (TSW1)
Over temperature Protection type : shut down o/p voltage, recovers automatically after
temperatures goes down
Relay contact rating(max.): 30V / 1A resistive Contact open = DC OK / Contact
Fault relay contact
FUNCTIONS closed = DC NOK
Boos mode Contact closed = boost mode Boost voltage =+4% above floating voltage
Working temp. (-)25 ~ (+)70°C (refer to ouput load derating curve)
ENVIRONMENT
Component: 10 ~ 500Hz, 2G 10min./1cycle, period for 60min. each along X, Y,
Vibration
Z axes ; Mounting: Compliance with IEC60068-2-6
Safety standards UL508 approved
Withstand voltage I/P-O/P:3KVAC I/P-FG:1.5KVAC O/P-FG:0.5KVAC O/P-DC OK:0.5KVAC
SAFETY Isolation resistance I/P-O/P, I/P-FG, O/P-FG:100M Ohm / 500VDC / 25°C / 70% RH
& EMC
EMI conduction & Compliance with EN55011 (CISPR11), EN55022 (CISPR22), EN61204-3 Class
radiation B
Compliance with N61000-4-2,3,4,5,6,8,11, ENV50204, EN61204-3, EN61000-
EMS immunity
6-2 (EN50082-2), heavy industry level, criteria A.
MTBF 268Khrs min MIL-HDBK-217F (25°C)
OTHERS
Dimensions 40 x 125.2 x 113.5mm (W x H x D)
Packing 0.65Kg; 20pcs/14Kg/1.16CUFT
temperature.
Ripple & noise are measured at 20MHz of bandwidth by using a 12" twisted pair wire terminated with a
NOTES 0.1µF & 47 % µF parallel capacitor.
The power supply is considered a component which will be installed into a final equipment. The final
equipment must be re-confirmed that it still meets EMC directives
Length of set up time is measured at cold first start. Turning ON/OFF the power supply very quick may lead
to increase of the set up time.

Unit: mm
Block diagram

3.5.6.3 BC1012
Features
DC voltage 12 V
Rated current 10 A
Current range 0 ~ 10 A
Rated power 120 W
OUTPUT Voltage adj. Range 12 ~ 15 V
Setup, rise time 2000ms, 70ms, 50ms/400VAC - 2000ms, 70ms, 10ms/230VAC at full load
Hold up time (typ.) Please adjust output voltage required with the potentiometer according to the battery
charger type before the commissioning
Voltage range 180 ~ 550VAC - 254 ~ 780VDC
Efficiency (typ.) 89.5% / 400V
INPUT
AC current (typ.) 0.55A/400VAC 1.2A/230VAC
Overload Protection type: constant current limiting recovers automatically after fault condition is
removed
PROTECTION
16 ~ 18V
Over voltage
Over temperature 105°C (+/-)5°C (TSW1)
Fault relay contact Protection type : shut down o/p voltage, recovers automatically after temperatures
goes down
FUNCTIONS
Boost mode Relay contact rating (max.): 30V / 1A resistive - Contact open = DC OK / Contact closed
= DC NOK
Working temp. Contact closed = boost mode - Boost voltage =+4% above floating voltage
Working humidity (-)25 ~ (+)70°C (refer to output load derating curve)
ENVIRONMENT Storage temp, humidity 20 ~ 90% RH non condensing
Temp. Coefficient (-)40 ~ (+)85°C, 10 ~ 95% RH
Vibration (+/-)0.03%/°C (0 ~ 50°C)
Safety standards Components: 10 ~ 500Hz, 2G 10min./1cycle, period for 60min. each along X, Y, Z
axes ; Mounting : Compliance with IEC60068-2-6
Withstand voltage UL508 approved
SAFETY
& EMC Isolation resistance I/P-O/P:3KVAC I/P-FG:1.5KVAC O/P-FG:0.5KVAC O/P-DC OK:0.5KVAC
EMI conduction &
I/P-O/P, I/P-FG, O/P-FG:100M Ohm / 500VDC / 25°C / 70% RH
radiation
EMS immunity Compliance with EN55011 (CISPR11), EN55022 (CISPR22), EN61204-3 Class B
MTBF Compliance with EN61000-4-2,3,4,5,6,8,11, ENV50204, EN61204-3, EN61000-6-2
(EN50082-2), heavy industry level, criteria A
OTHERS
Dimension 40 x 125.2 x 113.5mm (L x H x P)
Packing 268Khrs min MIL-HDBK-217F (25°C)
All parameters NOT specially mentioned are measured at 400V AC input, rated load and 25°C of ambient
temperature.
Ripple & noise are measured at 20MHz of bandwidth by using a 12" twisted pair wire terminated with a 0.1 µF &
47 µF parallel capacitor.
NOTES
The power supply is considered a component which will be installed into a final equipment. The final equipment
must be re-confirmed that it still meets EMC directives
Length of set up time is measured at cold first start. Turning ON/OFF the power supply very quick may lead to
increase of the set up time.

Unit: mm
Block diagram

3.5.6.4 BC1024
Features
DC voltage 24 V
Rated current 10 A
Rated power 240 W
OUTPUT
Load regulation (+/-) 1%
Hold up time (typ.) 18ms / 400VAC 18ms / 230VAC at full load
Information Please adjust output voltage required with the potentiometer according to the battery
INPUT
AC current (typ.) 1A/400VAC 2A/230VAC
Overload Protection type : Constant current limiting, unit will shut down after 3 sec., auto-recovery
after 1 minute if the fault condition is removed
29 ~ 33V
PROTECTION Over voltage Protection type : Shut down o/p voltage, auto-recovery after 1 minute if the fault condition
is removed
90°C (+/-)5°C (TSW1)
Over temperature Protection type : shut down o/p voltage, recovers automatically after temperatures goes
down
60VDC/0.3A, 30VDC/1A, 30VAC/0.5A resistive load - Contact open = DC OK / Contact closed
Fault relay contact
= DC NOK
FUNCTIONS
Contact closed = boost mode
Boos mode
Boost voltage =+4% above floating voltage
Working temp. (-)30 ~ (+)70°C (refer to output load derating curve)
ENVIRONMENT
Vibration Components: 10 ~ 500Hz, 2G 10min./1cycle, period for 60min. each along X, Y, Z axes ;
Mounting: Compliance with IEC60068-2-6
Safety standards UL508 approved, IEC60950-1 CB approved by SIQ, design refer to GL
Withstand voltage I/P-O/P:3KVAC I/P-FG:2KVAC O/P-FG:0.5KVAC O/P-DC OK:0.5KVAC
& EMC Emi conduction &
radiation Compliance with EN55011 (CISPR11), EN55022 (CISPR22), EN61204-3 Class B
EMS immunity Compliance with EN61000-4-2,3,4,5,6,8,11, EN55024, EN61000-6-2 (EN50082-2),

EN61204-3, heavy industry level, criteria A
MTBF 141.1K hrs min. MIL-HDBK-217F (25°C)
OTHERS Dimension 63 x 125.2 x 113.5mm (L x H x P)
Packaging 1.06Kg; 12pcs/13.7Kg/1.06CUFT
temperature.
Ripple & noise are measured at 20MHz of bandwidth by using a 12" twisted pair wire terminated with a 0.1 µF &
47 µF parallel capacitor.
NOTES
The power supply is considered a component which will be installed into a final equipment. The final equipment
must be re-confirmed that it still meets EMC directives

Unit: mm
Block diagram

3.5.6.5 BC2024
Features
DC voltage 24 V
Rated current 20 A
Rated power 480 W
OUTPUT
Load regulation (+/-) 1%
Hold up time (typ.) 18ms / 400VAC 16ms / 230VAC at full load
Information Please adjust output voltage required with the potentiometer according to the battery
INPUT
AC current (typ.) 1.6A/400VAC 4A/230VAC
Overload Protection type : Constant current limiting, unit will shut down after 3 sec. , auto-
recovery after 1 minute if the fault condition is removed
29 ~ 33V
PROTECTION Over voltage Protection type : Shut down o/p voltage, auto-recovery after 1 minute if the fault
condition is removed
95°C (+/-)5°C (TSW)
Over temperature Protection type : shut down o/p voltage, recovers automatically after temperatures
goes down
60VDC/0.3A, 30VDC/1A, 30VAC/0.5A resistive load Contact open = DC OK / Contact
Fault relay contact
FUNCTIONS closed = DC NOK
Boost mode Contact closed = boost mode -Boost voltage =+4% above floating voltage
Working temp. (-)30 ~ (+)70°C (refer to ouput load derating curve)
ENVIRONMENT
Vibration Components: 10 ~ 500Hz, 2G 10min./1cycle, period for 60min. each along X, Y, Z
axes ; Mounting: Compliance with IEC60068-2-6
Safety standards UL508 approved, IEC60950-1 CB approved by SIQ, design refer to GL
Withstand voltage I/P-O/P:3KVAC I/P-FG:2KVAC O/P-FG:0.5KVAC O/P-DC OK:0.5KVAC
& EMC Emi conduction &
radiation Compliance with EN55022 (CISPR22), EN61204-3 Class B, EN61000-3-2,-3
EMS immunity Compliance with EN61000-4-2,3,4,5,6,8,11, EN55024, EN61000-6-2 (EN50082-2),

EN61204-3, heavy industry level, criteria A
MTBF 112.8K hrs min. MIL-HDBK-217F (25°C)
OTHERS Dimension 85.5 x 125.2 x 128.5mm (L x H x P)
Packaging 1.7Kg; 8pcs/14.6Kg/0.9CUFT
All parameters NOT specially mentioned are measured at 400VAC input, rated load and 25°C of ambient temperature.
Ripple & noise are measured at 20MHz of bandwidth by using a 12" twisted pair wire terminated with a 0.1 µF & 47
µF parallel capacitor.
NOTES The power supply is considered a component which will be installed into a final equipment. The final equipment must
be re-confirmed that it still meets EMC directives

Unit: mm
Block diagram
Courbe de charge VS Tension d’entrée (VAC)

4 Handling
HANDLING PHASES - RISK OF DROPPING

Carefully read the safety instructions provided.
INDIVIDUALS HANDLING THE GENERATING SETS MUST BE PROPERLY TRAINED
AND AUTHORISED.
The generating set's handling equipment and the lifting points must undergo
regular inspection.
Before unloading or moving the generating set, check that the lifting equipment
DANGER used is able to bear the weight of the generating set as indicated on the unit's
identification plate (See dedicated chapter).
It is essential that the instructions, safety regulations and current legislation be
respected.
Only C.S.C containers can be stacked.

Refer to the nameplate of the lower container to determine the maximum
stacking load.
The stacking of other generating set models is prohibited.
Some generating sets are equipped with transport brackets, which are red,
facilitating their movement and transportation.
It is essential to remove the transport brackets before the generating set
concerned is installed in its final position.
Lifting a lighting column with the lifting ring fixed to the generating set is
prohibited; use the 4 lifting rings on the trailer.
IMPORTANT
Certain generating sets cannot be handled using the lifting ring mounted on the
enclosure or can only be handled when the fuel tank is empty: follow the
instructions on the sticker, as the case may be. If you have any doubt, please
contact one of our agents.
MGS_186_EN _17/07/2017 15:01 33532000201_6_1 Section_4 _Handling 39

4.1 Unloading the equipment
To unload the equipment from its transportation support, observe the following steps:
1. Select the unloading site for the equipment, in accordance with the following criteria:
- The proximity between the unloading site and the equipment's operating location;
- Ease of access to the equipment for the movement stages;
- Ease of movement between the unloading site and the location where the equipment will be used;
- The ability of the ground to support the load of the equipment and its handling apparatus.
2. Correctly place the transport support and the handling apparatus (crane, forklift, etc.).
3. If the transport support must be moved, make sure that the equipment to be handled is correctly secured.
4. If the ground does not have the prerequisites to support the load of the equipment and its handling apparatus, fit beams or
load distribution plates that are designed to support the entire load.
5. Select the appropriate method, handling equipment and apparatus according to the type of equipment being handled. Check
that the handling capacity is sufficient (weight and jib distance required to place the equipment).
6. Carefully read the instructions relating to the handling methods in the section entitled "Equipment handling" in this document
and call upon a professional to assist you.
4.2 Moving the equipment using slings

Reminder: It is important to know and apply the safety rules and good handling practices. The basic principles to be respected are
as follows:
- Have trained and qualified personnel,
- Use equipment that is in good condition,
- Use appropriate handling accessories,
- Implement organisational measures,
- Respect the regulatory and normative framework.
Each lifting point on the generating set is marked by a pictogram.

The lifting points identified by the pictogram are to be used exclusively.
IMPORTANT
PRIOR TO HANDLING OPERATIONS

- Personal protective equipment must be worn.
- Check the integrity of:
 lifting accessories,
 lifting points.
Should a defect be detected, do not perform the lifting operation and lock out the accessory. Inform the supervisor.
- Check the accessory's maximum working load marking and identification.
- Use lanyards, suction cups or other equipment allowing operators to distance themselves from the load.
- Ensure that the handling methods and accessories do not damage the equipment being handled, notably in the case of
generating sets without enclosures.
- Ensure that the hooks and hooking points are properly locked.
- Ensure that no one is in the load's environment when it is being lifted.
DURING HANDLING OPERATIONS

- Avoid all impact or brusque handling of the load.
- Prevent the load from swaying as much as possible.
- Ensure that no one passes underneath load.
General recommendations:
- Secure the lifting accessories to the generating set's lifting points provided for this purpose.
- Put tension on the lifting device slightly without lifting the generating set.
- Check that the lifting accessories are correctly attached and that the equipment is secure.
- Lift the generating set carefully and without jerking.
- Direct the generating set towards the chosen location and stabilise it.
- Carefully set down the generating set while continuing to position it.
- Slacken the lifting accessories, then remove them from the lifting points.
AFTER HANDLING OPERATIONS

- Check the integrity of the lifting points.
- Take the necessary measures to ensure that the equipment maintains its handling capacity.
40 Section 4 Handling 33532000201_6_1 MGS_186_EN _17/07/2017 15:01

4.2.1 Display of lifting points
Generating set without enclosure
Generating set with 4 fork pockets Generating set with 4 lifting brackets
Generating set with enclosure
Enclosure with 1 lifting ring Enclosure with 2 lifting brackets Enclosure with 4 lifting brackets
angle between slings ≤ 30° sling length ≥ 2x enclosure width
sling length
or
enclosure width
WARNING
Maximum sling angle for enclosed generating sets with lifting brackets
Container
X4
NOTE: A SPREADER must be used when lifting by upper ISO corners.

4.3 Moving the equipment using a forklift truck
as follows:
4.3.1 Handling generating sets with and without an enclosure
Each forklift pocket area of the generating set is marked by a pictogram.
IMPORTANT
Use a forklift truck with forks that are longer than the width of the frame.
IMPORTANT
1. Position the forklift's forks under the frame (except with generating sets fitted with "forklift pockets", in which case position
the forks in these pockets), making sure that only its cross members are resting on the forks.
2. Lift the equipment, handling it gently.
3. Set down the generating set in its unloading location.
Figure 24: Examples of handling using forklifts
4.3.2 Handling containerised generating sets
Only containers equipped with forklift pockets are authorised for handling.
Each forklift pocket area of the generating set is marked by a pictogram.
IMPORTANT
Use a forklift truck with forks that are longer than the width of the frame.
IMPORTANT
42 Section 4 Handling 33532000201_6_1 MGS_186_EN _17/07/2017 15:01

4.4 Moving the equipment using a mobile winch
as follows:
If you are using a room equipped with a suitable rail or mobile winch, proceed as described in the paragraph "Moving the equipment
by hoisting".
Figure 25: Handling example of a generating set using a mobile winch
4.5 Moving equipment by rollers or dolly systems

as follows:
Use equipment that is in good condition and suited to the material to be moved.
In the event a cable ratchet is used during rolling operations, an appropriate braking system in keeping with the load must be
implemented.
Only generating sets that do not have brackets built into the frame can be moved using rollers or dolly
systems.
The base frame support surface on the rollers must not be deformed.
IMPORTANT

5 Transporting and storing the generating set
It is prohibited to operate generating sets whilst they are being transported.
IMPORTANT
5.1 Preparing for transport
All transport operations must be carried out in compliance with the current regulations of the countries concerned.
Prior to all transport operations:
- Check the overall condition of the generating set and ensure that all threaded fasteners are tight;
- Check that all valves on the generating set are correctly closed (drain valve, fuel valve, etc.);
- Check for leaks;
- Protect the generating set so that it is not damaged during transport.
Certain elements of the generating set (exhaust stack, spark arrestor, exhaust extension, air conditioner, cooling towers, etc.) must
sometimes be dismantled for transport: protect them during their transport, plug their installation location and ensure that they are put
correctly back into place upon delivery.
5.2 Road transport
5.2.1 ADR regulations concerning the transport of dangerous materials
What is this all about?

ADR (formally, the European Agreement concerning the International Carriage of Dangerous Goods by Road (ADR)) is a United
Nations treaty signed 30 September 1957. This agreement, regularly amended since it was first passed, concerns the transport of
dangerous goods by road, and all operations associated with the loading or unloading of a rail car, inland navigation for the intention,
or after execution of such transport performed in full or in part within the territory of the European Union.
Which countries are concerned
The ADR signatory countries are as follows: Albania, Germany, Andorra, Austria, Azerbaijan, Belarus, Belgium, Bosnia and
Herzegovina, Bulgaria, Cyprus, Croatia, Denmark, Spain, Estonia, Republic of Macedonia, Russia, Finland, France, Greece,
Hungary, Ireland, Italy, Kazakhstan, Latvia, Liechtenstein, Lithuania, Luxembourg, Malta, Morocco, Moldova, Montenegro,
Netherlands, Norway, Poland, Portugal, Czech Republic, Romania, United Kingdom, Serbia, Slovakia, Slovenia, Switzerland, Tunisia,
Turkey and Ukraine.
And the generating sets?
The ADR regulation (2013) introduces special provision 363 to address the case of generating sets for which the fuel tank contains
fuel so that they can be operational without having to first fill their fuel tank.
- Where the means of containment has a capacity of more than 60 litres but not more than 450 litres,
the machinery or equipment is labelled on one external side in accordance [...] and where the capacity
is greater than 450 litres but not more than 1,500 litres the machinery or equipment is labelled on all
four external sides [...].
- Where the means of containment has a capacity greater than 1,500 litres, the machinery or equipment
is placarded on all four external sides [...] and the transport document includes the following additional
statement: ‘Carriage in accordance with special provision 363’.
44 Section 5 Transporting and storing the generating set 33532000201_6_1 MGS_186_EN _17/07/2017 15:01
5.2.2 Generating sets with and without an enclosure
When transporting generating sets by road, the following steps must be observed:
1. Select transport equipment (trailer, semi-trailer, etc.) suitable for this usage and which has all the safety guarantees in terms
of load bearing capacity and of the securing devices.
2. Place the generating set on the transport equipment: it should preferably be positioned over the axles and centred so as to
balance the load.
3. Chock and secure the generating sets to the deck of the transport equipment or use non-slip pads at the four corners of the
genset.
4. Strap the generating sets to their transport equipment, ensuring that their placement does not risk damaging the equipment
during transport.
For generating sets equipped with a towbar, the strap can be placed around the towbar.
5. Select a transport route which makes it possible to travel on roads suitable for vehicles, and whose quality will not damage
the on-board generating sets.
A poorly secured load is dangerous!

A poorly centred or poorly positioned load may cause it to tip over during transport. Always ensure that the
generating set is correctly secured and that the securing equipment is in good condition. The retaining straps
must be positioned to ensure the stability of the load without damaging it.
IMPORTANT
1. Place the slings over the top of the

enclosure, on the inside of the
lifting brackets.
20° - 30°
2. Secure the slings to the deck of the

Enclosure truck without crossing them: the
with two pairs angle of attachment must be
of lifting between 20° and 30°.
brackets
3. Chock and secure the generating

sets to the deck of the transport
equipment or use non-slip pads at
the four corners of the genset.
MGS_186_EN _17/07/2017 15:01 33532000201_6_1 Section_5 _Transporting and storing the generating set 45
1. Place the slings over the top of 20° - 30°
the enclosure, on each side of the
lifting brackets.
2. Secure the slings to the deck of

Enclosure
the truck without crossing them:
with one pair
the angle of attachment must be
of lifting
between 20° and 30°.
brackets

equipment or use non-slip pads
at the four corners of the genset.
20° - 30°
1. Place the slings over the top of the

enclosure, crossing them on each
side of the lifting eye.
2. Secure the slings to the deck of

Enclosure
the truck: the angle of attachment
with single
must be between 20° and 30°.
lifting eye

equipment or use non-slip pads at
the four corners of the genset.
Figure 26: Example of recommended lashings for generating sets with protective enclosures
5.2.3 Containerised generating sets
When transporting generating sets in containers on roads, the following steps must be observed:
1. Select transport equipment (container carrier) suitable for this usage and having all the safety guarantees in terms of load
bearing capacity and securing devices.
2. Select a transport route which makes it possible to travel on roads suitable for vehicles, and whose quality will not damage
the container or its contents.
5.3 Rail transport
Generating sets must be transported by rail in accordance with the specific rules governing rail transport.
For the transport of generating sets by rail, choose transport equipment appropriate for this usage, and having all the safety
guarantees both in terms of load-bearing capacity and securing devices.
Containers transported by rail must comply with the specific rules governing rail transport.
Containers must receive the necessary approvals for rail transport.
When transporting generating sets in containers by rail, choose transport equipment appropriate for this usage and having all the
guarantees in terms of load-bearing capacity and securing devices.
5.4 Shipping
It is prohibited to operate generating sets whilst they are being transported.

It is essential to plug the openings (air inlets and outlets, exhaust, etc.).
Only C.S.C containers can be stacked. It is prohibited to stack other models of generating sets which must be
IMPORTANT transported in cargo holds.
We strongly recommend that maritime containers be used to transport the generating sets. Choose the appropriate transport
equipment having all the safety guarantees in terms of protection, load-bearing capacity and securing devices. In the case of an LCL
(less-than-container-load) container, elements must be packed in SEI crates.
Before all maritime transport:

1. Ensure that the container is properly sealed: all openings must be plugged (air inlets and outlets, exhaust, etc.).
2. Check that the container has valid C.S.C. approval.
For C.S.C. approved containers :

Generating sets housed in approved containers can be transported as maritime containers. They can be stacked in a cellular ship,
and can be gripped from above.
For non-approved containers :

Transportation in cargo holds is recommended for generating sets in non-approved containers.
5.4.3 Accessories and spare parts
The transport of certain elements of the generating set or the installation must often be organised separately.
This involves, for example:
- For generating sets: exhaust stacks, cooling towers and other bulky components which must sometimes be dismantled for
transport, or spare parts.
- For installations: electrical cabinets, transformers, terrace-mounted cooling towers and other electrical or mechanical
components.
These components must be packaged in at least a SEI 4 shipping container, with category C protection (solid case under waterproof
cover) for electrical equipment.
5.5 Air transport

According to UN regulations, generating sets are classified as “dangerous goods” as per UN 3166 - class 9 - “Engine, internal
combustion (flammable liquid powered)”.
For air transport, the generating sets must be properly marked and labelled. Air shipments of generating sets are subject to prior
declaration to the air freight company.
Choose transport equipment appropriate for this usage, and having all the safety guarantees both in terms of load-bearing capacity
and securing devices. Electrical equipment such as electrical cabinets or transformers must be packed in an SEI 4 C case (solid case
with waterproof cover).
5.6 Generating sets on trailers
5.6.1 Safety instructions
ACCIDENT RISK
Before each use, check overall condition of the trailer and the fastening of the generating set.
At all times, ensure that:
- The manoeuvre cannot injure someone.
- No one is near the vehicle when it is being moved or its mobile elements are in use.
Perform the technical inspections required by current regulations.
The original adjustments must be maintained and checked by specialists.
It is essential that the instructions, safety regulations and current legislation be respected.
Any attempt to tow a trailer with a non-compliant device (bar, cables, lashing, etc.) runs the risk of
DANGER serious accidents.
5.6.2 Description
5.6.2.1 Weight characteristics
A.G.W.: Authorised Gross Weight.

T.W.: Tare Weight (G.1)*.
P.L.: Payload = A.G.W. – T.W.
A.G.V.W.: Authorised Gross Vehicle Weight.
* See vehicle registration.
Before each departure, check that the following loads are not exceeded:
- hitch load,
- A.G.W,
- A.G.V.W.
This information is indicated on the vehicle load plates.
5.6.2.2 Hitches
JEEP lift head coupler:

Perfect for pulling a trailer fitted with a hitching ring.
Standard BNA Ø68 int. tore Ø42
Standard NATO Ø76 int. tore Ø42
COMBINATION type coupler:

Perfect for pulling a trailer fitted with a ball-hitch coupler or ring.
Standard BNA Ø68 int. tore Ø42
Standard NATO Ø76 int. tore Ø42
MANEUVERING AND MAINTENANCE pin and clevis type coupler:

As its name implies, this type of coupler is not intended to permanently tow a trailer.
Adapter for BNA and NATO ring:

Completely prohibited by the legislation (dangerous).
5.6.2.3 Signalling
The trailer is equipped with a lighting device in compliance with European Directive 76/756/CE.
Lights/signalling (only for "on-road" trailers)
Warning lights are mandatory for on-road driving. Signalling must comply with current regulations in the country of use.
Front reflectors (white)

Red rear lights
+ direction indicator lamps
+ stop lights
Rear reflectors (red triangle)
Side reflectors (orange)
Figure 27: Signalling example for on-road trailers
5.6.2.4 Limits
Speed limits:
Our trailers are approved for a maximum speed of 140 km/h on roads suitable for vehicular traffic.
Our trailers are not designed for all-terrain use.
Specific limitation: road signs
Speed limits over obstacles (height / speed):
- Curb: 30 cm at 5 km/h
- Speed bump: 10 cm at 30 km/h
5.6.3 Use
The trailer must be hitched horizontally, particularly concerning dual-axle trailers. All 4 wheels must be in contact with the ground.
CORRECT CORRECT
véhicule
Towing vTowing
éhicule
tracteur
vehicle remorque tvehicle
racteur remorque
Trailer Trailer
INCORRECT INCORRECT
Towing
véhicule vTowing
éhicule
vehicle
tracteur tvehicle
racteur
remorque
Trailer
remorque
Trailer
The brake controls are designed to pull trailers behind passenger vehicles with soft suspension. If used behind an
HGV, the ball hitch must be fitted with a damper to prevent premature wear.
WARNING
5.6.3.1 Verifications prior to hitching
Before towing, check the following:

- Towing vehicle
o Check that the towing vehicle is approved to pull the trailer.
o The vehicle must be driven by a driver having the corresponding driving licence.
- Hitching zone
o Check the condition of the hitching ring or the ball-hitch coupler. They must not be damaged.
o Tighten and pin the locking levers on the drawbar arms (if fitted with an adjustable drawbar).
o The mounting hardware must not hinder the brake control in any way.
- Trailer
o Wheel tightness.
o Tyre pressure.
o The tyres must be free of cuts and not worn beyond the tyre wear indicators.
o The servicing and maintenance operations must have been carried out.
o Tightening of the generating set enclosure bolts.
o Enclosure doors closed.
The trailer may become unhitched from the tow vehicle if not hitched correctly. The release cable will engage
the parking brake (acting as an emergency brake) should the trailer become detached from the towing vehicle.
The following instructions must be followed in order for the braking system to operate effectively:
- The release cable MUST NOT be wound around the jockey wheel, as this would prevent the
emergency brake from working.
- The release cable MUST run as straight as possible, without being impeded at any point.
- The release cable must be long enough to allow turning, and it must not be stressed or impeded in
use, as this would trigger the parking brake while the vehicle is being towed.
IMPORTANT
Figure 28: Release cable
5.6.3.2 Hitching a trailer equipped with a hitching ring
The hitch must correspond to the type of brake control ring.

The rings are able to pivot around their horizontal axis +/-5° and, in accordance with BNA recommendations, the hook receiving the
ring must pivot.
After the ring is hooked, check that the locking devices (pins, clips, etc.) are correctly in place and serve their purpose.
Coupling
1. Drive the towing vehicle or move the trailer (after releasing the parking brake, if fitted) to the coupling position.
2. Put the trailer in the horizontal position using the guide wheel (jockey wheel).
3. Put the hitching ring above the towing vehicle hook, and then lower the adjustable draw bar (if fitted) or lower the front of the
trailer to secure the ring in the hook; the trailer must remain in the horizontal position after this adjustment. Make any
necessary height adjustments using the jockey wheel to enable coupling.
4. Once this has been done, raise the jockey wheel until it is lifted off the ground slightly and is not bearing any load.
5. Attach the release cable to the attachment point on the hitching point (see Figure: Release cable), then plug the electrical
cable controlling the lamps, indicators, etc. into the socket on the towing vehicle. Check that the lamps on both the vehicle
and the trailer operate correctly.
6. Lift up the jockey wheel completely and lock it in position, making sure that it is not impeding the brake rod or the release
cable. In the case of a retractable jockey wheel, make sure that the safety pin has been correctly put back in position.
7. Ensure that the parking brake (if fitted) is completely disengaged by pushing its handle down fully. If necessary, remove and
store the wheel chocks.
5.6.3.3 Hitching a trailer equipped with a coupling head (ball)
The ball must comply with standard ISO1103 (Ø50 mm).

Ensure that the hitch is properly coupled by attempting to raise the drawbar slightly with both hands. Ensure that there is no play.
Any play present in the hitch must be corrected.
Do not use the lever on the hitch coupler to manoeuvre the vehicle.
Regularly check the wear indicator on the hitch coupler.
5.6.3.3.1 Coupling
1. Drive the towing vehicle or move the trailer (after releasing the parking brake, if fitted) to the coupling position.
2. Open the coupling head. To do so, pull the coupling handle (see Figure: Coupling head example) in the direction of the arrow.
The coupling mechanism can remain open as long as the coupling head is not resting on the tow ball.
3. Put the trailer in the horizontal position using the guide roller (jockey wheel), and then mount the open coupling head on the
hitching joint by lowering the adjustable towbar, if fitted, or by lowering the front of trailer. This must remain in the horizontal
position after this adjustment.
If necessary, adjust the height using the jockey wheel. The coupling head will be engaged automatically, accompanied by a
clearly audible click; then lower the coupling handle. The coupling mechanism will then be engaged, and the coupling handle
cannot adopt a lower position (when manoeuvred by hand).
4. Once this has been done, raise the jockey wheel until it is lifted off the ground slightly and is not bearing any load.
5. Attach the cable to the attachment point on the hitching plate (see Figure: Release cable), then plug the electrical cable
controlling the lamps, indicators, etc. into the socket on the towing vehicle. Check that the lights on both the vehicle and the
trailer operate correctly.
6. Raise the jockey wheel completely and lock it in position, making sure that it is not impeding the brake rod or the release
cable. In the case of a retractable jockey wheel, make sure that the safety pin has been put back in place correctly.
7. Ensure that the parking brake (if fitted) is completely disengaged by pushing its handle down fully. If necessary, remove and
store the wheel chocks.
Figure 29: Example of a coupling head
5.6.3.3.2 Wear indicator (on certain models)
The coupling head has a wear indicator (see Figure: Wear indicator) that tells you whether the wear limit of the towing vehicle's tow
ball or that of the towed vehicle's coupling has been reached.
To use this indicator, couple the trailer and drive the towing vehicle approximately 500 m, so that the coupling head is positioned.
When you have done this, check the wear as indicated below.
green
red
Figure 30: Wear indicator

If the green section of the indicator can be seen on the coupling (hitched), the coupling head is in good condition, or tow ball wear is
below the prescribed limit.
If the green section of the indicator is completely masked, and if only the red section is visible, it can be assumed either that the tow
ball has reached the wear limit (diameter < 49.61 mm), or that the coupling head and tow ball both show signs of wear, or finally that
the tow ball is in good condition (diameter 50 mm), but that the coupling head is worn.
In these conditions, the coupling head may release the tow ball, and the trailer becomes detached from the
towing vehicle. Therefore, the coupling head and tow ball must be checked prior to each use. All defective
parts must be replaced.
IMPORTANT
5.6.3.4 Operation
"On-site" trailer
These trailers are not fitted with a main brake, and so cannot be braked in motion; the tyres allow
for a maximum speed of 27 km/h. It is therefore absolutely prohibited to exceed this speed.
Nor are these trailers fitted with signalling lights. On-road use is prohibited.
"On-road" trailer
Special attention must be paid to the tightening of the wheels on new vehicles and after each
removal/replacement.
In the first few miles' driving, heating of the brake hubs and drums will actually loosen the lug nuts. It is
therefore essential that the lug nuts be checked every 6 miles (10 kilometres) until no further loosening is
noted.
IMPORTANT
The lug nuts should nonetheless be checked prior to each use of the trailer.
Should the trailer be at a right angle with the vehicle in reverse, never continue reversing.
The way you drive and your speed must be suited to the condition of the land, roads and paths and how the trailer handles.
Check the brakes at a speed below 30 km/h.
Driving at high speed causes the tyres to heat up; it is thus important to stop from time to time and check them. Excessive heating
may result in a blow-out and therefore cause a serious accident. For reversing manoeuvres, remember to lock the inertia brake.
5.6.3.5 Uncoupling
1. Set the parking brake (if fitted), and immobilise the trailer by chocking the wheels.
2. Using the jockey wheel, unlock the coupling and raise the drawbar to release the hitch from the towing vehicle. The jockey
wheel retraction mechanism (if fitted) must lock automatically before the jockey wheel touches the ground. When you are
sure that the mechanism is locked and that the wheel is bearing the load, the trailer can be uncoupled from the vehicle.
3. Disconnect the electrical cable plug controlling the lights, indicators, etc. from the socket on the towing vehicle.
4. Remove the release cable from the hitching plate.
5.6.4 Technical information
5.6.4.1 General specifications
Available drawbars:
On-site trailer with straight drawbar (RCTD)
On-road trailer with fixed drawbar (RRTF)
On-road trailer with articulated drawbar (RRTA)
Braked on-road trailer with articulated drawbar

(RRFTA)
Views Enclosures AGW Available drawbars(1)
RRTA
M125 750 kg
RRTF
RCTD
750 kg RRTA
RRTF
M126
1300 kg RRFTA
M126 Double wall 1300 kg RRFTA
750 kg RTTA
M127
1600 kg RRFTA
M128 / M129 2500 kg RRFTA
M226 3500 kg RRFTA
(1) : Available drawbars: DIN40 ring / 68x42 ring / 76x42 ring / 50 mm ball.
5.6.4.2 Wheels and tyres
Respect the recommended tightening torque.

All tyres having received an impact must be checked.
The wheels and tyres must be replaced with wheels and tyres with identical size and characteristics.
Tyre pressure in bar
500 x 10 2.75 155 R 13 2.5 165 R 14 C 4.5 215/75 R 14 C 4.5
155/70 R 12 6.25 155/70 R13 2.2 175 R 14 C 4.5 185 R 15 C 4.5
135 R 13 2.4 165 R 13 2.3 185 R 14 C 4.5 225/75 R16 C 5.75
145 R 13 2.2 165/70 R 13 2.3 195 R 14 C 4.5
145/70 R 13 2.4 185/70 R 13 2.5 215 R 14 C 4.5
Lug nut tightening torque

10 mm shaft 60 N.m 14 mm shaft 120 N.m 16 mm shaft 120 N.m
5.6.4.3 Fastening the generating set on the trailer
Characteristics of the threaded fasteners used to secure the generating set to the trailer:
- Recommended threaded fasteners: M16 class 8.8 minimum
- Self-locking nuts
- Recommended tightening torque (dry fit):
232 N.m for M16 class 8.8 screws
5.6.4.4 Connection of electric harnesses
13-pin plug 7-pin plug
Keyed slot
Pin No. Allocation Colour Pin No. Allocation Colour

1 Left turn signal Yellow 1 Left turn signal Yellow
2 Fog lamp Blue 2 Fog lamp Blue
3 Earth White 3 Earth White
4 Right turn signal Green 4 Right turn signal Green
Right tail lamp + Right tail lamp +
5 Brown 5 Brown
registration plate lamp registration plate lamp
6 Stop Red 6 Stop Red
Left tail lamp + Left tail lamp +
7 Black 7 Black
registration plate lamp registration plate lamp
8 Reversing lamps Grey
9 +12V permanent Brown-Blue
10 +12V via Ignition lock Brown-Red
11 Earth for pin 10 White-Red
12 Unassigned
13 Earth for pin 9 White-Black
5.6.4.5 Maintenance schedule
When commissioning
Operations Frequency Every 6 months Every year
and before towing
General condition of the

vehicle
Tyre pressure 
Tighten the wheel nuts 
Efficiency of the automatic
 
brake
Efficiency of the parking
 
Check brake
Braking adjustment and
 
distribution across all wheels
Wear on brake linings and

drums
No play in the hubs 
Play in the clamping tube 
Play in the ball socket or ring 
Braking control hinges and
 
Lubricate joints
Stands and jockey wheel rod  
Lubricate or grease the moving parts on the coupling device (see lubrication points examples in the Figure: Trailer lubrication/greasing
points
Recommended lubricant: general purpose grease compliant with DIN 51825 KTA 3KA.
Figure 31: Trailer lubrication/greasing points
5.6.4.6
Fault observed Cause Solution
Faulty shock absorber Replace the faulty shock absorber*

Sudden braking
Incorrect linkage adjustment Readjust*
Jaws worn Replace the jaws*
MGS_186_EN _17/07/2017 15:01

Jaws not run in Fault will disappear by itself, after running in
Incorrect adjustment Readjust*
Braking too weak Significant friction on the plunger Grease the sliding parts
Plunger corrosion Remove the corrosion and lubricate with grease
Adjust the height so that the two parts are in the same horizontal
Troubleshooting tables
Hitch height does not match that of the towing vehicle

plane
ncorrect linkage adjustment Make adjustments*
33532000201_6_1
Drum temperature abnormally high Incorrect brake adjustment Make adjustments*
Jaws, springs, drums, brake cable or linkage deteriorated Replace the damaged parts*
Incorrect linkage adjustment Make adjustments*

Interfering elements on the plunger Remove, clean and grease*
Jerky braking Plunger corrosion Remove the corrosion and lubricate with grease
Damage to plunger guide rings Replace the rings and, if necessary, the plunger and grease*
Faulty shock absorber. Replace the shock absorber*
Cross-bar not balanced Adjust the cross-bars*

Different brake adjustment Adjust the brakes*
Trailer tends to swerve upon braking Cables damaged or incorrectly fitted Replace the deteriorated parts and redo the cable installation*
Faulty shock absorber Replace the shock absorber*
Damage to plunger or guide rings Replace the faulty parts and grease*
When starting, the trailer holds back Plunger corrosion Remove the corrosion and lubricate with grease
the towing vehicle Linkage damaged or incorrectly set Replace the damaged parts and make adjustments*
Faulty shock absorber Replace the shock absorber*
Play in the coupling head Head worn (see wear indicator) or ball worn Replace the head or the ball*
Incorrect adjustment Readjust*

Automatic lever:
Excessive J2 play (Max.: 8 mm). Readjust*
Parking braking too weak Excessive lever stroke
Ratchet lever:
Excessive J2 play (Max.: 2 mm). Readjust*
Notched sector damaged Replace the sector and completely readjust*
Lever ratchet worn Replace the lever*
Section_5 _Transporting and storing the generating set

*: operations to be performed by qualified personnel
57
6 Installation
The contents of this chapter are only general recommendations.

It is recommended that professionals are employed to ensure correct installation and start-up.
The company cannot be held responsible for breakdowns related to the conditions of installation.
IMPORTANT
6.1 General instructions, prerequisites for all installations
6.1.1 Determining the installation location
The generating set's installation location will be determined according to the application. There are no specific rules which govern the
choice of location, but the following elements are deciding factors:
- proximity to the electrical distribution panel;
- disturbances caused by noise;
- fuel supply;
- burnt gas evacuation;
- the nature of the ground.
The choice of location will therefore be the result of a carefully considered compromise!
Land too rough or soft

Incorrect ventilation and exhaust Undersized access
Incorrect generating set seating
Impossible to fill with fuel Impossible to open enclosure doors
Figure 32: Examples of problems that may be encountered
58 Section 6 Installation 33532000201_6_1 MGS_186_EN _17/07/2017 15:01

6.1.2 Creating the base for the generating set
The installation area should be flat enough for the frame to rest level on it and strong enough so that the generating set does not sink
down (on a slab, for example).
Furthermore, an operating generating set generates a certain amount of vibratory energy. This vibratory energy makes its way to the
ground via the frame. Installed on resilient mounts, our generating sets do not require a special support. However, the surface on
which the generating sets rest must be:
- strong enough to support the loading;
- detached from the rest of the construction;
- level;
- slab smoothed when poured;
- slab without separate screed.
If there is a risk of vibration transmission, the generating set can be mounted on a floating slab, insulated if necessary by a resilient
material. This solution is mainly used for very powerful generating sets.
Some generating sets are equipped with transport rollers (red in colour), facilitating their handling and
transport: the transport rollers must be removed prior to final installation of the generating sets concerned.
It is prohibited to rest the containerised generating sets on their ISO corners. A recess should be made for
IMPORTANT the ISO corners in the concrete slab.
CORRECT INSTALLATION
INCORRECT INSTALLATION
INCORRECT INSTALLATION
Figure 33: Containers placed directly on the ground
MGS_186_EN _17/07/2017 15:01 33532000201_6_1 Section_6 _Installation 59

6.1.3 Fuel management
6.1.3.1 Reminder of applicable regulations
The regulations concerning fuel are unique to each country. Refer to the regulations in force in the country concerned.
Example of current regulations in France:
Decree of 10/08/982.
Decree of 19/11/01 – Article EL73.
- Daily fuel tank
 The maximum capacity of the Daily Fuel Tank (DT) in the generating set room is 500 L for an Establishment Receiving
the Public (ERP).
 Place the DT in a separate room if the volume is greater than 500 L.
- Use a retention container with a capacity greater than the capacity of the DT.
- Fuel pipe:
 If the pipe is under load and underground: double skin.
 Use a safety valve between the main tank and the DT.
 Use a safety valve between the DT and the engine.
 It is prohibited to use hoses in the ERP.
Regulations concerning the installation of an underground fuel tank are unique to each country. Refer to the current regulations in the
country concerned.
Example of an underground fuel tank installation according to the current regulations in France:
Decree of 22/06/19984 articles 9 and 11.
VENT at least 4 m high,

3 m open flame - opening
10 metres EMERGENCY
EXIT
PROPERTY
PROPERTY
UNDERGROUND
FUEL OR GAS
STORAGE TANK
TRANSFER
PUBLIC ROAD
Figure 34: Figure: Example of a fuel tank installation in France
2 Decree of 10 August 1998 modifying the decree of 25 July 1997 relating to general advice applicable to installations classified for
the protection of the environment subject to the declaration under section no.2910 (Combustion).
3 Decree of 19 November 2001 concerning the approval of conditions complementing and modifying the safety regulations against
the risk of fire and panic in establishments receiving the public. Article EL 7 concerning the installation of generating sets.
4 Decree of 22/06/1998 relating to underground tanks storing flammable liquids and their related equipment.

6.1.3.2 Description of the installation
Since the fuel is classed as a "dangerous product", certain regulations for storage and distribution must be followed. It is also
necessary to consult current laws when carrying out the installation.
Do not use galvanised receptacles or brass coated receptacles for storing fuel.
IMPORTANT
Manual filling tank

Solution is valid for a manual start generating set that is visually monitored.
This tank is often integrated into the frame and comprises:
- a mechanical gauge;
- a filler neck;
- a drain port.
Automatic filling tank located in the room

This type of installation is subject to regulations.
Solution for automatic start generating sets. The tank is automatically filled by an electric drawing pump in a main storage tank. The
pressure limit for the supply to the daily service tank is 3 bar (risk of leaks and damage if exceeded).
There must be an overflow pipe going back to the main tank. Its cross-section should be at least twice that of the supply pipes.
To prevent unpriming, the tank is fitted slightly filled in relation to the diesel engine (except in covered parking areas).
This tank must also be fitted with a safety valve for which the control must be located outside the room.
RM 6 7
21 REC REM
1
ASM
24
8 9 3 11 12 13 11 4 5
ASM
P c
25 14 15
10
27 19 2
VB
23
20
26
17
16
1 - Daily service tank V1 10 - Non-return valve 19 - Filler
18 2 - Retention tank V2>V1 11 - 3-way valve 20 - Dipstick
22 3 - Electro-pump 12 - Filter 21 - Tank vent
4 - Manual pump 13 - Meter 22 - Earth plate
5 - DT leak detection 14 - Shut-off valve 23 - Safety valve
6 - DT dipstick 15 - Engine isolation valve 24 - Safety valve casing
7 - DT vent 16 - Single or double wall tank 25 - Shut-off valve casing
8 - Isolation valve 17 - Filling limiter 26 - Tracking
9 - Filter 18 - Foot valve with filter 27 - Leak detection (if double wall tank)
Figure 35: Example of an installation
Use a retention container capable of collecting leaks, with a capacity which is at least equal to 110% of the total volume of fluid
present in the generating set (fuel, oil and coolant).

6.1.4 Limiting noise pollution
Analyse any noise pollution that the equipment may cause in order not to disturb those living close by.
Be aware of the regulations in force, in order not to be vulnerable to future legal action.
The sound level of the set and reverberation effects on buildings must be taken into account.
Figure 36: Examples of an increase in sound level caused by reverberations and sound directivity
6.1.5 Install the additional equipment
For contractual reasons, certain logistics or technical equipment are either not delivered, delivered separately or delivered uninstalled.
Such items may include exhaust (protection from hot parts, spark arrestor, exhaust extension or outlet), cooling, and ventilation or
air-conditioning elements, as well as electrical elements such as cabinets. Before commissioning the generating set, install these
elements so as to ensure that the final product is compliant with the applicable regulations (e.g.: CE compliance). Call upon a
professional installer, if needed.
6.1.6 Protect against surges
Generating sets are not equipped with devices that protect against voltage surges from atmospheric discharges or due to handling
operations.
The company disclaims all liability for any accidents caused by these phenomena.
However, it is possible to install surge protectors considering that this assembly does not provide complete protection.

6.2 Generating sets without enclosures, installation in a room

IMPORTANT
6.2.1 Introduction
Note: failure to respect the main principles exposes the entire installation to damage and abnormal wear. The procedure described
lists the main requirements for installing a "standard" generating set composed of a heat engine, a generator and an electrical panel.
These requirements must be considered to be the general principles. For any special applications and if in doubt, our technical
services will advise you and assess your specific installation conditions. Moreover, the current regulations, requirements and laws
relating to installation locations should be respected.
FIRE RATED DOOR
EXHAUST GASES RELEASED

AIR OUTLET OUTSIDE THE ROOM
FUEL STORAGE
AIR INLET
ELECTRICAL CABLES
FUEL PIPE MOUNTING OF EARTH TERMINAL

GENERATING
SET TO FLOOR
PLATE
Figure 37: Example of a generating set room

6.2.2 Selecting the type of premises
There are two possible scenarios:

Use a simple sheltered location which
The sound level is not important. protects against bad weather (rain,
snow, storms, etc.).
Use a room constructed from poured

The low sound level is an important concrete or complete concrete blocks
criterion, e.g.: standby generating set or with a minimum thickness of 20 cm,
noise-sensitive area). coated with absorbent materials, a fire
wall and insulation.
The fire resistance rating must conform to the current legislation appropriate to the type of building.
IMPORTANT
6.2.3 Determining the dimensions and layout of the premises
The size and layout of the room are determined according to two requirements:
- Fixed requirements
These are the dimensions of the equipment installed and its peripherals, namely: daily fuel feed tank, electrical cabinet, silencer,
batteries, etc.
- Variable requirements
These are the dimensions which must be left around each
piece of equipment to allow for any maintenance and
dismantling operations.
A space of about 1 metre around the generating set is
considered the minimum required for carrying out problem-
free maintenance. This will leave enough space to check that
the doors of the covered generating sets open fully, that
equipment can be accessed for maintenance and that full
removal of the generating set can be carried out.
Figure 38: Example of the size of a room

for a generating set with a cover

6.2.4 Opening the premises for access and ventilation
Access
Ensure that there is an access door which allows the generating set and its accessories to pass through, preferably along the axis of
the floor plate of the generating set.
Ventilation
- Ensure the presence of fresh air inlets and hot air outlets which are suited to the conditions of use and the cooling system.
- Define appropriately sized openings, in accordance with the following elements:
 the generating set power;
 the atmospheric conditions;
 the cooling system;
 the soundproofing method (if necessary).
- Ensure that the air is swept in the following direction: Alternator  Engine  Radiator.
- Ensure that the air inlets and outlets are as direct as possible.
- Connect the cooling system to a sheath or outlet cover so that it is sealed in order to prevent any hot air from being
recirculated.
- Ensure that the air inlets and outlets are never located near to each other.
It is preferable to release the vapour from the crankcase outside the generating set room in order to prevent a
deposit from developing on the radiator which may cause the radiator to clog and affect its cooling ability.
Ensure that the crankcase vapours are recovered in order to preserve the environment.
IMPORTANT
Note: a heat engine generates a certain amount of heat, which must be evacuated outside the room to ensure that the generating set
works properly. The heat released by the generating set originates from different sources:
- cylinder cooling;
- radiation from the engine unit and exhaust duct;
- alternator cooling.
Insufficient ventilation would cause the ambient temperature to increase which, at the very least, would cause loss of engine power
and potentially cause the generating set to shut down.
6.2.5 Preparing a lifting system
The lifting system must, in general, form an integral part of the construction. It is composed of a mobile winch which moves along an
H- or I-shaped sealed steel rail in the walls and ceiling. This system is generally positioned above and in the longitudinal axis of the
generating set, directed towards the exit.
Figure 39: Example of a lifting system

6.2.6 Soundproofing the premises
6.2.6.1 Reminder of applicable regulations: Acoustics
Regulations concerning sound emissions are unique to each country. Refer to the regulations in force in the country concerned.
Decree of 25/07/97, section 29105 - 8.1
- Noise emissions produced by the installation must not, to begin with, have an emergence greater than the permitted values
specified in the following table in the statutory emergence zones:
Ambient noise level in the statutory Permitted emergence for the period from Permitted emergence for the period from
emergence zones (including noise from 7:00 am to 10:00 pm except for Sundays 10:00 pm to 7:00 am as well as on
the establishment) and bank holidays Sundays and bank holidays
Greater than 35 dB(A) and less than or

6 dB (A) 4 dB (A)
equal to 45 dB(A)
Greater than 45 dB(A) 5 dB (A) 3 dB (A)
The room will be soundproofed using two methods:

- Insulation
This method consists of preventing noise from penetrating the walls by using the mass, and therefore the thickness of the wall in
particular.
- Absorption
This method consists of using material which absorbs sound energy; it will therefore be used on the ventilation inlets. Consequently,
the cross-sections of the air inlets and outlets will be increased.
The interior walls of the room may also be lined with absorbent material in order to reduce the sound level in the room and,
consequently, through the walls, ventilation inlets and the door.
General conditions:
 building structure of poured concrete or complete concrete blocks with a minimum thickness of 20 cm;
 anti-vibration floor plate under the generating set, when the set is next to sensitive rooms;
 walls and ceiling possibly coated with absorbent material;
 choice of adapted exhaust silencer or silencers;
 soundproofed door giving access to the room and possibly an airlock in order to obtain a very low sound level;
 sound traps fitted in the air inlet and outlet sheaths.
Sound trap
Silencer
Sound trap
Soundproofed doors
Figure 40: Example of an installation
5 Decree of 25/07/97 relating to general advice applicable to installations classified for the protection of the environment subject to
the declaration under section no.2910 Combustion.

6.2.7 Defining the exhaust circuit
6.2.7.1 Reminder of applicable regulations: exhaust emissions
Regulations concerning exhaust emissions are unique to each country. Refer to the regulations in force in the country concerned.
Engine with a thermal power consumption greater than 2,000 kW.
Decree of 25/07/97 art. 6.2.6 - 2 modified by the decree of 15/08/00.
Pollutants
Carbon Volatile organic

Type of fuel Sulphur dioxides Nitrogen oxides (NOx) Dust (PM)
monoxide compounds
(CO) except methane
Natural gas and 350

50
liquefied petroleum 30 700 if dual fuel in gas mode 650 150
150 for existing installations
gas 500 if operating < 500 hrs/year
DFO: 160 1500 650 150

100
Other liquid fuels 2000 if operating < 500 hrs/year 50 if P > 10 MW and if agglomeration
Heavy fuel: 1500 > 250,000 inhabitants (art 6.2.9)
1900 if dual fuel in liquid fuel mode
3000 if overseas department and if 650 150
and if rotation speed < 1200 rpm 150 for existing installations
complying with Directive
1999/30/CE on air quality
Production
Applicability Production Production Production Production
Emergency
Units of measurement (mg/m3)

Study the evacuation of burnt gases by the generating set .

Ensure that the influencing criteria for this study are taken into account:
- pressure drops caused by the exhaust;
- thermal insulation;
- suspension of the pipes;
- sound level;
- air pollution.
Check that none of the components installed on the exhaust pipe cause pressure drops greater than the engine's admissible pressure.
Ensure that the exhaust circuit pipe has a smaller diameter than that of the generating set (contact us for significant lengths) and
ensure that it is positioned so that no gas can flow back into the room.
Check that an exhaust compensator is fitted at the engine outlet.
Check that the pipe is fixed so that the compensator is not supporting its weight. The compensator will be perfectly straight (any
alignment fault may cause a rupture).
1 - Exhaust pipe
2 - Elbows
3 - Compensator
4 - Condensation bleed
5 - Bulkhead crossing - roof outlet
6 - Exhaust outlet
7 - Suspension line
8 - Needle frame
9 - Column base
10 - Silencer suspension
11 - Thermal insulation
12 - Silencer
Figure 41: Example of a burnt gas exhaust circuit
Note 1: It should be noted that the more complicated a circuit, the more it causes drops in pressure and consequently, its diameter
will be large and heavy and its supports and silencers expensive.
Note 2: Exhaust circuit components marked in Figure: Example of a burnt gas exhaust circuit, are explained in the following
paragraphs.

Pipework components
No. 1: Pipes
It is recommended that you use seamless pipes. However, for
weight reasons, rolled steel pipes can be used. In any event,
welded "bars" inside the duct are to be avoided.
No. 2: Elbows
Elbows must have a minimum curve radius equal to 2 times the
diameter of the pipe, if possible in a single part. If the elbow is
made of welded steel, check that it includes at least 3 sectors for Figure 42: Examples of pipes and elbows
90° elbows.
No. 3: Compensators and hoses

- The compensator absorbs longitudinal movements due
to expansion (approx. 1 mm/metre/100°C).
- The hose allows for considerable sideways travel, but
with low longitudinal amplitude.
Figure 43: Example of a compensator and hose
No. 4: Condensation and rain water bleed

To be used in the lower section of the installation or for any
changes in horizontal/vertical travel to protect the silencer and
engine.
Figure 44: Examples of bleeds
No. 5: Bulkhead crossing - roof outlet

For each bulkhead passage and roof outlet.
Figure 45: Examples of bulkhead crossings
No. 6: Exhaust outlet

The exhaust outlets disperse the gases in the atmosphere and
protect the inner section of the pipes from bad weather.
Figure 46: Examples of exhaust outlets

Exhaust circuit mountings and suspensions
No. 7: Suspension line

Generally made up of a flat iron ring attached to the ceiling. The
suspension line enables the pipes to expand freely.
Figure 47: Examples of suspension lines
No. 8: Needle frame

Used for vertical sections, the needle frame allows the pipes to
expand while holding them laterally.
Figure 48: Examples of needle frames
No. 9 : Column base

The column base is designed to hold the weight of the vertical
pipes.
Figure 49: Examples of column bases
No. 10: Silencer suspension

The silencer suspensions are designed to hold the weight of the
silencers; they can be vertical or horizontal.
Figure 50: Examples of suspension lines

Thermal insulation
No. 11: heat insulation
Depending on the type of installation, it may be necessary to insulate the heat released in the room.
Once the insulation is complete, the surface temperature must not exceed 70°C. As the recommended material is rock wool (excluding
asbestos), it may be covered with an aluminium casing in order to improve the appearance of the installation and the heat insulation
capacity.
A minimum thickness of 50 mm should be considered for the rock wool.
Silencer
No. 12: Silencer
Silencers reduce noise by absorbing or dephasing the sound wave. The exhaust should be suspended correctly; under no
circumstances should the supports be reused on the generating set (except for original fittings).
Absorption silencer
Gas moves through a soundproofed duct composed of a highly
absorbent material protected by a perforated panel.
Figure 51: Example of an absorption silencer
Absorbent reactive silencer

The gas enters between an expansion chamber lined with an
absorbent material, secured by perforated panels in a
soundproofed absorbent duct.
Figure 52: Example of an absorbent reactive silencer
"Adapted" silencer
The "adapted" silencer is fitted directly onto the generating set or
in the cover. It is an absorption silencer.
Figure 53: Example of an adapted silencer

Exhaust chimney
Reminder of applicable regulations: Chimney height
Regulations concerning the chimney height are unique to each country. Refer to the regulations in force in the country concerned.
Minimum ejection speed: 25 m/s
Figure 54: Schematic diagram for calculating the chimney height
- Emergency operation of the main electrical supply with a building present within a radius of 15 metres of the installation:
Decree of 25/07/97 section 2910 - 6.2.2.E
 The height of the exhaust chimney should exceed the height of the buildings located less than 15 metres around
the installation by 3 metres, whilst being less than 10 metres.
For d < 15 m => Hchim = Hobst + 3

Description of the installation
There are various types of exhaust chimney.
Self-supporting chimney Wall-mounted chimney

Chimney mounted on a concrete foundation on the ground, with
load support on the building.
Free-standing chimney Telescoping chimneys

Chimney standing solely on a concrete foundation on the In the case of a facility with several generating sets, it is possible
ground. to route the various ducts to a single chimney. Each engine duct
must be fitted with a non-return valve.
The sizing of the chimney's support must factor in the
constraints of the site, and in particular the forces generated by
the wind.
Telescoping chimney
Figure 55: Examples of exhaust chimneys

Condensate collector
Rain entering the chimney flue results in soot loaded with burnt particles and other harmful waste and is collected in a receptacle at
the base of the chimney.
Fluid collected in this way produces sludge which is deposited at the bottom of the container and discharged outside through a trap
into a designated collector.
Chimney flue
Container
Trap
Receptacle
for condensate
Drain valve
Figure 56: Condensate collector

6.2.8 Cooling
Four types of produced heat must be dissipated:

- heat from the engine cooling circuit(s);
- heat radiation from the engine and exhaust;
- room ventilation air;
- exhaust gases.
The systems described below evacuate and channel the heat produced by the engine cooling circuit.
Ventilated radiator
The engine cooling circuit is connected to a tubular ribbed radiator at the end of the frame. This radiator is cooled by the fan controlled
directly by the engine.
In all cases, the air is blown in the Fan  Radiator direction.
Note: an expansion vessel can compensate for variations in the volume of coolant fluid according to the temperature.
Air cooler
The engine cooling circuit is connected to an air cooler located inside or outside the room.
When located in the room, it operates in the same way as a ventilated radiator. The fan or fans are either coupled to the engine or
driven by one or more electric motors.
If the air cooler is positioned outside, on the roof or in another room, the coolant pipes are extended, meaning that ventilation of the
room is separate from the cooling.
In these installations the degassing conditions should be considered even more carefully than for a radiator.
In all cases, the air cooler is cooled by the fan(s).
Lost water exchanger

This type of cooling consumes a sizeable amount of water and hence there is an operating cost to be taken into account. This is the
solution when local provisions ensure the flow of water and do not allow the ventilation provisions required for cooling by a ventilated
radiator or air cooler to be enacted.
These lost water installations consist mainly of an exchanger, with one of its circuits fitted with an expansion vessel, connected to the
engine cooling circuit. The latter's water pump ensures circulation. The second exchanger circuit, known as raw water, is connected
between the building's water supply and the drain. A valve fitted upstream of the exchanger can enable and cut off circulation. With
automatic generating sets, this valve should also come with an electric control (solenoid valve).
This system's heat exchange ensures engine cooling. The room will require a ventilation system and this type of installation requires
a detailed study.
Ventilation of the room

Extractor fans and/or air blowers can evacuate heat radiated from the engine and supply fresh air to the room and equipment in the
case of external air coolers or lost water exchangers.
If fans are being used, several fans will regulate the temperature better than one large one fan.
Ventilation of the premises requires a detailed study and should take into account the atmospheric air temperature and loss of
pressure of components located in the air inlet and outlet (grilles, sound traps etc.) in particular.
Note: if cooling using a radiator or air cooler in the room, the increase in temperature due to heat radiation for the sizing of the
installation should always be taken into account.

6.3 Generating sets with enclosure and containers, outdoor installation

IMPORTANT
6.3.1 Ensuring correct ventilation
Install the equipment, taking into account the prevailing winds: position the air inlets away from the wind to ensure there are no
difficulties in adverse weather conditions (entry of air, snow, sand, etc.).
Respect a minimum distance of 2 metres between the container air inlets and outlets and any ventilation obstacles.
Air inlet
2 m,
2 m, min.
min.
Air
discharge
Air inlet
Figure 57: Positioning constraints

6.3.2 Guaranteeing a correct exhaust system
Make sure that the air inlets are oriented away from the prevailing winds in order to avoid any inconvenience during difficult climatic
conditions (entry of air, snow, sand,...).
Arrange the equipment so that the exhaust fumes will not bother the control panel operator.
1. It is imperative to remove the exhaust outlet cover plate(s) (used for transport).
2. Install the extension ,supplied with the generating set, in place of the cover plate(s) .
IMPORTANT 3. It is imperative to maintain a clearance of 3mm between the extension and the roof of the canopy.
≈ 3 mm


Figure 58: Removing the cover plate Figure 59: Installing the extension
When using a tall chimney, preferably use a self-stabilising chimney installed next to the container.
Figure 60: Example of a container installation with self stabilising chimney

6.4 Mobile generating sets
- Respect the instructions provided in this manual.

- Reserve an installation area which is flat and strong enough so that the generating set does not sink into it. It could be made
of concrete or even large planks fitted together. Note: a generating set that does not rest correctly on its base (frame or
trailer) will be subject to vibrations that could cause significant damage to all the equipment.
- It is essential to respect the neutral system of the generating set associated with the current regulations, in order to ensure
personal protection.
- Earth the generating set. To do this, use a copper wire, with a minimum cross-section of 25 mm2 for stripped cable, and
16 mm2 for insulated cable, connected to the generating set's earth terminal, and a galvanised steel earthing rod embedded
vertically into the ground (see Chapter "Electrically connecting a generating set").
- A suitable construction should be used to protect generating sets not fitted with enclosures (see Chapter "Installing a
generating set in a room").
6.4.1 Trailer-mounted generating set
Operations to be carried out for the installation:

1. Ensure that the ground is strong enough for the assembly not to sink into it.
2. Unhitch the trailer in accordance with the paragraph "Road transportation / Generating sets on trailers / Hitching and
unhitching the trailer".
3. Immobilise the trailer by placing chocks under the wheels.
4. Fully engage the parking brake (if fitted).
5. Using the front wheel, position the generating set as horizontally as possible.
6. Lower the stands (if fitted), and lock them.

7 Installation
The general checks referred to in this section are performed in conjunction with the generating set's commissioning operations. They
must be adapted or complemented according to the actual commissioning conditions.
ELECTRICAL EQUIPMENT - RISK OF ELECTRIC SHOCK

The generating sets must only be commissioned by qualified personnel with
the necessary skills.
DANGER
- The generating set must meet the needs of the installation in terms of its power requirements and configuration.
- The installation must have been performed in compliance with recognised trade practices by a qualified person: the
installation must be clean, correctly maintained and regularly checked throughout the generating set's service life.
- Carefully read the operating and servicing manuals provided, note the maintenance to be performed and the associated
deadlines. Throughout the generating set's service life, regularly check that the deadlines are respected.
7.1 Electrically connecting a generating set
After all connections have been made, ensure that the cable passageways on the installation have been
properly sealed (notably concerning enclosed generating sets).
IMPORTANT
Installation supply without source inverter

When a generating set supplies power to an installation, it must be separated from the distribution grid by a disconnect device
(manual opening of the main circuit breaker, for example) and connected downstream from this main disconnection point. During
generating set operation, the disconnection point must be kept open by a blocking device or a lock-out panel.
Fixed installation
Head disconnect
point open
Grid
Generating set

7.1.1 Low-voltage installation
7.1.1.1 Low-voltage wiring
General information
Low voltage electrical installations are subject to the regulations set out in standard NFC 15.100 (France) or the standards in the
countries concerned based on international standard IEC 60364. Cable routing must comply with NFC 15.100, paragraph 528
“Electromagnetic disturbances” or lEC 60364-4-44 “Protection against voltage disturbances and electromagnetic disturbances”.
They must also adhere to the regulations in the NFC 15.401 application guide (France) or to the regulations and standards in the
relevant country.
Power cables
- Power cables should preferably be installed in ducts or on a cable tray for this purpose.
- Determine the cable cross-section and number of cables according to the cable type and the current standards to be
observed in the country of installation. The choice of conductors must comply with international standard IEC 30364-5-52.
Note: the power cables may be unipolar or multipolar according to the power of the generating set.
Three phase - Calculation hypothesis

Fitting method = wiring in cable runs or non perforated trays.
Permissible voltage drop = 5%
Multiconductors or single conductor joined when precision 4X…(1)
Cable type PVC 70°C (e.g. H07RNF).
Ambient temperature = 30°C.
Circuit breaker Cable sizes
rating 0 to 50 m 51 to 100 m 101 to 150 m
(A) mm²/AWG mm²/AWG mm²/AWG
10 1.5 / 14 2.5 / 12 4 / 10
16 2.5 / 12 4 / 10 6/9
20 2.5 / 12 4 / 10 6/9
25 4 / 10 6/9 10 / 7
32 6/9 6/9 10 / 7
40 10 / 7 10 / 7 16 / 5
50 10 / 7 10 / 7 16 / 5
63 16 / 5 16 / 5 25 / 3
80 25 / 3 25 / 3 35 / 2
100 35 / 2 35 / 2 4X(1X50) / 0
125 (1) 4X(1X50) / 0 4X(1X50) / 0 4X(1X70) / 2/0
160 (1) 4X(1X70) / 2/0 4X(1X70) / 2/0 4X(1X95) / 4/0
250 (1) 4X(1X95) / 4/0 4X(1X150) / 2350MCM 4X(1X150) / 2350MCM
400 (1) 4X(1X185) / 0400MCM 4X(1X185) / 0400MCM 4X(1X185) / 0400MCM
630 (1) 4X(2X1X150) / 2x 2350MCM 4X(2X1X150) / 2x 2350MCM 4X(2X1X150) / 2x 2350MCM
Single phase - Calculation hypothesis

Fitting method = wiring in cable runs or non-perforated trays.
Permissible voltage drop = 5%
Multiconductors.
Cable type PVC 70°C (e.g. H07RNF).
Ambient temperature = 30°C.
Cable sizes
Circuit breaker
0 to 50 m 51 to 100 m 101 to 150 m
rating (A)
mm²/AWG mm²/AWG mm²/AWG
10 4 / 10 10 / 7 10 / 7
16 6/9 10 / 7 16 / 5
20 10 / 7 16 / 5 25 / 3
25 10 / 7 16 / 5 25 / 3
32 10 / 7 25 / 3 35 / 2
40 16 / 5 35 / 2 50 / 0
50 16 / 5 35 / 2 50 / 0
63 25 / 3 50 / 0 70 / 2/0
80 35 / 2 50 / 0 95 / 4/0
100 35 / 2 70 / 2/0 95 / 4/0
125 50 / 0 95 / 4/0 120 / 2250MCM

Battery cables
- Install the battery or batteries in close proximity to the electric starter motor. The cables will be connected directly from the
battery terminals to the starter motor terminals (§ "Connecting/disconnecting the battery").
- Check that the polarities of the battery and starter motor correspond. (an inversion could cause severe damage to the
electrical equipment).
- The minimum cross-section of the cables is 70 mm2. This cross-section varies according to the power of the starter motor
but also the distance between the batteries and the generating set (voltage drops on the line).
Safety guidelines
References: NFC 15-100:2002 (France) - IEC: 60364-4-41.
In order to ensure that staff are protected against electric shocks, generating sets are equipped with a general residual current
protection device which is configured in the factory to be triggered instantly with a sensitivity of 30mA.
Any change to the setting on the general residual current device could pose a risk to personal safety. The
user will be held liable - any changes must only be made by trained, qualified engineers.
IMPORTANT
Note: when the generating set is disconnected from an installation after use, the general residual current device must be restored to
factory settings by a qualified engineer who can then check this.
To ensure that the device providing protection against electric shocks is effective, connect the generating set to the earth. To do
this, use a copper wire with a minimum cross-section of 25 mm2 for a stripped cable and 16 mm2 for an insulated cable, connected
to the generating set earth socket and a galvanised steel earthing rod embedded vertically into the ground.
Ensure that the resistance value of this earthing rod complies with the values indicated in the table below (use the highest
differential setting from the installation as a guideline).
UI
The resistance value is calculated in the following way: R 
I n
Maximum resistance value of the earth socket R (Ω) according to the differential unit operational
current (operation time should not be longer than 1 second)
Earth R Earth R
I Δn
(Ω) (Ω)
differential
Ul: 50 V Ul: 25 V
≤ 30 mA 500 > 500
100 mA 500 250
300 mA 167 83
500 mA 100 50
1A 50 25
3A 17 8
5A 10 5
10A 5 2.5
The Ul value: 25 V is required for site installations, and livestock buildings, etc
For a default voltage of 25 V and a default current of 30 mA, this rod must be of a minimum length of: see table below
Length of
Nature of ground rod in
metres
Thick arable land,
1
moist compact ballast
Lean arable land,
1
Gravel, coarse ballast
To obtain an equivalent length, you can use several earthing rods
Bare stony soils, dry sand,
3.6 connected in parallel and set apart by at least their length.
impermeable rock
Example: 4 interconnected 1 metre rods separated by 1 metre.
Note: for the United States (National Electrical Code reference NFPA-70).
The generating set must be earthed. To do this, use a copper wire with a minimum cross-section of 13.3 mm² (or AWG 6, at most)
connected to the generating set earth socket and a galvanised steel earthing rod embedded vertically and fully into the ground.
This earthing rod embedded fully in the ground must have a minimum length of 2.5 m.

7.1.1.2 Low-voltage earthing system
The Earthing system, or SLT (formerly Neutral system) of the electrical installation defines the situation of the generating set neutral
in relation to earth and the grounds of the electrical installation at the user end.
The purpose of the earthing systems is to protect personnel and equipment by managing the risks posed by insulation defects. For
safety reasons, any live conducting part of a facility must be insulated from the earth. This insulation may be achieved by distance,
or by using insulating materials. But with time, insulation may deteriorate (due to vibrations, mechanical impacts, dust, etc.), and
therefore generate an earth with dangerous potential. This defect poses risks for personnel and property, but also continuity of service.
Earthing systems are codified by two letters that define the connections:
- The first letter defines the neutral connection:
I Insulated or earthed via an impedance device
T Connected to earth
- The second letter defines the grounding situation of the electrical facility:
T Connected to earth
Connected to
N
neutral
E.g.: IT = Isolated Neutral + Ground earthed
Number of
Speed Detection Note
conductors
TT 4 poles Measurement of residual current Triggering of 1st fault by RCD
C 3 poles
Triggered by overcurrent protection
TN No measurement of residual current
upon 1st fault
S 4 poles
Triggered upon 2nd fault by overcurrent

IT SN 3 poles Insulation resistance measurement
protection

7.1.1.2.1 TT system
R R
Ph 1 Ph 1
Ph 2 Ph 2
id
Ph 3 Ph 3
N N
PE PE
id
R
Neutral connected Ground connected
R
to earth to earth
T T
id
Neutral earth Ground earth
Figure 61: Neutral TT system
The alternator neutral is earthed, and the grounds of the user equipment have their own earth connection.
This earthing system is the most frequent in the private sector in France.
In the TT system, automatic power cut-off via a Residual Current Device (RCD) is obligatory at the upstream part of the facility, to
ensure that personnel are protected (with a maximum 30 mA device on outlet circuits).
7.1.1.2.2 TNS system
In the TN system, the alternator neutral is earthed and the user grounds are connected to the main protective conductor (PE), itself
connected to the earth socket.
Ph 1 Ph 1
Ph 2 Ph 2
Ph 3 Ph 3
N N
PE PE
id
Ground to neutral SeparateSeparate
N Neutral conductor
protective conductor
id
id
Neutral connected
to earth
T
Neutral earth
Figure 62: Neutral TN-S system (separate earth and neutral)
In the TN-S system, the power supply is automatically cut by the opening of the overcurrent protection circuit breaker protecting the
faulty circuit.
TN-S is obligatory for networks with aluminium conductors which have a cross-section ≤ 16 mm2.

7.1.1.2.3 IT system
Ph 1
Ph 2
Ph 3
N
PE
Ground connected
Neutral insulated to earth
I T
Z CPI
Neutral earth Ground earth
Ph 1 Ph 1
id
Ph 2 Ph 2
Ph 3 id Ph 3
N N
PE PE
id
id
id
id id
Z CPI Z CPI
id
1st fault 2nd fault
Figure 63: Neutral IT system
In the IT earthing system, the alternator's neutral is earthed via an impedance device (Z) greater than
1000 Ohms, or insulated (Z=∞). The installation's grounds are earthed (see Figure: Neutral IT system). It should be noted that an
IMD (Insulation Monitoring Device) is connected in parallel to this impedance device Z to monitor the circuit's insulation at all times.
- First fault: the current flowing through the metal frame passes through the neutral impedance device Z, which means a very
low current (or practically zero if neutral is insulated), so the contact voltage is not dangerous. That is why hospitals, concert
halls, etc. use this system to avoid outages in the case of a first fault. The IMD (Insulation Monitoring Device) detects this
leak and reports it via an indicator light and/or an alarm.
- Second fault: both conductors concerned by insulation faults are interconnected, leading to a short-circuit. The power supply
is automatically cut by the opening of the over-current protection circuit breaker, as in the TN system. It should be noted that
the IT neutral system must not be used if you do not have a technician on call 24/7.
For the IT neutral system, in the case of a 20 kV/400V step-down transformer, it is necessary to provide overvoltage protection for
the 400V network. This protection must be mounted between earth and the neutral point, if available, or a phase if not available.
For an LV generating set with an IT system, this protection is not necessary, as the voltage cannot be over 500V.
The network's insulation voltage must be the value of the phase-phase voltage.

7.1.2 High-voltage installation
7.1.2.1 High-voltage installation
General information
Installations having a voltage range between 1 kV and 50 kV are referred to as “high voltage electrical installations” (HVA). These
high voltage electrical installations are subject to the regulations set out in standard NFC 13.100 and more particularly NFC 13.200
(France, voltage range from 1 kV to 33 kV) or the standards in the countries concerned based on international standard IEC 62271.
Cable routing must comply with NFC 13.200, paragraph 451 "Electromagnetic disturbances" or with IEC 62271-1 and IEC 62271-
200.
Equipment
The choice of the required equipment shall be made based on the following criteria:
Example:
The operating voltage must be below the rated voltage.
Voltage - Operating voltage: 20kV
This voltage shall define the isolation voltage.
- Rated voltage: 24kV
Short-time withstand current Example: 12.5kA/1s

Current
Continuous-duty current Example: 400A
Power cables
The high voltage cables must have metal shielding on the insulation or on the assembly of conductor cables, to ensure:
- earthing along the entire circuit,
- dissipation of capacitive currents,
- dissipation of phase-earth fault currents.
The cross-section shall be selected following the study of overcurrents and protections implemented.
Battery cables
- Install the battery or batteries in close proximity to the electric starter motor. The cables will be connected directly from the
battery terminals to the starter motor terminals (§ "Connecting/disconnecting the battery").
- Check that the polarities of the battery and starter motor correspond. (an inversion could cause severe damage to the
electrical equipment).
- The minimum cross-section of the cables is 70 mm2. This cross-section varies according to the power of the starter motor
but also the distance between the batteries and the generating set (voltage drops on the line).
Protection of persons
A set of protection and intervention equipment in good condition must be made available to operators in each room containing HVA
equipment (gloves, rescue pole, insulated stool, etc.).
Protection against direct contact:

Protection is ensured by keeping live parts out of reach. It is imperative
that HVA equipment be used that is compliant with current standards and
respect the manufacturer's implementation requirements.
Protection against indirect contact:

All grounds and conductive elements must be interconnected by means of
equipotential systems connected to the earthing connection of the
DANGER installation. The size of this protective conductor must be able to convey
the fault currents (calculation required) and must be at least 25 mm²
Copper or 35 mm² Aluminium.

7.1.2.2 High-voltage earthing system
Earthing system possibility

Standard NFC 13.000 indicates the following classification of earthing schemes. The neutral potential may be established in relation
to the earth according to five methods:
Type of neutral potential connection in

Benefit(s) Drawback(s)
relation to the ground
Isolated neutral Service continuity Overvoltages
Neutral connected to the ground through

Weak fault current No service continuity
a resistor
- Limitation of fault currents

Neutral connected to the ground through No service continuity on the faulty
- Selectivity
a weak reactance (impeding) feeder
- Low cost
Neutral connected through a - Limited overvoltages

High cost
compensation reactance - Service continuity
Neutral directly connected to the ground Simple High fault current
Neutral system recommendation

Among all these connection possibilities, it is advisable that the following operation be used:
EXTERNAL HVA PERMANENT OR REPLACEMENT

EXTERNAL SUPPLY GRID PRODUCTION SOURCES
HOMOPOLAR
GÉNÉRATEUR
INSTALLATION HOMOPOLAIRE
GENERATOR
Figure 64: Power supply diagram including external sources which may be coupled to the HVA grid
Protection against overcurrents:
All elements of the HVA installation must be protected by:

- Overload protection: this protection is ensured by a thermal image or temperature sensors.
- Short-circuit protection: this protection must disconnect the power supply of the elements in a
sufficiently short time so that they are not damaged.
In all cases, the overload and short-circuit currents specific to the installation must be calculated. The addition
IMPORTANT or the removal of a generator or receiver shall require verification of the resistance of the various elements of
the installation to overcurrents.

7.2 Fuels, lubricants and coolants
FUELS / FLAMMABLE PRODUCTS / PRESSURISED FLUID: BURN

RISK - FIRE HAZARD - EXPLOSION RISK
The fluids used by the generating sets, such as oils, fuels and coolants, are
dangerous products. Do not ingest, avoid all extended or repeated contact
with the skin (gloves are recommended), and keep out of the reach of
DANGER children.
All specifications (product features) are given in the engine and alternator maintenance manuals attached to this manual.
In addition to these documents, it is strongly recommended that the fuels, lubricants and coolants mentioned in the “Specifications”
chapter, be used.
7.2.1 Fuel specifications
General quality requirements
Good fuel quality is vital for good engine performance. This applies both to technical performance, such as longevity, power, and fuel
consumption as well as the ability to comply with the rules set out by the authorities regarding emissions. Only fuels complying with
current legal requirements and national and international standards must be used Consult the local fuel distributor to find out about
the characteristics of the diesel which is available in the region.
Examples of standards and requirements :
European standard (CEN) for automotive fuel - diesel engine fuels - requirements and test
EN 590
methods
American Society for Testing and Materials : basic requirement for the United States and
ASTM D 975 1-D and 2-D
Canada
JIS KK 2204 Japanese Industrial Standards
Emissions compliance
Certification measures confirming that the legal emissions limit values are adhered to shall be carried out using certified fuel
conforming to the requirements and standards referred to above.
Stability at low temperatures
In low outside temperatures diesel fuel may become insufficiently fluid due to build up of paraffin deposits. Also, in order to avoid any
malfunctions (blocked filters for example), procure, in winter, diesel fuel which is sufficiently fluid in cold temperatures.
Requirements to be met for different geographical regions and for different seasons (winter/summer) are specified in national
standards and/or regulations. Petroleum companies must always take care to supply fuels whose cold flow properties are correct for
any time of year. Generally, diesel contains additives so it can be used in low temperatures in the region where it is sold.
Any fuel additives must comply with the engine manufacturers recommendations and be of sufficient lubricity to suit the injection
systems. It is preferable to use fuels ready mixed with additives in the refinery than those which are mixed together in a storage tank.

General characteristics of diesel
Fuel used must have the following characteristics (non-exhaustive list) :

Sulphur content must correspond to the emissions regulations in place in the region where the generating
set is used.
In the United States and countries conforming to EPA regulations
Only use Ultra Low Sulphur Diesel (ULSD) with a maximum sulphur content of 15mg/kg for Tier 4 and
Interim Tier 4 certified engines.
In the European Union
Sulphur content
Directive 2009/30/CE which aims to limit atmospheric pollution, requires the use of diesel with a very low
sulphur content of 10mg/kg for non-road, mobile engines.
In France, this requirement has resulted in the creation of non-road diesel called "GNR" - Similar to red
diesel in the UK. The maximum permissible sulphur content is 10mg/kg. However, member states permit
diesel fuels to contain up to 20mg/kg of sulphur at the moment of distribution to the end user. It is not
recommended to store non-road use diesel for prolonged periods (any more than 6 months)
Viscosity and density have a direct effect on the performance (power and fuel consumption), emissions
and service life of the engine. A low level of viscosity and density reduces engine power and increases
fuel consumption. A too high level of density and viscosity seriously harms the service life and the working
Viscosity and density
of the fuel injection system.
In order to maintain adequate technical and environmental performance, the viscosity and density must
conform to the specifications indicated in the manual provided by the generating set engine supplier.
Lubricity (lubrication In order to protect the fuel injection system from excessive wear, it is important that the fuel is of sufficient
capacity or oiliness) lubricity (refer to the engine manufacturers manual supplied with our generating sets).
The combustion behaviour of diesel fuels is described by the cetane index. The cetane index is important
Cetane Index
for emissions, cold starting capacity and engine noise. The technical requirement is 45 minimum.
The fuel and the tank must not contain water. Water increases corrosion and wear of engine parts,
particular with regard to the injection system. In addition, water encourages the growth of bacteria and
Water and
fungus in the tank which can clog the fuel filter. Fuel must not contain any sort of residue. Organic
contaminants
contaminants (bacteria, fungus etc.) may block the fuel filters ; inorganic material in the fuel (dust, sand)
may cause severe damage to the injection equipment.

Authorised fuels :
Notes:
- 0.5% sulphur = 5000 ppm and 1% sulphur = 10000 ppm.
- EATS = Exhaust After Treatment System.
- HFRR (High Frequency Reciprocating Rig) : testing method used to evaluate the lubricating properties of diesel fuels.
- DFO: Domestic fuel oil
DFO : We recommend improving storage conditions by using fuel which has been pretreated in the refinery in order to stabilise the
fuel (avoid oxidation, bacterial growth and corrosion). We recommend adding a water separator between the main fuel storage tank
and the day tank.
Fuels containing biodiesel : We recommend improving storage conditions by using fuel which has been pretreated in the refinery in
order to stabilise the fuel (avoid oxidation, bacterial growth and corrosion)
Fuels Designation Details Restrictions

0.0015 % Sulphur Max HFRR 460 mm;
ASTM D975 1D (Road)
ASTM D975 0.05% Sulphur Max HFRR 460mm;
ASTM D975 2D Without EATS
0.5% Sulphur
Road diesel CSR 4.0.05
EN590 EN590 Biodiesel blend < 10%
Non road use diesel CSR 4-1-03
BS2869 2010 BS2869 2010 Class A2 Non-road use diesel 0.001 % sulphur content Biodiesel blend < 10%
Without EATS
Improve fuel pre-filtration with a
CSR 4.4.06
DFO DFO available in France water separator type pre-filter
DIN51603
between the main storage tank
and the day tank.
Max 7% EN12214 biodiesel blend with ASTM
Bio Fuel EN 12214
D975 diesel or DFO
Without EATS
Bio Diesel Max 7% ASTM D6751 biodiesel blend with
Bio Fuel ASTM D6751
ASTM D975 diesel or DFO
Note: KD Series engines (K135 and K175) will accept a blend of up to 10% biodiesel.
Identical to
NATO F-54 (Road) EN590 Biodiesel blend < 10%
CSR 4.0 05
Identical to
XF-51 (Non-road diesel) EN590 non-road Biodiesel blend < 10%
CSR 4.1.02 to CSR 4.1.03
NATO F34 or F35 or F44
NATO F-63 or XF-63
+ Additive S1750
Military grade Generally, kerosene will cause damage to a diesel engine :
fuels 1- Viscosity too low => jamming and wear of the injection system.
2- Cetane index too low => not starting or difficulty starting (prohibited for standby usage).
3- Negative impact on engine maintenance.
4- Negative impact on fuel consumption
5. Negative impact on emissions.
6- Negative impact on power.
The military version of kerosene based fuel with additives (Nato F-63 or XF-63) is the type of fuel most adapted
to our generating sets, however it still retains the negative impacts of points 3 - 6.
Use of NATO F-63 or XF-63 fuel is a replacement choice whereby the user of the genset must assume any
impact on service life of the engine and performance of the generating set.

7.2.2 Lubricant specifications
Selecting the right oil based on its use is essential for correct engine operation. Besides the lubrication function, an oil must also:
- cool certain parts;
- protect metal parts against corrosion;
- improve sealing, in particular between pistons, piston rings and cylinders;
- remove impurities (to the filter).
It is recommendable to use a premium lubricant for diesel engines. The table below lists the oils recommended for each engine
manufacturer.
ENGINE OIL
BRAND TYPE BRAND TYPE
KD27V12
K135 KD36V16 KOHLER. GENLUB EVOLUTION 15W40
KD45V20
GENLUB EVOLUTION 15W40 (*)
(*) Engine water preheating is required => system fitted as
KOHLER.
standard for ESP/DCP/LTP/PRP applications.
KD series KD62V12
K175 KD83V16 KOHLER.
Note: For applications without engine water preheating, use
KD103V20
viscosity 10W40 or 5W40.
(For example: Total Rubia works 2000 viscosity 10W40 / Shell
Rotella T6 viscosity 5W40)
LOMBARDINI
All KOHLER. 5W40 OIL
KOHLER.
JOHN DEERE All KOHLER. GENLUB EVOLUTION 15W40
MTU All KOHLER. GENLUB EVOLUTION 15W40
MITSUBISHI All KOHLER. GENLUB EVOLUTION 15W40

PERKINS Fuel KOHLER. GENLUB EVOLUTION 15W40
All, except
VOLVO KOHLER. GENLUB EVOLUTION 15W40
TAD 733GE
TAD-733GE (with breather API: CI-4 or CH-4
VOLVO
filter for closed system) (100% synthetic)
DOOSAN All KOHLER. GENLUB EVOLUTION 15W40
KD series Oil performance requirement:
Recommended viscosity class Base oil

KOHLER oil category Minimum classification All base oils must comply with high-
Engine family Engine family power turbocharged engines
K135 K175
SAE 10W-30
ACEA E5-02 or
Oil Category 1 SAE 10W-40 Prohibited Mineral base
API CH-4 or DHD-1
SAE 15W-40
SAE 5W-30
ACEA E4 or ACEA E7 or SAE 5W-40
SAE 10W-30
Oil Category 2 API CI-4 Plus or SAE 10W-40 Synthetic
SAE 10W-40
DHD-1 or JASO DH-1 SAE 15W-40 (*)
SAE 15W40
SAE 5W-30
SAE 5W-40
ACEA E6 or ACEA E9 or SAE 10W-30
Oil Category 2.1 SAE 10W-40 Synthetic
API CJ-4 or JASO DH-2 SAE 10W-40
SAE 15W-40 (*)
SAE 15W40
SAE 5W-30
ACEA E4-12
Oil Category 3 SAE 5W-40 SAE 5W-40 Synthetic, VI > 160,
or
(standard today) SAE 10W-30 SAE 10W-40 and additives for long-term use
ACEA E4 and ACEA E7
SAE 10W-40
ACEA E6-12 SAE 5W-30
Oil Category 3.1 OR both SAE 5W-40 SAE 5W-40 Synthetic, VI > 160,
(standard today) ACEA E6 and ACEA E9 SAE 10W-30 SAE 10W-40 and additives for long-term use
or API "CK-4" SAE 10W-40
(*) 15W40 can also be used for K175 engines with water preheating.
Note: To use an oil other than the KOHLER brand, it is necessary to obtain the approval of the KOHLER engineering and design
office or the after-sales department.

Viscosity
Viscosity is a measure of the flow resistance of a fluid. The viscosity of an engine oil is expressed by 2 SAE (Society of Automotive
Engineers) grades; one grade for cold weather and one grade for hot weather. The grade for cold weather appears before the letter
W.
The 1st grade represents the dynamic viscosity in cold weather, namely the ability to start the engine and to prime the oil pump (and
therefore to lubricate the various components quickly). The lower the number, the more fluid the oil.
The 2nd grade represents the kinematic viscosity in hot weather. The higher the number, the thicker the film of oil when hot (which
aids protection and sealing). The lower the number, the less friction there will be in hot weather (it helps to save fuel).
In order to ensure immediate protection when starting the engine, the choice of viscosity grade when cold is essential. More fluid oil
is quicker to flow when oil begins to circulate through the engine. It should be selected according to the ambient temperature. See
the table below.
KOHLER GENLUB EVOLUTION 15W40 oil specifications

GENLUB EVOLUTION is a specific, very high performance multigrade oil intended for generating set engines.
Use:
“Power generation”  Particularly intended for all-season lubrication of generating set engines, but also all stationary
engines.
All engines compliant  More generally, it is dedicated to all engines having to operate for long periods of time under
with standards
TIER 1, TIER 2 and TIER full load or repeated phases of acceleration and idle.
3  It is specially recommended for engines with the latest technology and rated to the EURO
Stage IIIa or US EPA TIER 3 emission standards.
Performance:
ACEA : E7 (E5)
API : CI-4 / CH-4 / CF
Classifications JASO : Level DH-1
The KOHLER GENLUB EVOLUTION 15W-40 formulation has been approved by engine
manufacturers who fit out the generating sets, such as:
MTU (Category 2)
Compliant with VOLVO (VDS-3)
specifications KOHLER KD series
Advantages:
Total safety  Excellent thermal stability ensuring good lubrication of hot engine parts, particularly during
intensive and continuous operation.
Extended oil change  Reinforced dispersion, detergent and anti-wear capability allowing the engine oil to resist
intervals
attacks between long oil change intervals: dust, soot, water, diesel fuel, and combustion acid.
Simplified engine  For the lubrication of all types of older and newer generation engines, regardless of brand and
lubrication type.
Specifications:
KOHLER GENLUB EVOLUTION Units 15W-40

Kinematic viscosity at 40 °C mm²/s (cSt) 103
Kinematic viscosity at 100 °C mm²/s (cSt) 14.0
Viscosity index / 141
TBN mg KOH/g 11.0
The values of the characteristics provided in this table are typical values provided for guidance purposes only.

KOHLER 5W40 oil specifications (excludes KD series)
A multigrade synthetic technology lubricant designed for petrol and diesel engines used in generating sets.
Use:
“Power generation”  Recommended for petrol engines (multi-valve and turbocharged engines fitted with or without
a catalytic converter) and diesel engines with or without a turbocharger.
Direct injection  Specially recommended to satisfy the requirements of direct injection diesel engines.
 Can be used under the most severe operating conditions.
The most intensive
applications
All seasons
Performance:
Classifications ACEA : A3/B4

API : SL/CF
The KOHLER 5W-40 formulation has been approved by engine manufacturers who fit out the
Compliant with generating sets, such as:
specifications KOHLER LOMBARDINI
Advantages:
High performance  Excellent engine protection, particularly against distribution wear and tear.
 Exceptional thermal and corrosion stability preventing deterioration even under very intensive
Increased use.
engine life
 KOHLER 5W-40 has been designed to satisfy the manufacturer’s requirements in terms of
Extended oil extended oil change intervals.
change intervals
Specifications:
KOHLER 5W40 Units 5W-40

Density at 15°C Kg/m3 853
Viscosity at 40°C mm2/s 85
Viscosity at 100°C mm2/s 14
Cleveland flashpoint °C 228
Pour point °C -39
The values of the characteristics provided in this table are typical values provided for guidance purposes only.

7.2.3 Coolant specifications
The engine's internal cooling system allows the engine to operate at a precise temperature.
The table below lists the coolants recommended for each engine manufacturer.
ENGINE
MAKE TYPE MAKE TYPE
KOHLER All KOHLER GENCOOL PC -26
MITSUBISHI LLC
MITSUBISHI All
KOHLER GENCOOL PC -26
MTU All KOHLER GENCOOL PC -26
JOHN DEERE All KOHLER GENCOOL PC -26
VOLVO All KOHLER GENCOOL PC -26
DOOSAN All KOHLER GENCOOL PC -26
Specifications of GENCOOL PC -26 coolant

Performance
GENCOOL PC -26 coolant is a ready-to-use cooling fluid which provides a high level of protection and is produced from an antifreeze
approved by the majority of manufacturers (Power Cooling concentrated antifreeze).
It offers the following:
- Improved anticorrosion: improves the effectiveness and service life of the cooling system.
- High temperature feature: promotes heat exchange.
- Long-term protection: against overheating and corrosion under extreme conditions of use.
- Compatible with the original fluid (however, it is recommended to drain the entire cooling system when replacing the fluid).
Specifications
Specifications Units Characteristics
Density at 20°C kg/m3 1053 ± 3
pH pH 7.5 to 8.5
Alkalinity reserve ML ≥ 10
Boiling temperature °C 105 ± 2
Freezing temperature °C -26 ± 2
Typical values given for information purposes

7.3 Inspect the generating set installation, commissioning
- Check the position of the generating set (stability, mounting, available space, ventilation, exhaust, etc.). See the chapter
entitled "Installation".
- Check that the plugs, blanking covers and protective adhesive strips have been removed.
- Ensure that the desiccant bags have been removed from the electrical elements (cabinet or control console, alternator, etc.).
- Check the electrical connections (See the chapter entitled "Electrically connecting a generating set"):
 earthing;
 electrical control connections;
 electrical power connections;
 starter battery charging system (rating and voltage) if so equipped.
- Check that the residual current devices are operating correctly.
- Check the tension of the drive belt(s).
- Check the alternator's insulation.
- Check the starter battery or batteries (connecting and charge). See the paragraph entitled "Starter batteries".
- Check the starter battery charging system (if so equipped).
- Check the levels See the engine's maintenance manual:
 coolant;
 oil;
 fuel.
- Check that the additional equipment is in good condition and operational (notably the air filter).
- Open the oil filler tap (if so equipped).
- Open the fuel tap (if so equipped).
- Select the fuel supply method (tank, day service tank, etc., as the case may be).
- Bleed the air from the fuel system and prime the system as required, taking all necessary precautions and in full respect of
the safety instructions (See engine maintenance manual).
For generating sets equipped with a MTU 2000Gx5 / MTU 2000Gx6 type engine and a Beaward
radiator: check that the shell is centred in relation to the radiator.
For generating sets equipped with MTU 4000 series engines: the engine flywheel blocking device must be removed (crankshaft
protection during transport) before the generating set is started for the first time.
For generating sets equipped with Lombardini / Kohler engines: These engines must be run in. Do not exceed 70% of the
rated power for the first 50 hours of operation.

7.3.1 Settings of the cooling tower temperature regulator and variator
Some generating sets are fitted with variable temperature controllers and regulators
which control the speed of rotation of the fans according to the level of cooling
required for the correct operation of the generating set.
To ensure this system operates correctly, certain adjustments and checks must be
made before starting up the generating sets. The procedure below describes these
operations and applies to Schneider systems fitted with an "ALTIVAR 21" variable
controller and a "REG48PUN1JLU" regulator.
All the operations are carried out while the generating set is running
IMPORTANT
Checking the settings on the temperature regulator
Check the values shown in the temperature regulator value settings table
DISPLAY NAME OF SETTING FUNCTION VALUES TO CHECK
Type of PV input Defines the type of input sensor 1 (PT 100Ω)
Defines the position of the decimal

Position of the decimal point 1 (one decimal)
point on the PV/SV display
Switches between operating

Operating control for the ramp and soak
states for the ramp and soak OFF (stop/end)
function
function
Prevents operating errors being

Key locking 0 (no locking)
displayed
Defines the range of the control

OUT2 range output (OUT2) (also configured for 4-20 (4 mA to 20 mA)
the retransmission output)
Defines the function of the USER 5 (Launch autotuning

USER key assignment setting
key (standard))

Note: the setpoint for starting the variable speed control is a water
temperature of 85°C.
 The temperature regulator display enables the reading to be taken
directly.
To modify this setpoint, use the keys opposite.
Launching the auto-configuration function

The auto-configuration function is launched with the generating set "On Load", with an output of approx. 75% of the rated
power.
The setpoint can be modified according to the generating set's environment (hot country, etc.).
The auto configuration function is launched by pressing and holding the On/Off button.
7.4 Preparing for operation of the generating set
- Become familiar with the generating set's operating controls.

- Read and understand the control unit's “user” menus.
- Prepare a maintenance plan adapted to the configuration of the installation and the generating set - see paragraph
“Maintenance plans”.
- Become familiar with the operation of the generating set at no load or under load - see "Checking the generating set after
starting".
- Become familiar with the fluid specifications (fuel, lubricant and coolant) see the paragraph entitled "Fuels, lubricants and
coolants" and the engine's maintenance manual.

The generating sets must only be started by qualified personnel with the
necessary skills.
DANGER
7.5 Checking the generating set before startup
For generating sets operating occasionally, throughout the service life of the unit, regularly check, or before each start-up, the overall
cleanliness, general condition of the installation and the generating set, and particularly the following points:
- Check for elements that may block the air inlets and outlets, radiators and fans (dirt and debris, ice, branches, etc.).
- Check the fluid levels - see the engine's maintenance manual:
 coolant;
 oil;
 fuel.
- Open the oil filler tap (if so equipped).
- Open the fuel tap (if so equipped).
- Select the fuel supply method (tank, day service tank, etc., as the case may be).
- Check the starter battery charging system (if so equipped).
- Check the starter battery or batteries (connecting and charge) - see the paragraph entitled "Starter batteries".

7.6 Starting the generating set
7.6.1 Generating sets equipped with a preheating boiler
Some of our generating sets are equipped with an optional auxiliary preheating system. It can be activated automatically or manually,
depending on the configuration chosen.
To turn the preheating system on manually:

1. Using the control unit, check the coolant temperature: if it is below 45 °C, the preheating boiler must be turned on.
2. Switch the generating set to manual operating mode - See control unit operating manual.
3. Check that the preheating valve is in the "Fuel boiler preheating unit” position.
4. Turn the boiler on by pressing the boiler start button (located on the control console).
The preheating boiler stops automatically when the temperature of the generating set reaches 55 °C. If not, stop it manually by
pressing the button.
7.6.2 Starting
The start-up procedure differs slightly according to the generating sets' configuration and their integration within the installation. For
generating sets equipped with a control unit, refer to the control unit's operating manual for information regarding the manual or
automatic start-up modes and the associated configurations. If in doubt, please contact your nearest agent.
7.7 Checking the generating set after startup
Off-load tests
- Carry out the safety checks (emergency shutdown, oil pressure, coolant temperature, etc.).
- Check the mechanical parameters:
 engine parameters (oil pressure, coolant temperature);
 absence of abnormal vibrations;
 absence of abnormal noises;
 absence of leaks.
- Check the electrical parameters:
 voltage, frequency, current;
 rotating field.
On-load tests
- Check the mechanical parameters:
 engine parameters (oil pressure, coolant temperature);
 absence of abnormal vibrations;
 absence of abnormal noises;
 absence of leaks.
- Check the electrical parameters:
 voltage, frequency, current;
 rotating field.

7.8 Operation
7.8.1 Avoid operation without load or underloaded
When operating at no load or low load (< 30% of nominal power), the operating conditions are such that the engine cannot be used
at its optimum level. The main reasons for this are:
- A small volume of burnt fuel in the combustion chamber means that full combustion cannot be attained; the thermal energy
resulting from the combustion is not great enough for the engine's optimum operating temperature to be reached.
- Supercharged engines have lower compression ratios (low compression ratio without supercharging), which are required for
full load, and not suitable for good combustion at low load.
The combination of these factors leads to engine clogging and, in particular, the piston ring and valve clogging which results in:
- accelerated wear and glazing of the cylinder liners;
- reduced leak tightness of the mating faces, with valve rod movement sometimes becoming less efficient (sticking).
Consequently, using any supercharged engine at low load (< 30%) during tests or normal use can only have negative implications
for engine operation and service life. Maintenance will have to be stepped up in order to cope with the severe operating conditions.
Shortening draining intervals, among other things, will enable you to change the oil more frequently, which will tend to be choked with
unburnt particles and contaminated with fuel. A ballast resistance is generally added to reduce periods of low load operation and to
enable full load to be reached periodically, which is necessary to unclog the engine.
Finally, when operation is taking place under load, we recommend that you pay close attention to the oil venting system, especially
for engines whose sump air vent is located at the supercharger inlet (risk of oil or oil vapour uptake and engine racing).
7.8.2 Take the necessary safety measures during operation
RISKS OF SERIOUS ACCIDENTS

A generating set in operation presents a certain danger. Maintenance operations must not be
performed on the generating set while it is in operation.
DANGER
On production generating sets (such as the CPU20 type or CPU40 type container or specific generating set), the upstream fuel filters,
mounted on the inside face of the side doors, can be replaced while the generating set is in operation. For these foreseen, yet
exceptional operations, all safety measures must be taken to prevent accidents, notably:
- Wear the necessary personal protective equipment,
- Prior to the operation, identify all potential hazards (rotating parts, hot parts, etc.),
- Locate the emergency stop and ensure that it can be easily activated at any time during the operation (by the operator or
by another person),
- Replace the filters one by one, shutting off the fuel supply progressively on each filter. Recover the fuel in a recipient provided
for this purpose.
Furthermore, while the generating set is in operation, the container may be under a slight positive or negative pressure (significant
suction or delivery of air by the cooling fans, depending on the configuration). This normal process may either cause the outward
opening side doors to open with slightly greater force when the generating set is in operation (take care when opening them, and only
when necessary), or cause doors to close unexpectedly and make them more difficult to open from the inside (in this case, use the
emergency stop button to shut down the generating set).
7.9 Switching the generating set off
The shut-down procedure differs according to the generating sets' configuration and their integration within the installation.
In all cases:
- The emergency stop button to stop the generating set should be reserved for exceptional situations in which the safety of
persons is at stake.
- Progressively lower the load demanded to the generating set and allow it to idle (0% load) for ten or so minutes before
stopping it.
For generating sets equipped with control units, refer to the control unit's operating manual for information regarding the manual or
automatic shut-down modes and the associated configurations. If in doubt, please contact your nearest agent.

8 Maintenance
RISKS OF SERIOUS ACCIDENTS

The maintenance operations must be carried out:
- under sufficient lighting conditions,
- generating set stopped and engine cold,
- starter battery disconnected,
DANGER - emergency stop button engaged.
Become aware of the safety instructions prior to all operations. Ensure that all adjustments and repairs are carried out by personnel
who have received appropriate training. Our dealers are highly qualified and can answer all of your questions. They can also supply
you with spare parts and other services and they have qualified staff to carry out preventive and corrective maintenance on generating
sets and even ensure their complete overhaul.
8.1 Maintenance plans
The user should check that the installation is in good working condition at all times.
- Perform the maintenance operations outlined in the documentation supplied with the generating set.
- Perform regular checks and tests to ensure that the installation is operating correctly.
These regular servicing operations, checks and tests must be recorded in a test log containing the following information: interval,
nature of the inspection and/or test performed, date and time carried out, report of operations, and the name and signature of
technician.
MGS_186_EN _17/07/2017 15:01 33532000201_6_1 Section_8 _Maintenance 99

8.1.1 Develop an adapted maintenance plan
The maintenance plans (periodic maintenance tables) are outlined in the respective documentation (service
manual) for the engines, alternators and for certain additional equipment. As a general rule, these plans make
a distinction between use under continuous operation and use under emergency operation. They also take
the consumables used into account, for example: the sulphur content of the diesel fuel or the grade of lubricant
oil.
The maintenance plan should be adapted based on the configuration of the installation, the generating
set and all the equipment.
IMPORTANT Preference should be given to the manufacturer's recommendations, and their servicing rules are to
be followed when performing the operations.
The operations below are to be performed in addition to the manufacturer's recommendations. If you
have any doubt, please contact one of our agents.
It is recommended that the following check be performed (non-exhaustive list):
Guide to good practices (2 x month) Comments

On the entire installation
Check overall cleanliness.
Check for leaks.
Check that air inlets and outlets are unobstructed.
Check fasteners and connections.
Check for faults and alarms on display units and/or control panel when powering up the unit (*).
Check for sheet metal corrosion and that safety-related stickers are in place.
Fuel system
Check the fuel level in the external tank and in the day service tank.
Check the operation of the automatic filling system on the day service tank (*).
Drain water and sediments from the tanks and fuel filter(s) (depending on the equipment).
Check the operation of the fuel supply shut-off valve reserved for emergency services (to be
performed only when the generating set is not in operation).
Preheating systems
Check the operation of the preheater(s) (*).
Compressed air system (depending on the equipment, refer to the manufacturer's
documentation)
Check the air pressure in the air system's compressed air cylinders.
Drain water and impurities from the cylinders.
Oil system
Check the engine crankcase oil level.
Check the oil level of the make-up tank (depending on the equipment).
Check the operation of the automatic make-up system (depending on the equipment) (*).
Cooling system
Check the coolant level.
Check the coolant's level of protection against freezing.
Check the overall cleanliness (clogging) of honeycomb elements.
Exhaust (depending on the equipment)
Drain the condensates from the exhaust line.
(*) Visual inspection to be performed during periodic tests
100 Section 8 Maintenance 33532000201_6_1 MGS_186_EN _17/07/2017 15:01

It is also recommended that an adapted schedule be prepared based on the table below:
GOOD PRACTICES TABLE

Refer to the manufacturer's documentation for the specific maintenance operations
FREQUENCY (h)
Comments
LEVEL (1)
Commissioning
Calendar limit
10h / 1 x day
After 20h
OPERATIONS
1000h
500h
GENERATING SET
Load testing at min. 50% of rated power (ideally 80%) for 1 hour after
stabilisation of parameters (2) and associated checks 1 1m
(Reminder: Does not replace the manufacturer's recommendations)
Check for leaks 1 6m X X X
Visually inspect general condition 1 6m X X X
Check the clogging indicator on air filter(s) (if fitted) 1 6m X X X
Check the condition and connections of hoses and pressure lines 1 6m X X X
Clean the generating set 1 6m X
Clean the relays and contactors with low-pressure compressed air 3 6m X
Check the condition and connections of the electrical equipment 1 6m X X X
Check the condition of drive belts 2 1y X X X
Check and retighten fasteners 1 1y X X X
Test the differential relay (3) 3 1y X
CONTAINER
Check and bleed the various fuel filters on generating set(s), as required 2 6m X X X X
Replace the various fuel filters on the generating set(s) 2 1y X
Check the condition and cleanliness of the air inlet and outlet elements 2 6m X X X
Check the condition and cleanliness of the radiators 2 1y X
Check the condition and cleanliness of the sound traps 2 1y X
BATTERIES
Check the charging system and the charge status of the starter batteries,
3 6m X X
remote control
Service the batteries (starter and remote control, if equipped) 3 1y X
EXHAUST SYSTEM
Check the condition of the elements (mechanical condition and alteration of
2 1y X
materials)
Check that the various fasteners are tight (support, frame, clamping or
2 1y X
mufflers)
Clean the spark arrester, if the generating set is so equipped 2 1y X

Check the catalysers, if the mufflers are so equipped 2 1y X
FAN
Clean and check the condition of the fan 2 1y X
Check that bird guards/safety grilles are secure and free of obstruction 2 1y X
Check for abnormal engine wear, signs of overheating 2 1y X

GOOD PRACTICES TABLE
Refer to the manufacturer's documentation for the specific maintenance operations
FREQUENCY (h)
Comments
LEVEL (1)
Commissioning
Calendar limit
10h / 1 x day
After 20h
OPERATIONS
1000h
500h
AIR COOLER
Purge the engines equipped with drain holes 2 6m X

Check the condition and cleanliness of the cooling coils 2 1y X
Check the condition and connections of the electrical equipment 3 1y X
Check all visible threaded fasteners 2 1y X
TRAILERS
Check the overall condition of the vehicle 2 6m X X X
Check the tyre pressure 2 6m X X X
Check wheel lug nut tightness 2 6m X X X
Check automatic brake efficiency 2 6m X
Check parking brake efficiency 2 6m X
Check the braking adjustment and distribution across all wheels 2 6m X
Check the braking control hinges and joints 2 6m X
Check the stands 2 6m X
Lubricate or grease the moving parts of the coupling device 2 6m X
Check the wear on brake linings and drums 2 1y X
Check that there is no play in the hubs 2 1y X
Check for play in the towing tube 2 1y X
Check for play in the ball-hitch coupler or ring 2 1y X
Grease the braking control hinges and joints 2 1y X
Grease the stands and jockey wheel rod 2 1y X
(1): 1 = Operator / 2 = Specialist (mechanic) / 3 = Specialist (electricity).
(2): Test to be performed if the generating set has not operated under full load for 1 month.
(3): Contact one of our agents.

8.2 Testing generating sets
Notes on operation at no load and under load

When operating at no load or low load (< 30% of nominal power), the operating conditions do not allow for optimum operation of the
engine. The main causes are as follows:
- The low volume of fuel burned in the combustion chamber leads to incomplete combustion; the resulting thermal energy
means that the optimum engine operating temperature cannot be reached.
- Overheated engines have lower compression ratios (low compression ratio without turbocharging), which are defined for full
load and not suitable for good combustion at low load.
All of these factors lead to choking of the engine, in particular the piston rings and valves, which leads to:
- accelerated wear and glazing of the cylinder liners;
- loss of sealing of seats, and sometimes sticking of valve stems.
Consequently, operating any turbocharged engine at low load (< 30%) during tests or normal use can only have adverse
repercussions on an engine's operation and its service life. Maintenance intervals will have to be shortened to accompany harsh
operating conditions. Shortening draining intervals, among other things, will enable you to change the oil more frequently, which will
tend to be choked with unburnt particles and contaminated with fuel. A ballast resistor is generally added to limit low load phases and
obtain the periodic full loads necessary to unchoke the engine.
Finally, when operating under load, we advise vigilance with regard to the oil breather circuit, and more particularly to engines which
have the crankcase vent connected to the turbocharger inlet (risk of oil or oil vapour absorption and accelerated engine speed).
Under load tests

It is recommended to test the generating set under load every month, for a period of around 1 hour after the parameters have
stabilised.
The load must be greater than 50% of nominal power (ideally 80%), to ensure unchoking of the engine and to obtain a decent picture
of the generating set operation.
Off load test (no load)

This test is not recommended; it should not last longer than 10 minutes and should not be repeated without the monthly test under
load. This test only allows you to check for correct engine start-up. It does not allow you to check that the generating set is working
properly.
Tests on emergency supply generating sets (only concerns France, see NF E 37-312)
For emergency supply generating sets (GSS), the following tests must be performed:
- periodic checks on the oil, coolant and fuel levels, the engine heating device and the condition of the source used for start-
up (battery or compressed air), for example every two weeks;
- automatic starting test with a minimum load of 50% of the nominal power of the generating set when used or on a ballast
resistor, for example every 6 months. During this test, the fuel supply cut-off valve, reserved for emergency purposes, must
never be used when the generating set is in operation.

8.3 Cleaning a generating set
Using a high pressure washer:
- Clean at an operating pressure below 120 bar,
- A minimum spray distance of 20 to 30 cm should be maintained between the sprayer nozzle and the
surface to be cleaned,
- Cleaning on the inside of the enclosures and containers is prohibited,
IMPORTANT
- Do not spray exterior electrical equipment (terminal strips, control unit, etc.).
8.3.1 Cleaning a generating set with an enclosure
The sealing between the cover and the frame and between the frame and the retention tank is ensured by a gasket.
It is essential to replace the gasket if the cover has been removed.
IMPORTANT
Users must maintain the enclosures and base frames to ensure that the paintwork retains all its protective properties.
8.3.1.1 Cleaning frequency
Carry out cleaning:

- whenever necessary;
- at least every 6 months;
- after sea transportation.
Clean generating sets more frequently if they are installed in wooded areas or corrosive atmospheres, or if soiled by dust or organic
matter (rotting leaves, foam, waste, etc.).
Check regularly that the holes for draining rain and condensation are not blocked. If there is a blockage, stagnant water can damage
the generating set's enclosure and fill the retention tank (if fitted, optional).
8.3.1.2 Cleaning procedure
Clean the inside and outside of the generating set regularly:
The use of abrasives is prohibited.

The insulation foam is fragile. Care should be taken not to damage it during the operation.
When cleaning, ensure that the drain holes are clear.
IMPORTANT
1. Open the doors of the generating set if necessary, then remove the panels and keep the bolts.
2. Clean the inside of the generating set: remove any plant debris, leaves and waste and check that the drainage holes are not
blocked.
3. Carefully screw the removable panels back on and close the generating set doors if necessary.
4. Wash the outside of the generating set using a cleaning agent (water with a mild detergent added, e.g. car shampoo).
5. Carefully rinse with clean fresh water to remove any trace of cleaning product at an operating pressure of less than 120 bar
(if using a high-pressure washer, maintain the washer nozzle at a distance of at least 20 to 30 cm from the surface to be
cleaned).
6. For generating sets equipped with a retention tank, perform the draining operation recovering the fluids and, when possible,
check the condition and operability of the retention tank's high level sensor.
7. Dry with a soft, absorbent cloth.
A cleaning foam may be used and wiped off using a soft, absorbent cloth. Stubborn stains may be removed using a suitable solvent
(white spirit or equivalent) and wiped off using a soft, absorbent cloth.
Curative treatment will be necessary to eliminate any major scratches. This treatment should be carried out by a trained professional.

DRAINAGE HOLES: NEVER PLUG
Ensure that all drainage holes are functional. Water must be able to drain outside in all circumstances.
IMPORTANT
M1xx enclosures
Drainage holes
Removable panel
M2xx enclosures
Removable panel Drainage holes
Removable panel
Drainage holes

M3xx enclosures
Drainage holes Air inlets

Removable panel
Drainage holes
Removable panel
M4xx enclosures
Removable panel Drainage hole
Figure 65: Drainage holes for generating sets with enclosure

8.3.2 Cleaning a containerised generating set
8.3.2.1 Cleaning frequency
Carry out cleaning:

- whenever necessary;
- at least every 6 months;
- after sea transportation.
Clean containerised generating sets more frequently if they are installed in wooded areas or corrosive atmospheres, or if soiled by
dust or organic matter (rotting leaves, foam, waste, etc.).
8.3.2.2 Cleaning procedure
Clean the inside and outside of the generating set regularly:
The use of abrasives is prohibited.

When cleaning, ensure that the drain holes are clear.
IMPORTANT
1. Open the container doors.

2. Inspect and clean the inside of the container: remove any plant debris, leaves and waste and check that the drainage holes
are not blocked.
3. Check the condition and operability of the retention tank's high level sensor (if installed).
4. Lubricate the hinges, locks and seals with silicon grease.
5. Wash the outside of the generating set using a cleaning agent (water with a mild detergent added, e.g. car shampoo).
6. Carefully rinse with clean fresh water to remove any trace of cleaning product at an operating pressure of less than 120 bar
(if using a high-pressure washer, maintain the washer nozzle a distance of at least 20 to 30 cm from the surface to be
cleaned).
7. Dry with a soft, absorbent cloth.
A cleaning foam may be used and wiped off using a soft, absorbent cloth. Stubborn stains may be removed using a suitable solvent
(white spirit or equivalent) and wiped off using a soft, absorbent cloth.
Curative treatment will be necessary to eliminate any major scratches. This treatment should be carried out by a trained professional.

DRAINAGE HOLES: NEVER PLUG
Ensure that all drainage holes are functional. Water must be able to drain outside in all circumstances.
IMPORTANT
CIR 20: drainage holes (X2)
Removable
panel

CPU20: drainage holes (X4)
CPU40: drainage holes (X9)

8.4 General principles for maintaining the circuits
This chapter outlines the general rules for maintaining the lubricating, fuel and cooling circuits.
Taking into account the configuration of the installation, the generating set and the associated equipment,
adapt the proposed procedures.
Preference should be given to the manufacturer's recommendations, and their servicing rules are to be
followed when performing the operations.
IMPORTANT
The operations below are to be performed in addition to the manufacturer's recommendations. If you have
any doubt, please contact one of our agents.
8.4.1 Oil circuit
Generating set to stop and battery isolator opened.

Engine at operating temperature.
Hot oil.
The oil may contain harmful combustive residues.
Danger of burning and poisoning!
DANGER - Wear protective clothes, gloves and masks.
- Avoid contact with the skin.
- Do not breathe the oil vapours.
8.4.1.1 Oil sampling
In order to correctly compare the results, it is necessary to make sure of the representativeness of the samples by means of a suitable
sampling method.
When in severe conditions of use, analyses should be carried out more frequently, for example when:
- in extreme climatic conditions ;
- subject to repeated starts ;
- the engine is running for a long time on low load ;
- there is high sulphur content in the fuel (from 0.5 to 1.5% by weight).
Some signs that the oil is no longer carrying out its function may include:
- Unusually large deposits or precipitations on the inside of the engine and its components such as filters, centrifuges or
separators, in particular when compared with the previous analysis ;
- unusual discolouration of components.
As a precaution, also send a bottle containing a new oil sample which will serve as a reference point for the analysis of the used oil.
SAMPLING POINT:
Sampling is carried out at a representative point in the system, preferably just after the machine is shut down:
- always at the designated sampling point(s)
- failing this, via the dipstick well with a syringe and flexible hose ;
- as a last resort, directly from the sump drain point after draining the polluted fluid at the bottom of the sump.
PREPARATION OF SAMPLING POINT:
In order to avoid contaminating the sample:

- the sampling point and the sampling equipment shall be meticulously cleaned before each sample is taken and before
opening the system ;
- as far as possible, avoid environmental disturbances when taking the sample (wind, dust, rain,...).
The laboratory supplied bottle should be filled to ¾ full. In the absence of a laboratory supplied bottle, make sure there is a minimum
amount of 125ml.
Use an appropriately labelled and cleaned bottle. Some important points to note during sampling are:
- brand and type of oil ;
- date of sampling ;
- type of equipment and serial number ;
- operating hours since commissioning
- operating hours since last draining ;
- type of Sampling: during "draining" or during a "sampling"
- any oil top ups, if this is the case, indicate how many litres were added ;
- interventions carried out.

The recommended tests for the analysis are as follows:
Physical parameters Units
Spectrometric analyses (wear) Units Viscosity at 40°C DIN 51562 mm²/s
Iron (Fe) DIN 51399-1:2012-5 mg/kg Viscosity at 100°C DIN 51562 mm²/s
Chromium (Cr) DIN 51399-1:2012-5 mg/kg
Tin (Sn) DIN 51399-1:2012-5 mg/kg Viscosity Index (VI) calc.
Aluminium (Al) DIN 51399-1:2012-5 mg/kg Oxidation DIN 51451, DIN 51453 A/cm
Nickel (Ni) DIN 51399-1:2012-5 mg/kg Nitration DIN 51451, DIN 51453 A/cm
Copper (Cu) DIN 51399-1:2012-5 mg/kg
Lead (Pb) DIN 51399-1:2012-5 mg/kg Sulphation DIN 51451, DIN 51453 A/cm
Molybdenum (Mo) DIN 51399-1:2012-5 mg/kg Dirt moving capability %
PQ Index TBN (total base
DIN ISO 3771 mgKOH/g
Impurities number)
Silicon (Si) DIN 51399-1:2012-5 mg/kg DIN EN 12634-1999-
TAN (total acid number) mgKOH/g
Potassium (K) DIN 51399-1:2012-5 mg/kg 02
Sodium (Na) DIN 51399-1:2012-5 mg/kg pH
Water DIN 51,451 % Additives
Glycol DIN 51375-1 % Calcium (Ca) DIN 51399-1:2012-5 mg/kg
Vegetable oil DIN 51639-4:2010-02 % Magnesium (Mg) DIN 51399-1:2012-5 mg/kg
Diesel fuel DIN 51375-1 % Boron (B) DIN 51399-1:2012-5 mg/kg
Biodiesel DIN 51375-1 % Zinc (Zn) DIN 51399-1:2012-5 mg/kg
Soot (SiO) DIN 51452 % Phosphorous (P) DIN 51399-1:2012-5 mg/kg
Barium (Ba) DIN 51399-1:2012-5 mg/kg
Molybdenum (Mo) DIN 51399-1:2012-5 mg/kg
Sulphur (S) DIN 51399-1:2012-5 mg/kg
SAMPLING METHOD:
1st method: sampling with a syringe:
1. Connect a flexible hose to the syringe.

2. Insert the other end of the hose into the dipstick well, taking care not to reach the bottom of the sump.
3. Draw the oil into the syringe until it is completely filled..
4. Once the syringe is full, remove the hose, empty the syringe into the bottle and seal it as soon as possible.
5. If necessary, repeat the operation until the bottle is ¾ full.
6. Close the bottle by tightly screwing the cap and check the information on the label.
2nd method: sampling at the drainage point:
This method can be used by adapting the periodic draining of the oil sump.
1. Place a basin under the drain point.

2. Open the drain point.
3. Allow a little liquid to flow out before collecting the sample
4. Fill the bottle tightly to ¾ full.
6. Close the drain point.
7. Top up if necessary.

8.4.1.2 Draining and replacing the oil filter
Figure 66: Examples of oil sump drain valves Figure 67: Oil drainage pump
1. Draining the oil:
a) Use a suitable container.

b) If applicable, close the valve on the oil top up tank.
c) Open the drain valve on the oil sump.
d) Using the manual drain pump, drain the oil from the engine sump.
2. Change the oil filter as follows:
a) Remove the filter using a suitable tool and dispose of the filter element.
b) Clean the sealing surface on the connecting part.
c) Check the sealing ring of the new filter and coat it with new oil
d) Screw the new oil filter on according to the manufacturers recommendations.
e) If applicable, replace the other filters in the same manner.
3. Close the oil drain valve.
4. Fill/Top up the oil circuit:
a) Open the fill cap.

b) Pour in suitable oil until it reaches the "max" mark on the dipstick
c) Close the fill cap.
5. Checking the oil level:
a) Remove the dipstick from the guide tube and wipe.

b) Insert the dipstick as far as it will go into the guide tube, remove it after 10 seconds and check
the oil level.
c) The oil level should be between "min" and "max".
max
min
d) If necessary, top up until the oil reaches the "max" mark
e) Insert the dipstick as far as it will go into the guide tube.
6. Starting the generating set.
a) If applicable, open valve on the oil top up tank.

b) If applicable, switch on the pre-lube system.
c) If possible turn the engine using the turning device and check the oil level again.
d) Start the generating set.
e) Inspect the engine oil pressure and the sealing on the oil filter.
f) Stop the engine and wait 10 minutes to inspect the oil level again.

8.4.2 Fuel circuit
FIRE AND EXPLOSION HAZARD!

Fuels are inflammable.
- Avoid open fire, electric sparks and sources of ignition
- Do not smoke.
DANGER
Generating set set to stop and battery isolator opened.
High pressure fuel in the fuel lines may cause serious injury.
Do not disconnect the fuel lines between the fuel pump and injectors.
Only drain the fuel system via the fuel filters.
Before carrying out any work make sure that the pressure in the fuel system has dropped.
DANGER
8.4.2.1 Fuel pre-filters
Additional fuel filters are fitted on some generating sets. In addition to the recommendations that appear in the maintenance manuals
for the engines (filters fitted by the engine manufacturers), the operations described in this paragraph must be performed.
A : FILTER
B: SEAL
C: WATER DRAIN D B
D: AIR BLEED VALVE
E : PRIMING PUMP E
F: WATER SENSOR A
B ISOLATION VALVES
D
B
A
A
B
B
A
B
B
F C
C
Figure 68: Pre-filter examples (changing filter using the bowl)
D ISOLATION VALVES
B
Figure 69: Prefilter examples (changing filter using the lid)

8.4.2.1.1 Pre-filter maintenance
How often you check for water in the fuel and replace the filter element depends on the quality of the fuel used and the level of
contaminants it contains.
For common use, the following intervals may be used :

- Check for water :
 in the case of loss of power ;
 once a day, if necessary.
- Replace the filter element at the same time as the main fuel filter
Note: the presence of water in the filter is easy to check ; with water having a greater density than the fuel, it will sink to the bottom of
the transparent bowl, appearing as a different colour to the lighter density oil above.
8.4.2.1.2 Bleeding
1. Shut down the generating set and wait for the engine to cool in order to avoid any risk of fire.
2. If the filters fitted in series are equipped with an isolation valve, alternately isolate the filter being purged
2. Place a container under the water drain tap.
3. Unscrew (around 2 turns) the water drain tap on the bowl and the air vent valve (if present). Drain the water.
4. Close the water drain tap and the air vent valve
5. Make sure the drain tap and vent valve are closed tightly.
8.4.2.1.3 Filter replacement
PRELIMINARY OPERATIONS:
1. Shut down the generating set and wait for the engine to cool in order to avoid any risk of fire.
2. Close the isolation valve between the tank and the filter if applicable.
3. If the filters are fitted in series and are equipped with an isolation valve, alternately isolate the filter being replaced.
PROCEDURE FOR REPLACING THE FILTER
Generally, the replacement instructions will come with the spare filter.
If necessary when finished replacing the filter, drain the fuel supply circuit.
1st case: changing filter using the bowl
1. Open the air bleed valve (if applicable).

2. Place a suitable container under the water drain tap to catch the fuel.
3. Unscrew (around 2 turns) the water drain valve on the bowl and drain the fuel.
4. Remove, by hand if possible, any components required to access the filter cartridge. Discard the used filter cartridge
5. Double check the integrity and cleanliness of the components (filter support, bowl, seals,...). Replace any questionable
elements.
6. Close the drain and bleed valves.
7. Lubricate the seals with oil or fuel and insert the new filter cartridge.
8. Fill the components with clean fuel.
9. Hand tighten the filter support.

2nd case: changing filter using the lid
8.4.2.2 Draining the fuel system
The procedure for priming the fuel supply circuit is generally described in the engine manufacturer manual. Follow these
recommendations.
Engines equipped with an automatic priming system do not require manual priming.
PROCEDURE FOR DRAINING THE FUEL SUPPLY SYSTEM
1st case: Without priming pump (the fuel source must be higher than the filter inlet)
1. Place a container under the air bleed valve to catch any fuel.
2. Open the shut-off valve which allows fuel to be supplied to the engine.
3. Unscrew (around 2 turns) the air bleed screw on the fuel filter until the fuel flows without bubbles.
4. Close the air bleed screw.
5. Start the engine and check there are no leaks.
2nd case: With a manual priming pump, without manual air bleed
2. Work the priming pump until it becomes difficult to pump (pressure point).
3. Wait a minute then repeat.
3nd case: With a manual priming pump and manual air bleed
1. Place a container under the air bleed valve to catch any fuel.
3. Unscrew (around 2 turns) the air bleed screw on the fuel filter.
4. Work the priming pump until the fuel flows without bubbles.
5. Close the air bleed screw. Continue to work the priming pump until it becomes difficult to pump (pressure point).
If it fails to start, repeat the procedure up to 3 times.

8.4.3 Cooling system
RISK OF SERIOUS BURNS

Coolant is a product which is toxic to your health and the environment.
Do not ingest!
Coolant is flammable.
Liquid escaping suddenly from the cooling system may cause serious burns.
DANGER Wear protective clothes, rubber gloves and protective goggles.
Shut down the engine.
Do not remove the fill cap until it has cooled enough to be turned with bare hands. Start by
turning the cap on the expansion tank to the first notch to release the pressure, then remove it
completely.
Different types of coolant must not be mixed.
After draining the cooling system, several successive refills are necessary to completely fill the circuit.
IMPORTANT Before starting to refill, make sure you have enough new coolant for the whole system (engine, pipes, radiator,...).
8.4.3.1 Drainage schedule
For common use, the following intervals may be used:

- Sampling for analysis:
 Once per year or every 1000 hours (whichever comes first)
 When draining.
- Drain: every 2 years or 2000 hours (whichever comes first)
8.4.3.2 Coolant sampling
In order to correctly compare the results, it is necessary to make sure of the representativeness of the samples by means of a suitable
sampling method.
Regular analyses of the coolant will allow you to prevent engine problems well before they present themselves, improve the running
of equipment and reduce costly repairs.
The test can detect:
- cavitation corrosion
- chemical distribution ;
- leakage of combustion gases ;
- contamination ;
- electrical earthing problems.
When in severe conditions of use, analyses should be carried out more frequently, for example when:
- in extreme climatic conditions ;
- subject to repeated starts ;
- the engine is often running for a long time on low load ;
Some signs that the coolant is no longer carrying out its function may include:
- Engine Overheating ;
- colour alteration ;
- deposits present.
SAMPLING POINT:
Sampling is carried out at a representative point in the system, preferably just after the machine is shut down:
- always at the designated sampling point(s)
- if not, then by the radiator coolant drain valve after draining the polluted fluid at the bottom of the radiator ;

PREPARATION OF SAMPLING POINT:
In order to avoid contaminating the sample:

- the sampling point and the sampling equipment shall be meticulously cleaned before each sample is taken and before
opening the system ;
- as far as possible, avoid environmental disturbances when taking the sample (wind, dust, rain,...).
- The laboratory supplied bottle should be filled to ¾ full. In the absence of a laboratory supplied bottle, make sure there is a
minimum amount of 250 ml.
Use an appropriately labelled and cleaned bottle. Some important points to note during sampling are:
- Brand and type ;
- date of sampling ;
- type of equipment and serial number ;
- operating hours since commissioning
- operating hours since last draining ;
- type of Sampling: during "draining" or during a "sampling"
- any oil top ups, if this is the case, indicate how many litres were added ;
- interventions carried out.
The recommended tests for the coolant analysis are as follows:
- pH:
- Spectrometric analyses (Phosphorus, Zinc, Calcium, ...) ;
- additives ;
- percentage of glycol/water ;
- physicochemical analyses (reserve alkalinity, density, ...);
- conductivity.
SAMPLING METHOD:
This method can be used by adapting the routine oil change.
1. Place a basin under the drain point.

2. Turn the cap on the expansion tank to the first notch to release the pressure, then remove it completely.
3. Open the drain point.
4. Allow one litre of liquid to flow out before collecting the sample
5. Collect about 1 litre of liquid.
7. Close the drain point.
9. Put the expansion tank cap in place and close.
8.4.3.3 Draining
Preliminary operations
1. Place a suitable container to collect the coolant under the drain valves and caps.
2. Turn off the pre-heating element (if applicable)
Drainage procedure:
2. Open the drain points and let the coolant flow from the following locations (depending on the configuration):
- radiator drain valve ;
- engine block ;
- pre-heater group;
- coolant pump body ;
- Injection pump ;
- thermostat case
- any cooling system pipes equipped with a drain.
3. Close all the open drainage points.
4. Put the expansion tank cap in place and close.

8.4.3.4 First fill
Prioritise filling with the help of a pump, through the lowest point in the circuit.
1st case: Filling with a pump
1. Connect a suitable pump to the lowest drain point with a flexible hose.
2. Loosen the permanent aeration points and the air bleed points. It is sometimes necessary also to bleed the body of the
pump and the thermostat housing.
4. Open the drain valve and fill the cooling circuit using the pump to a pressure of at least 0.5 bar.
5. During filling, when the liquid begins to flow without any bubbles, close, in succession, the drain and bleed points.
6. Fill the circuit until the level in the expansion tank is at its maximum.
7. Close the drain valve.
8. Check that the expansion tank cap is in good condition, clean the sealing surfaces if necessary.
9. Put the cap in place and close it.
10. Make sure there are no leaks anywhere in the cooling system.
11. Dismantle and clean the pump and hose.
2nd case: Alternative, filling through the expansion tank:
2. Loosen the permanent aeration points and the air bleed points. It is sometimes necessary also to bleed the body of the
pump and the thermostat housing.
3. Pour the coolant into the expansion tank.
4. During filling, when the liquid begins to flow without any bubbles, close, in succession, the drain and bleed points.
5. Fill the expansion tank until it reaches the maximum level.
6. Check that the expansion tank cap is in good condition, clean the sealing surfaces if necessary.
8. Cut off the fuel supply and start the engine for 10 seconds maximum.
11. Top up the cooling liquid until it reaches the max. level.
13. Start the engine again and repeat the operations described in the previous steps of this procedure as many times as
necessary until it is no longer necessary to top up the coolant.
8.4.3.5 Sealing test and addition
1. Start the engine without load until the water temperature reaches 60-70 °C.
2. Shut down the engine and let it cool down.
5. Top up the cooling liquid until it reaches the max. level.
6. Start the engine again and repeat the operations described in the previous steps of this procedure as many times as
necessary until it is no longer necessary to top up the coolant.
Check the coolant level in the expansion tank for the next two starts.

8.5 Air filter
Certain manufacturer documentation use only a clogging indicator to define air filter maintenance.
If such an indicator is absent, and without an additional servicing indication, the filter(s) should be
replaced at least yearly, or more often if necessary.
IMPORTANT
8.5.1 Air filter for dusty atmospheres
Certain generating sets are equipped with air filters for dusty environments : maintenance requirements for these filters is determined
by checking the maintenance indicator provided on these filters.
Note: The maintenance indicator may be specific to, or an original part by, the engine manufacturer. The maintenance indicator is
mounted on the engine air intake, just after the air filter.
Maintenance frequency
- Do not judge the condition of the filter by its visual appearance.
- Carrying out maintenance too frequently may cause :
 Damage to the filter cartridge ;
 Incorrect installation of the filter cartridge ;
 Accidental introduction of dust into the engine.
Specific maintenance indicator

The maintenance indicator signals the right time to clean and/or replace the filter cartridge. The
maintenance indicator is an instrument which measures static pressure. This measurement is
taken at the filter outlet, into the engine. It indicates the level of air restriction (air suction
resistance).
The dust particles captured by the filter gradually increase the level of restriction (air suction
resistance) of the filter. Once a certain level of resistance is reached, as defined by the
manufacturer, the maintenance indicator activates.
The maintenance indicator must be screwed on to the filter, by hand.
If the air filter is fitted with a dust removal valve (A), press on the B
tip of the valve to remove accumulated dust particles.
Check the maintenance indicator on the air filter (B). when the
indicator is red :
- If indicated, clean the air filter, when clogged, the

permitted number of times (in case of conflicting
information, respect the lowest number of times) ;
A
- If not, replace the filter cartridge every time it is clogged.
Reset the indicator.

Maintenance procedure
These operations must only be carried out when the generating set is shut down.
These operations must only be carried out by qualified personnel.
IMPORTANT
1. Carefully remove the cartridge. 2. Thoroughly clean the inside of the filter body as well as
the parts in contact with the seals, with a clean, damp
cloth.
3. Check the condition and elasticity of the seals on 4. Install the new cartridge and carefully close the cover.
the new filter cartridge.
5. Check that the whole air intake circuit is sealed 6. Reset the maintenance indicator by pushing the button
marked C after changing the filter cartridge.

8.6 Hoses
The service life of a hose and/or pressure line essentially depends on the internal and external stresses to which it is subjected. Also,
the action plan below should be implemented in order to adapt the hose and/or pressure line's service life.
Creation of a follow-up table, including:

- Date of manufacture
- Date of commissioning
- Replacement date
The follow-up table contains technical records that can be used to provide quality-related information about the service life of each
hose and/or pressure line and thus extend the replacement intervals where applicable.
Recommended monitoring plan

Visual inspection every 6 months or as often as necessary according to requirements.
Check for:
- significant permanent or local deformation (denting, crushing, blistering, elbows, etc.),
- external cracking or downgrading of the external texture,
- damage to the external layer through its entire thickness,
- cuts rendering the structure or reinforcement visible,
- slippage of the connection on the tube,
- traces of leakage or sweating, and
- incorrect operation of connectors or obvious loss of tightness.
Replacement after a predetermined service life

Generally speaking, the service life varies from 1 to 10 years, based on stresses to which it is subjected. Service life may be
determined based on previous experience, regulatory requirements, analysis of the strength of the hose or pressure line in relation
to stresses. The risk analysis may have an influence on the surveillance plan.
The remaining potential of a hose or pressure line can be evaluated at the time of its replacement. Its condition (visual inspection,
testing, ageing analysis, etc.) must be analysed. This analysis is required in order to consider extending its service life.

8.7 Starter batteries
DANGER
Risk of explosion or fire (oxygen and hydrogen present). The battery must never be
exposed to any naked flames or sparks.
Risk of sparks forming and an explosion. When fitting the battery, never invert the
polarities.
Do not short the battery terminals with a tool or other metal object.
Risk of injury. Battery electrolyte is extremely corrosive. Always protect your eyes, skin
and clothing when handling batteries. Always wear protective goggles and gloves.
In the event of contact with the skin, wash thoroughly with water and soap. If the eyes are
splashed, rinse thoroughly with water and consult a doctor immediately.
8.7.1 Checking the electrolyte level
The electrolyte level must be approximately 10 mm above the battery plates.

1. Top up with distilled water if necessary.
2. Pour the distilled water carefully to avoid any splashes.
Wear protective goggles and rubber gloves when handling the battery (adding
water, charging, etc.).
Note: some batteries requiring no maintenance form the subject of specific

instructions which must be respected.
After the battery has been topped up, it must be recharged for at least 30 minutes.
8.7.2 Checking the voltage/acid density
Every 2 months, the following checks must be performed:

1. Check the density of the acid contained in the cells (all the battery cells must have the same density; if this is not the case,
the battery must be replaced)
2. Check the voltage when idle.
Acid density Charge status Voltage when idle Observation / action

1.27 100% Above 12.60 V
1.25 80% 12.54 V
1.20 60% 12.36 V From 60% recharge
1.19 40% 12.18 V Risk of sulphation
1.13 20% Below 11.88 V Unusable
The results of the density and voltage measurements make it possible to define the charge status of the battery. If the charge status
is less than 60%, the battery must be recharged.

8.7.3 Connecting/disconnecting the battery
To connect the battery:

1. Connect the red connecting cable (+) to the positive battery terminal.
2. Then connect the black cable (-) to the negative battery terminal.
To disconnect the battery:
1. First disconnect the black cable (-).
2. Then disconnect the red cable (+).
8.7.4 Charging the battery
Highly discharged or sulphated batteries (formation of whitish lead sulphate deposit on the plates, which becomes hard) can no longer
regenerate or be charged in a generating set.
A discharged battery should be recharged immediately, or else it will suffer irreparable damage.
IMPORTANT
Battery charge
Example of charge:
- 12V 60 Ah battery = 6 A charging current;
- Charge status: 50% (acid density 1.19 and voltage when idle 12.30V);
- The battery is short 30 Ah, and this must be recharged.
- Charge factor: 1.2;
- 30 Ah x 1.2 = 36 Ah to be charged;
- Charging current: 6A, approximately 6 hours charging required; the charging current
must always be 1/10th of the nominal capacity of the battery.
Recharging is complete when the battery voltage and the acid density stop increasing.
The power of the charger must be suitable for the battery to be charged and the charging time available.
Note: if several batteries connected together are being recharged, the following points must be checked:
- Are the batteries connected in series?
- Is the voltage chosen exact? 1 battery x 12 V, 3 x 36V batteries.
- Adjust the charge current to the lowest battery.
- The power difference between the batteries must be as low as possible.
8.7.5 Cleaning the battery
Keep the batteries clean and dry. The presence of impurities and rust on the battery and
terminals may cause the current jumps, voltage drops and the battery to discharge,
particularly in humid weather.
1. Clean any signs of oxidation on the battery terminals and the cable terminals using a
brass brush.
2. Fully tighten the cable terminals and lubricate them with grease for battery terminals or
vaseline. A terminal which is not secured correctly may cause sparks and therefore
lead to an explosion.

8.8 Air coolers
Before starting any operation:

- Check that the installation has been switched off.
- Ensure that the power supply has been made safe.
- For an operation on the harness, reduce the temperature and the pressure.
Operations should only be carried out by qualified personnel.
IMPORTANT
Regularly check that the harness fins are not clogged and clean as often as local conditions require. Note: The cleanliness of the
device is a factor which will determine its performance and length of service life.
As the engines are fitted with an oil vapour recirculation system, the harness should not get greasy. As a general rule, using
compressed air directed parallel to the fins should be sufficient to clean the harness.
In all cases, cleaning should be undertaken with care to ensure the surface of the fins is not damaged.
The operating procedure described below is a theoretical operating procedure.

It will have to be adapted to the installation which is actually fitted. If in any doubt, please refer to a specialist.
IMPORTANT

1. Drain the high temperature (HT) and low temperature 2. Remove the flexible pipes connected to the engine.
(LT) cooling circuits via tapping points in the lower
section of the air cooler (drain boss and vents provided 3. Disconnect the wiring on all the extractor fans (after
on the manifolds or pipes). making the power supply safe), and then remove the
fans, starting at the top of the air cooler.
Drain
point
LT circuit
Drain
point
HT circuit
4. Carry out the same procedure for the other fans. 5. Remove the fan support panels.
6. Disconnect the servomotors from the motorised 7. Remove the motorised ventilation flap to gain access to
ventilation flap. the harness.
Servomotors Motorised
ventilation flap
Servomotor
connection unit
8. Using an industrial vacuum cleaner, remove all foreign bodies that might obstruct the harness. Blow the harness with
compressed air, if necessary.
9. If there are any traces of grease, use commercial solvents to clean the harness.
10. Refit the components in the reverse order to removal, then close the circuits and fill the harness with antifreeze coolant.

8.9 Maintenance of additional equipment
This section contains general descriptions and maintenance procedures concerning additional equipment which may be fitted to our
generating sets.
8.9.1 Exhaust mufflers
Maintenance must only be carried out when the generating set or installation is switched off, and the engine
and its components have cooled down.
IMPORTANT
The user must carry out the following checks annually (or more frequently if the installation or operating conditions require):
- check the mechanical performance of the components;
- check the tightness of the various fastenings;
- check that the drainage system operates correctly (cf. condensate collector);
- periodic cleaning of spark arresters if fitted to the silencer;
- periodic check of the catalytic converters (efficiency and condition) if fitted to the silencers.
All repairs must be carried out by qualified personnel.
8.9.2 JAPY manual pump
Deadlines:
Every week: check that the connections are well sealed and there are no leaks.
Every month: check the condition of the pump cover and body and keep it clean.
For a pump used every two or three days there is no special maintenance.
At the beginning of winter, drain the pump, protect it from freezing by wrapping it or disassembling and keeping it protected.
For a pump which isn't regularly used it is necessary after each usage to strictly follow the following instructions:
- make sure the pump is completely drained.
- lubricate the pump to make sure it doesn't rust.
IMPORTANT
Procedure for lubricating the manual pump
Compliance with these instructions is essential to keep the pumps in good working order:
1. Remove the top fitting
2. Tilt the pumps piston to 55° with the lever
3. Using an oil syringe equipped with an elbow fitting, apply a small amount of vaseline oil onto the
cylindrical wall of the pump body. Tilt the piston to the other side and perform the same operation,
always with a very small dose.
4. Work the lever a dozen times, through the full range of movement, in order to distribute the
lubricant to all the edges of the pump body.
5. Then leave the lever in the upright position.
6. Replace the fitting
Following a maintenance fault on a pump which hasn't been used for several weeks, the mechanism is at risk of
becoming blocked by rust on the cast iron components.
IMPORTANT In this case, it will be necessary to dismantle the pump (contact one of our agents).
In case of major difficulty using the lever during pumping, do not force it, and check to make sure there are no foreign bodies in the
suction circuit, drain the pump.

Sealing EP, BP and HL series pumps
1. Lever
2. Cap
3. Piston + valves + pins
4. Seat + valves + pins
5. Body
6. Fittings and seals
8. Packing gland + ring + packing
Sealing on EP, BP and HL series pumps is done using a packing gland and ET209 packing made of ramie yarn impregnated with
PTFE. The rotation speed of the piston pin is low and cannot cause wear of the piston even when it is dry.
This system cannot be sealed 100% and requires regular monitoring in-situ.
In case of leakage, the packing must be compressed by tightening the two bolts, gently and alternately, on the oval gland which rests
on a ring. This compresses the packing in its housing. After tightening, check the effort it takes to work the pump. The movement
should remain easy.
The advantage of this solution is that it is possible to make adjustments to the sealing externally without disassembling the cover of
the pump.
There is a complete seal kit.
Draining:
A small valve or screw, on the piping about 0.70 m below the pump, is indispensable. In case of prolonged periods without use, drain
the pump and apply some vaseline oil, by spray if possible, in order to avoid blockage of the internal components.

9 Storage/Removal from storage
A generating set which is left unused may have a damaging effect on the engine and alternator. To reduce these effects, it is advisable
to prepare and store the generating set correctly.
Storing the engine

- Clean the engine.
- Replace all fluids with protective fluids or fresh fluids.
- For details of storage or removal from storage, refer to the manufacturer's documentation.
Storing the alternator

- Store the alternator in a dry place (use of independent radiators is advised to keep the coils dry).
- For details of storage or removal from storage, refer to the manufacturer's documentation.
Storing batteries
- Batteries ready for use must be stored in a cool and dry place (frost-free) protected from the sun.
- Batteries must be transported and stored in a vertical position to prevent any risk of acid spillage.
- Leave the terminal cover on the positive terminal.
128 Section 9 Storage/Removal from storage 33532000201_6_1 MGS_186_EN _17/07/2017 15:01

10 Rapid identification of minor malfunctions
10.1 Generating set verifications

In the event of a malfunction, check the display on the control unit (if equipped) and refer to the meaning of the alarms, faults and
anomaly codes as required. The following points can be checked:
The generating set… Check that: Solutions to be applied:
The installation and the Redo the installation and commissioning

Has a mechanical problem,
commissioning were carried out operations, call upon an agent for
does not start or operates in NO
correctly. assistance, if necessary.
an abnormal manner
YES
The pre-start checks were performed
Re-check prior to start-up.
correctly. NO
YES
The battery is correctly connected and Perform minor troubleshooting on the
charged. NO batteries and battery chargers.
YES
The control unit parameters are
correct, it does not display a fault and Refer to the control unit operating manual.
is not in “out of service” mode. NO
YES
The maintenance operations were
Perform the necessary maintenance
performed correctly, in keeping with
operations, call upon an agent for
the established maintenance NO
assistance, if necessary.
schedule.
YES
Eliminate the cause of the triggering
The damper valve is open.
NO before resetting it.
YES
Have the generating set and the
installation checked by an agent.
The installation and the Redo the installation and commissioning

Has an electrical problem,
commissioning were carried out operations, call upon an agent for
does not deliver current, the NO
correctly. assistance, if necessary.
installation is not supplied.
YES
The electrical connections were made
Follow the recommendations of the
in compliance with the diagrams
NO diagrams provided.
provided.
YES
The control unit parameters are
correct, it does not display a fault and Refer to the control unit operating manual.
is not in “out of service” mode. NO
YES
The generating set is in compliance
with the installation, in terms of power Call upon an agent for assistance.
NO
and configuration.
YES
The maintenance operations were
Perform the necessary maintenance
performed correctly, in keeping with
operations, call upon an agent for
the established maintenance NO
assistance, if necessary.
schedule.
YES
Tripped circuit breaker(s). Call upon an agent for assistance.
NO
YES
The alternator delivers voltage. Call upon an agent for assistance.

NO
YES
Have the generating set and the
installation checked by an agent.
If the problem persists, call upon an agent for assistance. The serial numbers of the generating set, the engine, alternator and possibly
the control unit (if equipped) are often necessary.
MGS_186_EN _17/07/2017 15:01 33532000201_6_1 Section_10 _Rapid identification of minor malfunctions 129
10.2 Starter batteries
Fault observed Probable origin Measures or observations
Incorrect composition Cool
The acid heats up when a new battery is
Incorrect storage Charge the battery
filled
Prolonged storage in a damp place Check the acid density
The acid escapes through the filler holes The battery is too full Reduce the battery fluid level
Battery tray not leaktight Replace the battery
Acid level too low Considerable formation of gas due to a Check the charger and repair if
very high charging voltage necessary
Insufficient charge
Acid level too low Recharge the battery
Short circuit in the power circuit
Incorrect operation from start-up Check the electrical installation
Consumption fault
The battery has been filled with acid Reduce the acid level and fill with distilled
Acid density too high
instead of water water. Repeat the operation if necessary
Battery empty Recharge the battery
Starting problems Battery exhausted or faulty
Starting test incorrect Capacity too low Replace the battery
Battery sulphated
Incorrect electrical connection Tighten the ends of the battery cables or

Battery terminals melted replace them if necessary and replace
Battery cabling incorrect
the battery
One or two cells release a lot of gas at
Faulty cell(s) Replace the battery
high charge
Charge status too low Check the load
Short circuit in the power circuit
The battery discharges very quickly High self-discharge (for example:
through electrolyte contamination) Replace the battery
Sulphation (storage of discharged
battery)
Incorrect battery part no Define the correct battery part no. for the
recommended use
Short service life
Repeated deep discharging It is recommended to charge the battery
Battery stored too long without charge using a regulator
Overload
High water consumption Check the charger (voltage regulator).
Charging voltage too high
Sparks after battery charging
Short circuit
Connection or disconnection during
The battery explodes Replace the battery
charging
Internal fault (for example: interruption)
and low electrolyte level
130 Section 10 Rapid identification of minor malfunctions 33532000201_6_1 MGS_186_EN _17/07/2017 15:01
10.3 JAPY manual pump
Locating and resolving faults

- The pump no longer provides suction or loses prime:
 There is air ingress: check all the seals and suction pipes.
 The foot valve (suction valve) no longer works: there is probably dirt or some sort of waste under the valve which is
preventing it from resting on its seat; check it.
 There is dirt inside the pump blocking the valves: remove the cover, clean the inside and check that the valves move
freely.
- Stuffing box leak:

 Tighten the two nuts of the stuffing box bracket by one or two turns alternately. If necessary, remove this bracket, remove
the stuffing box located inside its housing. Clean this housing by removing the packing residue. Replace the packing
with graphite packing.
 In the case of a pump without a stuffing box, model 254, remove the cover, replace the O-ring, and ensure that the
piston pin is not oxidised. If so, clean it thoroughly. Also reapply graphite grease to the groove.
10.4 JAPY electric pump
The pumps do not have any particular maintenance requirements. Check for leaks around the seals if necessary.
Fault finding and resolution
The motor does not work
Possible causes Actions
No electric current Check the connections
Remove the pump from the motor

Rotor jammed
Look for any foreign bodies
No flow or insufficient pressure
Possible causes Actions
Suction height too high Bring the pump closer to the fluid to be pumped
Foot valve jammed Clean or replace
Filter clogged Clean the filter
Significant load loss Increase the diameter of the pipes
Bypass valve blocked Clean or replace
Air in the suction pipes Check that they are sealed
Check the pipe connections

Fluid leak
Replace the seals
MGS_186_EN _17/07/2017 15:01 33532000201_6_1 Section_10 _Rapid identification of minor malfunctions 131
11 Glossary
European Agreement Concerning the International Carriage of Dangerous Goods by Road: this
agreement stipulates the conditions for the merchandise involved, notably their packaging and labels,
ADR
and the conditions notably for the construction, equipment, and use of the vehicle transporting the
materials involved.
AIPR designates electrical equipment (cabinet or box) which houses the main circuit breaker
AIPR (downstream from the power alternator) and the auxiliary outgoing feeders. The AIPR is generally
mounted on the generating set base frame. It is used for housing circuit breakers of 800 A or more.
Auxiliaries
The electrical auxiliaries of a generating set comprise the electrical equipment which ensures the
(auxiliary electrical
correct operation of the generating set, in particular that of the internal combustion engine: battery
equipment of a generating
charger, preheating of the internal combustion engine, electric fuel supply pump, etc.
set)
Retention tank This is a vessel for collecting generating set leaks, to prevent them from polluting the environment.
Welding seam This is a welding bead.
Box This is the common name given to an ISO container.
Generating set connection terminal identified by a PE marking or by a standardised "Earth" symbol and
Earth terminal
provided to enable the generating set to be earthed. This terminal is internally connected to the earth
(of a generating set)
of the generating set and, according to the earthing system diagram (SLT), to the alternator neutral.
Low Voltage Low Voltage A: 50 V <LVA < 500 V alternating current
LV
Low Voltage B: 500 V <LVB < 1000 V alternating current
Multipolar cable Cable comprising more than one insulated conductor.
Tripolar cable Multipolar cable comprising three insulated conductors.
Single pole cable Cable comprising a single insulated conductor.
Checking the rotating field on a three-phase installation involves checking the rotation direction of the
phases using an instrument (phase rotation tester or rotophaser): when the instrument's connectors,
Rotating field
phase 1, phase 2, and phase 3, are connected to the corresponding phases of the network being
(rotating field check)
checked, the display on the instrument indicates whether or not the order 1-2-3 indicated by the
markings on the tested conductors (terminals, cables) is correct.
Application (or performance) classes: G1, G2, G3 and G4.
Standardised performance classes for generating sets defined by standard ISO 8528-1:
They define the particular requirements concerning precision and stability for the voltage and frequency
of a generating set during load variations in the installation to be supplied.
- Class G1: for an application where the connected loads are such that only basic parameters
of voltage and frequency are required;
Application classes
- Class G2: for an application where the demands on voltage characteristics are very much the
(or performance classes)
same as for the commercial power system;
- Class G3: for an application where the connected equipment may make severe demands on
frequency, voltage and waveform characteristics (for example: telecommunications and
thyristor-controlled loads);
- Class G4: for applications where the demands made on the frequency, voltage and waveform
characteristics are exceptionally severe (for example: data-processing equipment).
Output class: COP, PRP, LTP, ESP, DCP and MAX.
Output class
Standardised output class of a generating set defined by standard ISO 8528-1 and ISO 8528-8.
Standardised fitting on all 8 corners of ISO containers enabling containers to be handled and
ISO corner casting
transported.
IMD Insulation monitoring device.
132 Section 11 Glossary 33532000201_6_1 MGS_186_EN _17/07/2017 15:01

Container Safety Convention.
International convention governing container safety (or CSC convention), which was implemented in
France by Decree No. 80-837 of 20 October 1980 and the orders implementing it.
These orders define the process for obtaining CSC approval, and list the bodies authorised to issue
this approval. This approval, which comes in the form of a standardised plate permanently fixed on
each approved container, is obligatory for authorisation of sea transportation. The stacked load that the
container can bear is indicated on this plate.
This approval is obtained by the manufacturer, for each container model, by submitting a technical file,
subject to validation of standard tests by the approved body.
CSC
RCD Residual current device.

Fuel tank filler This is the filling pipe for a fuel tank.
Residual current device RCD.
Device protecting against the risks of an electric shock based on detecting an abnormal earth-leakage
current resulting from an insulation fault in an electrical installation.
This device is designed to cut off the power supply to the faulty electric circuit when the earth-leakage
current becomes greater than the maximum allocated residual current (sensitivity) of the device. The
sensitivity and the activation time may be fixed or adjustable depending on the model of the residual
current device.
They can be distinguished according to their sensitivity:
Earth fault
- high sensitivity (≤ 30 mA);
- average sensitivity (100 mA to 1 A);
- low sensitivity (3 A to 20 A).
There are three types of residual current devices:

- differential circuit breaker;
- differential switch;
- differential relay.
Differential circuit Differential device cutting off the supply to an electrical circuit when a fault current to earth has been
breaker detected or in the event of an overload or short circuit.
Emergence Difference between the sound pressure level ("sound level") measured at a given location near an
(acoustic) operating generating set and the level measured when this generating set is switched off.
PAB Public access building.
Parameter specific to an electrical installation at a given moment obtained by dividing the active power
P (kW) by the apparent power S (kVA) at this moment. The power factor varies according to the nature
of the devices being supplied at a given moment (for example: when powerful electric motors are
switched on, the power factor decreases).
Power factor:
In an installation, the active power P (kW) and the apparent power S (KVA) are related to the power
cos φ *
factor PF by the relationship: PF = P / S. In an installation comprising various devices in operation
(lights, computers, electric heating, lifts, etc.) the power factor is, on average, between 0.8 and 1.
* the power factor of an installation is sometimes referred to as the cosine PHI (cos φ) of this
installation.
Stacking This is the action of placing containers on top of each other.
NG Natural gas
ORD Off-road diesel
LPG Liquefied petroleum gas
High Voltage High Voltage A: 1000 V < HVA < 50 000 V alternating current
HV
High Voltage B: 50 000 V < HTB alternating current
MGS_186_EN _17/07/2017 15:01 33532000201_6_1 Section_11 _Glossary 133

Electrical impedance measures the opposition of an electrical circuit to the passage of asinusoidal
Impedance alternating current.
The concept of impedance is a generalisation of Ohm's law in the study of alternating current circuits.
Differential device cutting off the supply to an electrical circuit when an earth-leakage current has been
Differential switch detected. Unlike the differential circuit breaker, the differential switch does not provide protection
against overloads or short circuits.
Sound pressure level (of a generating set).
The sound pressure level LpA (commonly called "sound level") of a generating set is expressed in dBA
and is measured using a standardised method at a given distance from the generating set. It represents
the sound intensity emitted by the generating set and detected by the human ear at this point. The
sound pressure level depends on the sound power level LWA of the generating set and the distance
LpA
from the measuring point to the generating set; this distance should therefore always be specified when
a sound level is indicated.
- The sound pressure level indicated in the instruction manual for the generating set is
measured in an unobstructed spaced 1 m away from the generating set, in accordance with
the applicable European Directives.
Guaranteed sound power level (of a generating set).
Sound emission level in dB(A) characterising the acoustic energy radiated by a generating set. The
sound power level is a characteristic of the generating set which does not change; it must not be
LWA confused with the sound pressure level LpA (sound level).
The marking of the guaranteed sound power level LWA on the identification plate of generating sets
designed for use outside buildings in countries within the European Union meets a requirement of
European Directive 2000/14/CE.
Metal part of electrical equipment likely to be touched and which is not normally supplied with voltage
Earth but could be in the event of an insulation fault. All the earths of the generating set are connected to an
earthing busbar equipped with a generating set earth terminal.
The generating set earthing consists of establishing an electrical connection between the generating
Earthing set earth terminal and an earth connection or a local earth terminal of an installation using a cable
(of a generating set) (green AND YELLOW earth conductor which has a cross-section appropriate to the generating set
output).
Single-phase
A single-phase generating set (or an alternator), supplies the electrical current with a single-phase and
(generating set or
a neutral (2 poles).
alternator)
These are the rectangular apertures in the lower part of a base frame where the forks are inserted to
Forklift pockets
move the generating set.
Exhaust head loss When fluid is flowing in a pipe and energy is lost due to friction, we talk about head loss.
Mean effective pressure.
The MEP*, or mean effective pressure, is the pressure which, if applied constantly to the piston of an
internal combustion engine throughout its power stroke, would make it possible to obtain the same level
of work to that which is actually created. This is therefore a false measurement which is used to
MEP
compare various engines and to determine the application class of the generating set according to
standard ISO 8528 (class G1, G2 or G3). The MEP is indicated in bar or kPa in the technical
specifications of internal combustion engine manufacturers.
* in English: BMEP (Brake Mean Effective Pressure).
An electrically conductive element buried in the ground to establish an electrical contact with the local
Earth connection
earth (for example: earthing rod, earthing electrodes).
The active power P of a generating set is the actual power, measured in kW, supplied by this generating
set to an installation. It is the mechanical power of the internal combustion engine converted into
electrical power by the alternator. It is related to the apparent power (S) (kVA) and the power factor
(PF) through the relationship: P (kW) = S (kVA) x PF.
Active power (kW)
- The rated active power (kW) which appears on the identification plate of the generating set is
the maximum power that the generating set is capable of providing under the operating
conditions defined by the output class (COP, PRP, LTP or ESP) assigned by the manufacturer
to the generating set and indicated on the identification plate.

The apparent power (S) provided by a generating set to an installation is the power calculated in kVA
from the current (I) per phase and the voltage (U) between phases independently of the installation's
power factor (PF). The apparent power is calculated using the following formulas:
- Single-phase generating set: S (kVA) = U (V) x I (kA) I (kA) = I (A) / 1000
- Three-phase generating set: S (kVA) = U (V) x I (kA) x √3
Example: a three-phase generating set supplies 400 V between phases and 100 A per phase to an
installation. The apparent power S (kVA) = 400 x 0.100 x 1.732 = 69.28 kVA.
-
A three-phase generating set is designed and protected (circuit breaker setting) to be able to
Apparent power (kVA) provide its rated active power (kW) to an installation whose power factor (PF) can vary from 1
to 0.8.
- The rated apparent power (kVA) indicated on the identification plate of a three-phase
generating set is determined for a rated power factor (PF) of 0.8 and is therefore equal to the
rated active power (kW) divided by 0.8.
For example: If the rated active power of a three-phase generating set is 80 kW, the rated apparent
power in kVA is: 80 / 0.8 = 100 kVA.
- When the rated power factor (PF) indicated on the identification plate of a single-phase
generating set is 1, the rated apparent power (kVA) is equal to the rated active power (kW).
Maximum power in kW that a generating set is capable of supplying continuously under a constant load
for an unlimited number of hours per year, under the agreed operating conditions, provided that the
maintenance intervals and operating modes are observed in accordance with the manufacturer's
requirements.
Continuous Power COP
Legend
t time
P power
a
Continuous power (100%)
Maximum power in kW that a generating set is capable of supplying continuously under a variable load
for an unlimited number of hours per year, under the agreed operating conditions, provided that the
maintenance intervals and operating modes are observed in accordance with the manufacturer's
requirements.
The mean admissible power (Ppp) over a 24-hour period must not exceed 70% of the main power,
unless otherwise agreed by the manufacturer of the heat engine.
Prime Power: PRP
Legend
t time
P power
a
Prime power (100%)
b
Average permissible power in a 24h period (P pp)
c Actual average power in a 24h period (P pa)
d Shutdown
NOTE t1 + t2 + t3 + … … … + tn = 24h

Maximum power available in kW, for a variable power sequence, under the specified operating
conditions, that a generating set is capable of supplying up to 200 hours per year if the network energy
is interrupted or under test conditions, provided that the maintenance intervals and operating modes
being observed in accordance with the manufacturer's requirements.
The mean admissible power (Ppp) over a 24-hour period must not exceed 70% of the emergency
standby power, unless otherwise agreed by the manufacturer of the heat engine.
Emergency Standby
Power: ESP
Legend
t time
P power
a
Emergency standby power (ESP)
b
Average permissible power in a 24h period (P pp)
c Actual average power in a 24h period (P pa)
d Shutdown
NOTE t1 + t2 + t3 + … … … + tn = 24h
Maximum power in kW that a generating set is capable of supplying up to 500 hours per year, under
the agreed operating conditions, provided that the maintenance intervals and operating modes are
observed in accordance with the manufacturer's requirements.
NOTE: The limited running time power (100%) is limited to a maximum of 500 hours per year.
Limited Time Running

Power: LTP
Legend
t time
P power
Limited time power (LTP)
The power given by multiplying the current and voltage that the generating set is capable of providing
for at least 5 minutes within the following voltage and frequency limits.
Note 1: The prescribed output voltage must be within ± 10 % of the rated voltage and the output frequency must be
Maximum power: MAX within ± 8% of the nominal frequency.
Note 2: The protection device must not be activated within 5 minutes and the overload conditions must satisfy the
requirements of paragraph 6.4 Overload conditions from ISO 8528-8. The minimum ratio between rated power
(COP) and maximum power (MAX) should be such that Pnominal/Pmax ≥ 0,75.
Term sometimes used to designate the earthing system (SLT in French) of an installation (see
Earthing system
paragraph "Earthing system").
Differential device which only detects the fault current to earth in an electrical circuit. It is designed to
Differential relay be connected to the control of a circuit breaker which it opens in order to cut off the electrical supply
when a fault current is detected.

DT Daily service tank.
Jockey wheel This is the wheel located on the draw bar. It may be swivelling and height adjustable.
Earthing system.
SLT
(see paragraph "Earthing system").
Very low voltage. VLV < 50 V alternating current
VLV
VLV < 120 V direct current
Line-to-line voltage Voltage between any two phases of a three-phase system.
Line-to-neutral voltage Voltage between neutral and any one phase of a three-phase system with neutral.
Low voltage central control panel.
LVCCP This is the low voltage electrical switchboard of large electrical installations.
This switchboard forms the link between the supplier's incoming line and the customer network.
Heat tracing Electrical system (for example: heating tape) installed on pipes or fuel tanks to prevent them from
(fuel system) freezing.
Three-phase
A three-phase generating set (or an alternator), supplies the electrical current with three phases (3
(generating set or
poles) or with three phases and a neutral (4 poles).
alternator)
This is used to compensate for volume variations to which the mass of a fluid in the facility is subjected
Expansion vessel
due to temperature fluctuations.

12 Table of illustrations
Figure 1 : Example of a generating set identification plate ................................................................................................................. 13
Figure 2: Position of the identification plate for generating sets with and without protective covers ................................................... 14
Figure 3: Position of the identification plate for generating sets in a container ................................................................................... 14
Figure 4: Examples of engine identification plates ............................................................................................................................. 15
Figure 5: Examples of alternator identification plates ......................................................................................................................... 15
Figure 6: Example of an electrical cabinet identification plate ............................................................................................................ 15
Figure 7: General description of a generating set without a protective cover ..................................................................................... 16
Figure 8: General description of a generating set with a protective cover .......................................................................................... 17
Figure 9: General description of a generating set with a protective cover .......................................................................................... 18
Figure 10: Example of a mobile generating set on a trailer ................................................................................................................ 19
Figure 11: Example of a lighting column............................................................................................................................................. 19
Figure 12: Example of an ISO 20 container........................................................................................................................................ 21
Figure 13: Example of an ISO 40 container........................................................................................................................................ 21
Figure 14: Example of a CPU 20 container ........................................................................................................................................ 22
Figure 15: Example of a CPU 40 container ........................................................................................................................................ 22
Figure 16: Example of a CIR 20 container.......................................................................................................................................... 23
Figure 17: Example of a container on a trailer .................................................................................................................................... 23
Figure 18: Integrated fluid retention container .................................................................................................................................... 24
Figure 19: General view of the regulator ............................................................................................................................................ 25
Figure 20: Simplified diagram of valve action ..................................................................................................................................... 25
Figure 21: JAPY manual pump ........................................................................................................................................................... 26
Figure 22: JAPY JEV Electric pump ................................................................................................................................................... 27
Figure 23: Damper valve models ........................................................................................................................................................ 28
Figure 24: Examples of handling using forklifts .................................................................................................................................. 42
Figure 25: Handling example of a generating set using a mobile winch ............................................................................................. 43
Figure 26: Example of recommended lashings for generating sets with protective enclosures .......................................................... 46
Figure 27: Signalling example for on-road trailers .............................................................................................................................. 49
Figure 28: Release cable.................................................................................................................................................................... 51
Figure 29: Example of a coupling head .............................................................................................................................................. 52
Figure 30: Wear indicator ................................................................................................................................................................... 53
Figure 31: Trailer lubrication/greasing points ...................................................................................................................................... 56
Figure 32: Examples of problems that may be encountered .............................................................................................................. 58
Figure 33: Containers placed directly on the ground .......................................................................................................................... 59
Figure 34: Figure: Example of a fuel tank installation in France ......................................................................................................... 60
Figure 35: Example of an installation.................................................................................................................................................. 61
Figure 36: Examples of an increase in sound level caused by reverberations and sound directivity .................................................. 62
Figure 37: Example of a generating set room ..................................................................................................................................... 63
Figure 38: Example of the size of a room ........................................................................................................................................... 64
Figure 39: Example of a lifting system ................................................................................................................................................ 65
Figure 40: Example of an installation.................................................................................................................................................. 66
Figure 41: Example of a burnt gas exhaust circuit .............................................................................................................................. 68
Figure 42: Examples of pipes and elbows .......................................................................................................................................... 69
Figure 43: Example of a compensator and hose ................................................................................................................................ 69
Figure 44: Examples of bleeds ........................................................................................................................................................... 69
Figure 45: Examples of bulkhead crossings ....................................................................................................................................... 69
Figure 46: Examples of exhaust outlets.............................................................................................................................................. 69
Figure 47: Examples of suspension lines ........................................................................................................................................... 70
Figure 48: Examples of needle frames ............................................................................................................................................... 70
Figure 49: Examples of column bases................................................................................................................................................ 70
Figure 50: Examples of suspension lines ........................................................................................................................................... 70
Figure 51: Example of an absorption silencer .................................................................................................................................... 71
Figure 52: Example of an absorbent reactive silencer ........................................................................................................................ 71
Figure 53: Example of an adapted silencer ........................................................................................................................................ 71
Figure 54: Schematic diagram for calculating the chimney height ...................................................................................................... 72
Figure 55: Examples of exhaust chimneys ......................................................................................................................................... 73
Figure 56: Condensate collector ......................................................................................................................................................... 74
Figure 57: Positioning constraints ...................................................................................................................................................... 76
Figure 58: Removing the cover plate .................................................................................................................................................. 77
Figure 59: Installing the extension ...................................................................................................................................................... 77
Figure 60: Example of a container installation with self stabilising chimney ....................................................................................... 77
Figure 61: Neutral TT system ............................................................................................................................................................. 83
Figure 62: Neutral TN-S system (separate earth and neutral) ............................................................................................................ 83
Figure 63: Neutral IT system .............................................................................................................................................................. 84
Figure 64: Power supply diagram including external sources which may be coupled to the HVA grid ............................................... 86
Figure 65: Drainage holes for generating sets with enclosure .......................................................................................................... 106
Figure 66: Examples of oil sump drain valves .................................................................................................................................. 112
Figure 67: Oil drainage pump ........................................................................................................................................................... 112
Figure 68: Pre-filter examples (changing filter using the bowl) ......................................................................................................... 113
Figure 69: Prefilter examples (changing filter using the lid) .............................................................................................................. 113
138 Section 12 Table of illustrations 33532000201_6_1 MGS_186_EN _17/07/2017 15:01

MGS_186_EN _17/07/2017 15:01 33532000201_6_1 Section_12 _Table of illustrations 139
SPECIFICITES DES CAPOTS M137 ET M138
PASSAGES DE FOURCHES POUR CHARIOT ELEVATEUR RACCORDEMENT ELECTRIQUE DU PUPITRE

La hauteur des passages de fourches est limitée à 65 mm
1er perçage à 2ème perçage à
effectuer sur le effectuer sur la
joint en plaque en
caoutchouc aluminium
65 mm
M137 uniquement M137 uniquement
ELINGAGE ACCES POUR LA MAINTENANCE
Le point de levage central est en option Portes pour la maintenance quotidienne
Panneau démontable pour la maintenance préventive

Possibilité d’élinguer par le châssis avec un écarteur
VIDANGES
La vidange du bac de
rétention est à réaliser par
aspiration (montage client)
Vidange de l’huile et du liquide de refroidissement
Le carter d’huile et le radiateur sont équipés d’un robinet de vidange manuel et d’un tuyau de vidange.
Lors de la vidange, le tuyau est à passer à travers l’orifice de vidange extérieur du châssis (bouchon amovible).
33530065701_1_1
SPECIFICICATIONS FOR M137 AND M138 ENCLOSURES
FORKLIFT POCKETS CONTROL DESK WIRING

Height of forklift pockets is limited at à 65 mm
Second drilling
First drilling to to be performed
be performed on the
on the rubber aluminium plate
65 mm seal
M137 only M137 only
LIFTING MAINTENACE ACCESS
Central upper lifting point is an option Doors for daily maintenance
Removable pannel for preventive maintenance

Possibility to sling by the frame with a spreader
DRAINS
Retention frame is drained

by succion (customer
setup)
Oil and cooling drain
The oil tank and cooling radiators are equiped with a manual cock and drain hose.
Operating drain, pass the hose through hole in the frame dedicated for external draining (removable cap).
33530065701_1_1
ESPECIFICIDADES DE LOS CAPOTAJES M137 Y M138
PASAJES PARA HORQUILLA PARA CARRETILLA

CONEXIÓN ELÉCTRICA DEL PUPITRE
ELEVADORA
La altura de los pasos de la horquilla está limitada a 65 mm
2da perforación
Primer hoyo para hacer en la
que se hará en placa de
el sello de aluminio
65 mm
goma
sólo M137 sólo M137
ESLINGA ACCESO PARA EL MANTENIMIENTO
El punto de elevación central es opcional Puertas para el mantenimiento diario
Panel extraíble para mantenimiento preventivo

Posibilidad de colgar del chasis con un esparcidor
EXTRACCION
El drenaje del tanque de

retención se realizará por
succión (instalación del
cliente)
Drene el aceite y el refrigerante
El cárter de aceite y el radiador están equipados con una válvula de drenaje manual y una manguera de drenaje.
Al drenar, la tubería debe pasar a través del orificio de drenaje externo del chasis (tapa extraíble).
33530065701_1_1
SPEZIFIKATIONEN DER HAUBEN M137 UND M138
GABELPASSAGEN FÜR GABELSTAPLER ELEKTRISCHE VERBINDUNG

Die Höhe der Gabelkanäle ist auf 65 mm begrenzt
2. Bohren auf
1. Loch wird auf der
der Aluminiumplatte
65 mm Gummidichtung
angebracht
Nur für M137 Nur für M137
ANSCHLAGEN ZUGANG ZUR WARTUNG
Der zentrale Anschlagpunkt ist optional Türen für die tägliche Wartung
Abnehmbares Panel für vorbeugende Wartung

Möglichkeit, mit einem Streuer am Fahrgestell zu schlingen
ENTLEERUNG
Die Entleerung des

Auffangwanne für
Flüssigkeiten, integriert im
Tankchassis
erfolgt durch Absaugen
(Kundeninstallation)
Öl und Kühlmittel ablassen
Die Ölwanne und der Kühler sind mit einem manuellen Ablassventil und einem Ablassschlauch ausgestattet.
Beim Entleeren muss das Rohr durch das externe Abflussloch des Tankchassis geführt werden (abnehmbare Kappe).
33530065701_1_1
User Manual
User Level
Controller
APM303
Soft version : 1.1.0
33502030901_1_1
23/01/2015
 The "user level" user manual is designed for users who are qualified to set up an
installation (generating set and environment). These users must be able to monitor
that the generating set is operating correctly (start, stop, basic settings), to interpret
any indications (mechanical, electrical) and may be required to check one or more
parameters.
 The "operator level" user manual is designed for those who – in addition to the skills
required for users – have the skills required to modify one or more parameters, to
change the operation of an installation (generating set and environment). To do this,
the operator will have completed training provided by the manufacturer beforehand.
 The "specialist level" user manual is designed for those who – in addition to the
skills required for operators – have the skills required to make any special or complex
modification to an installation (generating set and environment). To do this, the
specialist will have completed training provided by the manufacturer beforehand.
APM303 - QUICK START GUIDE page 1/2
abbreviations used: GS = Generating Set 5 - Operation in MANUAL mode: GS off
ATS = Automatic Transfer Switch  Manually open the GS circuit breaker (the power is cut
1 - Safety instructions off).
Read the safety instructions on starting up Allow the engine to cool down for 3 minutes.
a GS. Press the STOP button, the RUN LED goes off, the engine
(see General and Safety Manual) stops.
When the GS is off, the control unit may be powered by a
dangerous voltage (preheating, battery charger). 6 - Operation in AUTO mode
When on, the APM303 is powered by a dangerous voltage.
The APM303 has been factory preconfigured; modifying its The AUTO mode is active only if the AUTO LED is fixed.
parameters may make the generating set unstable.
Check that the GS circuit breaker is closed.
Press the AUTO button, the AUTO LED lights up, AUTO mode
2 - Powering on is selected.
Close the battery isolator (if fitted), Start up is possible if the ALARM! LED is off.
Turn the switch on the front of the central console ON (if fitted). Start-up is launched on activation of the remote start/stop,
input, which must be a () potential-free contact (no AC or DC
3 - Checks before starting voltage).
Battery voltage, () e.g. coming from a self-regulating ATS.
Engine oil level,
Coolant level, On activation of the input, the RUN LED flashes and the GS
GS circuit breaker open. starts.
If the ALARM! LED is flashing, refer to section 7. When the voltage and frequency have stabilised, the RUN
4 - Front panel, buttons and LEDs LED becomes fixed and the GS takes over.
On deactivation of the remote start/stop input, the RUN LED
 STOP button flashes.
stops the GS and After a cooling period (3 minutes) (), the GS stops and the
acknowledges the fault (if RUN LED goes off.
ALARM! is flashing) The AUTO LED remains on, the GS is on standby, ready for
 AUTO button another start.
selects AUTO or MANUAL () If an ATS is fitted, the total number of cooling periods
mode must be correctly adjusted.
 START button
starts the GS MANUAL mode takes priority over active AUTO mode:
- pressing the START button activates MANUAL mode,
LED off - pressing the STOP button stops the GS.
 other buttons
LED on access to screens 7 - Appearance of an anomaly
LED flashing (see section 13) If the ALARM! LED flashes (see section 13), this means that
an anomaly (alarm or fault) has been detected.
ALARM! alarm = GS not stopped fault = GS stopped
no anomaly (alarm or fault) To view the anomaly, press or to show the screen
fault detected but cleared below:
anomaly detected (alarm or fault) A C
AUTO
MANUAL mode by default B D
AUTO mode selected
remote start/stop on/engine cooling E
RUN
GS stopped A The anomaly appears with an order number
GS started (MANUAL mode) Pictogram symbolising the anomaly (see sections 9 and
B 11)
start or stop in progress
C Anomaly status (fault only, see section 10)
5 - Operation in MANUAL mode: GS on Number of hours GS has been operating when anomaly
D appeared
MANUAL mode inhibits AUTO mode.
If the ALARM! LED is off (no fault present), it is possible to E See section 13 when  flashes
start the GS.
Press the START button, the RUN LED flashes, the GS starts. Note: this screen also shows the events (see section 12).
When the voltage and frequency have stabilised, the RUN LED
8 - Active and inactive alarm
becomes fixed.
active
 Manually close the GS circuit breaker; the GS takes load
or is ready to take load.
Check the electrical and mechanical values on the APM303 inactive
screens (see section 13).
An alarm cannot be cleared: it becomes inactive even after
intervention from the user.
APM303 - QUICK START GUIDE page 2/2
9 - List of alarms 13 - Displaying the different screens
Automatic scrolling through 7 screens ( 1 to 6 + INIT).
Battery voltage low or charging alternator not working
1
Manual scrolling through 6 screens ( 1 to 6 ), by pressing
flat battery repeatedly on or .
low fuel level INIT

GS overload
1
alternator phase rotation

alarm input no. x (x=1, 2 or 3)
GS maintenance to be carried out (non-contractual) INIT
activation conditions, see user manual, operator level
1
10 - Active and inactive faults - Clearing
active, not cleared
inactive, not
cleared main ()
active, cleared 2
after pressing
inactive, cleared
after pressing
currents & voltages ()

11 - List of faults
emergency stop
3
1
low fuel level

low oil pressure
1
coolant temperature high

power levels ()
speed too high
4
speed too low
max. alternator voltage (59)
min. alternator voltage (27)
max. alternator frequency (81H)
mechanical values ()
min. alternator frequency (81L)
5
alternator short circuit (50/51)
GS failure to start
GS failure to stop
fault input no. x (x=1, 2 or 3)
counters ()()
Circ. breaker pos. inconsistent
activation conditions, see user manual, operator level 6 
 visible in automatic
12 - Events list possible if 
scrolling if:
-alarm active is flashing
The APM303 is powered on
-fault active
start up in MANUAL mode -fault not acknowledged 12 - Events and anomalies
1
start up in AUTO mode When  is fixed (after 4 seconds), the list of events and
anomalies can be viewed by pressing .
stop in MANUAL mode
stop in AUTO mode
1
AUTO mode is activated

AUTO mode is deactivated etc.
GS stabilised When the no. 12 appears at the bottom of the screen, pressing
again displays screen 1 .
automatic start when battery low
automatic stop after battery recharge () non-contractual indications () RESET not possible
Modbus order received (see Modbus manual) 14 - Dual output report pack (optional)
"general alarm and fault" and "GS ready to take load"
User guide and maintenance manual
KOHLER
Engine
KDI 2504TM
ED0053030260
edition 7 - revision 8 33521019601_3_1
01/11/2018
KDI 2504TM
OWNER MANUAL
1
REGISTRATION OF MODIFICATIONS TO THE DOCUMENT
Any modifications to this document must be registered by the drafting body, by completing the following table.
Model Review
Released by Document code Edition Revision Issue date Edited by Endorsed
N° date
Technical Technical
ED0053030260 51343 7 8 10/2014 11/2018
Documentation Documentation
Translated from the original manual in Italian language.
Data reported in this issue can be modified at any time by KOHLER.
Important
Connect to http://iservice.lombardini.it and download the latest version of this manual onto your device.
NOTE: you can select the desired language before downloading the manual, as shown in the figure below.
The online manuals are provided with hyperlinks which direct you to each individual chapter. By clicking on;
-- The analytic index titles you can go directly to the selected subject.
-- The blue underlined words you can go directly to a paragraph, a table or a picture.
-- The chapter titles (headings) you come back automatically to the chapter initial page.
-- Clicking next to the bottom page number you come back to the analytic index.
_07
EN 2 ED0053030260 _08
INDEX 1
1 - GENERAL INFORMATION 5 - INFORMATION ABOUT MAINTENANCE

1.1 Manual's Purpose.............................................................6 5.1 Useful information about maintenance.......................23
1.2 Glossary and Definitions.................................................6 5.2 Periodic maintenance...................................................23
1.3 Emission-Related Installation Instructions...................6 5.3 Oil level check................................................................24
1.4 Service request................................................................6 5.4 Oil dipstick on cylinder head........................................24
1.5 Engine component identification...................................7 5.4 Air filter check................................................................24
1.6 Manufacturer and motor identification data................8 5.5 Check of the radiator heat - exchanger surface........25
5.6 Rubber hoses check......................................................25
2 - TECHNICAL INFORMATION
5.7 Check coolant level.......................................................26
2.1 General description of the engine...............................10 5.9 Check and setting alternator standard belt tension.26
2.2 Engine specifications....................................................10 5.9.1 Check...........................................................................27
2.3 Engine dimensions (mm)...............................................10 5.9.2 Adjustment..................................................................27
2.4 Oil....................................................................................11 5.10 Check Poly-V alternator belt.......................................28
2.4.1 SAE oil classification..................................................11 5.11 Control water filter cartridge fuel...............................28
2.5 Fuel..................................................................................12 5.12 Product preservation...................................................29
2.5.1 Fuel for low temperatures.........................................13 5.13 Engine storage up to 6 months..................................29
2.5.2 Biodiesel fuel..............................................................13 5.14 Engine storage over 6 months....................................29
2.5.3 Synthetic fuels: GTL, CTL, BTL, HV..........................13 5.15 Engine starting after storage.....................................29
2.5.4 Non-Road Fuels..........................................................13 5.16 Unused machine..........................................................29
2.5.5 Emission-Related Installation Instructions.............13 5.16.1 Operations for the engine........................................29
2.6 Coolant recommendation.............................................14
2.7 Battery recommendation..............................................14 6 - INFORMATION ABOUT REPLACEMENTS
6.1 Engine oil replacement.................................................30
3 - SAFETY INFORMATION
6.2 Oil filter cartridge replacement...................................31
3.1 Safety information.........................................................15
6.3 Filter cartridge and fuel check.....................................32
3.2 General remarks............................................................15
6.4 Air filter cartridge replacement...................................32
3.2.1 Note for OEM...............................................................15
6.5 Disposal and scrapping................................................33
3.2.2 Note for end user........................................................15
3.3 Safety signal description..............................................17 7 - INFORMATION ABOUT FAILURES
3.3.1 Adhesive safety plates...............................................17
7.1 Useful information about failures.................................34
3.3.2 Warnings......................................................................17
3.3.3 Safety guards..............................................................17 8 - INFORMATION ABOUT WARRANTY
3.4 Information and safety signals.....................................18
3.5 Safety and environmental impact................................18 Warranty terms...............................................................35
3.6 Location of safety labels on engine.............................19

9 - GLOSSARY
4 - INFORMATION ABOUT USE 9.1 Glossary..........................................................................38

Symbols and units of measurement............................40
4.1 Pre-start check..............................................................20
4.2 Running-in period..........................................................20
4.3 Starting and turning off................................................20
4.3.1 Starting........................................................................20
4.3.2 After starting...............................................................20
4.3.3 Turning off...................................................................20
4.4 Refuelling........................................................................21
4.5 Oil filling..........................................................................21
4.6 Coolant filling.................................................................22
_07
ED0053030260 _08 3 EN
1 NOTES
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_07
EN 4 ED0053030260 _08
NOTES 1
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_07
ED0053030260 _08 5 EN
1 GENERAL INFORMATION
1.1 Manual's purpose
• This manual contains the instructions needed to carry out • KOHLER reserves the right to make, at any time, changes in
proper use and maintenance of the engine, therefore it must the engines for technical or commercial reasons.
always be available, for future reference when required. • These changes do not require KOHLER to intervene on the
• This manual is an integral part of the engine, in the event of marketed production up to that time and not to consider
transfer or sale, it must be attached to it. this manual as inappropriate.
• Safety pictograms can be found on the engine and it is the • Any additional section that KOHLER will deem necessary to
operator's responsibility to keep them in a perfectly visible supply some time after the main text shall be kept together
place and replace them when they are no longer legible. with the manual and considered as an integral part of it.
• Information, description and pictures in this manual reflect • The information contained within this manual is the
the state of the art at the time of the marketing of engine. sole property of KOHLER. As such, no reproduction or
• However, development on the engines is continuous. replication in whole or part is allowed without the express
Therefore, the information within this manual is subject to written permission of KOHLER.
change without notice and without obligation.
1.2 Glossary and Definitions

The paragraphs, tables and figure are divided into chapter with their progressive numbers.
Ex: Par. 2.3 - chapter 2 paragraph 3.
Tab. 3.4 - chapter 3 table 4.
Fig. 5.5 - chapter 5 figure 5.
The references of the objects described in the text and in figure and number are indicated by letters, which are always and only
related to the paragraph you are reading unless there are specific references to other figures or paragraphs.
NOTE: All data, measurements and relevant symbols are shown in the glossary section.
1.3 Emission-Related Installation Instructions

Failing to follow the instructions in the applications guidebook when installing a certified engine in a piece of nonroad equipment
violates federal law (40 CFR 1068.105(b)), subject to fines or other penalties as described in the Clean Air Act.
OEM must apply a separate label with the following statement: “ULTRA LOW SULFUR FUEL ONLY” near the fuel inlet.
Ensure you are installing an engine appropriately certified for your application. Constant speed engines may only be installed
on constant speed equipment for constant speed operation.
If you install the engine in a way that makes the engine's emission control information label hard to read during normal engine
maintenance, you must place a duplicate label on the equipment, as described in 40 CFR 1068.105.
1.4 Service request

• The complete and updated list of authorized Kohler Co. service centers can be found on websites:
www.kohlerengines.com & dealers.kohlerpower.it.
• If you have any questions regarding your warranty rights and responsibilities or the location of the nearest
Kohler Co. authorized service location, you should contact Kohler Co. at 1-800-544-2444 or access our website at
www.kohlerengines.com (USA and North American).
_07
EN 6 ED0053030260 _08 Index
GENERAL INFORMATION 1
1.5 Engine component identification
SIDE VIEW A
Oil filler cap Turbocharger
Thermostat
Oil pressure sensor

Coolant
sensor
Oil filler cap
Starter motor
Coolant pump
Oil steam separator
Nameplate
Alternator Oil drain plug
SIDE VIEW B
Turbocharger
Oil filler cap
Injection pump
Oil filter
Oil cooler
Nameplate
Oil dipstick
Oil drain plug
Fuel filter
_07
Index ED0053030260 _08 7 EN
1 GENERAL INFORMATION
1.6 Manufacturer and motor identification data

The nameplate motor identification is find side A or side B.
SIDE VIEW A SIDE VIEW B
Engine type Engine serial number
Manufacturer identification
Peak
rpm Engine
version
Approval data and

"EC" directives
_07
EN 8 ED0053030260 _08 Index
NOTES 1
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_07
Index ED0053030260 _08 9 EN
2 TECHNICAL INFORMATION
2.1 General description of the engine

-- 4-stroke, in-line cylinders Diesel engine; -- Turbocharger with Waste-gate valve;
-- Liquid-cooling system; -- Common Rail - Direct injection.
-- 4 valves per cylinder with hydraulic tappets;
2.2 Engine specifications
2.1
UNIT
TECHNICAL DATA
OF MEASURE
Engine type KDI 2504 TM
cylinders n. 4
bore mm 88
stroke mm 102
displacement cm3 2482
max inclination during operation degree 30° max. 30 minutes
(even in combined) degree 35° max.1 minute
oil capacity (MAX standard version 11.5
level.) lt.
including oil filter with balancer device 9
dry weight Kg 300
2.3 Engine dimensions (mm)
541 734.4
735
_07
EN 10 ED0053030260 _08 Index
TECHNICAL INFORMATION 2
2.4 Oil
Important Danger
• The engine may be damaged if operated with improper oil • Prolonged skin contact with the exhausted engine oil can
level. cause cancer of the skin.
• Do not exceed the MAX level because a sudden increase in • If contact with oil cannot be avoided, thoroughly wash your
engine rpm could be caused by its combustion. hands with soap and water as soon as possible.
• Use only the recommended oil to ensure adequate • For the exhausted oil disposal, refer to Par. 6.5 DISPOSAL
protection, efficiency and service life of the engine. and SCRAPPING.
• The use of lubricants other than recommended may shorten
the engine life.
• Viscosity must be appropriate to the ambient temperature
to which the engine is to be exposed (Par. 2.4.1).
2.4.1 SAE oil classification

• In the SAE classification, oils are identified according • The code is made up of two numbers. The first number
to viscosity without considering any other qualitative refers to the viscosity when cold, for use during winter
characteristic. ("W"= winter), while the second number is for viscosity at
high temperatures.
2.2
RECOMMENDED OIL
15W-40 (-15°C ÷ +50°C)
10W-30 (-25°C ÷ +40°C)
VISCOSITY SAE 10W-40 (-25°C ÷ +50°C)
5W-30 (-30°C ÷ +40°C)
0W-40 (-40°C ÷ +50°C)
CI-4 Plus
API CI-4
WITH
CH-4
SPECIFICATIONS
E7
ACEA
E5
• Low S.A.P.S. oils, sulfate ashes <1% may not be used with fuels with a sulfur content >50ppm.
• Filtration of oils is critical to proper operation and lubrication; always change filters regularly as specified in this manual.
_07
Index ED0053030260 _08 11 EN
2.5 Fuel
Important Warning
• Use of other types of fuel could damage the engine. Do not • Clean fuel prevents the fuel injectors from clogging.
use dirty diesel fuel or mixtures of diesel fuel and water since Immediately clean up any spillage during refuelling.
this will cause serious engine faults. • Never store diesel fuel in galvanized containers (i.e. coated
• Any failures resulting from the use of fuels other than with zinc). Diesel fuel and the galvanized coating react
recommended will not be warranted. chemically to each other, producing flaking that quickly
clogs filters or causes fuel pump and/or injector failure.
2.3 FUEL COMPATIBILITY

EN 590 (biodiesel content max. 7% (V/V))
ASTM D 975 Grade 1-D S15
ASTM D 975 Grade 2-D S15
NATO F-54, equivalent to diesel fuel in accordance with EN 590
EN 590 or ASTM D 975 Grade 1, 2 -D S15 Arctic Diesel
JIS K 2204 No. 1, No. 2
NOTE: In a warranty case the customer must prove by a certificate from the fuel supplier that an allowed
fuel was used.
KDI Mechanical Injection Tier 3 – Stage IIIA certified Engines (w and w/o EGR)
Those engines are designed for fuels in accordance with EN 590 and ASTM D975 for a cetane number of at least 45. Since
those engines are not equipped with exhaust gas after-treatment, they can be operated with diesel fuels with sulfur content up
to 500 mg/kg (ppm). Compliance with the emission requirements is guaranteed only with sulfur content up to 15 mg/kg (ppm).
Engines operated with fuels as per EN 590 and ASTM D975 with sulfur content < 15mg/kg have an oil changing interval of
500hrs. Fuels with a sulfur content > 500 mg/kg demand a shorter lubricating oil change interval. This is set at 250hrs. However,
the engine oil must be changed when the Total Base Number TBN is reduced to 6.0 mgKOH/g test method ASTM D4739. With
high fuel sulfur content fuel this may happen at 125hrs. Do not use low SAPS oils.
KDI Mechanical Injection Uncertified Engines (no EGR Engines)
Those engines are designed for fuels in accordance with EN 590 and ASTM D975 for a cetane number of at least 45. Since
those engines are not equipped with exhaust gas after-treatment, they can be operated with diesel fuels with sulfur content
up to 2000 mg/kg (ppm).
Engines operated with fuels as per EN 590 and ASTM D975 with sulfur content < 15mg/kg have an oil changing interval of
500hrs. Fuels with a sulfur content > 500 mg/kg demand a shorter lubricating oil change interval. This is set at 250hrs. However,
the engine oil must be changed when the Total Base Number TBN is reduced to 6.0 mgKOH/g test method ASTM D4739.
_07
EN 12 ED0053030260 _08 Index
TECHNICAL INFORMATION 2
2.5.1 Fuel for low temperatures
• When operating the engine in ambient temperatures lower than 0 degrees C, use suitable low temperature fuel normally
available from fuel distributors and corresponding to the specifications of Tab. 2.3.
• These fuels reduce the formation of paraffin in diesel at low temperatures.
• When paraffin forms in the diesel, the fuel filter becomes blocked interrupting the flow of fuel.
2.5.2 Biodiesel fuel

• Fuels containing 10% methyl ester or B10, are suitable for use in this engine provided that they meet the specifications listed
in the Tab. 2.3.
• DO NOT USE vegetable oil as a biofuel for this engine.
2.4 BIODIESEL COMPATIBILITY

Biodiesel according to EN 14214 (only permissible for mixture with diesel fuel at max. 10% (V/V))
US biodiesel according to ASTM D6751 – 09a (B100) (only permissible for mixtures with diesel fuel at 10% (V/V))
2.5.3 Synthetic fuels: GTL, CTL, BTL, HV
It is a well-known fact that engines which are operated for longer periods with conventional diesel fuel and then converted
to synthetic fuels suffer shrinkage of polymer seals in the injection system and thus fuel leaks. The reason for this behavior is
that the aromatic-free synthetic fuels can lead to a change in the selling behavior of polymer seals.
Therefore, conversion from diesel fuel to synthetic fuel may only be done after changing the critical seals. The problem of
shrinkage does not occur when an engine was operated with synthetic fuel from the start.
2.5.4 Non-Road Fuels
Other non-road fuels may be used if they comply with all the limit values of EN 590 except for the fuel density, the cetane
number and the Sulfur content.
The following limits apply for these parameters:
2.5 FUEL PARAMETER UNIT LIMIT VALUE
Cetane number Min. 49
Fuel density at 15°C Kg/m3 820 - 860
Sulfur content mg/kg or ppm max. 500
2.5.5 Jet Fuels
Only for KDI Mechanical Injection Uncertified Engines (no EGR Engines).
The following jet fuels can be used but only adopting an additional fuel filter with lubricity doser:
2.6 FUEL
F-34/F-35 (kerosene, NATO designation) JP-8 (kerosene, US military designation)
F-44 (kerosene, NATO designation JP-5 (kerosene, US military designation)
F-63 (kerosene, NATO designation, equivalent to
Jet A (kerosene for civil aviation)
F-34/F-35 with additives)
F-65 (kerosene, NATO designation, 1:1 mixture of F-54
Jet A1 (kerosene for civil aviation)
and F-34/F-35)
2.5.5 Emission-Related Installation Instructions
Failing to follow the instructions in the applications guidebook when installing a certified engine in a piece of nonroad equipment
violates federal law (40 CFR 1068.105(b)), subject to fines or other penalties as described in the Clean Air Act.
OEM must apply a separate label with the following statement: “ULTRA LOW SULFUR FUEL ONLY” near the fuel inlet.
Ensure you are installing an engine appropriately certified for your application. Constant speed engines may only be installed
on constant speed equipment for constant speed operation.
If you install the engine in a way that makes the engine's emission control information label hard to read during normal engine
maintenance, you must place a duplicate label on the equipment, as described in 40 CFR 1068.105.
_07
Index ED0053030260 _08 13 EN
2.6 Coolant recommendation
A mixture of 50% demineralized water and 50% low silicate ethylene glycol based coolant liquid must be used.
Use a Long Life or Extended Life Heavy Duty OAT coolant free of: silicates, phosphates, borates, nitrites and amines.
The following ethylene-glycol based engine coolant for all models within KDI engine family may be used:
• OAT (Organic Acid Technology) Low Silicate: ASTM D-3306 D-6210
• HOAT (Hybrid Organic Acid Technology) Low Silicate: ASTM D-3306 D-6210
The above coolants in concentrated formulation must be mixed with distilled, deionized, or demineralized water. A pre-mixed
formulation (40-60% or 50-50%) can be used directly when available.
Important
• Do not mix ethylene glycol and propylene glycol based coolants. Do not mix OAT and HOAT based coolant. OAT performance
life can be drastically reduced if contaminated with nitrite-containing coolants.
• Never use automotive-type coolants. These coolants do not contain the correct additives to protect heavy – duty diesel
engines.
OAT coolants are maintenance free up to 6 years or 6000hrs of operation , provided that the cooling system is topped up using
the same type of coolant. Do not mix different coolant types. Test the coolant condition annually with coolant test strips.
HOAT are not all maintenance free and it is recommended to have SCA (Supplemental Coolant Additives) added at the first
maintenance interval
2.7 Battery recommendation

Battery not supplied by Kohler
2.7
RECOMMENDED BATTERIES
AMBIENT TEMPERATURE BATTERY TYPE
> - 15°C 12V 100 AH - 800 CCA/SAE
-15°C ÷ -25°C 12V 110 AH - 950 CCA/SAE
< - 25°C 12V 120 AH - 1000 CCA/SAE
_07
EN 14 ED0053030260 _08 Index
SAFETY INFORMATION 3
3.1 Safety information
• The intended use of the engine is in conformity with the • Those who carry out the use and maintenance on the
machine on which it is mounted. engine must wear the safety equipment and the accident-
• Any use of the machine other than that described cannot prevention guards.
be considered as complying with its intended purpose as • KOHLER declines all direct and indirect liability for failure
specified by KOHLER . to comply with the standards of conduct contained in this
• KOHLER declines all responsibility for any change to the manual.
engine not described in this manual made by unauthorized • KOHLER cannot consider every reasonably unforeseeable
KOHLER personnel. misuse that may cause a potential danger.
• A proper use of the engine, a strict observance of the
rules listed below and the rigorous application of all these
precautions will avoid the risk of accidents or injuries.
3.2 General remarks
3.2.1 Note for OEM
• The engine may only be assembled on a machine by

• When installing the KDI engines, always bear in mind that personnel specifically trained by KOHLER and who work in
any variation to the functional systems may result in serious compliance with the existing documentation.
failures to the engine. • The engine has been built to the specifications of a machine
• Any improvement must be verified at KOHLER testing manufacturer, and it is his responsibility to ensure that all
laboratories before application of the engine. necessary action is taken to meet the essential and legally
• In case the approval to a modification is not granted, KOHLER prescribed health and safety requirements. Any use of the
shall not be deemed responsible for any consequential machine other than that described cannot be considered
failures or damages to the engine. as complying with its intended purpose as specified by
KOHLER, which therefore declines all responsibility for
accidents caused by such operations.
3.2.2 Note for end user

• The following indications are dedicated to the user of the Avoid directing the nozzle on electrical components,
machine in order to reduce or eliminate risks concerning cable connections and sealed rings (oil seals etc).
engine operation and the relative routine maintenance work. Thoroughly wash and clean the area surrounding the
• The user must read these instructions carefully. Failure to do engine following the instructions provided by machine
this could lead to serious danger for his personal safety and manufacturer.
health and that of any persons who may be in the vicinity of • Fuel and oil are inflammable. The tank must only be filled
the machine. when the engine is off. Before starting, dry any spilt fuel.
• On starting, make sure that the engine is as horizontal as • Make sure that no soundproofing panels and the ground or
possible, unless the machine specifications differ. floor on which the machine is standing have not soaked up
• Make sure that the machine is stable to prevent the risk of any fuel.
overturning. • Fuel vapour is highly toxic. Only refuel outdoors or in a well
• The engine must not operate in places containing ventilated place.
inflammable materials, in explosive atmospheres, where • Do not smoke or use open flames when refuelling.
there is dust that can easily catch fire unless specific, • During operation, the surface of the engine can become
adequate and clearly indicated precautions have been dangerously hot. Avoid touching the exhaust system in
taken and have been certified for the machine. particular.
• To prevent fire hazards, always keep the machine at least • Before proceeding with any operation on the engine, stop it
one meter from buildings or from other machinery. and allow it to cool.
• Children and animals must be kept at a due distance from • Always open the radiator plug or expansion chamber with
operating machines in order to prevent hazards deriving the utmost caution, wearing protective garments and
from their operation. goggles.
• Thoroughly wash and clean all the external parts of the • The coolant fluid is under pressure. Never carry out any
engine before performing any operation, in order to avoid inspections until the engine has cooled.
the accidental introduction of impurities/foreign bodies. • If there is an electric fan, do not approach the engine when
Use only water and/or appropriate products to clean the it is still hot as the fan could also start operating when the
engine. If cleaning engine with a pressure washer or steam engine is at a standstill.
cleaner, it is important to maintain a minimum distance of at
least 200mm between the surface to be washed and the nozzle.
_07
Index ED0053030260 _08 15 EN
3 SAFETY INFORMATION
• Only check, top up and change the coolant fluid when

the engine is off and reached the ambient temperature.
Important Coolant fluid is polluting, it must therefore be disposed of
• The oil must be drained whilst the engine is hot. Particular in the correct way.
care is required to prevent burns. Do not allow oil to come • Do not use air and water jets at high pressures on cables,
into contact with the skin because of the health hazards connectors and injectors.
involved. It is recommended to use an oil intake pump.
• During operations that involve access to moving parts of
the engine and/or removal of rotating guards, disconnect
and insulate the negative wire (-) of the battery to prevent
Important
accidental short-circuits and to stop the starter motor from
being energized. • Only use the eyebolts A installed by KOHLER to move the
• Check belt tension only when the engine is off. engine (Fig. 3.1).
• Fully tighten the tank cap each time after refuelling. Do not • The angle between each lifting chain and the eyebolts shall
fill the tank right to the top but leave an adequate space for not exceed 15° inwards.
the fuel to expand. • The correct tightening of the lifting screws is 25Nm.
• To start the engine follow the specific instructions provided • Do not interpose spacers or washers between the eyebolts
in the engine and/or machine operating manual. Do not and engine head.
use auxiliary starting devices not originally installed on the • Provided that the above requirements are met, if the lifting
machine (e.g. Startpilot). eyebolts are subject to permanent deformation (inwards), all
• Before starting, remove any tools that were used to service subsequent lifting operations must be performed in order to
the engine and/or machine. Make sure that all guards have prevent them from bending in the opposite direction.
been refitted.
• Do not mix fuel with elements such as oil or kerosene.
Failure to comply with this prohibition will cause the non-
operation of the catalyst and non-observance of the
emissions declared by KOHLER.
• Pay attention to the temperature of the oil filter when the
filter itself is replaced.
α ≤ 15° α ≤ 15°
A A
_07
EN 16 ED0053030260 _08 Index
3.3 Safety signal description
• To ensure safe operation please read the following

statements and understand their meaning. • This manual contains safety precautions which are
• Also refer to your equipment manufacturer's manual for explained below.
other important safety information. • Please read them carefully.
3.3.1 Adhesive safety plates 3.3.2 Safety guards
The following is a list of the adhesive safety plates that may be Hereunder is a list of safety guards that must be worn prior
found on the engine, which indicate potential points of danger to carrying out any type of operation and to avoid potential
to the operator (Par. 3.6). harm to the operator.
Read the Operation and Maintenance handbook before Use protective gloves before carrying out the operation.
performing any operation on the engine.
Hot Parts. Use protective glasses before carrying out the

Danger of burns. operation.
Presence of rotating parts. Use sound absorbing protections before carrying out
Danger of jamming or cutting. the operation.
Presence of explosive fuel.

Danger of fire or explosion.
Presence of steam and pressurized coolant.

3.3.3 Warnings
Danger of burns.
Hereunder is a list of safety warnings that may be found in
the manual, which advise you to pay attention when carrying
out particular procedures that may be potentially dangerous
to the operator or things.
Lifting point.
Electrical shock.
Danger
Danger of severe scalding or death.
• This indicates situations of grave danger which, if ignored,
may seriously threaten the health and safety of individuals.
High pressure fluid.

Danger of fluid penetration.
Important
• This indicates particularly important technical information
that should not be ignored.
Lethal Exhaust Gases.
Danger of poisoning or death.
Warning
• This indicates that failure to comply with it can cause minor
damage or injury.
_07
Index ED0053030260 _08 17 EN
3 SAFETY INFORMATION
3.4 Information and safety signals
ACCIDENTAL START HIGH PRESSURE FLUID

RISK OF PUNCTURE
Accidental Starts can cause High Pressure Fluids can
severe injury or death. puncture skin and cause
severe injury or death.
Before working on the engine or equipment, disconnect the
Do not work on fuel system without proper training or safety
battery negative (-) wire.
equipment.
Fluid puncture injuries are highly toxic and hazardous.
HOT PARTS If an injury occurs, seek immediate medical attention.
Hot Parts can cause severe
burns. EXPLOSIVE FUEL
Engine components can get extremely hot from operation.
Do not touch engine while operating or just after stopping. Explosive fuel can cause fires
Never operate the engine with heat shields or guards and severe burns.
removed. Fuel is flammable and its vapours can ignite.
Store fuel only in approved containers, in well ventilated,
unoccupied buildings.
ROTATING PARTS
Do not fill the fuel tank while the engine is hot or running,
Rotating Parts can cause since spilled fuel could ignite if it comes in contact with hot
severe injury. parts or sparks from ignition.
Do not start the engine near spilled fuel.
Stay away while engine is in operation. Keep hands, feet, Never use fuel as a cleaning agent.
hair, and clothing away from all moving parts to prevent
injury.
Never operate the engine with covers, shrouds, or guards EXPLOSIVE GAS
removed.
Explosive Gas can cause
LETHAL EXHAUST GASES fires and severe acid burns.
Carbon Monoxide can cause Charge battery only in a well ventilated area.
severe nausea, fainting or Keep sparks, open flames, and other sources of ignition
death. away from the battery at all times.
Batteries produce explosive hydrogen gas while being
Avoid inhaling exhaust fumes and never run the engine in a
charged.
closed building or confined area.
Keep batteries out of the reach of children.
Carbon monoxide is toxic, odorless, colorless, and can
Remove all jewelry when servicing batteries. Before
cause death if inhaled.
disconnecting the negative (-) ground cable, make sure all
switches are OFF.
If ON, a spark will occur at the ground cable terminal which
ELECTRICAL SHOCK could cause an explosion.
Electrical Shock can cause
CALIFORNIA
injury.
PROPOSITION 65 WARNING
Do not touch wires while engine is running. Diesel engine exhaust and some of its constituents are
known to the State of California to cause cancer, birth
defects, and other reproductive harm.
3.5 Safety and environmental impact
Every organisation has a duty to implement procedures to In order to minimise the impact on the environment, KOHLER
identify, assess and monitor the influence of its own activities now provides a number of indications to be followed by
(products, services, etc.) on the environment. all persons handling the engine, for any reason, during its
Procedures for identifying the extent of the impact on the expected lifetime.
environment must consider the following factors:
-- All components and fluids must be disposed of in accordance
-- Liquid waste. with the laws of the country in which disposal is taking place.
-- Waste management. -- Keep the fuel and engine control systems and the exhaust
-- Soil contamination. pipes in efficient working order to limit environmental and
-- Atmospheric emission. noise pollution.
-- Use of raw materials and natural resources. -- When discontinuing use of the engine, select all components
-- Regulations and directives regarding environmental impact. according to their chemical characteristics and dispose of
them separately.
_07
EN 18 ED0053030260 _08 Index
3.6 Location of safety labels on engine
_07
Index ED0053030260 _08 19 EN
4 INFORMATION ABOUT USE
4.1 Pre-start check
• Non compliance with the operations described in the

following pages involves the risk of damages to the engine
and vehicle on which it is installed as well as personal and/
Important or property damage.
• Read carefully the following pages and carry out the • Increase the frequency of maintenance operations in heavy
operations described below in accordance with the working conditions (engine starts but stops, very dusty and
instructions specified. hot environments, etc...).
4.2 Running-in period
NOTE: For the first 50 hours of engine operation, it is advisable not to exceed 75% of the maximum power
supplied.
4.3 Starting and turning off

4.3.1 Starting
1. Check the level of the engine oil, fuel and coolant and fill if necessary (Par. 4.5 and Par. 4.6).
2. Put the ignition key in the ignition switch (if supplied).
3. Tun the key to ON position.
4. Turn the key beyond the ON position and release it when the engine starts (the key will return into ON position automatically).
Important
• At the first start-up, carry out the operations from point 4, in point 6 of Par. 6.3.
• Do not actuate the starter for more than 15 seconds at a time. If the engine does not start, wait for one minute before repeating attempt.
• If engine does not start after two attempts see Tab. 7.1 and Tab. 7.2 to found the cause.
Panel L can be assembled on the engine or machine.

In Tab. 4.1, are described the main functions are illustrated. L M
4.1
W1
POS. DESCRIPTION
M Hour-meter indicator W2
S Control switch to start the engine
W3
W1 Panel ignition indicator
W2 Warning Light - battery not charging W4
W3 Warning Light - engine oil not pressurised
W5
W4 Warning Light - high coolant temperature
S
W5 Warning Light - alarm general indicator 4.1
4.3.2 After starting
Warning
• Make sure that all the warning lights on the control panel are off when the engine is running.
1. Run at minimum speed for a few minutes according to table (except constant speed engine).
4.2
AMBIENT TEMPERATURE TIME

≤ -20°C 2 minutes
from -20° C to -10°C 1 minutes
from -10° C to -5° C 30 seconds
from -5° C to 5° C 20 seconds
≥ 5° C 15 seconds
4.3.3 Turning off
1. Do not turn off the engine when it is running at the maximum rotation speed (except constant speed engine).
2. Before turning it off, keep it idle at minimum speed for about 1 minute.
3. Turn the key to OFF position.
_07
EN 20 ED0053030260 _08 Index
INFORMATION ABOUT USE 4
4.4 Refuelling
Important
• Before proceeding with operation, read Par. 3.2.2.
Danger
• Fill the engine off.
• The only approved fuels are those listed in Tab. 2.3 pag. 12.
• In those countries where diesel has a high sulphur content, its is advisable to lubricate the engine with a high alkaline oil or
alternatively to replace the lubricating oil recommended by KOHLER more frequently.
• To avoid explosions or fire outbreaks, do not smoke or use open flames during the operations.
• Fuel vapours are highly toxic.Only carry out the operations outdoors or in a well ventilated place.
• Keep your face well away from the fuel fill to prevent harmful vapours from being inhaled.
• Dispose of fuel in the correct way and do not litter as it is highly polluting.
• When refuelling, it is advisable to use a funnel to prevent fuel from spilling out.The fuel should also be filtered to prevent dust
or dirt from entering the tank.
Do not overfill the fuel tank. Leave room for the fuel to expand.
NOTE: At the first fuelling or if the tank was empty filling the fuel system (Par. 6.3 point 8).
4.5 Oil filling
Important
• For safety precautions see Par. 3.1. • Before proceeding with operation, read Par. 3.2.2.
1. Loosen the oil filler cap A or the oil filler cap C if the cap
A is not accessible.
A C
2. Add the type oil recommended (Tab. 2.1 and Tab. 2.2).
4.2
3. Before checking oil engine needs to be level.
4. Remove the oil dipstick B and check that the level is up to

but does not exceed the MAX.
B
5. If level is not at the MAX. level, add additional oil. B
6. Re-tighten the cap A or C.

MAX
Important
MIN
• Do not use the engine with the oil level below the minimum.
4.3
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Index ED0053030260 _08 21 EN
4 INFORMATION ABOUT USE
4.6 Coolant filling
Important
Warning
• An anti-freeze protection liquid (ANTIFREEZE) - mixed with • As well as lowering the freezing point, the antifreeze also
decalcified water - must be used. raises the boiling point.
• The freezing point of the refrigerant mixture depends on • A 50% mixture is recommended to ensure a general level
the amount concentration in water. at protection prevents the formation of rust, galvanic
currents and calcium deposits.
NOTE: Before proceeding with any operation on

the engine, stop it and allow it to cool.
A
Warning
• Presence of steam pressurized coolant danger of burns.
1. Loosen the cap A and fill the radiator with coolant

composed of: 50% ANTIFREEZE and 50% decalcified
water.
2. Top liquid up until the pipes inside the radiator are covered
by about 5 mm. Do not overfill the radiator, but leave room
for the coolant to expand.
4.4
3. For engines equipped with expansion tank, pour in fluid
until reaching the max level mark.
4. Loosen the screw C, release any air and tighten the screw
C (Tightening torque of 50 Nm - Fig. 4.6).
5. Re-tighten the cap A.
6. After a few hours of operator, stop the engine and allow

the liquid to cool returns to a ambient temperature and
check the coolant level again.
4.5
4.6 4.7
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EN 22 ED0053030260 _08 Index
INFORMATION ABOUT MAINTENANCE 5
5.1 Useful information about maintenance

• This chapter shows all operations described in the Tab.
5.1, Tab. 5.2, Tab. 5.3 and Tab. 5.4 if you have the skills
Warning
appropriate may be directly carried out by the user. • Inspections must be made when the engine is off and cold.
• Periodic inspection and maintenance operations must • Place engine on level surface to ensure accurate
be carried out as indicated in this manual and are the measurement of oil level.
• Before starting, to avoid spillages of oil make sure that:
responsability of the user. -- the oil dipstick is inserted correctly;
• Failure to comply with these service and maintenance -- also check that:
intervals increases the risk of technical damage to the oil drain plug and
engine. Any non compliance makes the warranty become oil filler cap are tightened firmly.
null and void.
• In order to prevent personal and property damage read
carefully the instructions listed below before proceeding
with any operation of the engine. Important
5.2 Periodic maintenance
The intervals of preventive maintenance in Tab. 5.1, Tab. 5.2, Tab. 5.3 and Tab. 5.4 refer to the engine operating under normal
operating conditions with fuel and oil meeting the recommended specifications.
5.1 CLEANING AND CHECKING

PERIOD (HOURS)
OPERATION DESCRIPTION PAR.
100 250 500 5000
Engine oil level (8) 5.3
Coolant level (8) (9) 5.8
Water presence in fuel filter 5.11
Cartridge dry-type air filter (2) 5.5
Radiator heat-exchange surface and Intercooler (2) (8)
5.6
Standard alternator belt (8)
5.9
Poly-V alternator belt (8) 5.10
Rubber hose (intake air / coolant) 5.7
Fuel hose --
Starter Motor (6) --
Alternator (6)
--
5.2 REPLACEMENT
PERIOD (HOURS)
OPERATION DESCRIPTION PAR.
500 2000 5000 6000
Cartridge dry-type air filter (2) 6.4
Intake manifold hose (air filter - intake manifold) (6) (7) --
Coolant hoses (6) (7)
--
Fuel line hose (6) (7) --
Standard alternator belt (trapezoidal) (3) (6)
--
Alternator belt Poly-V belt heavy environmental condition (6)
--
Poly-V belt standard condition (6)
--
OAT (6)
Coolant --
HOAT (6) (10)
5.3 ENGINE OIL AND OIL FILTER CARTRIDGE REPLACEMENT

PERIOD (HOURS)
ENGINE VERSION PAR.
250 500
KDI Mechanical Injection Tier 3 – Stage IIIA (1) 6.1
KDI Mechanical Injection uncertified (1) (11) 6.2
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Index ED0053030260 _08 23 EN
5 INFORMATION ABOUT MAINTENANCE
5.4 FUEL FILTER AND PREFILTER CARTRIDGE REPLACEMENT

PERIOD (HOURS)
ENGINE VERSION PAR.
250 500
KDI Mechanical Injection Tier 3 – Stage IIIA (1)
6.3
KDI Mechanical Injection uncertified (1)
1. In case of low use: 12 months. 8. The first check must be done after 10 hours.
2. The period of time that must elapse before checking 9. Test the coolant condition annually with coolant test
the filter element depends on the environment in which strips.
the engine operates. The air filter must be cleaned and 10. It is recommended to have SCA (Supplemental Coolant
replaced more frequently under very dusty conditions. Additives) added at the first maintenance interval.
3. In case of low use: 36 months. 11. Read Cap. 2.5, "KDI Mechanical Injection Uncertified
6. The replacement must be carried out by authorized Engines (no EGR Engines)"
KOHLER workshops.
7. The replacement interval is only an indication, it strongly
depends from environmental condition and hose status
detected during regular visual inspection.
5.3 Oil level check

1. Loosen the oil filler cap A. Remove the oil dipstick B and
check that the level is up to MAX. B
B
2. Pour in recommended oil until reaching the MAX level
mark.
MAX
3. Reinstall the oil dipstick B completely.
4. Re-tighten the cap A and/or C (Fig. 5.2).

MIN
Important 5.1
• Do not use the engine with the oil level below the minimum.
5.4 Oil dipstick on cylinder head
A
B
MAX
MIN
5.2
5.3 5.4
5.5 Air filter check
NOTE: Components not necessarily supplied by
KOHLER.
A E D
1. Release the two clasps F of the cover A.
2. Remove the cartridge B.
3. Clean the inside components A and D with a damp cloth.
4. Do not use compressed air, repeatedly tap the front side

E on a flat surface.
5. Reinstall:
-- cartridge B. F B
-- the cover A checking the right tightness of clasps F.
5.5
_07
EN 24 ED0053030260 _08 Index
Danger
For safety precautions see Cap. 3.
5.6 Check of the radiator heat-exchanger surface

NOTE: Component not necessarily supplied by KOHLER.
Important
• Wear safety goggles when using compressed air. A
• The radiator heat-exchange surface must be cleaned on
both sides.
1. Check the radiator heat-exchange surface A.
2. Clean the surface with a brush soaked in special detergent

if it is clogged.
5.6
5.7 Rubber hoses check

E
The check is carried out by exerting a slight deflection or
bending along the pipe and near the hose clamps.
Components must be replaced if they have clear signs of

cracks, tears, cuts, leaks and do not retain a certain degree
of elasticity. E
F
Important
• If hoses are damaged contact an authorized KOHLER
workshop. E
1. Loosen the capscrews E. Remove guard F.

D
2. Check that the:
-- Fuel system hoses A are intact.
-- Hoses for the cooling circuit B1 and B2.
-- To access the control of the cooling hoses B1
unscrew the four screws E and remove the safe
guard F.
-- Vent system pipes C.
-- Air system ducts D. C
B1
When the control is finished the safe guard F mount and
tighten the screws E.
B2
5.7
_07
Index ED0053030260 _08 25 EN
5.8 Check coolant level

NOTE: Before proceeding with any operation on A
the engine, stop it and allow it to cool.
Warning
• Presence of steam pressurized coolant danger of burns.
NOTE: Component not necessarily supplied by

KOHLER.
1. Start the engine without the radiator cap A.
2. Top liquid up until the pipes inside the radiator are covered 5.8
by about 5 mm.
4. Do not overfill the radiator, but leave room for the coolant
to expand. B
MAX C
5. Reinstall radiator cap A.
6. For engines equipped with expansion tank (B), check that

the fluid is until reaching the max level mark.
NOTE: For coolant filling see Par. 4.6.
Warning
• Before starting make sure that the radiator cap and cap, if 5.9
present, are installed correctly to avoid spillage of liquid or
vapour at high temperatures.
_07
EN 26 ED0053030260 _08 Index
5.9 Check and setting alternator standard belt tension

5.9.1 Check
A p
1. Check the belt condition A if worn out or deteriorated,
replace it.
2. Check that at point p the tension value is between 70 and p

75 Hz for V-belt of 9 mm and 80 and 85 Hz for V-belt of
17 mm (H).Using the tool F (DENSO BTG-2) shown
in the picture (or a similar one) it is possible to check
the corresponding value in Newton, (which should
be) included between 200 and 230 N for V-belt of
9 mm and 350 and 450 N for V-belt of 17 mm (H).
F
Should the correct tool not be available, the belt tension 5.10
can be checked by applying a force in the direction of
arrow G of approx' 10kg on the point p. When correctly
tensioned the belt A must show a movement of less than
10 mm.

3. If not adjust it.
5.9.2 Adjustment
H
1. Loosen the fastening bolts B and C.
2. Pull the alternator outwards (in direction of the arrow D),

to tension the belt.
3. Tension the belt tightening the bolts B and C.
4. Tighten bolts B (tightening torque of 25 Nm) and C 5.11

(tightening torque of 69 Nm) in sequence with a torque
wrench E.
5. Check that at point p the tension value is

between 70 and 75 Hz for V-belt of 9 mm and
80 and 85 Hz for V-belt of 17 mm (Fig. 5.10) (H).
Using the tool F (DENSO BTG-2) shown in the

picture (or a similar one) it is possible to check the 10 m
m
corresponding value in Newton, (which should be) p
included between 200 and 230 N for V-belt of 9
mm and 350 and 450 N for V-belt of 17 mm (H).
Should the correct tool not be available, the belt tension can G
be checked by applying a force in the direction of arrow G
of approx' 10kg on the point p. When correctly tensioned
the belt A must show a movement of less than 10 mm. 5.12
Let the engine run for some minutes, then let it cool down
at ambient temperature and repeat the operations 2, 3, E
4 and 5 in case the belt tension results out of the above
mentioned values. B
NOTE: Contact KOHLER authorised workshops

for replacement.
C
E
5.13
_07
Index ED0053030260 _08 27 EN
5.10 Check Poly-V alternator belt

NOTE: The poly-v belt is not adjustable. B B
1. Check the belt A condition, if worn out or deteriorated,

replace it. A
NOTE: Make sure that the ribs of the belt A are p

inserted correctly into the grooves of the
pulleys B (as shown in D1 and D2).
2. Start the engine and run it for some minutes, then turn B
off it, and let it cool down at ambient temperature.
Check by the appropriate tool that at point p the tension
value is between 149 and 196 Hz.
5.14
NOTE: If the poly-v belt tension results out D2

of the above mentioned values contact
KOHLER authorised workshops for
replacement.
D1
5.15
5.11 Control water filter cartridge fuel

1. Gently loosen the water drain plug A without removing it.
2. Spill out the water if present.
3. Re-tighten the water drain plug A as soon as the fuel spills.
5.16
5.12 Product preservation 5.13 Engine storage up to 6 months

Before storing the engine check that:
Important • The environments are not humid or exposed to bad weather.

• If the engines are not to be used for 6 months, they must Cover the engine with a proper protective sheet against
be protected by carrying out the operations described in dampness and atmospheric contaminants.
Engine storage (up to 6 months) (Par. 5.13). • The place is not near electric panel.
• If the engine is still not in use after the first 6 months, it • Avoid storing the engine in direct contact with the ground.
is necessary to carry out a further operation to extend the
protection period (more than 6 months) (Par. 5.14).
• If the engine is not to be used for an extended period, the
protective treatment procedure must be repeated within 24
months of the previous one.
_07
EN 28 ED0053030260 _08 Index
5.14 Engine storage over 6 months 5.15 Engine starting after storage
Follow the steps described in Par. 5.13. 1. Remove the protective sheet.
1. Engine oil replacement (Par. 6.1).
2. Use a cloth soaked in degreasing product to remove the
2. Refuel with fuel additives for long storage.
-- The following additives are recommended: protective treatment from the external parts.
-- DEFA Fluid Plus (Pakelo Lubricants),
-- Diesel Treatment (Green Star), 3. Inject lubricating oil (no more than 2 cm3) into the intake
-- Top Diesel (Bardhal), ducts.
-- STP® Diesel Fuel Injector Treatment.
3. With expansion tank: make sure that the coolant is up to 4. Refill the tank with fresh fuel.
the maximum level.
5. Make sure that the oil and the coolant are up to the
4. Without expansion tank: maximum level.
Top liquid up until the pipes inside the radiator are
covered by about 5 mm. 6. Start the engine and keep it idle at minimum speed for a
Do not overfill the radiator, but leave room for the fuel to two about minutes.
expand.
5. Start the engine and keep it idle at minimum speed for 2 7. Bring the engine to 75% of maximum rated speed for 5
minutes. to 10 minutes.
6. Bring the engine to 3/4 of the maximum speed for 5÷10
minutes. 8. Stop the engine while the oil is still hot
(Par. 6.1), discharge the protective oil in a suitable
7. Turn off the engine.
container.
8. Completely empty the fuel tank.
9. Spray SAE 10W-40 on the exhaust and intake manifolds.
10. Seal the exhaust and intake ducts to prevent foreign
bodies from entering. Warning
11. When cleaning the engine, if using a pressure • Over time, lubricants and filters lose their properties, so
washer or steam cleaning device, avoid directing it is important consider whether they need replacing,
the nozzle on electrical components, cable
connections and sealed rings (oil seals etc). also based on the criteria described in Tab. 5.2.
If cleaning engine with a pressure washer or steam
cleaner, it is important to maintain a minimum distance 9. Replace the filters (air, oil, fuel) with original spare parts.
of at least 200mm between the surface to be washed and
the nozzle - avoiding absolutely electrical components 10. Pour new oil (Par. 4.5) up to the maximum level.
such as alternators, starter motors and engine control
units (ECU).
12. Treat non-painted parts with protective products. 11. Empty the cooling circuit completely and pour in the new
If the engine protection is performed according to the coolant up to the maximum level (Par. 4.6).
suggestions indicated no corrosion damage should occur. 0
5.16 Unused machine
If the machine is not used for a certain amount of time, follow the operations below:
5.16.1 Operations for the engine
5.5
POINT OPERATION
-- The place must be dry and fresh throughout the period in which the machine is not used.
unused ma- -- Consult the machine’s manual to disconnect the battery (before disconnecting the battery,
chine up to 2 wait for minimum 5 mins after turning off the engine).
1 months -- Make sure the engine is not exposed to direct sunlight.
-- Make sure the engine is not near any heat sources.
-- Before starting the engine, check Par. 5.2 for maintenance operations.
Starting -- Consult the machine’s manual to connect the battery and start the engine.
-- Perform the operations related to unused machine described in point 1.
-- Perform the operations described in Par. 5.6.
unused machi- -- Start the engine at least every 4 months as per operations described in point 1:
ne from 2 to 9 -- Avoid sudden accelerations for the first few minutes.
months
2 Bring the engine to the working temperature by pressing the accelerator 3/4 from MAX.
Leave the engine running at minimum speed for a few minutes and turning off the engine.
-- Before starting the engine, check Par. 5.2 for maintenance operations.
-- Avoid sudden accelerations for the first few minutes.
unused ma-
chine over 9 -- Perform the operations related to unused machine described in point 1 and 2.
months
3 -- Before starting the engine, check Par. 5.2 for maintenance operations.
-- Check the quality of coolant from the relative testing strips.
-- Avoid sudden accelerations for the first few minutes.
_07
Index ED0053030260 _08 29 EN
6 INFORMATION ABOUT REPLACEMENTS
Danger
• Disconnect the negative wire (-) from the battery to avoid accidental engine starting.
Important
• Before proceeding with operation, read Par. 3.2.2
6.1 Engine oil replacement
A
B
Important
• Place engine on level surface to ensure accurate
measurement of oil level.
• Before proceeding, perform the operation described in E
Par. 6.2 - Point 1.
D
NOTE: Perform this operation with warm engine,
to get a better fluidity of the oil and get
a full discharge of oil and impurities
contained in it.
1. Loosen the oil filler cap A (Fig. 6.1). 6.1
2. Remove the oil dipstick B.
3. Remove the oil drain plug D and the gasket E

(the oil drain plug is on both sides of the oil sump).
4. Drain oil in an appropriate container. (For

the exhausted oil disposal, refer to
Par. 6.5 DISPOSAL and SCRAPPING).
D
5. Replace gasket E.
6. Tighten the drain oil plug D (tightening torque at 50 Nm).
7. Perform the operations from point 2 to 5 of Par. 6.2.
8. Add the type and amount of oil recommended 6.2

(Tab. 2.1 and Tab. 2.2).
9. If the plug A is not accessible, use the oil filler cap C. C
Important
• Do not exceed the MAX level on the dipstick.
6.3
_07
EN 30 ED0053030260 _08 Index
INFORMATION ABOUT REPLACEMENTS 6
10. Fit and remove the oil dipstick B to check the level. Pour
in fluid until reaching the MAX level mark.
11. Upon completion, reinstall the oil dipstick B completely. B

B
12. Tighten the cap A or C.
MAX
MIN
6.4
Warning
filter cartridge replacement (Par. 6.2) and fuel filter replacement (Par. 6.3)
• Oil
• In case of low use replace it 12 months.
• For disposal of oil filter cartridge and fuel filter refer to Par. 6.5 DISPOSAL and
SCRAPPING.
6.2 Oil filter cartridge replacement
A
Warning A
• Electric/pneumatic screwdrivers are forbidden.
1. Unscrew cartridge holder cover A by performing three

complete turns and wait 1 minute. B
NOTE: this operation allows to oil contained in

the support F to flow into the oil sump in
the correct way. F
2. Unscrew cartridge holder cover A and check that the oil

in the lub. oil filter support F has flowed towards the oil 6.5
sump.
3. Remove the cap A as well as the oil cartridge B from the

oil filter support. D
4. Remove and replace the oil cartridge B with a new one.

C
Remove and replace the gaskets C, D and E with new
B
ones.
6.6
_07
Index ED0053030260 _08 31 EN
6 INFORMATION ABOUT REPLACEMENTS
5. Fit and tighten the cover A on the oil filter support F,

tightening it with a torque wrench G (tightening torque of
25 Nm).
6.7
6.3 Fuel filter cartridge replacement

1. Procure a suitable container to collect the fuel.
2. Rotate the filter A to take it to the unlocked position and B

remove it.
3. Lubricate the gasket C of the new cartridge. Assemble C

the new filter A on the support B and rotate it until reaches
A
the lock position.
A
Important
• Do not fill the new cartridge A with fuel.
6.8
4. Turn the key on the control
panel to the ON position.
The electric pump D sends E
fuel to the filter B and then G
the injection pump G.
The air inside the circuit
and the filter will begin to
escape from the screw F
and E.
5. Loosen the air bleeding

screw F on fuel filter
bracket B and the screw
E on the injection pump G. F
G
6. Tighten the bleeding screw
F and E (tightening torque D
of 1.5 Nm) when the fuel 6.9
begins to flow.
6.4 Air filter cartridge replacement

NOTE: Component not necessarily supplied by A
KOHLER.
1. Release the two fastenings F of the cover A.
2. Remove the cartridge B.
3. Reinstall:
-- the new cartridge B.
-- the cover A checking the right tightness of fastenings F.
F B
6.10
_07
EN 32 ED0053030260 _08 Index
INFORMATION ABOUT REPLACEMENTS 6
6.5 Disposal and scrapping
• In case of scrapping, the engine shall be disposed of in • The parts only composed of plastic material, aluminium
appropriate locations, in conformity with the law in force. and steel can be recycled if collected by the appropriate
• Before scrapping, it is necessary to separate the rubber or centers.
plastic parts from the rest of the components. • Waste oil must properly be recycled and disposed of in the
correct way to safeguard the environment. According to the
laws in force, it is classified as hazardous waste, therefore it
must be collected by the appropriate centers.
_07
Index ED0053030260 _08 33 EN
7 INFORMATION ABOUT FAILURES
7.1 Useful information about failures

• This chapter contains information about the problems that may appear during engine operation with its causes and trouble
shooting Tab. 7.2.
• In some cases, you shall turn off the engine immediately to avoid further damage Tab. 7.1.
7.1
7.6 THE ENGINE MUST BE IMMEDIATELY TURNED OFF WHEN
1 Warning RED light turn on
2 The oil pressure indicator light turns on while running
3 The engine rpms suddenly increase and decrease
4 A sudden and/or unusual noise is heard
5 Colour the exhaust fumes suddenly darkens
7.2
7.7 TROUBLES POSSIBLE CAUSE SOLUTION PAR.
Warning YELLOW light
Engine ECU has detect a malfunctions Contact KOHLER authorised workshops --
turn on
Sulphated battery terminals corroded Clean the battery terminals --
Battery voltage too low Recharge the battery or replace it --
Low fuel level Refuel 4.4
Frozen fuel Contact KOHLER authorised workshops --
The engine does not Clogged fuel filter Replace with a new filter 6.3
start Air suction in fuel system Contact KOHLER authorised workshops --
Clogged air filter Replace with a new filter 6.4
Clogged pipes Contact KOHLER authorised workshops --
Open fuse Replace with a new fuse --
Intake or exhaust system clogged Contact KOHLER authorised workshops --
Inefficient electrical connections Clean the electrical contacts --
Sulphated battery terminals Clean the battery terminals --
Engine starts but stops Replace with a new filter and clean the
Clogged fuel filter --
tank
Clogged fuel pipes Contact KOHLER authorised workshops --
Safety protocol in starting Wait some seconds
Engine doesn't rev up Release the throttle and wait some --
Throttle to MAX in starting
seconds
RPM instability at idle
Clogged fuel pipes Contact KOHLER authorised workshops --
speed
Low Clogged fuel pipes Contact KOHLER authorised workshops --
idle speed Poor quality fuel Clean the tank and refuel with quality fuel 2.5
High oil sump level Replace the engine oil --
Blue smoke
Excessive fuel Clogged air filter Replace with a new filter 6.4
consumption High oil sump level Replace the engine oil --
Engine lost its initial Clogged fuel pipes Contact KOHLER authorised workshops --
performance Cheap fuel Clean the tank and refuel with quality fuel --
High oil sump level Replace the engine oil --
Slow acceleration Clogged fuel filter Replace the fuel filter 6.3
Engine jerking Clogged fuel pipes Contact KOHLER authorised workshops --
Insufficient coolant level Fill up to the level 4.6
Engine overheats High oil sump level Replace the engine oil --
Clogged radiator Clean the radiator --
-- In the event that the solutions proposed in Tab. 7.2 do not eliminate the trouble, contact a KOHLER authorized workshop.
_07
EN 34 ED0053030260 _08 Index
INFORMATION ABOUT WARRANTY 8
KOHLER DIESEL ENGINES GLOBAL WARRANTY TERMS

1. WARRANTY PERIOD
Kohler Co. warrants to the End User that each Diesel engine will be free from manufacturing defects in materials or workmanship
in normal service for the applicable coverage period or operating hours (whichever comes first) set forth below, provided the
engine is operated and maintained in accordance with Kohler Co.’s instructions and manuals.
ENGINE SERIES WARRANTY PERIOD OPERATING HOURS WARRANTY COVERAGE
KOHLER Diesel (non KDI) 3 Years 0 – 2.000 100% Parts & Labor
0 – 2.000 100% Parts & Labor

KOHLER KDI 3 Years
2.001 – 6.000 Major Components Only*
Lombardini Diesel 2 Years 0 – 2.000 100% Parts & Labor
*Major component defects are failures related to crankcase casting, cylinder head casting, crankshaft, crankshaft pulley,
camshaft, connecting rod, flywheel, oil pump.
For the Warranty Period stated above, the period begins on the date of purchase of the finished equipment on which the engine
is installed. If no hour meter is installed on the application, the Operating Hours will be calculated as 4 hours of use per day
for 5 days per week beginning on the date of purchase.
Kohler Co.’s obligation under this warranty is expressly limited, at its option, to an appropriate adjustment, repair or replacement
of such part or parts as found to be defective following an inspection by Kohler Co. or an authorized service facility designated
by Kohler Co.
SPARE PARTS WARRANTY PERIOD OPERATING HOURS WARRANTY COVERAGE
KOHLER and Lombardini

2 Years 0 – 2.000 100% Parts & Labor
Diesel Parts
Parts/components that are scheduled to be replaced as part of the required maintenance schedule will be covered under Kohler
Co.’s warranty from date of purchase of the part up to the first scheduled replacement point for the subject parts/ components.
All other Spare Parts items are covered by the above warranty provided that the repairs have been executed by Kohler Co or
by an Authorized Kohler Service Dealer.
2. EXCLUSIONS
The following items are not covered by this warranty.

• Damage caused by: (i) an accident or casualty; (ii) unreasonable use or neglect; (iii) normal wear; (iv) premature wear from
improper maintenance; (v) improper storage; (vi) old or contaminated fuel left within the fuel system, which includes but is not
limited to tanks, fuel lines, or fuel injection components; (vii) unapproved modifications.
• Failures caused by: (i) faulty repairs made by any party other than Kohler Co. or an authorized service facility designated by
Kohler Co.; (ii) use of non-Kohler replacement service parts; or (iii) additional damages caused by a lack of prescribed actions
as a result of an alarm light activation, either caused by fault or negligence or un-attended use of the engine; (iv) an act
beyond the control of Kohler Co., which includes but is not limited to theft, vandalism, fire, lightning, earthquake, windstorm,
hail, volcanic eruption, flood or tornado.
• Transportation charges or travel expenses in connection with the repair or replacement of defective parts on the engine.
• Engine accessories such as fuel tanks, clutches, transmissions, power drive assemblies, and batteries, unless supplied or
installed by Kohler Co.
• Engines installed in an application not formally reviewed by Kohler.
• Rental of other equipment during performance of warranty repairs All items subject to wear and to periodical maintenance
such as listed in the Use & Maintenance Manual (such as air, oil or fuel filters, belts etc.) are warranted for a period equal to
the prescribed interval of replacement as listed in the Manual.
• Fuel, lubricating oil, coolant/antifreeze.
_07
Index ED0053030260 _08 35 EN
8 INFORMATION ABOUT WARRANTY
IMPLIED OR STATUTORY WARRANTIES, INCLUDING THOSE OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR
PURPOSE, ARE EXPRESSLY LIMITED TO THE DURATION OF THIS WRITTEN WARRANTY. KOHLER CO. MAKES NO OTHER
EXPRESS WARRANTY, NOR IS ANYONE AUTHORIZED TO MAKE ANY ON KOHLER CO.’S BEHALF. KOHLER CO. AND/OR
THE SELLER SHALL NOT BE LIABLE FOR SPECIAL, INDIRECT, INCIDENTAL, OR CONSEQUENTIAL DAMAGES OF ANY KIND.
3. TO OBTAIN WARRANTY SERVICE
The repair shall be executed by a KOHLER Authorized Service Dealer designated by Kohler.
USA & CANADA:

List of Authorized dealers can be found by visiting www.kohlerengines.com or telephone 1-800-544-2444 (U.S.A. and Canada)
ENGINE DIVISION, Kohler Co., Kohler Wisconsin
EUROPE, MIDDLE EAST, AND ASIA

List of Authorized dealers can be found by visiting dealers.kohlerpower.it.
CENTRAL AND SOUTH AMERICA:

CHINA AND ASIA PACIFIC

INDIA
Note: Specific Warranty Terms and conditions do apply to engines directly sold in India.
4. OWNER'S WARRANTY RESPONSIBILITIES
1. As the off-road engine owner, you are responsible for the performance of the required maintenance listed in your Use &
Maintenance Manual. Kohler Co. recommends that you retain all receipts covering maintenance on your off-road & marine
engine, but Kohler Co. cannot deny warranty solely for the lack of receipts or for your failure to ensure the performance of
all scheduled maintenance.
2. As the off-road & marine engine owner, you should however be aware that Kohler Co. may deny you warranty coverage if
your off-road & marine engine or a part shows signs of malfunction or failed due to abuse, neglect, improper maintenance
or unapproved modifications.
3. Your engine is designed to operate on diesel fuel only. Diesel fuel an all other fluids used shall comply with the recommendation
listed in the Use & Maintenance Manual. Use of any other fuel or fluids may result in your engine breakage, premature wear
or no longer operating in compliance with the California & US EPA emissions requirements.
4. You are responsible for initiating the warranty process. The ARB & US EPA suggests that you present your off-road &
Marine engine to a Kohler Co. dealer as soon as a problem exists. The warranty repairs should be completed by the dealer
as expeditiously as possible.
5. COVERAGE
Kohler Co. will repair or replace emission control system parts, components and sub-assemblies found to be defective with
respect to materials or workmanship at no cost to you including engine exhaust system related diagnosis, labor and parts,
provided that no un-authorized modification of any kind has been executed on the engine, and its parts, components and
sub-assemblies.
The choice and responsibility of the decision to repair or replace an emission control system defect will be solely that of Kohler
Co. Emission control system parts/ components covered by the Federal and California Emission Control Systems Limited
Warranty are listed below
engine is defective, the part will be repaired or replaced by Kohler Co.
Fuel injector(s) Electronic control unit (ECU) if equipped

Injection pump(s) Sensors associated with ECU operation
Exhaust manifold Emission control information labels
Intake manifold Turbocharger (if equipped)
Exhaust gas recirculation (EGR) tube Fuel limiting device
Aftertreatment Systems if equipped and other components
Crankcase ventilation valve
when present
_07
EN 36 ED0053030260 _08 Index
INFORMATION ABOUT WARRANTY 8
Parts/components that are scheduled to be replaced as part of the required maintenance schedule will be covered under
the warranty provisions for a period of time up to the first scheduled replacement point for the subject parts/ components.
Subsequent damage to other engine components as a direct result of a warrantable failure an exhaust emission part/ component
will be covered under the warranty provisions described herein.
6. MAINTENANCE AND REPAIR REQUIREMENTS
The owner is responsible for the proper use and maintenance of the engine. Kohler Co. recommends that all receipts and
records covering the performance of regular maintenance be retained in case questions arise. If the engine is resold during the
warranty period, the maintenance records should be transferred to each subsequent owner. Kohler Co. may not deny warranty
repairs solely because of the lack of repair, maintenance or failure to keep maintenance records.
Normal maintenance, replacement or repair of emission control devices and systems may be performed by any repair
establishment or individual; however, warranty repairs must be performed by a Kohler authorized service center.
7. CALIFORNIA AND FEDERAL EMISSION CONTROLWARRANTY STATEMENT, OFF-ROAD & MARINE DIESEL
ENGINES (USA ONLY)
The California Air Resources Board (CARB), U.S. environmental protection agency (EPA), and Kohler Co. are pleased to
explain the emission control system warranty on your [current model year – {2+ current model year}] off-road compression
ignition and marine (diesel) engine. In California (“the state”) and US EPA regulated region, new heavy-duty off-road & marine
engines must be designed, built and equipped to meet the state’s and US EPA anti-smog standards. The warranty period
shall begin on the date the engine or equipment is delivered to an ultimate purchaser. Kohler Co. must warrant the emission
control system on your engine for the periods of time listed in the section below, provided there has been no abuse, neglect
or improper maintenance of your engine.
Your emission control system may include parts such as the fuel injection system and the air-induction system. Also included
maybe hoses, belts, connectors and other emission related assemblies.
When a warrantable condition exists, Kohler Co. will repair your heavy-duty off-road & marine engine at no cost to you including
diagnosis, parts and labor.
The owner shall not be charged for diagnostic labor that leads to the determination that a warranted part is in fact defective,
provided that such diagnostic work is performed at a warranty station.
MANUFACTURER’S WARRANTY COVERAGE:
The [current model year – {2+ current model year}] heavy-duty off-road & marine engines are warranted for the periods listed
below. If any emission-related part on your engine is defective, the part will be repaired or replaced by Kohler Co.
1,500 HOURS OR TWO

VARIABLE SPEED OR
KW <19 ANY SPEED YEARS, WHICHEVER
CONSTANT SPEED
COMES FIRST.
1,500 hours or two years,
Constant speed 19 ≤kW <37 3,000 rpm or higher
whichever comes first.
3,000 hours or five years,
Constant speed 19 ≤kW <37 Less than 3,000 rpm
3,000 hours or five years,
Variable speed 19 ≤kW <37 Any speed
Variable speed or constant 3,000 hours or five years,
kW ≥37 Any speed
speed whichever comes first.
MARINE DIESEL ENGINE
ENGINE POWER WARRANTY PERIOD
kW < 19 1,500 hours or 2,5 years, whichever comes first.
19 ≤ kW < 37 2,500 hours or 3,5 years, whichever comes first.
37 ≤ kW < 75 5,000 hours or 5 years, whichever comes first.
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Index ED0053030260 _08 37 EN
9 GLOSSARY
A component that transforms mechanical energy into AC

A Alternator:
electrical energy.
Authorised workshop: Kohler authorised service centre.
B Bore: Internal diameter of the cylinder in combustion engines.
C Catalyst: A device in charge of filtering exhausted gas.

Chemical reaction of a mixture composed of fuel and fuel
Combustion:
(air) inside a combustion chamber.
A high-pressure "Common Duct" that produces a constant

Common Rail:
supply of fuel directly to the injectors.
E EC: European Community.
ECS: Emission Control System
F Fig.: Figure.
G Galvanised: Material that has undergone surface protection treatment.
Type of extreme condition referred to the work environment

H Heavy conditions: in which the engine is used (very dusty - dirty area, or in a
contaminated environment due to various types of gas).
Air-cooling element under pressure from the turbo situated

I Intercooler:
between the turbine and intake manifold.
K KDI: Kohler Direct Injection
A group of maintenance actions that have the sole
objective to control and replace elements on their expiry,
M Maintenance - periodic: without modifying or improving the functions carried out
by the system, neither increasing the value nor improving
performance.
MAX: Maximum.
It is a mixture of products by means of a chemical
Methyl ester conversion of oils and animal and/or vegetable fat, which is
used to produce Biofuel.
Min.: Minutes.
MIN: Minimum.
Model, engine identification plate, which indicates the

Model:
engine's model.
N N/C: Normally Closed, referred to switches (oil-pressure switch).
P Par.: Paragraph.
Paraffin: Fatty and solid substance that may form inside the diesel.
Poly-V, the name associated with a service belt, which
Poly-V: derives from the profile of its section that is constructed with
joined Vs.
R Ref.: Reference.
Serial number (engine identification name plate) indicating

C s/n:
the engine identification series/chassis number.
Specification, (engine identification name plate) indicating

Spec.:
the engine version.
_07
ENEN 38 ED0053030260 _08 Index
GLOSSARY 9
T Tab.: Table.
A term indicated for installation of threaded components
Tightening torque: and which is determined by means of a unit of measurement
Nm.
TM: Turbo Mechanical
Device that compresses air intake by sending it to the intake

Turbocharger:
manifold by means of a turbine.
Oil altered by operation or time, which is no longer

U Used oil:
compliant for correct lubrication of the components.
A device, which is directly or automatically controlled, used

W Waste-Gate valve:
to limit the pressure of exhaust gas inside the turbine.
_07
Index ED0053030260 _08 39 EN
9 GLOSSARY
SYMBOLS AND UNITS OF MEASUREMENT

SYMBOL UNIT OF MEASUREMENT DESCRIPTION EXAMPLE
a degree Rotation/inclination angle 1°
cm 2
square centimetre Area 1 cm2
Ø millimetre Circumference Ø 1 mm
Nm newton-metre Torque 1 Nm
mm millimetre 1 mm
1/1000 of a millimetre Length
μm 1 μm
(micron)
h hour Time 1h
grammes per kilowatt per
g/kWh Specific consumption 1 g/kWh
hour
kg/h kilogramme per hour Max. flow rate 1 kg/h
Lt./min. litres per minute 1 Lt./min.
Flow rate
Lt./h litres per hour 1 Lt./h
ppm parts per million Percentage 1 ppm
N newton Force 1N
A Ampere Intensity of electrical current 1A
gr. gramme 1 gr.
Weight
kg kilogramme 1 kg
W Watt 1W
Power
kW kiloWatt 1 kW
pa pascal 1 pa
KPa Kilopascal 1 KPa
Pressure
bar barometric pressure 1 bar
mbar (1/1000 bar) barometric pressure 1 mbar
Resistance to electrical cur-
R Resistance rent (referred to a 1Ω
component)
Resistance of electrical
Ω ohm 1Ω
current
Rpm revs per minute Rotation of an axis 1 Rpm
average roughness ex-
Ra Roughness Ra = 1
pressed in microns
°C degree centigrade Temperature 1°C
V Volt Electrical voltage 1V
Ã millimetre Hex-head capscrew Ã 1 mm
cm3 cubic centimetre 1 cm3
Volume
Lt. litre 1 Lt.
_07
ENEN 40 ED0053030260 _08 Index
NOTES 9
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_07
Index ED0053030260 _08 41 EN
9 NOTES
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_07
ENEN 42 ED0053030260 _08 Index
NOTES 9
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_07
Index ED0053030260 _08 43 EN
9 NOTES
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_07
ENEN 44 ED0053030260 _08 Index
NOTES 9
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_07
Index ED0053030260 _08 45 EN
9 NOTES
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_07
ENEN 46 ED0053030260 _08 Index
NOTES 9
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CALIFORNIA
........................................................................................................................................................
PROPOSITION 65 WARNING
........................................................................................................................................................
Diesel engine exhaust and some of its constituents are
known to the State of California to cause cancer, birth
defects, and other reproductive harm.
........................................................................................................................................................
_07
Index ED0053030260 _08 47 EN
Lombardini s.r.l. is a part of Kohler Group. E U RO PE U S A & C AN AD A FR AN C E
Lombardini has manufacturing facilities
Lombardini Srl Kohler Co. Lombardini France S.a.s.
in Italy, Slovakia and India and sales
Via Cav. del lavoro 444 Highland Drive, 47 Alléè de Riottier,
subsidiaries in France, Germany, UK, Spain
A. Lombardini n° 2 Kohler - Wisconsin (53044), US 69400 Limas, FRANCE
and Singapore. Kohler/Lombardini reserves
the right to make modifications without prior
42124 Reggio Emilia, ITALY T. +1 920 457 4441 T. +33-(0)474-626500
T. +39-(0)522-389-1 F. +1 920 459 1570 F. +33-(0)474-623945
notice.
F. +39-(0)522-389-503
www.lombardini.it
D E UTS CHLAND UK ES PAÑ A C H I N A & R O APAC

Lombardini Motoren GmbH Lombardini U.K. Ltd Lombardini ESPAÑA, S.L. Kohler China INVESTMENT Co. Ltd
Fritz-Klatte-Str. 6, Bürogebäude 2 1, Rochester Barn - Eynsham Road P.I. Cova Solera 1-9 no.158, Jiang Chang San Road,
D – 65933 Frankfurt OX2 9NH 08191 - Rubí (Barcelona) 200436, Zhabe, Shanghai
Hessen, DEUTSCHLAND Oxford, UK ESPAÑA CHINA
T. +49-(0)69-9508160 T. +44-(0)1865-863858 T. +34-(0)9358-62111 Tel: +86 400-0120-648
F. +49-(0)69-950816-30 F. +44-(0)1865-861754 F. +34-(0)9369-71613 Fax: +86 21 61078904
User guide and maintenance manual
KOHLER
Alternator
KH00263T-KH00310T-KH00351T-KH00370T
KH00390T-KH00405T-KH00440T-KH00461T
KH00462T-KH00521T-KH00590T-KH00600T
KH00601T-KH00602T-KH00682T-KH00720T
KH00750T-KH00751T-KH00752T-KH00810T
KH00811T-KH00910T-KH00911T-KH01050T
KH01100T-KH01190T-KH01220T-KH01340T
KH01341T-KH01420T-KH01421T-KH01630T
KH01640T-KH01641T-KH01741T-KH02070T
KH02100T-KH02101T-KH02400T-KH02401T
KH02450T-KH02610T-KH02850T-KH02880T
KH02971T-KH03003T-KH03390T-KH03541T
KH03542T-KH03603T-KH03890T-KH04402T
KH04403T-KH04404T-KH04406T-KH04450T
KH04972T-KH04973T-KH04974T-KH04976T
KH05090T-KH05793T-KH05794T-KH06521T
KH06522T-KH06931T-KH06932T-KH08560T
13/03/2019 33521034901_5_1
MUE_ 33521034901
CONTENTS
1 Preface........................................................................................................................................................................................ 2
1.1 General guidelines ............................................................................................................................................................. 3
1.2 Instructions and safety regulations (personal protection) ................................................................................................... 3
2 Applicable directives and standards ............................................................................................................................................ 3
3 Specifications .............................................................................................................................................................................. 4
3.1 Mass ................................................................................................................................................................................... 4
4 Maintenance ............................................................................................................................................................................... 4
4.1 General checking of the installation.................................................................................................................................... 4
4.2 Cleaning the alternator ....................................................................................................................................................... 4
4.3 Checking the ventilation circuit ........................................................................................................................................... 5
4.4 Checking bearings.............................................................................................................................................................. 6
4.4.1 Bearings lubricated for life.............................................................................................................................................. 6
4.4.2 Regreasable bearings .................................................................................................................................................... 6
4.5 Checking the winding ......................................................................................................................................................... 6
4.6 Checking the windings and rotating diodes using separate excitation................................................................................ 7
4.7 Maintenance of the regulator .............................................................................................................................................. 7
4.7.1 Recommendations ......................................................................................................................................................... 7
4.7.2 Access to connections and the regulation system ......................................................................................................... 7
4.7.3 Access to complete regulators manuals ........................................................................................................................ 7
4.7.4 Regulator R180 (Scenario 1) ......................................................................................................................................... 7
4.7.4.1 Presentation of the regulator ..................................................................................................................................... 7
4.7.4.2 Setting the regulator .................................................................................................................................................. 8
4.7.5.2 Setting the regulator .................................................................................................................................................. 9
4.7.6.2 Setting the regulator ................................................................................................................................................ 10
4.7.7 Regulator R438 (Scenario 1) ....................................................................................................................................... 10
4.7.7.1 Presentation of the regulator ................................................................................................................................... 10
4.7.8 Regulator R449 ............................................................................................................................................................ 11
4.7.9 Regulator R450 or R450M/R450T (scenario 1)............................................................................................................ 12
4.7.10 Regulator D510C ..................................................................................................................................................... 14
4.7.10.1 Presentation of the regulator ............................................................................................................................... 14
4.7.10.2 Setting the regulator ............................................................................................................................................ 16
5 Repairing faults ......................................................................................................................................................................... 16
5.1 Mechanical faults.............................................................................................................................................................. 16
5.2 Electrical faults ................................................................................................................................................................. 17
5.2.1 R180 ............................................................................................................................................................................ 17
5.2.2 R220/R250/R438/R450/R450M/R450T ....................................................................................................................... 18
5.2.3 R449 ............................................................................................................................................................................ 18
5.2.3.1 In case of 1F, parallel operation between alternators .............................................................................................. 18
5.2.3.2 Example of 2F and 3F ............................................................................................................................................. 19
5.2.4 D510C .......................................................................................................................................................................... 20
MUE_624_EN_14/03/2019 11:46 33521034901 1

1 Preface
2 possibilities for the type of excitation:
- Case 0: KH00404TN4N - short-circuit not maintained at 3 In for 10 seconds("N" for "No")
- Case 1: KH00404TO4N - short-circuit maintained at 3 In for 10 seconds ("Y" for "Yes")
Regulator:
Case 0 (N) R220/R250/R450 (_/M/T)/D510C
Case 1 (Y) R180/R438/R449/R450 (_/M/T)/D510C
Standard configuration:
Alternator
KH00263T KH00310T KH00351T KH00370T KH00390T KH00405T KH00440T KH00461T
reference
Case 0 0 1 0 0 1 0 1
Regulator R220 R220 R438 R220 R220 R438 R220 R438
Alternator
reference
Case 1 0 1 0 1 1 0 1
Alternator
reference
Case 1 0 1 1 1 1 0 0
Alternator
reference
Case 1 0 1 0 0 0 0 1
Regulator R450M R250 R450 R250 R250 R250 R250 R450M
Alternator
reference
Case 0 1 1 1 1 1 0 0
Regulator R250 R450 R450M R450M R450 R450M R250 R250
Alternator
reference
Case 1 0 1 1 1 1 1 1
Regulator R450M R250 R450 R450M R450M R450 R450M R450
Alternator
reference
Case 1 1 1 1 1 1 1 1
Regulator R450 D510C D510C D510C D510C R450 D510C D510C
Alternator
reference
Case 1 1 1 1 1 1 1 1
Regulator D510C D510C R450 D510C D510C D510C D510C D510C
Alternator
KH06932T KH08560T KH00590T KH00752T
reference
Case 1 1 1 1
Regulator D510C D510C R180 R180
2 Section 1 Preface 33521034901 MUE_624_EN _14/03/2019 11:46

1.1 General guidelines
Before using your machine, it is important to read the whole of this maintenance manual. All necessary operations and interventions
on this machine must be performed by a qualified technician.
Our technical support service will be pleased to provide any additional information you may require.
The various operations described in this manual are accompanied by recommendations or symbols to alert the user to the potential
risk of accidents. It is vital that you understand and take notice of the different warning symbols used.
In this manual, the warning messages are used as follows:
Immediate danger.
Indicates an imminent danger which may result in death or serious injury. Failure to follow the instruction
shown may pose serious risks to the health and life of those concerned.
DANGER
Potential danger.
Indicates a dangerous situation if the warning is not heeded. Failure to follow the instruction indicated may
cause minor injuries to those concerned or damage to equipment.
IMPORTANT
Note : The manufacturer reserves the right to modify the characteristics of its products at any time to incorporate the latest
technological developments. The information contained in this document are subject to change without previous notice.
1.2 Instructions and safety regulations (personal protection)
RISK OF INJURY.
During operation, do not allow anyone to stand in front of the air outlet guards, in case anything is ejected from
them.
Do not allow children younger than 14 to go near the air outlet guards.
IMPORTANT
RISK OF BURN.
Never touch the alternator during operation or immediately after the stopping of the unit because some surface
parts might still be very hot.
IMPORTANT
It is forbidden to spray or put any liquid containers on electrical parts.

Electric rotating machines have dangerous parts : when operating they have live and rotating components.
Therefore:
- improper use,
- the removal of protective covers and the disconnection of protection devices,
IMPORTANT - inadequate inspection and maintenance can cause personal injury or property damage.
2 Applicable directives and standards

DIRECTIVES:
- Low Voltage Directive no. 2006/95/EC of 12 December 2006
- Machinery Directive no. 2006/42/EC of 17 May 2006
- EMC Directive no.2004/108/EC of 15 December 2004
STANDARDS:
- EN 55011, Group 1, Class B : “Industrial, scientific and medical equipment – Radio-frequency disturbance characteristics –
Limits and methods of measuring”
- EN and IEC 60034 – 1 "Rotating electrical machines - Part 1: Rating and Performance"
- IEC 60034 – 5 – “Rotating electrical machines, Part 5: Degrees of protection provided by the integral design of rotating
electrical machines”
- ISO 8528 – 3 – “Reciprocating internal combustion engine driven alternating current generating sets – Part 3: Alternating
current generators for generating sets”
MUE_624_EN _14/03/2019 11:46 33521034901 Section_2 _Applicable directives and standards 3

3 Specifications
3.1 Mass
Masses (kg)
Units : kg :
Alternator KH00263T KH00310T KH00351T KH00370T KH00390T KH00405T KH00440T KH00461T

Single bearing 73 80 87 117 92 122 102 133
Dual bearings 82 89 96 129 101 134 109 145
Single bearing 133 112 165 165 165 181 186 295
Dual bearings / 121 170 170 / 185 190 301
Single bearing 295 187 187 332 332 368 569 398
Dual bearings 301 207 / 338 338 374 569 404
Single bearing 599 433 433 674 682 976 754 754
Dual bearings 599 439 439 674 682 996 754 754
Single bearing 1113 1113 888 888 1420 1427 450 1289
Dual bearings 1126 1126 888 888 1445 1483 544 1302
Single bearing 1574 1372 2290 1635 1788 2490 1837 1820
Dual bearings 1616 1392 2330 1677 1829 2530 1878 1845
Single bearing 2760 3705 3705 3737 3737 2980 3950 3950
Dual bearings 2800 3724 3748 / / 3010 3991 3991
Single bearing 3989 3989 3260 4433 4435 4625 4924 4924
Dual bearings / / 3300 4476 / / 4967 4967
Alternator KH06932T KH08560T KH00590T KH00752T
Single bearing 4738 5935 262 295
Dual bearings / / / /
4 Maintenance
4.1 General checking of the installation
ELECTRICAL EQUIPEMENT – RISK OF ELECTRICAL SHOCK

All work on the alternator terminals during reconnection or checks must be made
with absolute certainty of no tension in them.
DANGER
- Check the operation at regular intervals (no abnormal noise or vibration).

- Check the tightness of all nuts and bolts in particular of the electric connections.
4.2 Cleaning the alternator

Electrical part
Do not use: trichlorethylene, perchlorethylene, trichloroethane or any alkaline products.
IMPORTANT
- Use commercially-available volatile degreasing agents.
Nota : The insulating components and the impregnation system are not at risk of damage from solvents.
- Avoid letting the cleaning product run into the slots.

- Apply the product with a brush, sponging frequently to avoid accumulation in the housing.
- Dry the winding with a dry cloth and let any traces evaporate before reassembling the machine.
- Check the winding insulation.
4 Section 3 Specifications 33521034901 MUE_624_EN _14/03/2019 11:46

Mechanical part
These operations must be performed at a cleaning station, equipped with a vacuum system that collects and
flushes out the products used.
IMPORTANT
Cleaning the machine using water or a highpressure washer is strictly prohibited.

Any problems arising from such treatment are not covered by our warranty.
Use compressed air only in low pressure for the alternator external cleaning.
IMPORTANT
- Degrease the alternator using a brush and detergent(suitable for paintwork).

- Dust using an air gun.
- If the machine is fitted with air inlet and outlet filters, clean them routinely at regular intervals.
- In the case of dry dust, clean the filter using compressed air and/or replace it if it is clogged.
- After cleaning the alternator, it is essential to check the winding insulation
4.3 Checking the ventilation circuit

Removing the filters should be done when the installation is stopped, this operation gives
access to parts that could be under voltage.
DANGER
- Ensure that air flow is not reduced by partial blocking of the suction and discharge grids: mud, fiber, grease, etc ...
- Check for corrosion or abrasion grids air outlet.
If your system is equipped with filters:
- Remove the grid and remove the filter.
- Clean the filter with low pressure compressed air or replace if it is clogged.
.
Air inlet
Filter
Support
MUE_624_EN _14/03/2019 11:46 33521034901 Section_4 _Maintenance 5

4.4 Checking bearings
4.4.1 Bearings lubricated for life
The approximate lifetime of the grease (depending on use) is 20 000 hours or 3 years.
- Control the temperature rising of the bearings which must not exceed 90 ° C.
- In the case of exceeding this value, stop the alternator and proceed to a checking.
- Contact an authorized agent for bearings change.
4.4.2 Regreasable bearings
It is imperative to lubricate the alternator during operation.

Before using another grease, check for compatibility with the original one.
IMPORTANT
If your equipement is doted of regreasable bearings, it is recommended to :

- lubricate the alternator during operation.
- Check for the temperature rising of the bearings.
KH01100T - KH01220T KH01630T - KH01741T KH02400T - KH02401T

KH02971T - KH03541T
Alternator reference KH03890T - KH04450T
KH05090T
KH02100T - KH02101T KH03603T
Quantity of grease (g) : LITHIUM - standard - NLGI 3
Front bearing 33 41 60 60
Rear bearing 30 30 50 50
Lubrication frequency (h)
4000 3500 4500 3600
KH04402T - KH04404T
KH04406T - KH04972T KH04403T - KH04976T
Référence Alternateur KH04451T - KH05020T KH04973T - KH04974T KH06931T - KH06521T
KH05793T - KH05794T KH06522T
KH06932T - KH08560T
Quantity of grease (g) : Mobil polyrex EM – NLGI 2
Front bearing 70 70 70
Rear bearing 35 40 40
Lubrication frequency (h)
1700 2100 1500
4.5 Checking the winding
The insulation must be higher than 1 MΩ for the stator and 100 000 Ω for the other windings.
Damage caused to the AVR in such conditions is not covered by our warranty.
IMPORTANT
- Disconnect all AVR wires.

- Check the winding insulation by performing a high voltage test.
To restore the minimum values of 1 M Ω and 100 000Ω, two methods are possible :
- Dry out the machine for 24 hours in a drying oven at a temperature of 110 °C (without the regulator).
- Blow hot air into the air intake, having made sure that the machine is rotating with the exciter field disconnected.
6 Section 4 Maintenance 33521034901 MUE_624_EN _14/03/2019 11:46

4.6 Checking the windings and rotating diodes using separate excitation

During this procedure, make sure that the alternator is disconnected from any
external load and inspect the terminal box to check that the connections are fully
tightened.
DANGER
1. Stop the unit, disconnect and isolate the AVR wires.

2. Connect a 12 V battery in series with a rheostat of approximately 50 ohms - 300 W and a diode on both exciter field wires
(5+) and (6-).
This system should have characteristics which are compatible with the field excitation power of the machine(see the nameplate).
3. Run the unit at its rated speed.
4. Gradually increase the exciter field current by adjusting the rheostat or the variac and measure the output voltages on L1 -
L2 - L3, checking the excitation voltage and current at no load (see the machine nameplate or ask for the factory test
report).
When the output voltage is at its rated value and balanced within 1% for the rated excitation level, the machine is in good working
order. The fault therefore comes from the AVR or its associated wiring (ie. sensing, auxiliary windings).
4.7 Maintenance of the regulator
4.7.1 Recommendations
During the warranty period, this operation should only be carried out in an approved workshop or in our
factory, otherwise the warranty may be invalidated.
Whilst being handled, the machine should remain horizontal (rotor not locked in position). Check how much
the machine weighs before choosing the lifting method.
IMPORTANT
4.7.2 Access to connections and the regulation system
Access directly by removing the box lid or the AVR access door.
4.7.3 Access to complete regulators manuals
For distributors, full manuals for regulators are available on https://gaia.sdmo.com.

Enter the regulator or alternator reference.
4.7.4 Regulator R180 (Scenario 1)
4.7.4.1 Presentation of the regulator
UFRO selection line:

Open 60 Hz operation mode.
Closed 50 Hz operation mode.
UFRO Pot.
45 Hz to 55 Hz in 50 Hz mode.
55 Hz to 65 Hz in 60 Hz mode.
Voltage
The operating voltage is set by the potentiometer marked "V".
Droop
The droop is set by the potentiometer marked "Droop".
Entry-level accessory and external pot.
The entry-level accessory is set by the potentiometer marked "Acc". This potentiometer sets the maximum voltage range
of the external potentiometer or the entry-level accessory range.
Stability
The potentiometer is used to set the stability of the alternator output voltage; move it clockwise to increase the speed. The
desired setting is obtained by moving the stability potentiometer clockwise into the position at which the voltage becomes
unstable, then reducing the setting by 1 turn.

Display
- Over excitation limit
- Loss of voltage detection
- UFRO
4.7.4.2 Setting the regulator
Immediate danger.
To prevent electric shock and personal injury care be taken not to touch live parts.
DANGER
Potential danger.
Adjustments be done carefully and gradually while alternator is running otherwise the system may experience
fluctuations.
IMPORTANT
- VOLT : Full CCW

- STAB : Centre of Travel
- UFRO : Select 50Hz or 60Hz mode
Start - Up
- Check that all connections, the position of the encoder, the straps and add-ons are repositioned identically than the initial
regulator.
- Start the prime-mover and bring the alternator to rated speed (rpm).
- The terminal voltage will show voltage build-up.
- Adjust the terminal voltage using voltage adjust pot.
- If oscillations are seen on the voltmeter (A.C.) indicating the alternator terminal voltage, gradually turn the «STABILITY»
trimmer on R180 clock-wise and stop turning it at the position where oscillations disappear.
- If oscillations are not seen at build-up, turn the «STABILITY» trimmer CCW till oscillations appear and then slightly turn it
CW to remove oscillations. This will help tune the controller and alternator time constants.
- Set Ufro knee point at 47.5Hz for 50Hz or 57Hz for 60Hz.
- If external voltage adjust potentiometer is required, stop the alternator and connect 1Kohms potentiometer in place of Link
at terminal A1 and A2.
- If droop is required connect droop current transformer at Q1 and Q2.

R220
regulator.
- Make the adjustement of the regulator as follows :
1. Set the P1 potentiometer (voltage adjustment) fully anti-clockwise.
2. Set the voltage adjustment potentiometer in centre position.
3. Run the alternator at its rated speed. If the voltage does not increase, the magnetic circuit should be
remagnetized.
4. Turn the AVR voltage adjustment potentiometer P1 slowly until the output voltage rated value is obtained.
5. Adjust the stability setting using P2.
R250

regulator.
- Make the adjustement of the regulator as follows :
1. Set the P1 potentiometer (voltage adjustment) fully anti-clockwise.
2. Set the voltage adjustment potentiometer in centre position.
3. Run the alternator at its rated speed. If the voltage does not increase, the magnetic circuit should be
remagnetized.
4. Turn the AVR voltage adjustment potentiometer P1 slowly until the output voltage rated value is obtained.
5. Adjust the stability setting using P2.
R438
Check that all connections, the position of the encoder, the straps and add-ons are repositioned identically than the initial regulator.
Stability adjustments in standalone operation

Make the adjustment of the regulator as follows :
Adjust the potentiometers in their Initial settings (see table below).
Action Factory setting Pot.
400V - 50 Hz
Voltage minimum fully anti-clockwise
(Input0 - 380 V)
Not set
Stability
(centre position)
Voltage quadrature droop

(// operation with C.T.) Not set
- 0 quadrature loop fully (fully anticlockwise)
anti-clockwise.
Excitation ceiling
Limit of excitation and 10 A
short-circuit current, maximum
minimum fully anti-clockwise.

1. Remote voltage adjustment potentiometer : centre (ST4 jumper removed).
2. Install a D.C. analogue voltmeter (needle dial) cal. 50V on terminals E+, E- and an A.C. voltmeter cal 300 - 500 or 1000V
on the alternator output terminals.
3. Make sure that the ST3 jumper is positioned on the desired frequency (50 or 60 Hz).
4. Voltage potentiometer P2 at minimum, fully anti-clockwise. Stability potentiometer P3 to around 1/3 of the anti-clockwise
limit.
5. Start the engine and set its speed to a frequency of 48 Hz for 50 Hz, or 58 for 60 Hz.
6. Set the output voltage to the desired value using P2. Rated voltage UN for solo operation (eg. 400 V). Or UN + 2 to 4% for
parallel operation with C.T. (eg. 410 V) If the voltage oscillates, use P3 to make adjustments (try both directions) observing
the voltage between E+ and E- (approx. 10V D.C.).
The best response times are obtained at the limit of the instability. If no stable position can be obtained, try disconnecting or repla-
cing the ST2 jumper (normal/fast).
7. Check LAM operation : ST5 closed.

8. Vary the frequency (speed) around 48 or 58 Hz according to the operating frequency, and check the change in voltage
from that observed previously (~ 15%).
9. Readjust the speed of the unit to its rated no-load value.
4.7.8 Regulator R449
R449
Contact an authorized agent.

4.7.9 Regulator R450 or R450M/R450T (scenario 1)
R450
R450M/R450T

Adjusting the voltage and the stability

Make the adjustment of the regulator as follows :
1. Adjust the potentiometers in their Initial settings (see table below).
Action Factory setting Pot.
Voltage minimum fully anti-clockwise 400V -50Hz
Not set
Stability
(centre position)
10A
Excitation ceiling - Factory-sealed
maximum
Voltage quadrature droop (// operation

with C.T.) - 0 quadrature droop fully anti- Not set (fully anti-clockwise)
clockwise
2. Install a D.C. analogue voltmeter (needle dial) cal. 100 V on terminals F+, F- and an A.C. voltmeter cal. 300 - 500 or 1000
V on the alternator output terminals and check the rotating switch selection.
3. Adjust the voltage potentiometer P1 at minimum, fully anti-clockwise then adjust the stability potentiometer P2 around 1/3
in from the anti-clockwise stop..
4. Start the engine and set its speed to a frequency of 48 Hz for 50 Hz, or 58 for 60 Hz.
5. Set the output voltage to the desired value using P1, rated voltage UN for solo operation (eg. 400 V) or UN + 2 to 4% for
parallel operation with C.T. (eg. 410 V -). If the voltage oscillates, use P2 to make adjustments (try both directions),
observing the voltage between F+ and F- (approx. 10 V D.C.). The best response time is obtained at the limit of the
instability. If no stable position can be obtained, try selecting the fast position.
6. Check LAM operation: depending on the rotating switch selection.
7. Vary the frequency (speed) around 48 or 58 Hz according to the operating frequency, and check the change in voltage
from that observed previously (~ 15%).
8. Readjust the speed of the genset to its rated no-load value.

4.7.10 Regulator D510C
D510C
Supply
Terminals Signals Scheme

X1 Power supply
X2 - Auxiliary winding input
Z1 - PMG input
Z2 - SHUNT input
Up to
180 V
L1 Mains voltage measurement

L2 Main
Up to
530 V

Terminals Signals Scheme
U Alternator voltage measurement
V For single-phase: use V and W
W
Up to
530 V
IU = (s1, s2) Alternator current measurement

IV = (s1, s2)
IW = (s1, s2)
AI1 Analog inputs:

AI2 External setting
DI1 Digital inputs:

DI2 U=U and PF/kVAR regulation
B+ DC power supply
B
11V to
30V
F+ Field excitation: 6 A
F up to 15 A/10 s
CTP Temperature sensors

PT100_1
PT100_2
PT1003
CAN_H CAN BUS

CAN_L
USB_D+ USB 2.0 communication port

USB_D

The LEDs serve to inform the user whether the AVR is working correctly or not.
LEDs
Name Colour Meaning

Power ON Green The board is supplied with power
Hz Red Speed drop

Red Problem of overvoltage or undervoltage
Volt
Red Problem of overexcitation or underexcitation
Exc.
Red Problem on the exciter field diode bridge
Fault
Manu Yellow Manual mode enabled
PF / KVAR Yellow Regulation of the power factor or reactive power enabled
U=U Yellow Alternator voltage = Mains voltage
USB Blue AVR connected to a PC
EasyReg is a Software which allows to :

- Easily configure the digital regulator D510C.
- Monitor several important parameters such as alternator output voltage, excitation current, active and reactive power,
etc…
- Optimize the regulation loop.
- Set the AVR parameters.
- Configure the inputs and outputs.
- Display faults and parameter measurements.
It is the interface between the user and the digital AVR.
Contact an authorized agent.
5 Repairing faults
When working on the rotating diodes, the excitation (induced, inductors) or the main field, contact an
authorized dealer.
IMPORTANT
5.1 Mechanical faults

Fault Action
Excessive overheating of one or both - If the bearing has turned blue or if the grease has turned black,
bearings (bearing temperature 80°C change the bearing.
Bearing
above the ambient temperature) (With or - Bearing not fully locked (abnormal play in the bearing cage)
without abnormal bearing noise) - End shields incorrectly aligned
- Air flow (inlet-outlet) partially clogged or hot air is being recycled
Excessive overheating of alternator
Abdnormal from the alternator or engine
frame (more than 40° C above the
temperature - Alternator operating at too high a voltage (>105% of Un on load)
ambient temperature)
- Alternator overloaded
- Misalignment (coupling)
Vibrations Too much vibration - Defective mounting or play in coupling
- Rotor balancing fault (Engine - Alternator)
16 Section 5 Repairing faults 33521034901 MUE_624_EN _14/03/2019 11:46

Fault Action
Excessive vibration and humming noise - Phase imbalance
coming from the machine - Stator short-circuit
- System short-circuit
- Misparalleling
Possible consequences
Alternator damaged by a significant
- Broken or damaged coupling
Abnormal noise impact, followed by humming and
- Broken or bent shaft end
vibration
- Shifting and short-circuit of main field
- Fan fractured or coming loose on shaft
- Irreparable damage to rotating diodes/AVR, surge suppressor
5.2 Electrical faults

After operational testing, replace all access panels or covers.
DANGER
5.2.1 R180
Symptom Cause Action

No voltage build-up Fuse links blown Change the fuse links.
Low residual voltage Run alternator at correct RPM. If problem persist, disconnect AVR and
across X1 and X2 connect 24dc battery between F1 and F2. This process will increase
residual voltage.
Incorrect wiring Verify and repair wiring as per interconnection drawing.
Voltmeter defective Replace voltmeter
Faulty regulator Replace regulator
Voltage too high Incorrect voltage setting Set according to requirement
Low voltage External pot link open Connect link or pot according to requirement
Sensing voltage absent Connect according to diagram
Prime mover rpm falls Set RPM
Poor regulation Prime mover rpm falls Set RPM
High distortion Non- Reduce non-linear load
linear load
Alternator running on very P.F. correction required
low P.F.
Unbalanced load Redistribute the load equally to three phases.
Rotating diodes failed Replace diodes
Droop connected Remove droop connection if not needed
Voltage unstable Incorrect wiring Verify and repair wiring. Make sure that the contacts are firm.
Stability setting incorrect Set stability pot
Voltage builds-up but Incorrect wiring Verify and repair wiring. Make sure that the contacts are firm.
collapses/ erratic behavior Electronic card settings Set as per instructions in the manual
not correct
MUE_624_EN _14/03/2019 11:46 33521034901 Section_5 _Repairing faults 17

5.2.2 R220/R250/R438/R450/R450M/R450T
Fault Action Effect Check/Cause

The alternator builds up
and its voltage is still correct
- Lack of residual magnetism
when the battery is
Connect a new
removed.
battery of 4 to 12
The alternator builds up but its - Check the connection of the voltage reference to
volts to terminals
No voltage at no voltage does not reach the rated the AVR
E-(F-) and E+(F+),
load on start-up value when the battery is - Faulty diode
respecting the
removed. - Armature short-circuit
polarity, for 2 to 3
- Faulty AVR
seconds The alternator builds up but its
- Field windings open circuit (check winding)
voltage disappears when the
- Main field winding open circuit (check the
battery is removed.
resistance)
Check the AVR connections (possible AVR failure)
- Field windings short-circuited
Correct speed - Rotating diodes burnt out
Check the drive - Main field winding short-circuited
Voltage too low
speed - Check the resistance
Increase the drive speed (do not touch the AVR
Speed too low voltage pot. (P2) before running at the correct
speed)
Adjust AVR voltage
Voltage too high Adjustment ineffective Faulty AVR
potentiometer
- Check the speed : possibility of cyclic irregularity
- Loose connections
Voltage Adjust AVR stability If no effect : try normal / fast
- Faulty AVR
oscillations potentiometer recovery modes (ST2)
- Speed too low when on load (or AVR LAM set too
high)
R438
Scenario 1 : U<10V
Voltage correct Scenario 2 : U<20V Check the speed (or AVR LAM set too high)
Run at no load
at no load and R450
and check the
too Scenario 1 : U<10V
voltage between
low when on R438
E-(F-) and E+(F+) on - Faulty rotating diodes
load Scenario 1 : U>15V
the AVR - Short-circuit in the main field. Check the
(*) Scenario 2 : U>30V
resistance.
R450
- Faulty exciter armature. Check the resistance.
Scenario 1 : U>15V
(*) Warning : During single-phase operation, check that the sensing wires from the AVR are connected to the correct output
terminals.
Check the AVR, the
Voltage surge suppressor, - Exciter winding open circuit
disappears the rotating diodes, The voltage does not return - Faulty exciter armature
during and replace any to the rated value. - Faulty AVR
operation (**) defective - Main field open circuit or short-circuited
components
(**) (R438/R450/R450M/R450T) Warning : The AVR internal protection may cut in (overload lost connection, short circuit).
(1) R250/R438/R450/R450M/R450T
5.2.3 R449
5.2.3.1 In case of 1F, parallel operation between alternators
Symptom Probable causes Solutions

- No residual magnetism or polarity inversion - Voltage built-up is required.
between the excitation output and the
exciter input.
- De-energising contacts open. - Close this contact.
- The speed is less than the rated speed. - Adjust the speed.
- Connection lost between the regulator and - Check the wiring.
Absence of voltage on start-up,
the exciter.
at no load.
- Alternator loaded or short-circuited. - Remove the load from the alternator.
- External potentiometer connected - Check the wiring.
incorrectly.
- Faulty regulator. - Test it or change it.
- Faulty exciter or rotating diode bridge. - Check the exciter and the diodes.
- Fuses blown. - Replace the fuses.

- Incorrect voltage at the sensing terminals. - Check the wiring of the 0, 110V, 220V, 380V
terminals on terminal block J1.
Voltage too high and adjustment - Loss of sensing. - Check the wiring.
potentiometer not operating. - The external potentiometer has an incorrect - Set a potentiometer with the correct value.
value.
- Voltage potentiometer set too high. - Adjust voltage potentiometer P2 or the external
Voltage too high, but adjustable potentiometer..
by the adjustment - Regulator sensing incorrect. - Check the wiring and the sensing value, at 0V
potentiometer. and 110V, 220V, 380V terminals.
- Regulator faulty. - Test it or change it.
- ST3 and ST4 jumpers - Check the presence of the ST3 and ST4
Voltage too low, but adjustable
jumpers.
by the adjustment
- The speed is too low. - Set to the correct speed.
potentiometer.
- Exciter and rotating diodes. - Check the exciter and the rotating diodes.
- Distortion of the waveform, non-linear load. - Contact manufacturer.
- Unbalanced load. - Balance the load or change the sensing points.
Incorrect regulation. - The speed is not at the correct value. - Adjust the speed.
- Exciter or rotating diodes faulty. - Check the exciter and the rotating diodes.
- Frequency unstable. - Check the stability of the drive system speed.
- Secondary sensing of a transformer - Provide separate sensing for the alternator.
Voltage unstable. supplying other devices.
- Stability potentiometer P3 is incorrectly set. - Adjust stability potentiometer P3.
- Stability adjustment. - Adjust stability potentiometer P3 and the ST2
Response time too long. jumper.
- Speed regulator response too long. - Adjust the stability of the speed.
- Vectorial composition fault between the - Check the wiring of the sensing and parallel
Considerable drop in voltage,
voltage and the current. operation CT.
on-load.
- The parallel operation CT ratio is incorrect. - Correct the CT ratio.
- Quadrature droop potentiometer needs - Adjust the quadrature droop potentiometer.
adjusting.
kVAR not stable between - The no-load voltages are not identical. - Check that all the alternators have the same
alternators (reactive current no-load voltage value.
circulation). - Phases not connected to the sensing - Check the sensing wiring.
correctly.
- The CT is not on the correct phase. - Check the position of the parallel operation CT.
5.2.3.2 Example of 2F and 3F

- - Vectorial composition fault between the - - Check the sensing wiring and the parallel
sensing voltage and the stator current. operation CT.
- - R 726 faulty. - - Change the module.
Incorrect regulation of PF, PF
- - R 726 ST2 jumper missing.
potentiometer not operating.
- - Wiring fault between the R 449 and the R - - Check the wiring, in particular the wires
726. between 1 and 2 of terminal block J1 on the R
726.
PF range incorrect. - - Settings on potentiometers P2 incorrect. - Reset the range as shown above.
The LEDs will not light up. - - Contacts 2F and 3F missing. - Check the wiring.
Cannot adjust the voltage - The sensing voltage is incorrect or - Check the wiring and the value of the voltage.
matching circuit. incorrectly connected.

5.2.4 D510C


User and Maintenance Manual For Generating Sets: K44 - APM303

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User and Maintenance Manual For Generating Sets: K44 - APM303

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User and maintenance manual

for generating sets

GENERAL ENGINE DATA EXHAUST

GENERAL DATA OTHER DATA

The APM403 is a versatile control unit which allows

GENERAL – SAFETY – INSTALLATION

MGS_186_EN_17/07/2017 15:01 33532000201_6_1 1

2 Section 0 CONTENTS 33532000201_6_1 MGS_186_EN _17/07/2017 15:01

MGS_186_EN _17/07/2017 15:01 33532000201_6_1 Section_0 _CONTENTS 3

1.1 Description of the documentation for generating sets

4 Section 1 Preface 33532000201_6_1 MGS_186_EN _17/07/2017 15:01

MGS_186_EN _17/07/2017 15:01 33532000201_6_1 Section_1 _Preface 5

2.1 Meaning of the pictograms on the generating set

Reading the manual

Important: Draining the

Water spray Flammable products,

Lifting point Forklift required for Class 3 danger: Transport bracket,

6 Section 2 Safety instructions 33532000201_6_1 MGS_186_EN _17/07/2017 15:01

Installing the equipment

Using the equipment

- Information for personnel:

- Protection for individuals and equipment:

Maintaining the equipment

MGS_186_EN _17/07/2017 15:01 33532000201_6_1 Section_2 _Safety instructions 7

- Cleaning the equipment:

- Respecting the environment:

8 Section 2 Safety instructions 33532000201_6_1 MGS_186_EN _17/07/2017 15:01

HANDLING PHASES - RISK OF DROPPING

2.4 Risk of electrocution

ELECTRICAL EQUIPMENT - RISK OF ELECTRIC SHOCKS

2.4.1 Safety precautions in case of electrical shock

In the event of an electric shock, observe the following instructions:

MGS_186_EN _17/07/2017 15:01 33532000201_6_1 Section_2 _Safety instructions 9

FUELS / FLAMMABLE PRODUCTS / PRESSURIZED

Supply gas (concerns generating sets running on gas) :

10 Section 2 Safety instructions 33532000201_6_1 MGS_186_EN _17/07/2017 15:01

EXHAUST GAS - TOXIC PRODUCTS - TOXIC RISK

Corrosion inhibitor in the coolant (contains alkali)

Fuels and oils

If splashes get into the eyes:

MGS_186_EN _17/07/2017 15:01 33532000201_6_1 Section_2 _Safety instructions 11

HIGH SOUND LEVEL - RISK OF HEARING LOSS

2.8 Guidelines for protecting the environment

12 Section 2 Safety instructions 33532000201_6_1 MGS_186_EN _17/07/2017 15:01

There are 3 main types of generating set:

3.1 Identification plates

3.1.1 Identifying sets

Figure 1 : Example of a generating set identification plate

MGS_186_EN _17/07/2017 15:01 33532000201_6_1 Section_3 _General description of the equipment 13

3.1.3 Location of plates on containerised generating sets

The identification plate for containers is affixed by the emergency stop.

Figure 3: Position of the identification plate for generating sets in a container

14 Section 3 General description of the equipment 33532000201_6_1 MGS_186_EN _17/07/2017 15:01

Figure 4: Examples of engine identification plates

Figure 5: Examples of alternator identification plates

Figure 6: Example of an electrical cabinet identification plate

MGS_186_EN _17/07/2017 15:01 33532000201_6_1 Section_3 _General description of the equipment 15

3.2.1 Generating set without protective cover

Figure 7: General description of a generating set without a protective cover

1 Air filter 5 Engine 9 Frame

16 Section 3 General description of the equipment 33532000201_6_1 MGS_186_EN _17/07/2017 15:01

Figure 8: General description of a generating set with a protective cover

1 Lifting ring 6 Engine 11 Frame