00 JohnDeerePoweredManual

Generating Sets
Installation Recommendations and Operations Manual
John Deere Powered
Dear Aksa Generating

Set Operator;
First of all, we would like to
thank you for your choice of
Aksa Power Generation.
This operating and maintenance
manual is designed and
developed to make you familiar
with the generator system.
This manual gives general
information about
mounting, operation and
maintenance of the
generating set. Tables and
diagrams are also
available outlining your
generating set.
Never operate, maintain
or repair your generating
set without taking general
safety precautions.
1. INTRODUCTION ..............................................................
1.1 Generating Set Label and Serial Number ...........................
1.2 Engine Serial Number........................................................
2. SAFETY ............................................................................
2.1 General .............................................................................
2.2 Installation, Handling and Towing .....................................
2.3 Fire and Explosion .............................................................
2.4 Mechanical........................................................................
2.5 Chemical ...........................................................................
2.6 Noise.................................................................................
2.7 Electrical............................................................................
3. FIRST AID FOR ELECTRIC SHOCK....................................
3.1 Open the airway ...............................................................
3.2 Breathing ..........................................................................
3.3 Circulation.........................................................................
3.4 If no Breathing but Pulse is Present ...................................
3.5 If no Breathing and No Pulse.............................................
3.6 Recovery Position ..............................................................
4. GENERAL DESCRIPTION..................................................
4.1 Generating Set Description and Identification....................
4.2 Major Components ...........................................................
4.3 Diesel Engine.....................................................................
4.4 Engine Electrical System ....................................................
4.5 Cooling System .................................................................
4.6 Alternator .........................................................................
4.7 Fuel Tank and Baseframe ..................................................
4.8 Vibration Isolation .............................................................
4.9 Silencer and Exhaust System .............................................
4.10 Control System................................................................
5. INSTALLATION, HANDLING AND STORAGE..................
5.1 General .............................................................................
5.2 Canopies ...........................................................................
5.3 Moving the Generating Set ...............................................
5.4 Location ............................................................................
5.5 Foundations Vibration Isolation ........................................
5.6 Combustion Air Inlet .........................................................
5.7 Cooling and Ventilation.....................................................
5.8 Exhaust .............................................................................
5.9 Fuel System .......................................................................
5.9.1 Day Tank.......................................................................
5.9.2 Bulk Storage Tank ..........................................................
5.9.3 Fuel Lines .......................................................................
6. INSTALLATION OIL RECOMMENDATIONS FOR
JOHN DEERE ENGINES...................................................
6.1 Engine Break-in Oil ............................................................
7. BATTERIES.......................................................................
7.1 Battery Maintanance .........................................................
7.2 Control of the Battery .......................................................
8. ELECTRICAL CONNECTION .............................................
8.1 Cabling..............................................................................
8.2 Protection .........................................................................
8.3 Loading.............................................................................
8.4 Power Factor.....................................................................
8.5 Grounding / Earthing Requirements.................................
8.6 Alternator Reconnection....................................................
8.7 Parallel Running ................................................................
8.8 Insulation Test...................................................................
9. ACOUSTIC SILENCING.....................................................
4.13.1 Exhausts Silencers ........................................................
4.13.2 Canopies ......................................................................
4.13.3 Other Sound Attenuation.............................................

10. TOWING ........................................................................
10.1 Preparing to Low.............................................................
10.2 Towing............................................................................
10.3 Parking............................................................................
11. STORAGE.......................................................................
11.1 Engine Storage................................................................
11.2 Alternator Storage ..........................................................
11.3 Battery Storage ...............................................................
12. ENGINE JACKET WATER HEATER ................................
13. GENERATING SET MAINTENANCE ...............................
14. GENERAL PRECAUTIONS AND CONTROLS WHICH
MUST BE DONE BEFORE STARTING UP THE
GENERATING SET .........................................................
15. STARTING THE GENERATING SET ................................
15.1 Starting with ME 40 Panel...............................................
15.2 Starting with P 500 .........................................................
15.2.1 Manual Operation ........................................................
15.2.2 Automatic Mode of Operation .....................................
15.3 Starting With P300 Automatic Control Panel
15.3.2 Automatic Mode Of Operation
15.3.3 Test Mode of Operation
15.4 Starting With P 2010 Panel .............................................
15.5 Starting with P 2020 Automatic Panel............................
15.5.3 Test Operation .............................................................
16. GENERAL PRECAUTIONS AND CONTROL WHICH MUST
BE DONE AFTER STARTING UP THE GENERATING SET
17. STOPPING THE GENERATING SETS ..............................
17.1 At Manual Models...........................................................
17.2 At Automatic Models ......................................................
18. GENERATING SET CONTROL SYSTEMS ........................
18.1 Control Panels .................................................................
18.1.1 Manual Control System ME40 ......................................
18.2.1 Automatic Control System P 500 Panel ........................
18.3.1 Control System P300 Panel
18.4.1 Automatic Control System P 2020 Panel ......................
18.5.1 Autostart Control System P 2010 Panel ........................
18.6. Panel Equipments...........................................................
18.6.1 AC Voltmeter ...............................................................
18.6.2 Voltmeter Selector Switch ............................................
18.6.3 AC Ammeter ................................................................
18.6.4 Frequencymeter ...........................................................
18.6.5 Hoursrunmeter.............................................................
18.6.6 Water Temperature Gauge...........................................
18.6.7 Oil Pressure Gauge .......................................................
18.6.8 Emergency Stop Pushbutton ........................................
18.6.9 Alternator Protection....................................................
18.7 The Placement and Instulation of Transfe Switch.............
19. ALTERNATOR TROUBLESHOOTING ...............................
20. DIESEL ENGINE TROUBLESHOOTING.............................
21. MAINTENANCE ..................................................................
22. ENGINE STORAGE GUIDELINES.......................................
23. PREPARING ENGINE FOR LONG TERM STORAGE........
24. REMOVING ENGINE FROM LONG TERM STORAGE ....
25. WARRANTY ........................................................................
1. INTRODUCTION
2. SAFETY
Aksa Generating set is designed to be commissioned, when delivered,
2.1 General
as soon as the necessary cooling water, antifreeze, fuel, lubrication
The generating set is designed to be safe when used in the correct
oil and fully charged battery are provided.
manner. However responsibility for safety rests with the personnel
With its long years of experience, Aksa manufactures efficient,
who install, use and maintain the set. If the following safety
reliable and quality generating set.
precautions are followed, the possibility of accidents will be
This operating and maintenance manual is prepared to assist the
minimized. Before performing any procedure or operating technique,
operator in operation and maintenance of the generating set.
it is up to the user to ensure that it is safe. The generating set
Observing the advices and rules in this manual will ensure that the
should only be operated by personnel who are authorized and
generating set operates in maximum performance and efficiency
trained.
for a long time.

WARNING
1.1 Generating Set Label and Serial Number
Care should be taken to perform more frequent maintenance in
Read and understand all safety precautions and warnings before

operating or performing maintenance on the generating set.
dirty and dusty environments in order to keep the generating set
Failure to follow the instructions, procedures, and safety
in good working condition.
precautions in this manual may increase the possibity of accidents
Necessary adjustments and repairs should be made only by authorized
and injuries.
and qualified persons.
Each generating set has a model and a serial number indicated on
Do not attempt to operate the generating set with a known

unsafe condition.
a label on the base frame. This plate also indicates the manufacturing
date, voltage, current, power in kVA and kW, frequency, power
If the generating set is unsafe, put danger notices and disconnect

the battery negative (-) lead so that it cannot be started until
factor and weight of the generating set. These datas are necessary
the condition is corrected.
in spare part orders, for warranty validity and for service calls.
Disconnect the battery negative (-) lead prior to attempting any

repairs or cleaning inside the enclosure.
Install and operate this generating set only in full compliance

with relevant National, Local, or Federal Codes, Standards or
other requirements.
Do not allow skin contact with fuel, oil, coolant and other
chemicals for al long time.
Lower the air, water and oil pressure of the genset before
starting any repairs.
Do not attempt to repair or operate the genset, wearing a tom

protective cloth.
!
1.2 Engine Serial Number
Each John Deere Engine has a 13 digit serial number. Please record
serial number (B), model number (C) and consumption ratio (D)
after the installation of your genset.
Do not remove the radiator filler cap ntil the coolant has cooled.
2.2 INSTALLATION, HANDLING AND TOWING
2.3 FIRE AND EXPLOSION
This manuel covers procedures for installation, handling, and towing
Fuel and fumes associated with generating sets can be flammable
of generating sets. That chapter should be read before installing,
and potentially explosive. Proper care in handling these materials
moving and lifting the generating set or towing a mobile set. The
can dramatically limit the risk of fire or explosion. However, safety
following safety precautions should be noted:
dictates that fully charged BC and ABC fire extinguishers are kept
on hand. Personnel must know how to operate them.
WARNING
!
Make electrical connections in compliance with
WARNING
relevant Electrical Codes, Standards or other
requirements. This includes requirements for
properly ventilated.
grounding and ground/earth faults.

!
set clean. When spills of fuel, oil, battery
storage systems, make sure such systems are installed in
electrolyte or coolant occur, they should be cleaned up
compliance with relevant Codes, Standards or other requirements.
immediately.
Engine exhaust emissions are hazardous to personnel. The
Never store flammable liquids near the engine.
engine exhaust for all indoor generating sets must be piped
Do not smoke or allow sparks, flames or other sources of ignition
outdoors via leak-free piping in compliance with relevant Codes,
around fuel or batteries. Fuel vapours are explosive. Hydrogen
Standards and other requirements. Ensure that hot exhaust
gas generated by charging batteries is also explosive.

!
the battery charger
Ensure that fumes from the exhaust outlet will not be a hazard.
before making or breaking connections
Never lift the generating set by attaching to the engine or
with the battery.

!
tools) away from exposed live electrical parts (such as terminals)
Ensure that the lifting rigging and supporting structure is in
Sparks and arcing might ignite fuel of vapours.
good condition and has a capacity suitable for the load.
Avoid refiling the fuel tank while the engine is running.
Keep all personnel away from the generating set when it is
Do not attempt to operate the generating set with any known

leaks in the fuel system.
When towing the mobile genset observe all codes, standards
or other regulations and trafficlaws. These include those

minimum speeds.
Do not permit personnel to ride on the drawbar or to stand or
walk between the generating set and the towing vehicle.
!
There must be an emergency exit for evacuating the personnel

in times of a fire.
regulations specifying required equipment and maximum and

!
The avoiding arcing keep grounded conductive object (such as
baseframe or canopy.
suspended.
!
Turn off or disconnecting the power to
guarded for personnel protection per safety requirements.
alternator lifting lugs, instead use the lifting points on the

!
Keep the room, the floor and the generating
For stationary generating sets with remote fuel
silencers and piping are clear of combustible material and are
Ensure that the generating set room is
Do not install or operate the genset in a dengerous environment

unless it is specially designed.
2.4 MECHANICAL
2.5 CHEMICAL
The generating set is designed with guards for protection from
Fuels, oils, coolants, lubricants and battery electrolyte used in this
moving parts. Care must still be taken to protect personnel and
generating set are typical of the industry. However, they can be
equipment from other mechanical hazards when working around
hazardous to personnel if not treated properly.
the generating set.

WARNING
WARNING
!
with fuel, oil, coolant, lubricants or
generating set with the safety
battery electrolyte. If swallowed, seek
guards removed. While the
medical treatment immediately. Do not
generating set is running do not
induce vomiting if fuel is swallowed.
attempt to reach under or around
For skin contact, wash with soap and water.
the guards to do maintenance or for any other reason.

!
Do not swallow or allow skin contact
Do not attempt to operate the
Keep hands, arms, long hair, loose
Do not wear clothing that has been contaminated by fuel or

lube oil.
clothing and jewellery away from
Wear an acid resistant apron and face shield or goggles when
pulleys, belts and other moving
servicing the battery. If electrolyte is spilled on skin or clothing,
parts.
flush immediately with large quantities of water.
Attention: Some moving parts can

!
!
not be seen clearly when the set is running.
2.6 NOISE
If equipped keep access doors on enclosures closed and locked
Generating sets that are not equipped with sound attenuating
when not required to be open.
enclosures can produce noise levels in excess of 105 dBA. Prolonged
Avoid contact with hot oil, hot coolant, hot exhaust gases, hot
exposure to noise levels above 85 dBA is hazardous to hearing.
surfaces and sharp edges and corners.

!
Wear protective clothing including
WARNING
gloves and hat when working
Ear protection must be worn when
around the generating set.
operating or working around an
Do not remove the radiator filler
operating generating set
cap until the coolant has

cooled. Then loosen the cap slowly to relieve any excess pressure
2.7 ELECTRICAL
before removing the cap completely.
Safe and efficient operation of electrical equipment can be achieved

only if the equipment is correctly installed, operated and maintained.
WARNING
!
3. FIRST AID FOR ELECTRIC SHOCK
The generating set must be connected

to the load only by trained and qualified
WARNING
electricians who are authorized to do
so, and in compliance with relevant
of electricity has been turned off.
Electrical Codes, Standards and other
Switch off power if possible other wise pull the plug or the
If this is not possible, stand on dry insulating material and pull
requlations.
!
cable away from the viation.
Ensure that the generating set, including a mobile set is effectively

grounded/earthed in accordance with all relevant regulations
the victim clear of the conductor, preferably using insulated
priorts operation.
material such as dry wood.
The generating set should be shutdown with the battery negative
(-) terminal disconnected prior to attempting to connect or

!
Do not attempt to connect or disconnect load connections while
If victim is unconscious, perform resuscitation as required:
Do not touch electrically energized parts of the generating set

and/or interconnecting cables or conductors with any part of
3.1 OPEN THE AIRWAY
the body or with any non insulated conductive object.
Tilt the victims head back and lift
Replace the generating set terminal box cover as soon as
the chin upwards.
connection or disconnection of the load cables is complete. Do
If victim is breathing, turn the victim into the recovery position

described below.
standing in water or on wet or soggy ground.

!
If victim is breathing, turn thi victim clear of the conductor,

preferably using insulated material such as dry wood.
disconnect load connections.

!
Do not touch the victims skin with bare hands until the source
Remove objects from the mouth or
not operate the generating set without the cover securely in
throat (including false teeth, tobacco,
place.
or chewing gum).
Connect the generating set only to loads and/or electrical

systems that are compatible with its electrical characteristics
3.2 BREATHING
and that are within its rated capacity.
Check that the victim is breathing by looking, listening and
Keep all electrical equipment clean and dry. Replace any wiring
feeling for the breath.
where the insulation is cracked, cut, abraded or otherwise

degraded. Replace terminals that are worn, discolored or
3.3 CIRCULATION
corroded. Keep terminals clean and tight.
Check for pulse in the victims neck.
Insulate all connections and disconnected wires.
Use only Class BC or Class ABC extinguishers on electrical fires.

3.4 IF NO BREATHING BUT PULSE IS PRESENT
Pinch the victims nose firmly.
Take a deep breath and seal your lips
around the victims lips.
Blow slowly into the mouth watching
for the chest to rise. Let the chest fall
completely. Give breaths at a rate of
10 per minute.
If the victim must be left to get help, give 10 breaths first and
then return quickly and continue.
Check for pulse after every 10 breaths.
When breathing restarts, place the victim into the recovery
position described later in this section.
3.5 IF NO BREATHING AND NO PULSE
4. GENERAL DESCRIPTION
Call or telephone for medical help.

Give two breaths and start chest compresion as follows:
4.1. GENERATING SET DESCRIPTION AND IDENTIFICATION
Place heel of hand 2 fingers breadth
Aksa Generating Set has been designed as a complete package to
above ribcage/breastbone junction.
provide superior performance and reliability.
Place other hand on top and interlock
Figure 4.2 identifies the major components. This figure is of a typical
fingers.
generating set. However, every set will be slightly different due to
Keeping arms straight, press down 4
the size and configuration of the major components. This section
5 cm (1.5-2 inch) at a rate of 15 times per minute.
briefly describes the parts of the generating set. Further information
Repeat cycle (2 breaths and 15 compressions) until medical help
is provided in later sections of thi manual.
takes over.
If condition improves, confirm pulse
4.2. MAJOR COMPONENTS
and continue with breaths.

Check for pulse after every 10 breaths.
When breathing restarts, place the

victim into the recovery position
3
11
8
described below.
10
3.6 RECOVERY POSITION
Turn the victim onto the side.
Keep the head tilted with the jaw

forward to maintain the open airway.
Make sure the victim cannot roll
12
forwards or backwards.
Check for breathing and pulse regularly.
If either stops, proceed as above.
WARNING
!
Do not give liquids until victim is
Control Panel (1)
Chassis (5)
Air Filter (9)
Control Module (2)
Battery (6)
Starter (10)
Engine (3)
Fuel Tank (7)
Battery charging
Alternator (4)
Radiator (8)
alternator (11)
Genset label (12)
conscious.
4.3. DIESEL ENGINE
The diesel engine powering the generating set (Item 3) has been
chosen for its reliability and the fact that it has been specifically
designed for powering generating sets. The engine is of the heavy
duty industrial type with 4 stroke compression ignition and is fitted
with all accessories to provide a reliable power supply. These
accessories include, among others, a cartridge type dry air filter
(item 9) and a mechanical or an electronic engine speed governor.
4.4. ENGINE ELECTRICAL SYSTEM
The engine, electrica system is 12 volts or 24 volts DC, negative
ground/earth. This system includes an electric engine starter, a
battery (item 6) and a battery charging alternator (item 11). For
12 volts electrical system one battery is given. For 24 volt system
two lead-acid batteries are given. Other types of batteries may be
fitted if they were specified.
4.5. COOLING SYSTEM
5. INSTALLATION, HANDLING AND STORAGE
The engine cooling system is either air cooled or water cooled. The
air cooled system consists of a high capacity fan to pull cool air
5.1 GENERAL
across the engine to cool it. The water cooled system is comprised
Once the size of the generating set and any associated control
of a radiator (item 8), a pusher fan and a thermostat. The alternator
systems or switchgear have been established, plans for installation
has its own internal fan to cool the alternator components.
can be prepared. This section discusses factors important in the

effective and safe installation of the generating set.
4.6. ALTERNATOR
The output electrical power is normally produced by a screen
5.2 CANOPY
protected and drip-proof, self-exciting, self-regulating, brushless
All canopy parts are designed with modular principles without
alternator (item 4) fine tuned to the output of this generating set.
welding assembly.
Mounted on top of the alternator is a sheet steel terminal box.
All metal canopy parts are painted by electrostatic polyester

powder paint.
4.7. FUEL TANK AND BASEFRAME
Exhaust silencer is protected against envirenmental influences
The engine and alternator are coupled together and mounted on
and an emergency stop push button is installed on canopy.
a heavy duty steel bareframe. This baseframe includes a fuel tank
Canopy enables easy lifting, maintenance and operation. It also
with a capacity of approximately 8 hours operation at full load.
protects the genset from unauthorized usage and envioronmental

influences.
4.8. VIBRATION ISOLATION

The generating set is fitted with vibration isolators which are
5.3 MOVING THE GENERATING SET
designed to reduce engine vibration being transmitted to the
The generating set baseframe is specifically designed for ease of
foundation on which the generating set is mounted. These isolators
moving the set. Improper handling can seriously damage
are fitted between the engine/alternator feet and the baseframe.
components.
Using a forklift, the generating set can be lifted or carefully
4.9 SILENCER AND EXHAUST SYSTEM
pushed/pulled by the baseframe. If pushing, do not push the
An exhaust silencer is provided loose for installation with the
baseframe directly with fork. Always use wood between forks and
generating set. The silencer and exhaust system reduce the noise
the baseframe to spread the load and prevent damage.
emission from the engine and can direct exhaust gases to safe
outlets.
4.10 CONTROL SYSTEM
One of several types of control systems and panels may be fitted
to control the operation and output of the set and to protect the
set from possible malfunctions. (item 1)
J E N E R AT R
Figure 5.1 Lifting generating set by using a winch
WARNING
5.5. FOUNDATIONS VIBRATION ISOLATION
Never lift the generating set by attaching to the engine or
The generating set is shipped assembled on a rigid baseframe that
alternator lifting lugs.
precisely aligns the alternator and engine and needs to be bolted
Ensure the lifting rigging and supporting structure is in good
down only to a suitably prepared surface.
condition and is suitably rated.

!
!
Keep all personnel away from the generating set when it is
Foundation
suspended.
A reinforced concrete pad provides a rigid support to prevent
If the generating set is going to be lifted, it should be lifted by
deflection and vibration. Typically the foundation should be 150
the lifting points fitted on canopied sets and most open sets.
mm to 200 mm (6 to 8 inches) deep and at least as wide and long

as the generating set. The ground or floor below the foundation
5.4 LOCATION
should be properly prepared and should be structurally suited to
Selecting a location for the generating set can be the most important
carry the weight of the foundation pad and the generating set.
part of any installation procedure. The following factors are important
(If the generating set is to be installed above the ground floor the
in determining the location:
building structure must be able to support the weight of the
Adequate ventilation.
generating set, fuel storage and accessories). If the floor may be
Protection from the elements such as rain, snow, sleet, wind
wet from time to time such as in a boiler room, the pad should be
driven precipitation, flood water, direct sunlight, freezing
raised above the floor. This will provide a dry footing for the
temperatures. or excessive heat.
generating set and for those who connect, service or operate it.
Protection from exposure to airborne contaminants such as
It will also minimize corrosive action on the baseframe.
abrasive or conductive dust, lint, smoke, oil mist, vapors, engine

exhaust fumes or other contaminants.
5.6. COMBUSTION AIR INLET
Floor of generating set room must be smooth and strong.
Air for engine combustion must be clean and as cool as possible.
Protection from impact from falling objects such as trees or
Normally this air can be drawn from the area surrounding the
poles, or from motor vehicles or lift trucks.
generating set via the engine mounted air filter. However, in some
Clearance around the generating set for cooling and access for
cases due to dust, dirt, or heat, the air around the set is unsuitable.
service: at least 1 meter (3.3 feet) around the set and at least
In these cases an inlet duct should be fitted. This duct should run
2 meters (6.6 feet) headroom above the set.
from the source of clean air (outside the building, another room,
Access to move the entire generating set into the room. Air
etc.) to the engine mounted air filter. Do not remove the air filter
inlet and outlet vents can often be made removeble to provide
and mount it at a remote location as this can increase the possibility
an access point.
of dirt leaking through the ductwork and into the engine inlet.
Limited access to unauthorized personnel.

If it is necessary to locate the generating set outside of the
5.7. COOLING AND VENTILATION
building, the generating set should be enclosed in a canopy.
The engine, alternator, and exhaust piping radiate heat which can
A canopy is also useful for temporary installations inside or
result in a temperature high enough to adversely affect the
outside the building.
performance of the generating set. It is therefore important that

adequate ventilation is provided to keep the engine and alternator
cool. Proper air flow, as shown in Figure 4.4, requires that the air
comes in at the alternator end of the set, passes over the engine,
through the radiator and out of the room via a flexible exhaust
duct. Without the ducting of the hot air outside the room, the fan
will tend to draw that hot air around and back through the radiator,
reducing the cooling effectiveness.
5.8 EXHAUST
The purpose of the engine exhaust system is to direct the exhaust
outside to a location and height where the fumes and odors will
not become an annoyance or hazard, and to reduce noise. A suitable
exhaust silencer must be incorporated into the exhaust piping to
reduce the noise level from the engine.
(See Figure 5.4 - 5.5)
WARNING:
Figure 5.2 Directing the air thrown from the radiator with deviating wings
Engine exhaust emmissions are hazardous to personnel. The
Sharp corners on the radiator, hot air outlet channel or its chimney
engine exhaust for all indoor generating
must be avoided. Some rearrangements to turn thrown air should
sets must be piped outdoors via leak
be done (Figure 4.2 and 4.3).
free piping in compliance with relevant

Codes, Standards and other
requirements.
!
Ensure hot exhaust silencers and piping are clear of combustible

material and are guarded for personnel protection per safety
requirements.
Ensure that fumes from the exhaust outlet will not be a hazard.
In designing an exhaust system, the primary consideration is to
not exceed the allowable back pressure permitted by the engine
manufacturer. Excessive back pressure seriously affects engine
Figure 5.3 Weak ventilation installation
output, durability and fuel consumption. To limit the back

pressure the exhaust piping should be as short and straight as
possible. Any required bends should have a curve radius of at
least 1.5 times the inside diameter of the pipe.
Other exhaust design criteria are as follows:
!
A flexible connection between the exhaust manifold and the

piping system should be used to prevent transmission of engine
vibration to the piping and the building and to allow for thermal
expansion and any slight misalignment of the piping.
(See Figure 5.4)
J E N E R AT R
The exhaust gas pipes should be supported by the building in

order to prevent the dead weight carried by the engine manifold
Figure 5.4 Air ventilation
and turbocharger. For that, stretching, elements should be used.
The air inlet and outlet openings should be large enough to ensure
(See Figure 5.5)
free flow of air into and out of the room. As a rough guide the
Exhaust system components located within the generator room
openings should each be at least 1.5 times the area of the radiator
should be insulated to reduce heat radiation and noise levels.
core.
Pipes and the silencer, whether located inside and outside the
Both the inlet and outlet openings should have louvres for weather
building, should be located well clear of any combustible material.
protection. These may be fixed but preferably should be movable
The outer end of the exhaust pipe, if horizontal, should be cut
in cold climates so that while the generating set is not operating
at 60 to the horizontal or should be fitted with a rain hood or
the louvres can be closed. This will allow the room to be kept warm
cap, if vertical, to prevent rain or snow from entering the exhaust
which will assist starting and load acceptance. For automatic starting
system.
generating sets. If the louvres are movable they must be automatic-
ally operated. They should be programmed to open immediately
The exhaust pipe must not be connected to exhausts from other

generating sets.
upon starting the engine.
Exhaust pipes must be made up of black iron pipe.
Figure 5.5 Generating set room
Generating Sets
Model
Standby
Power
Dimensions
(mm)
A
B
C
Room
Dimensions
(mm)
(kVA) Length Width Height Length Width Height
Radiator Hot
Air Outlet
Openings
Louvers
(mm)
D
Air Inlet
Openings
Total Area
(m2)
Rooms
Door
Dimensions
Exhaust
(mm)
P
M (inch) (mm)
Diameter
AJD 33
33
1600
880
1300 2800 3000
2400
750
650
530
0,5
1200 2000
1750
AJD 44
44
1860
930
1360 3000 3000
2400
750
650
585
0,5
1500 2000
1750
AJD 70
70
1860
930
1350 3200 3000
2400
750
650
550
0,5
1500 2000
1750
AJD 90
90
2180 1030
1500 3500 3000
2400
850
850
550
0,8
1500 2000
1900
AJD 110
110
2180 1030
1550 3500 3000
2400
850
850
550
0,8
1500 2000
2000
AJD 132
132
2340 1130
1550 3700 3000
2400
900
900
550
1500 2000
2000
AJD 170
170
2440 1130
1580 3800 3000
2400
900
900
550
1500 2000
2000
AJD 200
200
2350 1130
1580 3800 3000
2400 1000 1000
550
1500 2000
2000
AJD 275
275
2900 1150
1870 4300 3000
2500 1150 1200
620
1,5
1500 2000
2200
AJD 33-6
33
1600
880
1300 2800 3000
2400
750
650
530
0,5
1200 2000
1750
AJD 50-6
50
1860
930
1360 3000 3000
2400
750
650
585
0,5
1500 2000
1750
AJD 77-6
77
1860
930
1350 3200 3000
2400
750
650
550
0,5
1500 2000
1750
AJD 98-6
98
2180 1030
1500 3500 3000
2400
850
850
550
0,8
1500 2000
1900
AJD 132-6
132
2180 1030
1550 3500 3000
2400
850
850
550
0,8
1500 2000
2000
AJD 154-6
154
2340 1130
1550 3700 3000
2400
900
900
550
1500 2000
2000
AJD 200-6
200
2440 1130
1580 3800 3000
2400
900
900
550
1500 2000
2000
AJD 225-6
225
2350 1130
1580 3800 3000
2400 1000 1000
550
1500 2000
2000
AJD 330-6
330
2900 1150
1870 4300 3000
2500 1150 1200
625
1,5
1500 2000
2200
Table 5.1.1 Aksa open type diesel gen-set dimensions and room sizes, air inlet and outlet openings dimensions and exhaust pipe dimensions. Without acoustic treatment.
Single sets. (please look figure 5.5. genset room)
10
5.9 FUEL SYSTEM
5.9.2 Bulk Storage Tanks
The fuel system for the generating set must be capable of delivering
For extended operation. a separate bulk fuel storage tank is required.
a clean and continuous supply of fuel to the engine. For most
The bulk tank should generally be located outside the building
installations this will include a small day tank, a bulk storage tank
where it will be convenient for refilling, cleaning and for inspection.
and fuel lines.
It should not, however, be exposed to freezing weather because

fuel flow will be restricted as viscosity increases. The tank may be
WARNING:
located either above or below ground.
For stationary gene-rating sets with
A vent must be installed on the bulk tank to relieve the air pressure
remote fuel storage systems, make sure
created by filling the tank or created by evaporation and expansion.
such systems are installed in compliance
It will also prevent a vacuum as the fuel is consumed. The base of
with relevant Codes, Standards or other
the tank should have a slope, so the water and the sediment can
requirements.
be collected. A sludge drain valve should be installed at the low
point to allow removal of water and sediment on a regular basis.
around fuel. Fuel vapours and oil vapours are explosive.

5.9.3 Fuel Lines
5.9.1 Daily Tank
The fuel lines can be of any fuel compatible material such as steel
Daily tanks provide a readily available supply of fuel directly to the
pipe or flexible hoses that will tolerate environmental conditions.
generating set and should therefore be located within the generator
Flexible piping should be used to connect to the engine to avoid
room. The baseframe is designed to contain a day tank.
damage or leaks caused by engine vibration.

The fuel delivery line should pick up ful from a point no lower than
50 mm (2) from the bottom at the high end of the tank (away
from the drain plug).
Figure 5.6 Typical fuel installation using a base tank fed from a bulk tank
8. Outlet valve
9. Supply line to day tank
10. Electric fuel transfer pump
11. Electric fuel shutoff valve
12. Optional band
13. Day tank incorporated in baseframe
14. Float control switches
1. Fill cabinet with overfill alarm and gauge

2. Tank fill line
3. Vent
4. Contents gauge
5. Bulk storage tank
6. Sludge drain
7. Bund tank
15. Manual fill and vent

16. Level gauge
17. Drain
18. Leakage alarm unit (optional)
19. Fuel filter
20. Engine fuel pump
RECOMMENDATIONS FOR FUEL PIPING

Recommended
Pipe Diameter
(inch)
Generator
Stand-By Power
(kVA)
Maximum Fuel
Pipe Length
(m)
Maximum
Vertical Height
(m)
Maximum Pipe
Fittings Quantity
40-800
0,9
800-1500
0,9
1 1/2
1500-2200
0,9
11
IMPORTANT
Do not use John Deere PLUS-50 oil or engine oils meeting API
CG4, API CF4, ACEA E3, ACEA E2 or CCMC D5 performance levels
during the first 100 hours of operation of a new or rebuilt engine.
These oil will not allow the engine to break-in properly.
Use oil viscosity based on the expected air temperature range during
the perod between oil changes.
6. LUBRICATING OIL RECOMMENDATION FOR

JOHN DEERE ENGINES
Oil system of diesel engineis one of the most important elements
of the engine. Correctly made engine overhaul (this subject includes
oil change periods, filter change periods, paying attention about
The following oil is preferred

John Deere PLUS-50
John Deere PLUS-50 engine oil and a John Deere oil filter are used,
the service interval for oil and filter changes may be extended by
50 hours.
selecting the true type of oil) prolongs the life of the engine and
it decreases the life cycle cost of the engine.
6.1. ENGINE BREAK IN OIL
New engines are filled at Aksa with John Deere ENGINE BREAK -
The following oil is also recommended

John Deere TORQ - GARD SUPREME
Other oils may be used if they meet one or more of the following:
John Deere UNI GARDTM
API Service Classification CG-4
API Service Classification CF-4
ACEA Specification E3
ACEA Specification E2
CCMC Specification D5
IN OIL. During the break-in period add John Deere ENGINE BREAK
- IN OIL as needed to maintain the specified oil level.
Change the oil and filter after the first 100 hours of operation of
a new or rebuilt engine.
After engine overhaul, fill the engine with John Deere ENGINE
BREAK - IN OIL.
If John Deere ENGINE BREAK - IN OIL is not avaible, use a diesel
engine oil meeting one of the following during the first 100 hours
of operation:
Multi-viscosity diesel engine oils are preferred

If diesel fuel with sulfur content greater than 0.5% is used, reduced
the service interval by %50
(15W-40 Lub-oil should be prefered for 6081 model engine).
API Service Classification CE

ACEA Specification EI
After the break-in period, use John Deere PLUS-50 or other diesel
engine oil as recommended in this manual.
Figure 6.1 Recommended SAE viscosity degrees
12
7. BATTERIES
8. ELECTRICAL CONNECTION
Only fully qualified and experienced electrical technicians should
WARNING
!
carry out electrical installation, service and repair work.

around batteries. Hydrogen gas generated by charging batteries
WARNING
is explosive.
Wear an acid resistant apron and face shield or goggles when
Make electrical connections in compliance with relevant Electrical

Codes, Standards or other requirements.
servicing the battery. If electrolyte is spilled on skin or clothing,

!
!
!
flush immediately with large quantities of water.
8.1 CABLING
Take out the metalic things in your wrist
Due to movement of generating sets on their vibration mounts,
and protect your
wrist and hand.
the electrical connection to the set should be made with flexible
Disconnect the battery negative (earth) lead first and reconnect
cable.
last.
The cable should be protected by laying it in a duct or cable tray.
Always ensure that battery charging is carried out in a well
The cable must be suitable for the output voltage of the generating
ventilated area.
set and the rated current of the set. In determining the size,
The starting batteries should be located as close as possible to
allowances should be made for ambient temperature. method of
the generating set while still being accessible for servicing. This
installation, proximity of other cables. etc.
will prevent electrical losses from long cale that could impact
All connections should be carefully checked for integrity.
on the engine starting capability of the batteries.
Current carrying capacity of power cables that will be used for

generator and the cable cross sections which must be used according
7.1 BATTERY MAINTENANCE
to the generator powers has been given in (table 8.1).
1. Keep the top of the battery and its terminals clean.
On the other hand, there is a one more important point while cable
2. Cover the battery terminals and its connections with vaseline.
cross sections are being selected. If the distance between load and
3. Tighten the terminals but not tighten it hardly.
generator is too length, voltage falling at the load side can be too
4. Control the electrolyte level periodically. It must be 10 mm.
much at the transient current duration. In this case you should
above the plates.
calculate the cable cross sections with electrical formula which has
5. Control the abrasion in the charge alternator belt and check
been given below.

x L x x (R Cosj + X Snj)
periodically the belt tension according to the producers
e=
recommendation.
e : Voltage falling (volt)
6. Ensure that your battery is not uncharged.
L : Cable length (meter)
7.2 CONTROL OF THE BATTERY
R : Resistance of cable (ohm/m)
Conduct an inspection every time before testing the battery.
: Current (Amper)
: Reactance of cable (ohm/m)
1. A white powdered element causes abrasion to the pole-heads,

its surndings and the connections. Remove the connections and
8.2 PROTECTION
wash them with hot water to purify the axidation. Reconnect
The cables connecting the generating set with the distribution
it and coat with vaseline.
system are protected by means of a circuit breaker to automatically

disconnect the set in case of overload or short circuit. (Manual
2. Check if any untightened connections exist.
models only).
13
8.3 LOADING
8.8 INSULATION TEST
When planning the electrical distribution system, it is important to
Before starting the generating set after installation, test the insulation
ensure that a balanced load is presented to the generating set. If
resistance of the windings. The Automatic Voltage Regulator (AVR)
loading on one phase is substantially higher than the other phases
should be disconnected and the rotating diodes either shorted out
it will cause overheating in the alternator windings, imbalance in
with temporary links or disconnected. Any control wiring must also
the phase to phase output voltage and possible damage to sensitive
be disconnected.
3 phase equipment connected to the system. Ensure that no
A 500V Megger or similar instrument should be used. Disconnect
individual phase current exceeds the current rating of the generating
any earthing conductor connected between neutral and earth and
set. For connection to an existing distribution system, it may be
megger an output terminal to earth. The insulation resistance should
necessary to reorganize the distribution system to ensure these
be in excess of 1M
loading factors are met..
less than 1M
8.4 POWER FACTOR
CABLE
SECTION
(mm2)
The power factor (cosj) of the connected load should be determined.

Power factors below 0.8 lagging (inductive) can overload the
2.5
4
6
10
16
25
35
50
70
95
120
150
185
240
generator. The set will provide its kilowatt rating and operate
satisfactorily from 0.8 lagging to unity power factor (1.0). Particular
attention must be given to installations with power factor correction
equipment such as capacitors to ensure that a leading power factor
is never present. This will lead to voltage instability and may result
in damaging overvoltages. Generally whenever the generating set
is supplying the load any power factor correction equipment should
be switched off.
8.5 GROUNDING/EARTHING REQUIREMENTS
The frame of the generating set must be connected to an earth
ground. Since the set is mounted on vibration isolators, the ground
connection must be flexible to avoid possible breakage due to
vibration.
to earth. Should the insulation resistance be
the winding must be dried out.

0,6/1 KV, NYY TYPE CABLE CURRENT CAPACITY
Soil
Multiple
Core
25C at air
Multiple
Core
Multiple
Core
40C at air
Single
Core
36
46
58
77
100
130
155
185
230
275
315
355
400
465
25
34
44
60
80
105
130
160
200
245
285
325
370
435
22
30
38
53
71
94
114
138
176
212
248
238
322
380
25
33
42
57
76
101
123
155
191
228
267
305
347
-
HO7RN-F
21
28
36
50
67
88
110
138
170
205
245
271
310
-
Table 8.1 Current carrying capacity of power cables (PVC - ISOLATED CABLES YVV
(NYY) SUTABLE TO 0.6/1 KV VDE NORMS AND TS)
Ground connection cables or straps should have at least full load

current carrying capacity and meet applicable regulations.
8.6 ALTERNATOR RECONNECTION
Most alternators can be reconnected to suit different output
voltages. Ensure that all other components such as circuit breakers,
current transformers, cables and ammeters are suitable before
operating at a different voltage.
8.7 PARALLEL RUNNING
Extra equipment must be fitted for the standard generating sets
to be operated in parallel with other generating sets or with mains
power.
14
9. ACOUSTIC SILENCING
10. TOWING (Mobile Generating Sets)
Control of generating set noise is becoming very important in most

installations. There is a range of components available to control
10.1 PREPARING TO TOW
the noise level.
Inspect all components of the coupling equipment on the towing

vehicle and the generating set for defects such as excessive wear,
WARNING
corrosion, cracks, bent metal, or loose bolts.
Inspect tyres for condition and proper inflation. Check that all tail
Ear protection must be worn when operating or working around
an operating generating set.
lights, if equipped, are operating properly and that all reflectors

are clean and functional.
9.1 EXHAUST SILENCERS

As discussed in Section 5.8 the exhaust silencer will decrease sound
10.2 TOWING
levels from the engine.
Whenever towing a mobile generating set, remember that

manoeuvra-bility and stopping distance will be affected by the
9.2 CANOPIES
weight of the trailer.
Section 5.2 discusses sound attenuating canopies that lower the

noise level of the entire generating set.
WARNING
!
When towing mobile generating set, observe all Codes, Standards
9.3 OTHER SOUND ATTENUATION
or other regulations and traffic laws. These include those
For installations in buildings there are other types of equipment
regulations specifying required equipment and maximum and
such as acoustic louvers, splitter vents and fan silencers, as well as
minimum speeds.
sound absorbing wall coverings, that can be used to reduce the
noise levels of generating sets.
Do not permit personnel to ride on the mobile generating set.

Do not permit personnel to stand or ride on the drawbar or to
stand or walk between the generating set and the towing
vehicle.
Avoid gradients and avoid potholes, rocks or other obstructions

and soft or unstable terrain.
Ensure the area behind and under the mobile set is clear before
reversing.
Check all the connecting.
Check the brakes and the vibration.
Apply the hand-brake every time you park the vehicle.
10.3 PARKING
Park the set on a dry level area that can support its weight. If it
must be located on a slope, park it across the grade so that it does
not tend to roll downhill. Do not park the set on grades exceeding
15. Do not start the genset on a slope.
15
11 STORAGE
14.GENERAL PRECAUTIONS AND CONTROLS WHICH MUST
Long term storage can have detrimental effects on both the engine
BE DONE BEFORE STARTING UP THE GENERATING SET
and alternator. These effects can be minimized by properly preparing
Make a general visual inspection on the engine and alternator.
and storing the generating set.
Check if there is any breakage, crack, indentation, leakage or

looseness. Never operate the generating set before removing
11.1 ENGINE STORAGE
any fault, if any.
The engine should be put through an engine preservation
Take out foreign materials such as keys, tools, cleaning wool,
procedure that includes cleaning the engine and replacing all the
papers etc. on the engine and the alternator.
fluids with new or preserving fluids.
Check the fuel level in the day tank. Refill with fuel if it is low.
(See section 22)
Check the engine oil level on the dip stick. Refill with an
appropriate oil if it is low. Oil level normally must be close to
11.2 ALTERNATOR STORAGE
the maximum level line.
When an alternator is in storage, moisture tends to condense in
Look at the water level by opening the radiator tap. If it is
the windings. To minimize condensation, store the generating set
inadequate add more water. Water level must be 30 mm. lover
in a dry storage area. If possible use space heaters to keep the
than the water filling neck.
windings dry.
Engine cooling water must include antifreeze according to the
(See engine maintenance and operation manual)
coolest weather conditions in the area. A mixture of 50%
After removing the generating set from storage, perform an
antifreeze and 50% water provides a good protection in all area.
insulation check.
Inspect the radiator air outlet hood, open if clogged and clear
away all obstructions in front of the air outlet.
11.3 BATTERY STORAGE
Check the air filter gauge. Clean or replace the air filter, if
While the battery is stored, it should receive a refreshing charge
necessary.
every 8 weeks up to a fully charged condition.
Keep the inlet opening open.

Make sure that the generating set can easily take air from te
12. ENGINE JACKET WATER HEATER
environment.
Jacket water heater is used in order to startup the generating set
Check the battery connection cables. Take care to tighten the
more easily and to take the load. In automatic generating sets,
loosened battery terminals with spanner and, cover with special
jacket water heater is standard. In manual type generating sets it
substance and keep clean in order to avoid oxidation.
is an option. Heater warms up the jacket water of the engine when
Open the battery caps and check the liquid level in the cells.
the generating set is not working.
Add distilled water, if necessary, so as to be 1 cm higher than

the separation. Never fill the cells with tap water, acid water
13. GENERATING SET MAINTENANCE
or acid. This control is not necessary for maintenance free type
A good maintenance program is the key to long generating set
batteries.
life. The recommended maintenance program is provided on the
Check if the circuit breaker outlet switch is in OFF position.
Periodic Maintenance Chart. This chart is given with all generating
Make sure that the emergency stop button is not pressed.
sets.
Maintenance and service should only be carried out by qualified
15.STARTING THE GENERATING SET
technicians. The maintenance and service which are done must be
To control and monitor the generating set, an electronic control
recorded to the Maintenance Record Form. In General, the generating
system has been used. Depending on the requirements of the set,
set should be kept clean. Do not permit liquids such as fuel or oil
one of several different standard control systems may be fitted.
film to accumulate on any internal or external surfaces. Wipe down
These include ME 40 model Manual Control Systems, P 500 and
surfaces using an aqueous industrial cleaner. (See section 21)
P300 Automatic Control System (with AMF), P 2010 Auto start

Control System and P 2020 Automatic Control System (with AMF).
Control panel provides a means of starting and stopping the
generating set, monitoring its operation and output and automatically
shutting down the set in the event of a critical condition arising
such as low oil pressure or high engine temperature.
16
15.1 STARTING WITH ME 40 MANUAL CONTROL PANEL
When the engine fires, the starter motor is disengaged and
Check the precautions and controls before starting up the
locked out at 20 Hz measured from the Alternator output.
generating set
After the starter motor has disengaged, the Safety On timer is
To start the generating set, turn the key switch to the hand
position, which
activated, allowing Oil pressure, High Engine Temperature,
will power up the unit (DSE 701 module)
Under -speed, Charge Fail and any delayed Auxiliary fault inputs
Pressing start button (1) will energise the Fuel solenoid, then
to stabilise without triggering the fault. The generator will run
the starter motor. The button should be pressed for the duration
off load, unless the mains supply fails or Remote start on load
of the crank period.
signal is applied, at which point the load will be transferred to
the generator. If Auto mode is selected, and the mains supply
locked out at 20 Hz measured from the alternator output.
is healthy with the remote start on load signal not active, then
After the starter motor has disengaged, safety on timer is
the Remote Start Delay Timer begins, after which, the load is
activated (which is fixed at 12 seconds), allowing oil pressure,
disconnected. The generator will then run off load allowing the
high engine temperature and charge fail to stabilise without
engine a cooling down period.
triggering the fault.
Selecting STOP de-energises the fuel solenoid, bringing to stop.
If the generator has not started when the start button has been
released or generator fails once it is running, the key switch
must be turned to stop (0) and then back to hand position
This mode is activated by pressing the
before another start cn be invoked.
pushbutton. An LED indicator beside the button confirms this action.
Check the alternator output voltage and frequency and engine
AUTO
Whether the start sequence is initiated by mains (utility) failure or
oil pressure, engine temperature.
remote input, the following sequence is followed:
The gen set should run 2-3 minute no load
After Start Delays the Fuel Solenoid is energised, then one second
When the engine warm after alternator output circuit breaker
later, Starter Motor is engaged.
sholud be ON position.
The engine is cranked for 10 second period. If the engine fails to

fire during this cranking attempt then the starter motor is disengaged
for a 10 second rest period. Should this sequence continue beyond
the 3 starting attempts, the start sequence will be terminated and
Fail to Start
fault will be illuminated. When the engine fires,
the starter motor is disengaged and Safety On timer activated.

If the remote start is being used and has been configured to Remote
Figure 15.2
Model DSE 704 module
start is on load or the mains has failed, the load will be transferred
Figure 15.1
Model DSE 701 module
to the generator.
On the return of mains supply, (or removal of the Remote Start
15.2. STARTING WITH P500 AUTOMATIC
signal if the set was started by remote signal), the Stop delay timer
CONTROL PANEL (with AMF)
is initiated. Once it has timed out, the load is transferred back to

the mains (utility). The Cooling timer expires the Fuel Solenoid is
15.2.1 Manual Operation
de -energised, bringing the generator to a stop.
Check the precautions and controls starting up the

generating set.
To initiate a start sequence in MANUAL, press the push
button and the start sequence is initiated.
After fuel solenoid is energised, then the starter motor is
engaged.
Engine cranked for a 10 second period, If the engine fails to
fire during this cranking attempt then the starter motor is
disengaged for a 10 second period. Should this sequence
continue terminated and fail to start
fault will be
illuminated.
17
15.3 STARTING WITH P300 AUTOMATIC CONTROL PANEL
The engine is cranked for 10 seconds. If the engine fails to fire
The DSE 720 automatic mains failure controls generating set system.
during this cranking attempt than the starter motor is disengaged
Module has been designed to monitor the mains (utility) supply.
for 10 seconds. Should this sequence continue beyond the 3

cranking attempts, the start sequence will be terminated and
Fail to Start
pushbutton.
fault will be displayed.
A LED indicator beside the button confirms this action.
locked out.
Press the
Delayed alarms (under speed, low oil pressure etc) will be
button to begin the start sequence (There is no
Start Delay in this mode of operation)
monitored after the end of the Safety On Delay.
After the Fuel Solenoid is energised, then the Starter Motor is
If the romote start is being used and has been configured to
is engaged.
Remote Start is on load, or the mains has failed, the load will
The engine is cranked for 10 sec. If the engine fails to fire during
be transferred to the generator.
this cranking attempt then the starter motor is disengaged for
On the return of the mains supply, the Stop delay timer is
10 sec. If the engine fails to fire during this cranking attempt
initiated, once it has timed out, the load is transferred back to
then the starter motor is disengaged for 10 sec. Should this
the mains (utility). The cooling timer is than initiated, allowing
sequence continue beyond the 3 cranking attempts, the start
the engine a cooling down period (180 sec) off load before
sequence will be terminated and Fail to Start
shutting down. Once the cooling timer expires the fuel solenoid
fault will
be displayed.
is de-energised, bringing the generator to a stop.
Selecting STOP
locked out.
the generator to a stop.
15.3.3 Test Mode of Operation
monitored after the end of the Safety On delay.
The generator will run off load unless the mains supply fails.
A LED indicator beside the button confirms this action.
The generator will continue to run on load regardless of the
Press the
state of the mains supply.
After the Fuel Solenoid is energised, then / second later,
If auto mode is selected, and the mains supply is healthy then
the Starter Motor is engaged.
the Remote Stop Delay Timer begins, after which, the load is
The engine is cranked for 10 seconds. If the engine fails to fire
transferred to the mains. The generator will then run off load
during this cranking attempt then the starter motor is disengaged
allowing the engine a cooling down period.
for 10 seconds. Should this sequence continue beyond the 3
Selecting stop
cranking attempts, the start sequence will be terminated and
de-energises the fuel solenoid, bringing the
generator to a stop.
de-energises the fuel solenoid, bringing
pushbutton.
button to begin the test sequence.
Fail to Start
fault will be displayed.

AUTO
locked out.
pushbutton.
An LED indicator beside the button confirms this action.
monitored after the end of the Safety On Delay. The load will
Should the mains (utility) supply fall outside the configurable
be transferred to the generator and the set will run on load
limits for longer than the period of the delay start timer, the
untill Auto mode is selected or Stop is pressed.
mains is healthy indicator will estinguish. Additionaly, while in
Selecting Stop
AUTO mode, the remote start input is monitored.
de-energises the fuel solenoid, bringing the
Whether the start sequence is initiated by mains failure, or by

remote start input, the following sequence is followed:
To allow for short term mains supply transient conditions or false

remote start signals, the start delay timer is initiated.
After the Fuel Solenoid is energised, then / second later, the Starter
Motor is engaged.
Figure 15.3 DSE 720 Control Module
18
15.4 STARTING WITH P2010 AUTOSTART CONTROL PANEL
The Remote Start Active indicator illuminates (if configured)

To allow for false signals the Start Delay timer is initiated.
After this delay the Fuel Solenoid is energized, then one second
later, the Starter Motor is engaged. The engine is cranked for
generating set.
a pre-set time period. If the engine fails to fire during this
NOTE: If a digital input configured to panel lock is active, the
cranking attempt then the strter motor is disengaged for the
LCD will display the
pre-set period. Should this sequence continue beyond the set
icon. When in panel lock, changing
modules will not be possible.

Viewing the instruments
number of attempts, the start sequence will be terminated and

and event logs
is not
Fail to Start
affected by panel lock.
fault will be displayed accompanied by a
flashing shutdown
To initiate a start sequence in MANUAL press the
push
symbol.
When the engine fires, the starter motor disengaged and locked
button. When the controller is in the manual button), pressing
out at a pre-set frequeny from the alternator output. Rising oil
the START (1) button will initiate the start sequence.
pressure can also be used to disconnect the starter motor,
NOTE: There is no Start Delay in this mode of operation.
however it cannot be used for under speed or over speed
The Fuel Solenoid is energized, then the Starter Motor is engaged.
detection.
The engine is cranked for a preset time period. If the engine
If an auxiliary output has been selected to give a load transfer
fails to fire during this cranking attempt then the starter motor
signal, this would then active.
is disengaged for the preset rest period. Should this continue
On removal of the Remote Start signal, the stop delay timer is
beyond the set number of attempts, the start sequence will be
initiated, once it has timed out, the Load Transfer is de-energise,
terminated and fail to start
removing the load. The cooling timer is then initiated, allowing
fault will be displayed
accompanied by a flashing shutdown
indicator.
the engine a cooling down period off load before shutting
down. Once the Cooling timer expires the Fuel Solenoid is de
out at a pre-set frequency from the Alternator output. Rising
energised, bringing the generator to a stop.
oil pressure can also be used to disconnect the starter motor,
Should the Remote Start signal be re-activated during the cooling
down period, the set will return on load.
detection.
Scroll
button
The generator will run off load, unless a Remote Start signal is
Config /
log button
LCD display
applied, and if Load Transfer has been selected as a control

source, the appropriate auxiliary output selected will active.
User configurable
LCD indicators
with text insert
Alarm
indicators
If the Remote Start signal is removed, the generator will continue

to run On load until Auto mode is selected. The Remote Stop
Load
indicators
Delay Timer will time out, the load is then disconnected. The
Generator
indicators
generator will then run off load allowing the engine a cooling
down period.
Selecting STOP (0) de-energises the Fuel Solenoid, bringing the
Stop mode Manual mode

(config.)


Viewing the instrument
and event logs
is not

Start button
Auto mode
(config enter) (when in manual)
Figure 15.4 Desription of Controls on DSE5210 module
15.4.2 Automatic Mode of Operation

Config+
AUTO
push button.

When a Remote Start signal is applied to the remote start input,
the following sequence is initiated:
19
15.5 STARTING WITH P 2020 AUTOMATIC
15.5.2 Automatic Mode of Operation
CONTROL PANEL (WITH AMF)

Viewing the instrument
generating set.
AUTO
push button.

is not

and event logs
When a Remote Start signal is applied to the remote start input,

and event logs
is not
the following sequence is initiated:

To initiate a start sequence in MANUAL press the
The Remote Start Active indicator illuminates (if configured)

push
To allow for false signals the Start Delay timer is initiated.
button. When the controller is in the manual button), pressing
After this delay the Fuel Solenoid is energized, then one second
the START (1) button will initiate the start sequence.
later, the Starter Motor is engaged. The engine is cranked for
a pre-set time period. If the engine fails to fire during this
cranking attempt then the starter motor is disengaged for the
pre-set period. Should this sequence continue beyond the set
number of attempts, the start sequence will be terminated and
is disengaged continue beyond the set number of attempts,
Fail to Start
the start sequence will be terminated and fail to start
flashing shutdown
fault will be displayed accompanied by a flashing shutdown
fault will be displayed accompanied by a

symbol.
indicator.
out at a pre-set frequency from the alternator output. Rising oil
pressure can also be used to disconnect the starter motor,
out at a pre-set frequency from the Alternator output. Rising
oil pressure can also be used to disconnect the starter motor,
detection.
If an auxiliary output has been selected to give a load transfer
detection.
signal, this would then active.
The generator will run off load, unless a Remote Start signal is
On removal of the Remote Start signal, the stop delay timer is
applied, and if Load Transfer has been selected as a control
initiated, once it has timed out, the Load Transfer is de-energise,
source, the appropriate auxiliary output selected will active.
removing the load. The cooling timer is then initiated, allowing
If the Remote Start signal is removed, the generator will continue
the engine a cooling down period off load before shutting
to run On load until Auto mode is selected. The Remote Stop
down. Once the Cooling timer expires the Fuel Solenoid is de
Delay Timer will time out, the load is then disconnected. The
energised, bringing the generator to a stop.
generator will then run off load allowing the engine a cooling
Should the Remote Start signal be re-activated during the cooling
down period.
down period, the set will return on load.
Selecting STOP (0) de-energises the Fuel Solenoid, bringing the

20
15.5.3 Test Operation
16.GENERAL PRECAUTIONS AND CONTROLS WHICH MUST

BE DONE AFTER STARTING UP THE GENERATING SET
Check for any abnormal noise or vibration on the

generating set.
and event logs
is not
Check if the exhaust system has any leakage.
Monitor the generating set operation by means of the gauges
To initiate a start sequence in TEST, press the
push button.
on the control panel.
When the controller is in the test mode (indicated by an LED
Check the engine temperature and oil pressure by means of
indicator beside the button), pressing the START (1) button will
the gauges on the panel. Oil pressure must reach the normal
initiate the start sequence.
value 10 seconds after the generating set operation.
Monitor the generating set outlet voltage and frequency by
means of the gauges on the panel. Check on the voltmeter, if
the voltage between phases is 400 V and between phase and
neutral is 230 V. Check that the frequency at idle is 51-52 Hz
is disengaged for the pre-set rest period. Should this sequence
(for 50 Hz operation or 61-62 Hz for 60 Hz operation) on
continue beyond the set number of attempts, the start sequence
generating sets with mechanical governors and 50 Hz or 60 Hz
will be terminated and Fail to Start
on generating sets with electronic governors. Outlet voltage is
accompanied by a flashing shutdown
fault will be displayed

indicator.
adjusted ex-factory. Adjustments should be done only by
The generator will continue to run on load regardless of the
authorized personnel.
state of the mains supply or remote start input until the Auto
If an engine block water heater is not available, put the generating
mode is selected. If Auto mode is selected, and the mains supply
set under load after warming with a 10 minute idle run (manual
is healthy with the remote start on load signal not active, then
models).
the Remote Stop Delay Timer begins, after which, the load is
Putting the generating set under load must be done as follows:
disconnected. The generator will then run off load allowing the
Set the alternator outlet switch on the panel to ON position.
engine a cooling down period.
Set the load switches (or fuses) on the distribution panel to ON
Selecting STOP (0) removes the Close Generator output (if
position one by one. This way, the generating set cannot be
configured) and de-energises the Fuel Solenoid, bringing the
suddenly put under full load. Otherwise, the engine stalling or
alternator winding insulation deformation or burning can occur.
Scroll
button
Config /
log button
Set the alternator outlet switch on the circuit to OFF position

LCD display
User configurable
LCD indicators
with text insert
before you stop the generating set.

Continue to run the unloaded diesel engine for the purpose
of cooling for 5 minutes and then stop.
Alarm
indicators
Never operate the generating set before removing any fault,
Load
indicators
if any.
Generator
indicators
17.STOPPING THE GENERATING SET

Stop mode Manual mode
(config.)
Config+
17.1 AT MANUAL MODELS
Start button
Auto mode
(config enter) (when in manual)
Before stopping the generator, alternator output, circuit braker
Figure 15.5 Desription of Controls on DSE5220 module
should be OFF position.

The genset should run 2-3 minute with no load.
To stop the generator turn the key switch to the STOP O
position, de-energises key switch the fuel solenoid, bringing the
21
17.2 AT AUTOMATIC MODELS
DSE 701 MODULE FEATURES
The genset should run 2-3 minute with no load.
Engine supervision and protection
Selecting STOP O position, de-energises the fuel solenoid,
Key switch operation on the fron panel
bringing the generator to a stop.

DSE 701 MODULE EMERGENCY LEDs
18.GENERATING SET CONTROL SYSTEMS
High engine temperature, shutdown
To control and monitor the generating set, an electronic control
Low oil pressure, shutdown
system has been used. Depending on the requirements of the set,
Over speed, shutdown
one of several different standard control systems may be fitted.
Charge failure, warning
These include ME 40 Model Manual Control panel or P 500, P2020

Auto Mains Failure panel and 2010 Autostart Panel Control panel
provides a means of starting and stopping the generating set,
monitoring its operation and output, and automatically shutting
down the set in the event of a critical condition arising such as low
oil pressure or high engine temperature.
18.1 CONTROL PANELS
Control, supervision and protection panels are mounted on the
generator base frame.
Figure 18.2 DSE 701 Manuel Control Module
18.1.1 Manual Control System - ME 40

Control with DSE 701 Module
3 Ammeters
1 Hours run meter
1 Volt - Frequencymeter (by LED) and selector switch
Engine oil pressure gauge
Engine coolant temperature gauge
Emergency stop push button
11
3 pole alternator circuit braker
12
CY S
EME
GEN
TO
AUTO
Figure 18.3 P500 Automatic Control Panel
18.2.1 Automatic Control System P 500 Panel Spesification

Control with DSE 704 module
3 Ammeters
1 Hours run meter
1 Volt-Frequencymter (by LED) and selector switch
Engine oil pressure gauge
Engine coolant temperature gauge
Figure 18.1 ME 40 Manual Control Panel

Static battery charger
Thermally delayed overload protection
Engine water heater control
22
Metering via LCD display
DSE 704 Module Features

Three phases mains sensing
Engine protection
Automatic engine starting and stopping
Simple push button controlled operation
Stop-Reset/Manual/Auto
Micro processor based design
Configurable via front panel
Configurable timer setting
Adjustable mains fail voltage level
Mains/Generator, change-over contactor control
External remote start input
Generator Volt (F-N)
Engine oil pressure
Generator Ampere (L1, L2, L3) Engine speed

Generator Frequency (Hz)
Engine hours run
Mains Volts (F-F / F-N)
Plant battery volt
Engine temperature
Alarms
Under generator voltage
High engine temperature
Over current
Low battery volt
Over speed
Charge fail
Under / Over mains volt
Start failure
Under / Over mains frequency Emergency stop

Low oil pressure
Led indications
Mains available
Generator available
Mains on load
Generator on load
Figure 18.4 DSE 704 Automatic Start and Control Module
Status Fault Conditions Displayed by LED Illumination
Figure 18.5 DSE 720 AMF Control Module
18.4.1 Automatic Control System P 2020 Panel
High engine temperature, shutdown
Control with DSE 5220 Full Automatic mains failure module

Static Battery Charger
Low oil pressure, shutdown

Over speed, shutdown
Charge eltarnator fault, warning
NCY S
18.3.1 Control System P 300 Panel Specifications:
GE
TO
EMER
Start failure, shutdown
Control with DSE 720 Automatic Mains Failure module

Static battery charger
Figure 18.6 P 2020 Automatic Control Panel
18.4.1.1 DSE 5220 Module Features

Monitoring AC mains supply
Automatic controls generating set, start and shutdown
Provides signal to change over switch gear
Remote communication via RS 232 port or RS 485 modbus
output.
Front panel programming of the module settings
Scrolling digital LCD display
Event logging of shutdown alarms
Easy pushbutton control
Stop/Reset, Auto, Manual, Test
18.3.1.1 DSE 720 Module features :

To monitoring AC mains supply
Automatic controls generating set, start and stop
Provide signal to change over switch
Front panel configuration of timers and alarm trip points
Easy push button control
STOP/RESET
MANUAL
AUTO
TEST
START
LCD display Scroll push button
23
Metering via LCD display
18.5.1 Autostart Control System P 2010 Panel Specifications
Generator volts (F-F/F-N)
Control with DSE 5210 Autostart Module
Generator amperes (L1, L2, L3)
Emergency stop shutdown push button
Generator frequency (Hz)

Generator kVA
Generator kW
Generator Cos j
Engine oil pressure (PSI & Bar)
Engine temperature (C & F)
Engine speed RPM
E MER
NCY S
Mains volts (F-F / F-N)
GE
TO
Engine hours run

Mains frequency (Hz)
Plant battery volts
Figure 18.7 P 2010 Autostart Control Panel
18.5.1.1 DSE 5210 MODULE FEATURES

Automatic start and stop the genset
Provides signal to Load Transfer
Remote communication via RS 232 port or RS 485 modbus
output.
Front panel programming of the module settings
Figurel 18.7 DSE 5220 AMF Control Module
Event logging of shutdown alarms

Easy pushbutton control
Multiple Alarms
Stop/Reset, Auto, Manual, Test
Under/over generator volts; Pre-Alarm and Shutdown

Under/over generator frequency; Pre-Alarm and Shutdown
Metering via LCD display with the following
Under/over mains volts
instrumentation displays
Under/over mains frequency
Generator volts (F-F / F-N)
Over current; Shutdown
Generator amperes (L1, L2, L3)
Low oil pressure; Pre-Alarm and Shutdown
Generator frequency (Hz)
High engine temperature; Pre-Alarm and Shutdown
Generator kVA
Under/over speed; Shutdown
Generator kW
Low coolant level; Shutdown
Generator Cos j
Fail to start; Shutdown
Engine oil pressure (PSI & Bar)
Fail to stop; Warning
Engine coolant temperature (C & F)
Low/High Battery volts; Warning
Engine speed RPM
Charge fail; Warning
Engine hours run
Emergency stop; Shutdown
Plant battery volts
Can Data Fail; Shutdown

Can ECU Fail; Pre-Alarm and Shutdown
The Event Log
5220 control module maintains a log of the last 15 shutdown
alarms to enable the operator or engineer to view the past alarms
history.
Figurel 18.8 DSE 5210 Autostart Control Module
24
Multiple Alarms
18.65.4 Frequency Meter
Under/over generator volts; Pre-Alarm and Shutdown
A meter that indicates the output frequency of the generating set.
Under/over generator frequency; Pre-Alarm and Shutdown
The engine maintain a relatively constant speed under governor
Over current; Shutdown
control so as to provide the proper operating frequency of 50 Hz
Low oil pressure; Pre-Alarm and Shutdown
or 60 Hz when the generating set is operating at full load. In
High engine temperature; Pre-Alarm and Shutdown
practice, if the generating set has a manual governor control system,
Under/over speed; Shutdown
no load frequencies of approximately 52-62 Hz for 50 Hz and 60
Low coolant level; Shutdown
Hz respectively, are considered. The frequencies will fall, as the set
Fail to start; Shutdown
is loaded, to 50 Hz and 60 Hz at full load.
Fail to stop; Warning

Low / High Battery volts; Warning
18.6.5 Hours Run Meter
Charge fail; Warning
A meter that indicates the total number of hours of generating set
Emergency stop; Shutdown
operation to aid in maintenance.
The Event Log
18.6.6 Water Temperature Gauge
5220 control module maintains a log of the last 15 shutdown
A temperature gauge connected to a sensor in the engine to
alarms to enable the operator or engineer to view the past alarms
monitor engine coolant temperature. Normal level of the engine
history.
coolant temperature is approximately 85C (185F).
18.6 PANEL EQUIPMENTS
18.6.7 Oil Pressure Gauge
Before starting or running the generating set, the operator should
A gauge to monitor engine oil pressure from the moment the
become fully acquainted with the instruments and controls. The
engine is cranked. On cold engines the oil pressure will be significantly
instuments should be observed from time to time while the
higher until the engine warms up.
generating set is running so that any abnormal readings can be

detected before problems arise. Some of our standard manual and
18.6.8 Emergency Stop Pushbutton
automatic control panels are shown in figures 18.1 and 18.3. In
A red lockdown pushbutton that immediately shut dow the
addition optional equipment items can be added to the panel so
generating set and will inhibit start until the pushbutton has been
the panel fitted on the generating set may be slightly different
released by turning it.
from the typical ones shown.

18.6.9 Alternator Protection
18.6.1 AC Voltmeter
In our standard production, the alternators in automatic operation
A voltmeter that indicates the AC voltage generated at the alternator
generating sets are protected with a thermic protector against
output terminals. The reading indicated on the voltmeter will vary
overload (with P 500 control panel).
depending on the connections made inside the alternator terminal
In our standard production of manual operated generating sets,
box, the setting of the voltage regulator and the position of the
the alternators are protected against overload and short circuit by
voltmeter selector switch.
a thermic magnetic switch and then the generating set is given

load.
18.6.2 Voltmeter Selector Switch

A selector switch allowing the operator to select voltage reading
between phases.
18.6.3 AC Ammeter
An ammeter that indicates the AC electrical current being delivered
which is dependend on the connected load. There are three
ammeters.
25
18.9 ICONS AND LCD IDENTIFICATION ON DSE 5210 and DSE 5220 MODULE
18.9.1 PUSH BUTTONS
Display
Description
Display
Description
Stop / Reset
AUTO
Auto mode
Manual mode
Start (when in
manual mode)
Scrool
Configure / log
Display
Description
18.9.2 STATUS / MEASUREMENT UNITS
Display
Description
Display
Description
Display
Description
L1
Phase
L2
Phase
L3
Phase
L1 - N
Phase - Neutral
L1 - N
Phase-Neutral
L1 - N
Phase-Neutral
L1 - L2
Phase - Phase
L2 - L3
Phase-Phase
L3 - L1
Phase-Phase
BAR
Pressure
Kpa
Kpa Oil Pressure

Units
PSI
Pressure
Voltage
Temperature
Hz
Frequency
Amperes
Temperature
RPM
Speed
kW
KiloWatts
kVA
Apparent Power
Cos j
kW divided by
kVA
Hours Run
AC
Generator
Timer in progress
DC
Factory (load)
Fuel Level
Event log
Configuration
mode active
Panel locked by
configurable input
18.9.3 ALARM INDICATIONS
Display
Description
Description
Display
Description
Warning Alarm
Shutdown Alarm
Fuel
Low Oil Pressure
High Current
Warning
Charge Fail
High Coolant
Temperature
Fail to start
(Over-crank)
v
v
Over Voltage
(AC)
Under Voltage
(AC)
Emergency Stop
Display
Over Voltage
(DC)
Over-Speed
Under Voltage
(DC)
Under-speed
Auxiliary Indication
Auxiliary Alarm
(Warning or Shutdown
26
Electrical Trip
Hz
Hz
Over Frequency
Under Frequency
18.7 THE PLACEMENT AND INSTALLATION
Current from one phase should not exceed the nominal current.
OF TRANSFER SWITCH
Two different power cables, which will be used between the
The placement of the transfer switch and its mountings:
generating set and the transfer switch is on the generating set.
Position the transfer switch near the emergency power panel.
(Main supply cable and power cable for emergency power
Locate the transfer switch in a place where it is clean, not over
panel)
heated, and having a good ventilation. If the environment
If the transfer switch panel is apart from the generating set,
temperature is above 40 C, fuses and breakers will open more
transfer switch must be placed as close as possible to the
easily. There must be enough working place around the transfer
distributor panel. In this case power cables are drawn from
switch.
generating set, mains panel and emergency power panel.
Having a fuse or breaker between the generating set and the
Furthermore 8 x 2.5 mm control cable must be drawn from the
transfer switch is optional. (Connection cables used in transfer
generating set control panel.
switch).
Currents from the generating set must be distributed equally
to the three phase if possible. Current from one phase should
not exceed the nominal current.
MAINS
GENERATING SET
CUSTOMER DISTRIBUTION PANEL

MAINS
BREAKER
EMERGENCY
OVER CURRENT
PROTECTION
TRANSFER
SWITCH
OTHER
CUSTOMER DISTRIBUTION PANEL

Figure 11 Typical emergency power system installation
27
19. ALTERNATOR TROUBLESHOOTING
Symptom
Alternator does not excite
Possible Cause
Blown fuse
Insufficient residual voltage
No residual voltage
Connections are interrupted
Corrective Action
Replace fuse
Increase speed by 15%
For an instant apply on the (+) and
(-) terminals of the electronic regulator a
12 V battery voltage with 30 ohm resistor
in series respecting the polarities.
After being excited

alternator does no excite
Connections are interrupted
Check connection cables as per

attached drawings.
Low voltage at no load
Voltage potentiometer out of setting

Intervention of protection
Winding failure
Reset voltage
Check engine speed
Check wingings
High voltage at no load

Failed regulator
Reset voltage
Substitude regulator
Lower than rated voltage

at load

Intervention by protection
Reset voltage potentiometer

Current to high, power factor lower than
0.8;
Speed lower than 4% of rated speed
Failed regulator
Rotating bridge failure
Check diodes, disconnect cables
Higher than rated voltage

at load

Failed regulator
Reset voltage potentiometer

Unstable voltage
Speed variation in engine

Regulator out of setting
Check regularity of rotation

Regulate stability of regulator by
acting on stability potentiometer
28
20. ENGINE TROUBLESHOOTING

The starter motor turns the engine too slowly
Battery capacity to low
Bad electrical connection
Fault in starter motor
Wrong grade of lubrication
Engine over load

Blue or white exhaust smoke
Fault in cold start system
Engine temperature is too low
The engine knocks
Fault in fuel lift pump
Fault in atomisers or atomisers of an incorrect type
Wrong type or grade of fuel used
Engine temperature is too high
Incorrect valve clearances
The engine does not start or difficult to start

Starter motor turns engine too showly
Fuel tank empty
Fault in fuel control solenoid
Restriction in a fuel pipe
Dirty fuel filter element
Air in fuel system
Fault in atomisers
Cold start systems used incorrectly
Restriction in a fuel tan vent
Restriction in exhaust pipe
The engine runs erractically

Fault in fuel control
Restriction in a fuel system
Restriction air filter/cleaner or induction system
Air in fuel system
Restriction in fuel tank vent
Restricted movement of engine speed control
Not enough power to start

Air in fuel system
Restriction in fuel tank vent
Engine temperature is too high or low
Vibration
Fan damaged
Fault in engine mounting or flywheel housing
Misfire
Air in fuel system
Incorrect valve clearance
The pressure of the lubrication oil is too high

Wrong grade of lubrication oil
Defective gauge
The engine temperature is too high
Fan damaged
Too much lubrication oil in sump
Restriction in air or water passages of radiator
Insufficiant coolant system
The pressure of the lubriation oil is too low

Not enough lubrication oil in sump
Defective gauge
Dirty lubrication oil filter element
High fuel consumption
Crankcase pressure
Restriction in breather pipe
Vacuum pipe leaks or fault in exhauster
Bad compression
The engine starts and stops
Air in fuel system
Black exhaust smoke

The engine shuts down after approximately 15 seconds

Bad connection towards oil pressure switch/coolant
temperature switch
29
21. MAINTENANCE
Using hour meter as a guide, perform all services at the hourly
intervals indicated on following. At each maintenance interval,
perform all previous maintenance operatons in addition to the ones
specified. Keep a record of hourly intervals and services performed.
21.2. 4045/6068/6081 MODEL ENGINES MAINTENANCE

INTERVAL CHART:
Daily or every 10 Hours maintenance
Check engine oil, fuel and coolant level
Check air filter (a)
Visual walk around inspection
Check engine coolant heater at automatic genset
IMPORTANT
Recommended service intervals are for normal operating conditions.
Service MORE OFTEN if engine is operated under adverse conditons.
Neglecting maintenance can result in failures or permanent damage
to the engine.
Every 2 weeeks (for Standby Power only)

Operate engine at rated speed and 50% - 70% load a minimum
of 30 minutes
Use correct fuels, Lubricants and coolant.
Every 250 Hours or 6 Mounts

Check service battery
Change engine oil and replace oil filter (b)
Check water pump weep hole foam filter (6081 engine)
Service fire extinguisher
21.1. 3029/4039 MODEL ENGINES MAINTENANCE

INTERVAL CHART
Daily or every 10 Hours maintenance
Check engine oil, fuel and coolant level
Check air filter (a)
Visual walk around inspection
Check engine coolant heater at automatic genset

Clean crankcase vent tube
Check air intake hoses, connections & system
Replace fuel filter element
Check cooling system
Check automatic belt tension and belt wear
Every 2 weeks (for Standby Power only)

Operate engine at rated speed and 50% - 70% load a minimum
of 30 minutes
Every 1200 Hours or 24 Month

Check and adjust engine speeds
Check fuel injection system
Inspect turbocharger
Check crankshaft vibration damper
Flush cooling system
Pressure test cooling system

Check service battery
Change engine oil and replace oil filter (b)
Check V - Belt tension
Service fire extinguisher
400 Hours
Initial valve clearance adjustment (c)
Every 2000 Hours

Check and adjust engine valve clearance

Clean crankcase vent tube
Check air intake hoses, connections, & system
Replace fuel filter element
Check cooling system
(a) Clean air filter element, replace filter element after 6 cleanings
or once a year.
(b) Change oil and filter after the first 100 hours maximum of
operation, then every 250 hours there after. If PLUS - 50 oil is
used, the oil and filter change interval may be extended by 50
percent to to every 375 hours.
(c) Have your authorized servicing dealer or engine distributor
adjust valve clearance after the first 400 hours of operation.
Then, have the valve clearance at 1200 hour or 2 year.

Check and adjust engine valve clearance
Check and adjust engine speeds
Check fuel injection system
Check crankshaft vibration damper
Flush cooling system & replace thermostats
Pressure test cooling system
30
22. ENGINE STORAGE GUIDELINES

1. John Deere engines can be stored outside for up to three (3)
months with no long term preparation IF COVERED BY
WATERPROOF COVERING.
10. Clean the exterior of the engine with salt free water and touch
up any scratched or chipped painted surfaces with a good
quality paint.
11. Coat all exposed (machined) metal surfaces with grease or
corrosion inhibitor if not feasible to paint.
2. John Deere engines can be stored in a standard overseas shipping

container for up to three (3) months with no long term
preparation.
12. Seal all openings on engine with plastic bags and tape supplied
in storage kit. Follow instructions supplied in kit.
3. John Deere engines can be stored inside, warehoused, for up

to six (6) months with no long term preparation.
13. Store the engine in a dry protected place. If engine must be

stored outside, cover it with a waterproof canvas or other
suitable protective material and use a strong waterproof tape.
4. John Deere engines expected to be stored more than six (6)

months with no long term preparation.
24. REMOVING ENGINE FROM LONG TERM STORAGE

Refer to the appropriate section for detailed services listed below
or have your authorized servicing dealer or angine distrubutor
perform services that you may not be familiar with.
MUST BE taken. (See PREPARING ENGINE FOR LONG TERM

STORAGE).
5. For John Deere engines not yet installed in machines, run a line
from a container of AR41937 Nucle Oil (from AR41785 Engine
Storage Kit) to the fuel transfer pump intake, and another line
from the fuel return manifold to the tank, so that Nucle Oil is
circulated through the injection system during cranking.
1. Remove all protective coverings from engine.

Unseal all openings in engine and remove covering from electrical
systems.
2. Remove the battery from storage. Install battery (fully cherged)
and connect the terminals.
23. PREPARING ENGINE FOR LONG TERM STORAGE

The following storage preparation are good for long term engine
storage up to one year. After that, the engine should be started,
warmed up, and retreated for an extended storage period.
3. Install fan/alternator belt if removed.

4. Fill fuel tank.
IMPORTANT
Any time your engine will not be used for over six (6) months,
the following recommandations for storing it and removing it
from storage will help to minimize corrosion and deterioration.
Use the AR41785 Engine Storage Kit. Follow recommended
service procedure included with storage kit.
5. Perform all appropriate prestarting checks.

IMPORTANT
DO NOT operate starter more than 30 seconds at a time. Wait
at least 2 minutes for starter to cool before trying again.
6. Crank enginefor 20 seconds with starter (do not allow the
engine to start). Wait 2 minutes and crank engine an additional
20 seconds to assure bearing surfaces are adequately lubricated.
1. Change engine oil and replace filter. Used oil will not give
adequate protection. (See CHANGING ENGINE OIL AND FILTER).
2. Service air cleaner. (See CLEAN OR REPLACE AIR FILTER).
7. Start engine and run at no load for several minutes. Warm up

carefully and check all gauges before placing engine under load.
3. Draining and flushing of cooling system is not necessary if

engine is to be stored only for several months. However, for
extended storage periods of a year or longer, it is recommended
that the cooling system be drained, flushed, and refilled. Refill
with appropriate coolant.
8. On the first day of operation after storage, check overall engine

for leaks and check all gauges for correct operation.
4. Drain fuel tank and add 30 ml (1 oz) of inhibitor to the fuel

tank for each 15 L (4 U.S. gal) of tank capacity. Completely
drain fuel filter and close fuel valve, if equipped.
5. Add 30 ml (1 oz) of inhibitor to the engine crankcase for each
0.95 L (1 qt) of crankcase oil.
6. Disconnect air intake pipping from the manifold. Pour 90 ml
(3 oz) of inhibitor into intake system and reconnect the piping.
7. Crank the engine several revolution with starter (do not allow
the engine to start).
8. Remove fan/alternator belt, if desired.
9. Remove and clean battery. Store them in a cool, dry place and
keep them fully charged.
31
OUR COMPANY DOES NOT TAKE THE RESPONSIBILITY OF THE

DAMAGES ON THE MAINS SUPPLY CONTACTOR OF THE
AUTOMATIC GENERATING SETS DUE TO OVERCURRENT, LOW
OR HIGH VOLTAGE.
GENERAL PRECAUTIONS ABOUT WARRANTY

DEAR AKSA GENERATING SET OPERATOR
PLEASE TAKE CARE TO THE FOLLOWING IN ORDER TO PREVENT
THE GENERATING SET WARRANTY TO BECOME INVALID BEFORE
THE TERMINATION OF THE WARRANTY PERIOD AND TO ENSURE
TROUBLE-FREE OPERATION OF THE GENERATING SET WITH A LONG
LIFE!...
NEVER REMOVE THE BATTERY TERMINALS WHILE THE

GENERATING SET IS IN USE. EVEN A MOMENT OF
DISCONNECTION CAN CAUSE A DAMAGE ON THE ELECTRONIC
CLOSING RELAY OF THE CHARGE ALTERNATOR AND ON THE
ELECTRONIC ENGINE SPEED CONTROL CIRCUIT. THESE
CONDITIONS ARE NOT COVERED BY THE WARRANTY.
MAINTENANCE AND REPAIR WORKS WILL NOT BE COVERED

BY THE WARRANTY UNLESS THE WARRANTY CERTIFICATE,
INVOICE OR DELIVERY CERTIFICATE OF THE GENERATING SET
IS SUBMITTED.
FAILURES DUE TO OVERLOAD AND UNBALANCED LOAD IN

EXCESS OF THE GENERATING SET POWER (SUCH AS
ALTERNATOR AND CONTACTOR FAILURES) ARE NOT COVERED
BY THE WARRANTY.
THE WARRANTY OF THE GENERATING SET WILL BECOME

INVALID IN CASE OF ANY INTERVENTION OF ANY PERSON
OTHER THAN AUTHORIZED AKSA SERVICES OR BY PRIOR
WRITTEN APPROVAL FROM AKSA POWER GENERATION ON
THE GENERATING SET FOR ANY REASON.
FAILURES DUE TO OVERLOAD AND UNBALANCED LOAD IN

EXCESS OF THE GENERATING SET POWER (SUCH AS
ALTERNATOR AND CONTACTOR FAILURES) ARE NOT COVERED
BY THE WARRANTY.
CONTROL AND MAINTENANCE WORKS INDICATED IN THE

PERIODICAL MAINTENANCE SCHEDULE AND THE OPERATING
MANUAL MUST BE CARRIED OUT COMPLETELY AND TIMELY.
THE FAILURES DUE TO INCOMPLETE OR UNTIMELY
MAINTENANCE ARE NOT COVERED BY THE WARRANTY.
WHEN THE MANUAL GENERATING SET IS STARTED UP, IT

SHOULD BE WARMED BY OPERATING AT IDLE FOR 5 MINUTES.
WHEN STOPPING THE DIESEL ENGINE, IT SHOULD BE UNLOADED
AND THEN CONTINUED TO BE OPERATED FOR COOLING FOR
10 MINUTES BEFORE STOPPING. OTHERWISE, PROBLEMS WHICH
ARE LIKELY TO OCCUR WILL NOT BE COVERED BY THE
WARRANTY.
GENERATING SET SHOULD BE MOUNTED AS INDICATED IN

THE OPERATING MANUAL. OTHERWISE, THE PROBLEMS WHICH
WARRANTY.
WARRANTY PERIOD IS 1 YEAR BEGINNING FROM THE

PURCHASE DATE.
CUSTOMER IS RESPONSIBLE FOR THE FAILURES WHICH ARE

LIKELY TO OCCUR IN CASE THAT THE DIESEL OIL USED
CONTAINS DIRT OR WATER.
THE OIL TYPE INDICATED IN THE OPERATING MANUAL SHOULD
BE USED IN THE ENGINE. OTHERWISE, THE FAILURES WHICH
WARRANTY.
BATTERIES WILL NOT BE COVERED BY THE WARRANTY IF THEY
ARE SUBJECTED TO BREAKAGE, EXCESSIVE ACID FILL OR
HARDENING BY LEAVING UNCHARGED.
ON MODEL KSD 501 MANUAL GENERATING SETS WITH START
PANEL, THE IGNITION KEY SHOULD BE RELEASED IMMEDIATELY
AFTER THE ENGINE IS STARTED-UP. IN CASE THAT THE ENGINE
DOES NOT START UP, THE STARTING SEQUENCE SHOULD NOT
BE APPLIED MORE THAN 3 TIMES EACH WITH 10 SECOND
INTERVALS. OTHERWISE, STARTING GEAR CAN BE BROKEN OR
STARTER MOTOR CAN BURN. THESE CONDITIONS ARE NOT
COVERED BY THE WARRANTY.
ON MANUAL GENERATING SETS, NEVER START OR STOP THE
DIESEL ENGINE WHEN THE GENERATING SET IS UNDER LOAD.
ENGINE SHOULD BE STARTED AND STOPPED AFTER LOAD IS
DISCONNECTED AND THE GENERATING SET IS AT IDLE
CONDITION. OTHERWISE, THE VALVES CAN BE SEIZED, THE
VOTAGE REGULATOR, TRANSFORMER AND DIODES CAN BE
BROKEN DOWN. THESE CONDITIONS ARE NOT COVERED BY
THE WARRANTY.
32
Genset
3,9
4 - In Line
Recommended Power Cable

Section (YVV) for each phase
Cable Max. Current Capacity
at 40 C ambient temperature
Prime Load Current (%100)
50
138
35
114
71
53
115
16
91
1620
10
57
1345
220
16,5
17
21,5
1300
2,15x1,03x1,55
ASM 5
4,5
96,5
4045 H
80
100
88
110
AJD 110
176
70
144
1690
3,11x1,06x1,75
1185
mm2
40
ASM 4
1020
2,15x1,03x1,5
220
14,4
12
21,5
82
ME 40
A
132
1,86x0,93x1,35
2,5x0,97x1,57
1230
890
1,86X0,93X1,36
132
10,3
13,2
21,5
62
Manual Control Panel Type
1005
2,12x0,915x1,48
ASM 3
800
1,6x0,88x1,3
115
9,5
21,5
106 x 110
39
4045 T
P 300
Kg
Kg
5,2
12
2,9
3 - In Line
30,5
4039 T
Automatic Control Panel Type
Attenuated Type Dry Weight
(Length x With x Height)
Attenuated Type Dimensions
Canopy Model
Open Types Dry Weight
Open Type Dimensions
Fuel Tank Capacity
L/h
Total Oil Capacity
Fuel Consumption at 3/4 Load
mm
Bore & Stroke
Coolant Capacity
kWm
4039 D
64
50,4
32
22,4
KW
3029 D
80
72
90
AJD 90
63
56
70
AJD 70
40
35
44
AJD 44
28
26,4
33
AJD 33
KVA
KW
KVA
Cubic Capacity
Cylinder and Build
Standby Net Power
Model
Prime Power
Standby Power
Model
50 Hz Technical Specification
Generator
230/400 Vac
50 Hz
John Deere Diesel Engine
Genset
33
212
95
173
1970
1370
2,34x1,13x1,55
370
18,5
12
30,3
106 x 110
115
6068 T
96
120
105
132
AJD 132
2x95
4240
283
248
361
P 2010
P 2020
2880
3,98x1,21x2,05
ASM 7
2130
150
263
2270
1670
2,9x1,15x1,87
420
41
32
44
116x129
8,1
246
6081 H
120
222 / 216
2170/2090
3,25x1,16x1,89
ASM 6
1550/1410
370
30
19
34,5
183
2,34x1,13x1,58
6 - In Line
2,4x1,13x1,55
370
25
19
25,5
6,8
148
6068 H
200
144
123 / 120
6068 H
250
220
275
AJD 275
180
160
200
AJD 200
154 / 150
136 / 132
170 / 165
AJD 170
AJD 165
Genset
ASM 3
800
1,6x0,88x1,3
115
4 - In Line
Recommended Power Cable

Section (YVV) for each phase
Cable Max. Current Capacity
at 40 C ambient temperature
Prime Load Current (%100)
1230
220
20,6
17
21,5
117
70
176
50
138
94
53
133
1620
25
106
1345
ASM 5
1225
212
95
182
1690
3,11x1,06x1,75
1185
10
68
ASM 4
1020
2,5x0,97x1,57
890
mm2
45
220
16
12
21,5
4,5
ME 40
A
132
12,5
13,2
21,5
86
Manual Control Panel Type
1005
3,9
73,5
4045 H
370
24,7
12
30,3
106 x 110
134
6068 T
112
140
123
154
AJD 154-6
248
120
212
1970
1370
1,86X0,93X1,36 1,86x0,93x1,35 2,15x1,03x1,5 2,15x1,03x1,55 2,34x1,13x1,55
132
8,3
9,5
21,5
106 x 110
47
4045 T
P 300
Kg
m 2,12x0,915x1,48
Kg
6,3
12
2,9
3 - In Line
32
4039 T
96
120
105
123
AJD 132-6
Automatic Control Panel Type
Attenuated Type Dry Weight
Attenuated Type Dimensions
Canopy Model
Open Types Dry Weight
Open Type Dimensions
Fuel Tank Capacity
L/h
Total Oil Capacity
Fuel Consumption at 3/4 Load
mm
Bore & Stroke
Coolant Capacity
kWm
4039 D
70
56
36
24
KW
3029 D
88
78
98
AJD 98-6
70
61
77
AJD 77-6
45
40
51
AJD 51-6
30
26,4
33
AJD 33-6
KVA
KW
KVA
Cubic Capacity
Cylinder and Build
Standby Net Power
Model
Prime Power
Standby Power
Model
60 Hz Technical Specification
Generator
230/400 Vac
60 Hz
John Deere Diesel Engine
Genset
34
370
36
19
34,5
6 - In Line
199
420
47,7
32
44
116x129
8,1
292
6081 H
AS 400
3060
848
496
352
322
638
4x95
P 2010
P 2020
4300
2x120
437
2880
3,98x1,21x2,05 4,4x1,41x2,27
ASM 7
2130
2x70
311
2270
1670
185
276
2170 / 2090
3,25x1,16x1,89
ASM 6
1550 / 1410
3,15x1,15x2
660
70
42
66
127x165
12,5
437
6125 H
336
230
164
6068 H
420
404
505
AJD 505-6
288
264
330
AJD 330-6
205
180
225
AJD 225-6
2,4x1,13x1,55 2,34x1,13x1,58 2,9x1,15x1,87
370
31,8
19
25,5
6,8
177
6068 H
145
182
160
200
AJD 200-6
37
Notes
HEAD OFFICE
Aksa Jeneratr Sanayi A.S.
Factories
TURKEY
Glbahar Caddesi 1. Sokak 34212 Gneli, stanbul - TURKEY

Tel: +90 212 478 66 66 (pbx) Fax: +90 212 657 55 16
E-mail: aksa@aksa.com.tr
TURKEY
UNITED KINGDOM
ALGERIA
CHINA
DUBAI, UAE
IRAN
IRAQ
KAZAKHSTAN
KYRGHZISTAN
NIGERIA
SINGAPORE
Glbahar Caddesi 1. Sokak 34212

Gneli, stanbul - TURKEY
Tel : +90 212 478 66 66 (pbx)
Fax : +90 212 657 55 16
Taoca Yolu No: 22 Mahmutbey

Baclar, stanbul - TURKEY
Tel : +90 212 446 43 01
Fax : +90 212 446 43 00
Branch Offices & Warehouses

Aksa Algeria
Cit des PTT, Villa 35A
16405
Hydra / Alger, Algeria
Tel : +213 21 60 81 48
Fax : +213 21 48 41 44
e-mail: aksaalgerie@aksa.com.tr
Aksa Iran
Apt. 22, the 6th Floor Dasto
Building No: 1421, Vali-e Asr Ave.
Tehran - Iran
Tel : +98 21 2205 4212 / 2201 6502
Fax : +98 21 2201 8921
e-mail: aksatehran@gmail.com
Aksa Central Asia Ltd.
40 Manas Str. Bishkek,
Kyrghyz Republic
Tel : +996 312 21 17 79
Fax : +996 312 66 23 23
e-mail: aksaasia@elcat.kg
Aksa Chine (Suzhou)

Zhongxin City, 128 Donghuan
Road, Room 706, Suzhou China
215021 P.R. China
Tel : +86 512 6725 1137
Fax : +86 512 6725 1317
Aksa Iraq
Sahet Al-Wathik, Al Wahda St. 909
Baghdad - Iraq
Tel : +964 7901 916 086
+964 7901 916 089
e-mail: aksa_baghdad@yahoo.com
Aksa Generators (W.A) Ltd.

99, Oduduwa Crescent,
Ikeja Gra, Lagos, Nigeria
Tel : +234 1 481 3121
Fax : +234 1 482 3013
e-mail: aksanigeria@yahoo.com
Aksa International (UK) Ltd.

Lister Petter Industrial Estate,
Church Road Cam
Dursley Glos, GL11 5 PY, UK
Tel : +44 1453 549 223
Fax : +44 1453 549 227
Aksa Middle East

Post Box No, 18167 Warehouse
No. RA08 / LC07 Jebel Ali Free
Zone, Dubai, United Arab Emirates
Tel : +971 4883 3292
Fax : +971 4883 3293
e-mail: sales@aksa.ae
Aksa Central Asia Kazakhstan Ltd.
111/48 Furmanova Str.
Almaty, Kazakhistan 480091
Tel : +7 32 72 50 67 31 / 41
Fax : +7 32 72 50 67 91
e-mail: aksa@arna.kz
Aksa Far East (Pte.) Ltd.

94 Tuas Avenue 11
Singapore 639103
Tel : +65 6863 2832
Fax : +65 6863 0392 - 6863 2956
e-mail: aksafe@aksafareast.com.sg
Aksa International (UK) Ltd.

Lister Petter Industrial Estate
Church Road Cam
Dursley Glos, GL11 5 PY, UK
Tel : +44 1453 549 223
Fax : +44 1453 549 227
e-mail: sales@aksa-uk.com
27.09.06
UNITED KINGDOM
Aksa Service & Spare Parts

TURKEY
Basn Ekspres Yolu, Cemal Ulusoy Caddesi

No: 33 Yeni Bosna, stanbul - TURKEY
Tel : +90 212 471 34 34 (pbx)
Fax : +90 212 696 20 29
E-mail: info@aksaservis.com.tr
www.aksa.com.tr

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Generating Sets

Installation Recommendations and Operations Manual

John Deere Powered

Dear Aksa Generating

4.13.3 Other Sound Attenuation.............................................

Aksa Generating set is designed to be commissioned, when delivered,

as soon as the necessary cooling water, antifreeze, fuel, lubrication

The generating set is designed to be safe when used in the correct

oil and fully charged battery are provided.

manner. However responsibility for safety rests with the personnel

With its long years of experience, Aksa manufactures efficient,

reliable and quality generating set.

precautions are followed, the possibility of accidents will be

This operating and maintenance manual is prepared to assist the

minimized. Before performing any procedure or operating technique,

operator in operation and maintenance of the generating set.

it is up to the user to ensure that it is safe. The generating set

should only be operated by personnel who are authorized and

generating set operates in maximum performance and efficiency

for a long time.

Care should be taken to perform more frequent maintenance in

Read and understand all safety precautions and warnings before

dirty and dusty environments in order to keep the generating set

Failure to follow the instructions, procedures, and safety

in good working condition.

precautions in this manual may increase the possibity of accidents

Necessary adjustments and repairs should be made only by authorized

and qualified persons.

Each generating set has a model and a serial number indicated on

Do not attempt to operate the generating set with a known

date, voltage, current, power in kVA and kW, frequency, power

If the generating set is unsafe, put danger notices and disconnect

the condition is corrected.

Disconnect the battery negative (-) lead prior to attempting any

Install and operate this generating set only in full compliance

Do not attempt to repair or operate the genset, wearing a tom

2.2 INSTALLATION, HANDLING AND TOWING

2.3 FIRE AND EXPLOSION

This manuel covers procedures for installation, handling, and towing

Fuel and fumes associated with generating sets can be flammable

of generating sets. That chapter should be read before installing,

and potentially explosive. Proper care in handling these materials

can dramatically limit the risk of fire or explosion. However, safety

following safety precautions should be noted:

Make electrical connections in compliance with

relevant Electrical Codes, Standards or other

requirements. This includes requirements for

grounding and ground/earth faults.

set clean. When spills of fuel, oil, battery

storage systems, make sure such systems are installed in

electrolyte or coolant occur, they should be cleaned up

compliance with relevant Codes, Standards or other requirements.

Engine exhaust emissions are hazardous to personnel. The

Never store flammable liquids near the engine.

engine exhaust for all indoor generating sets must be piped

Do not smoke or allow sparks, flames or other sources of ignition

outdoors via leak-free piping in compliance with relevant Codes,

around fuel or batteries. Fuel vapours are explosive. Hydrogen

Standards and other requirements. Ensure that hot exhaust

gas generated by charging batteries is also explosive.

the battery charger

before making or breaking connections

Never lift the generating set by attaching to the engine or