Operation Manual

OPERATION MANUAL
SCANGEN
DIESEL GENERATOR
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USER INFORMATION
USER’S NAME : …………………………………………………………………………
USER’S ADDRESS : …………………………………………………………………………
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TELEPHONE NO. : …………………………………………………………………………
GENERATOR SET MODEL : …………………………………………………………………………
GENERATOR SET SERIAL NO. : ...………………………………………………………………………
ENGINE MODEL : …………………………………………………………………………
ENGINE SERIAL NO. : …………………………………………………………………………
ALTERNATOR MODEL : …………………………………………………………………………
ALTERNATOR SERIAL NO. : …………………………………………………………………………
DEALER’S NAME : …………………………………………………………………………
CONTACT PERSON : …………………………………………………………………………
DEALER’S ADDRESS : …………………………………………………………………………
…………………………………………………………………………
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TELEPHONE NO. : …………………………………………………………………………

CONTENTS OF GENERATOR SET OPERATION MANUAL
1. Introduction ............................................................................................................. 1
2. Safety Guide ………………………………………………………………………………………………………….. 2
3. General Description .................................................................................................. 11
4. Installation …………………………………………………………………………………………………….……... 13
5. Operation System …………………………………………………………………………………………………. 25
6. Maintenance …………………………………………………………………………………………………………. 49
7. Commissioning ……………………………………………………………………………………………….. 57
8. Fault Finding …………………………………………………………………………………………………… 64
CONTENTS OF BRUSHLESS A.C. GENERATOR OPERATION MANUAL
1. Introduction ........................................................................................................... 70
2. Safety ………….…………….………………………………………………………………………………………… 71
3. Qualification of Operator ......................................................................................... 75
4. General Identification .......…………………………………………………………………………….……... 76
5. Mechanical Construction …..…………………………………………………………………………………. 77
6. Initial Inspection and Coupling ..…………………………………………………………………………. 77
7. Excitation System .………………………………………………………………………………………….. 78
8. Characteristic ….……………………………………………………………………………………………… 79
9. Standard Voltage Selection Tables ………………………………………………..……………………. 79
10. Optional Equipments ………………………………………………………………………….……………….. 80
11. Operation ……………………………………………………………………………………………………………. 80
12. Maintenance ……………………………………………………………………………………………………….. 81
13. Trouble Shooting ………………………………………………………………………………………………… 86
14. Service Information ……………………………………………………………………………………………. 86
CONTENTS OF AUTOMATIC VOLTAGE REGULATOR (AVR) OPERATION MANUAL
1. Introduction .......................................................................................................... 88
2. Safety ………….…………….………………………………………………………………………………………… 88
3. Product Description ................................................................................................. 90
4. Outline Drawing .......………………………………………………………………………………..….…….... 91
5. Installation ………………………..…………………………………………………………………………………. 92
6. Operation ..……………………………………………………………………………………………………………. 95
7. Maintenance …………………………………………………………………………………………………… 97
8. Trouble Shooting ….………………………………………………………………………………………… 98
9. Connection Diagram …………………………….………………………………………..……………………. 101
Enclosure :
I. AC & DC Schematic Diagram

II. Fault Finding
OPERATION MANUAL
SCANGEN GENERATOR SET
SG SERIES
Generator Set Operation Manual
7. Maintenance
1. Introduction
1. Introduction
Generating set is an industry generating set designed to be ready to run when it arrives at
site, requiring only the addition of coolant, fuel and assemble the noise reduction kits. Years of
diesel generating set experience have gone into the set to produce a quality source of electrical
power that is efficient and reliable.
Genset merupakan pembangkit tenaga listrik yang telah didesain untuk siap dioperasikan di lokasi
dimana genset dibutuhkan dengan sedikit persiapan, dengan hanya memberikan tambahan coolant,
bahan bakar dan pemasangan peralatan peredam suara, genset sudah dapat dioperasikan. Pengalaman
selama bertahun-tahun dalam industri genset, telah membawa kami untuk dapat menghasilkan
pembangkit listrik yang efisien dan dapat diandalkan.
This Technical Operational and Servicing Maintenance Manual have been prepared to
assist maintenance and operation of the generating set. It includes Practical Safety, Installation,
Commissioning, Operation System, Generating Set Maintenance and Fault Finding approach to
help end user to understand the product. Further more using this manual in conjunction with
the Engine Manual and Alternator Manual will help to ensure that the generating set keeps
operating at maximum performance and efficiency for a long life cycle.
Buku teknis perawatan dan pengoperasian ini telah dipersiapkan untuk dapat membantu proses
perawatan dan pengoperasian dari genset. Termasuk didalamnya panduan keselamatan, cara
pemasangan, commissioning, sistem operasi, petunjuk perawatan genset dan proses penelusuran
terhadap kerusakan yang diharapkan dapat membantu pemakai untuk dapat lebih memahami cara
pengoperasiannya.
Always ensure that servicing, repairs and adjustments are done by authorized personnel
who are properly trained.
Pastikan selalu bahwa proses pemeliharaan, perbaikan dan penyetelan dilakukan oleh tenaga ahli
terlatih.
Each and every generating set is uniquely defined by a generating set tag indicated on a
rating plate generally affixed to the alternator housing or control panel. This tag reflects
necessary technical data to the end user. This also helps, in future, when required to order
spare parts or when service and warranty work is required.
Tiap generator set memiliki label identifikasi yang berbeda dan terpasang pada badan alternator
atau control panel. Semua data teknis yang diperlukan pemakai tertera pada label tersebut. Dikemudian
hari, hal ini juga diperlukan pada saat melakukan proses pemesanan suku cadang dan garansi perbaikan.
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7. Maintenance
2. Safety Guide
2.1. GENERATING SET SAFETY GUIDE
BEFORE OPERATING THE GENERATING SET, ENSURE THAT THE FOLLOWING

CONDITIONS ARE SATISFIED.
SEBELUM GENSET MULAI BEROPERASI, PASTIKAN BAHWA KONDISI TERSEBUT DIBAWAH INI
TELAH TERPENUHI.
1. The operator is familiar with the operation of all Controls and the location of manually
operated valves and shutdown devices. (Refer to instruction Manual).
Genset dioperasikan oleh operator yang mengerti fungsi kendali operasional genset, cara
pengoperasian dan pemadaman unit secara manual.
2. The information about First Aid procedure and facilities is displayed near the generating set.
Informasi mengenai prosedur P3K dan fasilitas genset tertera di dekat unit genset.
3. The operator is familiar with Health and Safety Guides concerning fuel and lubricating oil.
Operator mengerti panduan kesehatan dan keselamatan kerja berkenaan dengan pemakaian BBM
dan pelumas.
4. The “Code of Practice” for personnel exposed to noise is exercised.
Kode praktek untuk operator saat bekerja pada tingkat kebisingan tertentu harus dibiasakan.
5. Before any maintenance work is carried out all supplies to generating set must be isolated.
The generating set must also be prevented from starting by disconnecting the battery
circuit. A suitable warning plate “MAINTENANCE IN PROGRESS” must be displayed. Before
disconnecting the battery, the DC Isolator switch should be selected OFF and its key
removed.
Sebelum melakukan perawatan, pastikan bahwa semua bagian yang terhubung ke genset telah
terisolasi, dan putuskan hubungan sirkuit baterei untuk menghindari aktifasi genset. Tanda “ Dalam
proses perbaikan” juga harus dicantumkan pada unit. Sebelum memutuskan baterei, saklar DC harus
pada posisi OFF dan lepaskan kuncinya.
6. Appropriate fire-fighter equipment is to be easily hand reached.
Peralatan pemadam kebakaran yang layak harus ada pada posisi yang mudah dijangkau.
7. The metal work on the generating set must be connected by means of an Earth Continuity
Conductor to an effective earth point.
Bagian genset yang berbahan logam harus terhubung melalui penghantar ke titik pusat bumi dalam
hal ini ke lantai atau tanah tempat genset berada.
8. The system neutral earth requirements must be complied at all time. (Refer to the
installation and Maintenance Manual).
Sistem penetralan ke kutub bumi ini harus diterapkan sepanjang waktu sesuai dengan petunjuk
pemasangan dan perbaikan.
9. Care must be taken to avoid spillage from batteries and naked flames must not be used in
the vicinity of the batteries.
Perawatan harus dilakukan untuk menghindari tumpahan cairan baterei dan jauhkan baterei dari
percikan api.
1O. All safety guards and covers must be securely fitted. All cubicle doors must be closed and
removable access covers e.g. load terminal box covers, must be secured firmly in place.
Pastikan semua pintu tertutup, cover pelindung semisal cover terminal box harus terpasang pada
tempatnya.
11. Auto start warning: Remember that when the plant is selected to AUTOSTANDBY, it may
start at any time without warning.
Peringatan Auto start: Harap diperhatikan bahwa pada saat genset berada pada fungsi
AUTOSTANDBY, genset mungkin beroperasi secara otomatis tanpa peringatan terlebih dahulu.
12. No loose items or combustible material should be left on or against any part of the
generator.
Pastikan bahwa tidak ada perlengkapan atau bahan yang mudah terbakar tertinggal pada unit
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7. Maintenance
2. Safety Guide
genset.
13. Do not risk injury by coming into contact with moving parts of the plant. Or by allowing
anything to be drawn in by the cooling fan or air intake system.
Hindari kontak dengan bagian bergerak dari genset untuk mencegah kecelakaan, juga untuk tidak
membiarkan benda tertarik dekat ke kipas pendingin dan sistem sirkulasi udara.
14. Slow speed running is harmful and will damage the generator.
Beroperasi pada kecepatan rendah sangat berbahaya dan dapat merusak unit genset.
This symbol warns of electric shock hazards, which result in severe personnel injury or death.
Simbol tersebut melambangkan bahaya sengatan arus listrik yang dapat mengakibatkan kecelakaan
bahkan kematian.
This symbol refers to hazard or unsafe practice, which can result in severe personnel injury,
death, or property damage.
Simbol tersebut melambangkan bahaya atau pengoperasian yang tidak aman dapat mengakibatkan
kecelakaan, kematian atau kerusakan pada unit genset.
2.2. FIRST AID IN CASE OF ELECTRIC SHOCK
1. Switch off the electricity supply. If this is not possible, protect yourself with insulating
material and pull the victim clear of the conductor. Do not touch the victim with your bare
hands until he is clear of the conductor, but do not waste time.
Putuskan arus listrik, jika hal ini tidak dapat dilakukan, lindungi diri anda dari kontak langsung
dengan penghantar arus listrik dan tarik korban dari area beraliran listrik. Jangan menyentuh korban
dengan tangan terbuka, kecuali yakin telah terbebas dari aliran arus listrik, dan jangan membuang
waktu.
2. Lay the victim on his back. Quickly loosen his waistband and clothing round his neck. If his
mouth is open, sweep a finger through his mouth to clear any obstruction. Remove his
dentures, if they are loosened.
Baringkan korban, longgarkan ikat pinggang dan pakaian korban, terutama disekitar lehernya. Jika
mulutnya terbuka, bersihkan dengan jari anda dari benda yang menghalangi saluran pernafasannya,
termasuk melepas gigi palsu korban, apabila korban memakai gigi palsu tidak permanen.
3. Place one hand on the back of the crown of his head. Lift casualty head illustration Victim’s
neck and the other on the and tilt it backward as shown in the illustration.
Letakkan tangan anda pada tengkuk dan kepala korban, angkat dan miringkan perlahan sampai
kepala korban berada pada posisi tengadah seperti terlihat pada gambar dibawah.
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7. Maintenance
2. Safety Guide
4. Hold the head tilted as far back as possible and lifts up the jaw firmly, closing his lips. This
keeps the victim’s airway clear by straightening the breathing passage.
Tahan kepala korban semiring mungkin, angkat rahangnya perlahan dan katupkan mulutnya. Hal ini
akan melancarkan aliran udara dengan meluruskan saluran pernafasannya.
5. Take a deep breath. Open your mouth as wide as you can. Seal your lips on the victim’s
cheeks around his nose. Blow air into his nose until you see the chest rise.
Ambil nafas dalam-dalam dan buka lebar mulut anda untuk kemudian ditiupkan melalui hidung
korban sampai terlihat dadanya mengembang.
6. Remove your mouth, allow his mouth to open to let him breath out. His chest will fall as he
does so.
Lepaskan mulut anda dan biarkan mulut korban terbuka untuk menghembuskan udara sampai
dadanya kembali mengempis.
7. Take another deep breath and repeat steps 5 and 6 at a rate of 10 — 15 times a minute.
Watch the victim’s chest for signs of the victim’s breathing without assistance and stop.
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7. Maintenance
2. Safety Guide
Ambil nafas dalam dan ulangi kembali langkah 5 dan 6 sampi kira-kira 10-15 kali dalam semenit.
Perhatikan dada korban sampai ia dapat bernafas tanpa bantuan, hentikan bantuan pernafasan.
8. If you fail to inflate his lungs through the nose, try the mouth, as follows:
Keep his head tilted well back. Lift the jaw and hold his mouth slightly open. Seal your lips
around his open mouth and press you cheek against his nostrils to stop air leakage. Blow
into his mouth to inflate his chest, allowing him to breathe out as in steps 6 and 7.
Jika proses pemompaan paru-paru melalui hidung korban mengalami kegagalan, cobalah melalui
mulutnya :
Angkat dan miringkan kepalanya, angkat rahang korban dan buka mulutnya perlahan dan tahan.
Katupkan mulut anda pada mulut korban, tekan hidung korban dengan pipi anda untuk mencegah
bocornya udara, tiupkan udara sampai dadanya mengembang dan biarkan udara dihembuskan
kembali seperti pada langkah 6-7.
Continue the treatment until the victim is breathing without assistance or until medical
assistance becomes available.
Lanjutkan perawatan sampai korban dapat bernafas tanpa bantuan atau sampai bantuan medis tiba.
NOTE: DO NOT GIVE LIQUIDS UNTIL THE VICTIMS IS COMPLETELY CONSCIOUS.

JANGAN MEMBERI CAIRAN / MINUMAN SAMPAI KORBAN SEPENUHNYA SADAR.
If, after 5 or 6 effective inflations of the victim’s lungs, there is:

¾ No improvement in the color of face and lips
¾ No construction of the dilated pupils of the eyes.
¾ No pulse to be felt in the neck or elsewhere:
Jika setelah 5 atau 6 kali pemompaan pada paru-paru korban, dan:
¾ Tidak ada perubahan pada warna kulit muka dan bibir korban
¾ Pupil mata korban tidak mengembang
¾ Tidak ada denyut nadi pada leher atau bagian tubuh lainnya.
Carry out External Cardiac Massage
Lakukan pijat pacu jantung pada korban
NOTE : if the victim is small child, the first aide’s mouth should cover and seal around
both the nose and mouth of the child. Take great care not to blow too hard. This
could result in damage to the victim’s lungs.
Jika korban kanak-kanak, mulut penolong harus dikatupkan menutupi mulut dan hidung
korban, lalu tiupkan udara secara perlahan, untuk mencegah kerusakan paru-paru
korban.
2.3. EXTERNAL CARDIAC MASSAGE
1. a) Lay the victim on his back on the ground or on some other firm surface.
Baringkan korban pada lantai atau permukaan rata lainnya.
b) Place the heel of one hand, with the other on top of it, on the lower part of the
sternum (breast bone), in the middle of the chest. See Note 1 below.
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7. Maintenance
2. Safety Guide
Letakan kedua tangan anda pada bagian bawah, ditengah rangka dada korban, dengan posisi
telapak tangan satu berada diatas punggung tangan yang lain. Lihat catatan 1 dibawah.
c) Apply firm pressure vertically downward, aided by the weight of the body, about 60
times a minute.
Lakukan pemijatan dengan menekan dada korban pada posisi lurus kebawah menggunakan
berat badan penolong, sekitar 60 kali permenit.
d) At the end of each pressure stroke, the hands are lifted slightly to allow full recoil of
the Victim’s chest.
Pada tiap akhir pemompaan, angkat tangan anda segera agar dada korban dapat segera
mengembang.
e) Sufficient pressure should be used to depress the sternum about an inch towards the
vertebral column (spine).
Tekanan yang cukup harus diberikan untuk menekan rongga dada kira-kira satu inchi ke arah
bawah (tulang belakang).
2. Artificial respiration must continue simultaneously with external cardiac massage at the rate
of about 5 compressions of the heart to once inflation of the lungs.
Bantuan pernafasan harus terus dilakukan bersamaan dengan pemijatan pacu jantung dengan
perbandingan 5 kali pijat pacu jantung korban untuk 1 kali pemompaan paru-paru melalui mulut
korban.
3. Massage should continue until the victim’s pulse is clearly felt and the color returns to
normal, or until medical assistance arrives.
Pemijatan harus terus dilakukan sampai denyut nadi teraba dan warna kulit korban menjadi normal
kembali, atau sampai bantuan medis tiba.
NOTES
1. Do not attempt cardiac massage if there is obvious damage to the victim’s chest
wall.
Jangan melakukan pemijatan apabila ternyata ada kerusakan pada rongga dada korban.
2. There is a real danger of damage to internal organs by the improper use of external
cardiac massage.
Ada kemungkinan bahaya kerusakan organ dalam korban akibat pemijatan yang tidak sesuai.
3. Particular care must be taken with infants and small children, with whom much less
pressure is required to depress the sternum than is the case with adults. In these
cases, the fingers should be used in preference to the palms of the hands.
Diperlukan Perawatan khusus terhadap bayi dan anak-anak, dimana mereka hanya
memerlukan sedikit tekanan dibandingkan perawatan terhadap orang dewasa. Dalam hal ini
penggunaan jari tangan lebih dianjurkan untuk pemijatan dibandingkan memakai telapak
tangan.
IMPORTANT
When normal breathing recommences, place the casualty in the recovery position.
Ketika korban mulai dapat bernafas dengan normal, letakkan korban dalam posisi penyembuhan.
2.4. CORRECT PROCEDURE FOR HANDLING ELECTROSTATIC SENSITIVE DEVICES
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7. Maintenance
2. Safety Guide
CAUTION
Printed circuit boards (PCB’s), which carry this symbol, can be damaged by Electrostatic
discharge and must be handled in accordance with this procedure.
PCB yang memiliki simbol di atas dapat rusak karena pelepasan listrik statis dan harus ditangani
sesuai dengan prosedur berikut.
New or spare PCB’s will arrive electrostatic protective packaging. Never remove the
boards from this packaging or from their place in the complete equipment assembly until you
are familiar with ALL the precautions given in this section.
Setiap PCB baru atau cadangan akan memiliki kemasan pelindung terhadap listrik statis. Jangan
pernah membuka atau melepas PCB dari kemasan lengkapnya sampai anda sepenuhnya memahami
paparan berikut.
The electrostatic protective packaging usually takes the form of a conductive antistatic
plastic bag. These bags are costly and should be kept for re-use.
Kemasan pelindung ini biasanya berupa kantung berbahan plastik anti statis. Kantung ini cukup
mahal dan harus disimpan agar dapat dipergunakan kembali.
When a PCB is to be removed from a complete equipment assembly it must be
immediately placed into electrostatic protective packaging.
PCB harus segera disimpan pada kemasan pelindungnya saat dilepas dari rakitan.
When a PCB is removed from its Electrostatic protective packaging, it must be
immediately placed and connected into the complete equipment assembly.
PCB harus segera dipasangkan pada rakitan saat dikeluarkan dari kemasan pelindungnya.
When a PCB is removed from its Electrostatic protective packaging and placed into the
complete equipment assembly, or visa versa, the following precautions must be taken :
Berikut adalah hal-hal yang harus diperhatikan Ketika PCB dikeluarkan dari kemasan pelindungnya
dan ditempatkan pada rakitan lengkap, atau sebaliknya :
1. Avoid using nylon clothing, particularly in dry frosty weather.
Hindari memakai pakaian berbahan dasar nilon, umumnya pakaian musin dingin.
2. Simultaneously touch the metal frame of the complete equipment assembly with one hand
and the conductive packaging with the other hand in order to discharge any potential
differences.
Usahakan satu tangan anda untuk terus memegang rangka besi dari rangkaian dan tangan lainnya
memegang kemasan pelindung untuk mengalirkan beda potensial yang mungkin terjadi.
3. Avoid any unnecessary handling of PCB’s.
Hindari penanganan yang tidak perlu terhadap PCB.
4. Wear a conductive wrist strap.
Kenakan pelindung pergelangan tangan.
2.5. WARNING - DANGEROUS VOLTAGE
The voltage of the mains, generator and control system is high enough to endanger life.
When the equipment is opened for inspection and testing, it will sometimes expose live parts.
work in live equipment is only to be undertaken by qualified personnel who are fully aware of
the risks involved and who have taken precautions to avoid direct contact with dangerous
voltages.
Ketika perlengkapan Tegangan induk listrik, generator dan sistem kendali kelistrikkan dibuka untuk
diperiksa dan diuji coba, hal tersebut dapat membahayakan bagi keselamatan anda, juga untuk bagian
kelistrikan yang terbuka dan menyala. Bekerja dengan perlengkapan dalam kondisi hidup seperti itu
hanya boleh dilakukan oleh tenaga ahli yang sepenuhnya mengerti resiko, bahaya dan cara menghindari
kontak langsung dengan tegangan listrik.
So far as is possible medium voltage equipment must be entirely disconnected and
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7. Maintenance
2. Safety Guide
isolated from the system before any repairs or maintenance is commenced and tests made to
prove that the relevant equipment is completely dead. Positive safeguards should be employed
to prevent the circuit from being inadvertently energized whilst work is in progress and a
danger warning notice should always be displayed in the vicinity of exposed live connections.
Sebisa mungkin, peralatan bertegangan menengah harus sepenuhnya terputus dan terisolasi dari
sistem sebelum dilakukannya proses perbaikan ataupun perawatan dan perlu dilakukan test untuk
memeriksa apakah peralatan tersebut telah benar-benar terputus arus listriknya. Pelindung kutub positif
harus dipergunakan untuk melindungi sirkuit dari ketidak hati-hatian yang mungkin terjadi selama
pekerjaan berlangsung, selain itu, tanda peringatan bahaya juga harus selalu terpasang disekitar koneksi
kelistrikan yang aktif.
WARNING!
Electricity can kill, must be very careful when handling.
Arus listrik dapat menyebabkan kematian, tangani dengan hati-hati.
2.6. CAUTION — NOISE
Prolonged exposure to the noise levels in the vicinity of a diesel generator may result in
hearing loss unless proper precautions are taken.
Beroperasi di dekat generator set untuk jangka waktu yang lama dengan tingkat kebisingan yang
tinggi akan menyebabkan hilangnya pendengaran kecuali tindakan pencegahan yang benar dilakukan.
The use of ear defenders by operating and maintenance personnel is therefore strongly
recommended.
Direkomendasikan bagi operator untuk memakai pelindung telinga selama mengoperasikan atau
memperbaiki genset dalam keadaan beroperasi.
WARNING!
The above sign show that ear protection must be worn when operating working around
an operating generating set
Simbol diatas menandakan perlunya pemakaian pelindung telinga selama bekerja di sekitar genset
yang sedang beroperasi.
2.7. CHEMICAL SAFETY
Fuels, oils, coolants, lubricants and battery electrolyte used in this generating set are
typical of the industry. However, they can be hazardous to personnel if not treated properly.
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7. Maintenance
2. Safety Guide
Bahan bakar, oli, coolant, cairan baterei, dan pelumasan lainnya yang dipergunakan pada genset
adalah bahan-bahan industri yang dapat membahayakan pemakai apabila tidak ditangani dengan benar.
2.8. FIRE AND EXPLOSION
Fuels and fumes with generating sets can be flammable and potentially explosive. Proper
care in handling these materials can dramatically limit the risk of fire or explosion.
Bahan bakar dan asap emisi genset sangat mudah terbakar dan dapat menimbulkan ledakan.
Penanganan yang benar dapat menghindari resiko akan terjadinya bahaya kebakaran atau ledakan.
WARNING!
Ensure the generating set room is properly ventilated.
Pastikan ruangan tempat genset berada memiliki saluran udara yang cukup.
Keep the room, the floor and the generating set clean. When spills of fuel, oil, battery
electrolyte or coolant occur, they should be cleaned up immediately.
Pastikan agar ruangan, lantai dan genset dalam kondisi bersih, ketika ada tumpahan solar, oli,
cairan baterei atau coolant, harus segera dibersihkan.
Never store flammable liquids near the engine.
Jangan pernah menyimpan cairan yang mudah terbakar di dekat mesin.
Do not smoke or allow sparks, flames or other sources of ignition around fuel or batteries.
Fuel vapors are explosive. Hydrogen gas generated by charging batteries is also explosive.
Jangan merokok, membiarkan percikan api atau sumber pengapian lainnya disekitar baterei. Uap
bahan bakar dapat menyebabkan ledakan. Gas hidrogen yang dihasilkan dari proses pengisian baterei
juga dapat menyebabkan ledakan.
Do not attempt to operate the generating set with any known leaks in the fuel sistem.
Jangan mengoperasikan genset apabila terjadi kebocoran pada sistem suplai bahan bakarnya.
Keep grounded conductive objects, such as tools, away from exposed live electrical parts,
such as terminals, to avoid arcing. Sparks and arcing might ignite fuel or vapors.
Jauhkan benda kerja yang menghantarkan arus listrik dari bagian kelistrikan yang terbuka, seperti
terminal, untuk menghindari percikan bunga api yang dapat memicu bahan bakar atau uapnya untuk
meledak.
2.9. MECHANICAL SAFETY
The generating set is designed with guards for protection from moving parts. Extra care
must always be taken to protect personnel and equipment from other mechanical hazards when
working around the generating set.
Genset telah di desain sedemikian rupa dengan pelindung pada bagian-bagian mekanisnya. Selama
beraktifitas disekitar genset, pastikan selalu untuk melindungi operator dan peralatan lainnya dari bahaya
mekanis bagian yang bergerak dari genset.
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7. Maintenance
2. Safety Guide
WARNING!
Do not attempt to operate the generating set with safety guards removed. While the
generating set is running do not attempt to reach under or around the guards to do
maintenance or for any other reason.
Jangan mencoba untuk mengoperasikan genset dengan kondisi alat pelindung tidak terpasang.
Selama genset beroperasi, jangan meraih ke bagian belakang atau sekitar pelindung, meski untuk
melakukan perbaikan atau melakukan hal lainnya.
Keep hands, arms, long hair, loose clothing and jeweler away from pulleys, belts and
other moving parts.
Jauhkan tangan, lengan, rambut terurai, pakaian yang longgar dan perhiasan dari puli, tali puli dan
benda bergerak lainnya.
Attention: Some moving parts cannot be seen clearly when not required to be open.
Perhatian: Beberapa benda mungkin tidak terlihat bergerak apabila dalam kondisi tidak terbuka.
Keep access doors on enclosures, if equipped, closed and locked when not required to
open.
Jika unit genset dilengkapi dengan pintu, pastikan pintu tertutup saat beroperasi. Tutup dan kunci
jika memang tidak diperlukan.
Avoid contact with hot oil and coolant, hot exhaust gases, hot surfaces and sharp edges
and corners.
Hindari kontak dengan bagian-bagian yang panas, seperti oli, gas emisi, permukaan panas lainnya
dan sudut-sudut yang tajam dari genset.
Do not remove the radiator filler cap until the coolant has cooled. Then loosen the cap
slowly to relieve any excess pressure before removing the cap completely.
Jangan membuka tutup radiator sampai coolant telah benar-benar dingin. Buka tutup radiator
dengan perlahan untuk melepaskan tekanan udara berlebih sebelum membuka sepenuhnya.
2.10. ELECTRICAL SAFETY
Safe and efficient operation of electrical equipment can be achieved only if the equipment
is correctly installed, operated and maintained.
Peralatan elektronik dapat beroperasi dengan efisien dan aman apabila terpasang, dioperasikan
dan dirawat dengan benar.
- 10 -
2. Safety Guide 7. Maintenance
3. Description
WARNING!
The generating set must be connected to the load only by trained and qualified
electricians who are authorized to do so, and in compliance with relevant Electrical Codes,
Standards and other regulations. Where required, their work should be inspected and accepted
by the inspection agency prior to operating the generating set.
Koneksi genset untuk pembebanan harus dilakukan oleh tenaga ahli terlatih berdasarkan standard
dan peraturan yang berlaku. Jika diperlukan, dilakukan pemeriksaan oleh lembaga pemeriksa terhadap
cara kerja pengoperasian genset.
Ensure the generating set; including a mobile set is effectively grounded / earthed in
accordance with all relevant regulations prior to operation.
Pastikan genset dan peralatan pengangkutnya telah dinetralkan ke bumi sesuai dengan peraturan
sebelum pengoperasian.
The generating set should be shutdown with the battery negative (-) terminal
disconnected prior to attempting to connect or disconnect load connections.
Pada saat mematikan genset, pastikan bahwa kutub negatif baterei yang terlebih dahulu
diputuskan, juga pada saat menghubungkan dan memutuskan koneksi pembebanan.
Do not attempt to connect or disconnect load connections while standing in water or on
wet or soggy ground.
Jangan menghubungkan atau memutuskan koneksi pembebanan saat genset sedang berada diatas
permukaan yang basah atau berair.
Do not touch electrically energized parts of the generating set and/or interconnecting
cables or conductors with any of the body or with any non-insulated conductive object
Jangan menyentuh bagian genset yang beraliran listrik atau menghubungkan kabel atau
penghantar lainnya ke body genset atau penghantar lainnya yang tidak terisolasi.
Replace the generating set terminal box cover as soon as connection or disconnection of
the load cables is complete. Do not operate the generating set without the cover securely in
place.
Pasangkan segera tutup terminal box setelah proses koneksi dan pemutusan koneksi kabel untuk
pembebanan selesai. Jangan mengoperasikan genset sebelum tutup terminal box telah benar-benar
terpasang.
Connect the generating set only to loads and/or electrical systems that are compatible
with its electrical characteristic and that are within its rated capacity.
Genset hanya boleh dihubungkan ke instalasi listrik atau proses pembebanan dengan karakteristik
dan kapasitas pembebanan yang sesuai.
Be sure all electrical power is disconnected from electrical equipment being serviced.
Pastikan bahwa semua sumber arus listrik telah terputus sebelum melakukan perbaikan.
Insulate all connections and disconnected wires.
Isolasi semua rangkaian kabel, baik yang terpasang maupun yang tidak terpasang.
3.1. GENERAL DESCRIPTION
This generating set has been designed as a complete package to provide superior
performance and reliability. Each generating set is provided with a Diesel Engine Generating
Rating Label, which generally affixed to the alternator housing or control panel. This label
contains Generator Model and S/No, Engine Model and S/No, Alternator Model and S/No,
weight, year of manufacturing, standby and prime in KW and KVA. Voltage, ampere, frequency
and phase are also given for reference. The model and serial numbers uniquely identify the
generating set and are needed when ordering spare parts or obtaining. Service or warranty
work for the set.
Genset telah di desain sedemikian rupa sebagai perangkat lengkap yang siap memberikan kinerja
- 11 -
7. Maintenance
3. Description
dan keandalan yang tinggi. Tiap genset memiliki label identifikasi sendiri dan biasanya terpasang pada
body alternator atau pada control panel. Tercantum di dalamnya model genset dan nomor seri, model
mesin dan nomor seri, model alternator dan nomor seri, berat unit, tahun pembuatan unit, daya standby
dan prime dalam satuan KW dan KVA. Sebagai acuan juga diberikan data mengenai Voltase, ampere,
frekuensi dan fase listrik dari unit. Model dan nomor seri yang berbeda untuk tiap unitnya diperlukan
sebagai identifikasi unit pada saat kita melakukan pemesanan suku cadang atau pada saat melakukan
garansi perbaikan.
The diesel engine powering the generating set has been selected to power the generating
set for its reliability and authentic performance. The engine is of the heavy-duty industrial type
with 4 strokes and is fitted with all accessories to provide a reliable power supply.
Mesin yang dipilih sebagai tenaga penggerak genset adalah mesin diesel yang telah dikenal karena
kinerja dan keandalannya. Mesin tersebut merupakan jenis mesin industri 4 tak yang telah dilengkapi
dengan perlengkapan tambahan agar dapat menghasilkan sumber tenaga yang andal.
The engine electrical system is negative ground/earth and either 24Volts DC depending
on the size of the set. This system includes an electric engine starter, battery and battery rack
which may also be located on the base skid, and battery-charging alternator. Most sets are
provided with lead-acid batteries.
Sistem kelistrikan pada mesin bersifat negatif, 24 Volt DC, tergantung besarnya unit genset.
Termasuk di dalamnya electric engine starter, baterei dan rak baterei yang biasanya terletak pada base
skid atau rangka penyangga dudukan mesin dan alternator, juga baterei-charging alternator. Sebagian
besar genset memakai baterei basah.
The engine cooling system is comprised of radiator, a high capacity pusher fan and a
thermostat. The alternator has its own internal fan to cool the alternator components. Note that
the air is “pushed” through the radiator so that the cooling air is drawn past the alternator, then
past the engine and finally the radiator.
Sistem pendingin pada mesin menggunakan radiator, kipas bertenaga pendorong tinggi dan
thermostat. Alternator memiliki kipas pendingin sendiri untuk mendinginkan suhu komponennya. Perlu
diketahui bahwa udara didorong melalui radiator, sehingga udara mengalir melewati alternator, lalu
mesin dan keluar melewati radiator.
The output electrical power is normally produced by a screen protected and drip-proof,
self-exciting, self-regulating, brush-less alternator fine-tuned to the output of this generating
set. Mounted on top of the alternator is a sheet steel terminal box.
Keluaran tenaga listrik genset dihasilkan oleh alternator yang memiliki kasa pelindung anti bocor,
dapat membangkitkan tenaga sendiri dan melakukan penyetelan sendiri, tanpa sikat penggerak sehingga
keluaran tenaga listrik yang dihasilkan genset cukup baik. Terpasang pada bagian atas alternator sebuah
terminal box.
The engine and alternator are coupled and mounted on a heavy-duty steel base frame.
Except for the largest sets, this base frame includes a fuel tank with a capacity of approximately
8 hours operation at full load. An extended capacity fuel tank of approximately 24 hours
operation may be fitted. Where a fuel tank is not provided with the base frame, a separate fuel
tank must be provided.
Mesin dan alternator terkopel bersama dan dipasangkan pada rangka penyangga besi yang kokoh.
Terkecuali pada unit genset yang lebih besar, biasanya dilengkapi tangki dengan kapasitas BBM untuk
dapat beroperasi sekitar 8 jam pada pembebanan penuh. Tangki dengan kapasitas tambahan agar dapat
beroperasi selama 24 jam juga dapat dipasangkan. Pada rangka penyangga yang tidak memiliki tangki,
tangki terpisah harus disediakan.
The generating set is fitted with vibration isolators, which are designed to reduce engine
vibration being transmitted to be the foundation on which the generating set is mounted. These
isolators are fitted between the engine/alternator feet and the base frame. Alternately, on
larger models the engine/alternator is rigidly mounted on the base frame and the vibration
isolators are supplied loose and to be fitted between the base frame and the foundation. An
exhaust silencer is provided loose for installation with the generating set. The silencer and
- 12 -
3. Description 7. Maintenance
4. Installation
exhaust systems reduce the noise emission from the engine and can direct exhaust gases to
safe outlets.
Genset telah dilengkapi dengan peredam getaran, yang di desain untuk mengurangi getaran mesin
yang merambat ke dudukan tempat mesin terpasang. Peredam ini terpasang antara kaki mesin atau
alternator dengan rangka penyangga, sebaliknya, pada unit genset yang lebih besar, biasanya kaki mesin
dan alternator terpasang langsung ke rangka penyangga dan peredam getaran dikirim sebagai barang
terpisah untuk dipasangkan antara rangka penyangga dan lantai. Saluran pembuangan emisi gas
disediakan terpisah pada unit genset. Silencer dan sistem pembuangan dipasang untuk mengurangi
tingkat emisi dan suara dari mesin dan langsung dialirkan keluar.
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.
Satu dari beberapa jenis sistem kontrol dan panel mungkin terpasang untuk mengendalikan
pengoperasian dan keluaran dari genset, juga untuk melindungi genset dari kemungkinan kegagalan
beroperasi.
To protect the alternator, a suitably rated circuit breaker selected for the generating set
model and output rating is supplied mounted in a steel enclosure. In some cases the output
circuit breaker may be incorporated in the automatic transfer system or control panel.
Untuk melindungi alternator, circuit breaker yang sesuai harus disertakan dan terpasang pada
rangka besi. Pada beberapa kondisi, circuit breaker mungkin terpasang bersama ATS atau juga control
panel.
4.1. INSTALLATION AND MOUNTING THE GENERATOR SET
Fig 1. Show typical installation when wind prevailing exhausts system.
Site installation for generator set
Most generator set installation has to be designed carefully and must function properly
under all anticipated operation conditions. The following are some general guide when locating
or installing of generator set.
Genset telah di desain untuk dapat dioperasikan dalam berbagai kondisi pengoperasian di
lapangan, berikut adalah beberapa panduan umum untuk proses penempatan atau pemasangan genset.
- 13 -
4. Installation
If an engine room layout drawing is provided, the plant should be positioned as shown,
otherwise, select an out-building in a position where a good supply of air available. The engine
and alternator need a good supply of air for cooling. The exhaust pipe must be vented outside
the building and in no circumstances should the exhaust gases be allowed to foul the engine
room air, which the engine (and personnel) breathes. The air inlet should be placed as far away
as possible form the exhaust gas and air outlets. Ensure that the exhaust gas and outlet air
cannot be drawn back into the engine through the air inlet.
Jika denah untuk penempatan mesin tersedia, mesin harus ditempatkan pada bangunan seperti
denah tersebut, atau jika tidak, pilihlah ruangan terbuka yang memiliki aliran udara yang cukup, karena
mesin dan alternator memerlukan suplai udara yang banyak untuk proses pendinginan. Saluran
pembuangan harus dialirkan keluar bangunan untuk mencegah gas buangan kembali ke ruangan mesin
dan terhisap oleh mesin atau operator. Saluran udara masuk harus terletak jauh dari saluran
pembuangan emisi gas dan pastikan agar gas pembuangan tidak mengalir kembali ke saluran masukan
udara.
4.2. FOUNDATION
The plant must be mounted on a perfectly level strong concrete bed block. The
importance of having a robust foundation cannot be over-emphasized. A poor foundation is
certain to cause unnecessary vibration of the plant.
Bangunan tempat unit genset berada harus memiliki lantai beton yang kokoh. Pondasi yang kokoh
adalah satu keharusan, karena jika tidak, getaran dari genset akan dengan mudah mengakibatkan
kerusakan pada bangunan.
The concrete should be made from the best possible mixtures — i.e. one part of best
cement, two parts of clean sharp sand, four parts of washed ballast or clean hard broken stones
not larger than 25mm. The length and width of the bed block should be 457mm larger than the
plant on all sides.
Beton harus dibuat dari bahan campuran yang sebaik mungkin, yaitu dengan perbandingan 1
bagian semen, 2 bagian pasir dan 4 bagian batu kerikil dengan ukuran tidak lebih dari 25mm. Panjang
dan lebar dari lantai beton harus lebih lebar 457mm dari ukuran tempat genset berada, dari segala sisi.
Caution
Make sure the concrete is completely set and hardened before tightening the bolts or
positioning the plant.
Pastikan bahwa lantai beton telah benar-benar selesai dikerjakan dan keras sebelum memasang
dan mengencangkan unit genset diatasnya.
Consult the General Arrangement drawing of the plant when anti-vibration mountings are
used, to ensure that the correct type are fitted and that they are positioned correctly under the
engine and alternators.
Konsultasikan proses pengaturan ruangan apabila genset yang akan dipasang menggunakan
peredam getaran, agar dapat dipastikan bahwa peredam getaran yang sesuai telah terpasang dengan
benar dibawah mesin dan alternator.
4.3. EXHAUST
The silencer should, if possible, be hung from the roof of the engine room and connected
to the engine exhaust manifold by a piece of flexible exhaust piping or bellows of the correct
diameter.
Jika memungkinkan, silencer harus tergantung pada atap ruangan mesin dan terhubung ke
manifold mesin dengan menggunakan pipa fleksibel yang berdiameter sesuai sebagai saluran
pembuangan.
- 14 -
4. Installation
Outlet
Roof
Engine
Exhaust Silencer is hang
Manifold from the roof
Fig 2. Silencer position
Fit a length of rigid pipe to the other end of the silencer to lead the exhaust gases out of
the building and ensure that the outlet is positioned so that rain cannot collect in the pipe.
Sesuaikan panjang pipa pada ujung silencer yang mengarahkan gas buangan mengalir ke luar
ruangan dan pastikan bahwa saluran pembuangan telah diposisikan sedemikian rupa sehingga pada saat
hujan, air tidak akan masuk dan menggenang dalam pipa.
A suitable exhaust silencer must be incorporated into the exhaust piping to reduce the
noise level from the engine.
Silencer yang sesuai harus terpasang pada pipa saluran pembuangan untuk mengurangi tingkat
kebisingan mesin.
In designing an exhaust system, the primary consideration is to not exceed the allowable
backpressure permitted by the manufacturer. Excessive backpressure seriously affects engine
output, durability and fuel consumption. To limit the backpressure the exhaust piping should be
as short as possible.
Dalam merancang saluran pembuangan, hal utama yang harus dipertimbangkan adalah bahwa
tekanan udara balik yang dihasilkan oleh sistem tidak melebihi batasan yang diperbolehkan pihak
pabrikan mesin. Tekanan balik berlebih dapat mempengaruhi tingkat keluaran tenaga dari mesin,
ketahanan dan konsumsi bahan bakar. Untuk membatasi tekanan balik tersebut, pipa saluran
pembuangan harus dibuat sependek mungkin.
WARNING!
Engine exhaust emissions are hazards to personnel.
Gas emisi yang dihasilkan mesin sangat berbahaya bagi operator.
The engine exhaust for all indoor generating sets must be piped outdoors via leak-free
piping in compliance with relevant Codes, Standards and other requirements.
Saluran gas pembuangan yang dihasilkan mesin pada genset harus dialirkan melalui pipa yang
tahan bocor sesuai dengan standard yang berlaku.
Ensure hot silencers, piping and turbochargers, if fitted, are clear of combustible material
and are guarded for personnel protection per safety requirements.
Pastikan bahwa bagian yang panas dari sistem pembuangan seperti silencer, pipa dan
turbocharger jauh dari bahan yang mudah terbakar dan memiliki pelindung panas demi keselamatan
operator.
Ensure that fumes from the exhaust outlet will not be a hazard.
Pastikan bahwa asap yang dihasilkan pipa keluaran tidak menimbulkan dampak yang berbahaya.
4.3.1. Other exhaust design criteria are as follow:

Hal lain yang harus diperhatikan dalam mendesain saluran pembuangan :
- 15 -
4. Installation
• Exhaust components including turbochargers can be very hot must be guarded where
they could be accidentally touched.
Komponen pada sistem pembuangan gas dapat menjadi sangat panas dan harus memiliki
pelindung karena dapat menyebabkan kecelakaan apabila tersentuh.
• 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.
Sambungan antara manifold mesin dan pipa pembuangan harus memakai sambungan fleksibel
untuk mencegah merambatnya getaran mesin ke pipa dan bangunan, juga untuk meredam pergeseran
posisi pipa dan untuk menyalurkan panas dari manifold.
• Ensure that the silencer and all pipes are well supported to limit strain on the
connectors, which could result in cracks or leaks.
Pastikan bahwa sambungan antara silencer dan pipa telah disangga dengan baik untuk
mencegah ketegangan yang dapat menyebabkan keretakan atau kebocoran pada sambungan pipa.
• Exhaust system components located within the generator room should be insulated to
reduce heat radiator and noise levels. Pipes and the silencer, whether located inside or outside
the building, should be located well clear of any combustible material.
Komponen dari sistem pembuangan yang terletak di dalam ruangan tempat genset berada harus
diisolasi untuk mengurangi radiasi panas dan tingkat kebisingan yang dihasilkan mesin. Pipa dan silencer,
baik itu yang terletak di dalam atau di luar ruangan, harus terbebas dari bahan-bahan yanng mudah
terbakar.
• Any long horizontal or vertical piping should slope away from the engine and include
drain traps at their lowest points to prevent water from reaching the engine or silencer.
Semua pipa yang terpasang pada posisi horizontal ataupun vertikal harus membentang jauh dari
mesin, juga saluran pembuangan air harus berada pada posisi yang lebih rendah untuk mencegah air
mengenai dasar mesin atau silencer.
• On generating sets of high rating, the silencer installation must include a purge plug for
venting of the event of difficult starting. The plug should be located adjacent to the exhaust
flange and positioned to allow access.
Plug pembersih harus terpasang pada silencer genset berdaya tinggi agar dapat melakukan
pembersihan apabila timbul masalah pada saat starting genset. Plug harus terletak dekat flens pipa
pembuangan dan mudah dijangkau.
• Where the pipe goes through a wall through there should be a sleeve in the opening to
absorb vibration and isolate combustible material from the pipes. There may also be an
expansion joint in the pipe to compensate for lengthwise thermal expansion or contraction.
Bantalan untuk meredam getaran dan mengisolasi pipa dari bahan yang mudah terbakar pada
lubang dinding tempat pipa saluran pembuangan keluar harus terpasang. Sambungan tambahan juga
dapat dipasangkan untuk meredam perambatan panas dan getaran dari pipa.
• The exhaust pipe must not be connected to exhausts from other generating sets or
other equipment, such as a furnace or boiler.
Pipa saluran pembuangan tidak boleh terhubung ke sistem pembuangan unit genset yang lain,
atau peralatan lain seperti furnace atau boiler.
• The outer end of the exhaust pipe, if horizontal, should be cut at 600 to the horizontal or
should be fitted with a rain hood or cap, if vertical, to prevent rain or snow from entering the
exhaust system.
Jika pipa pembuangan terentang pada posisi horizontal, ujung pipa harus dipotong dengan sudut
600. Tutup pelindung juga harus dipasang jika pipa terentang pada posisi vertikal, untuk mencegah
masuknya air hujan atau salju ke dalam pipa saluran pembuangan.
4.4. FUEL SYSTEM
The fuel system for the generating set must be capable of delivering a clean and
continuous supply of fuel to the engine. For most installations, this will include a small day tank
- 16 -
4. Installation
(usually incorporated in the base frame), a bulk storage tank and the associated pumps and
plumbing.
Sistem suplai bahan bakar pada genset harus dapat mengalirkan bahan bakar yang bersih secara
kontinyu ke mesin, dimana Genset pada umumnya memiliki tangki BBM (terpasang pada rangka
penyangga), tangki penimbun BBM, bersama pompa dan pipa.
WARNING!
For stationary generating sets with remote fuel storage systems, make sure such systems
are installed in compliance with relevant Codes, Standard or other requirements.
Pada genset yang diletakan permanen dan memiliki sistem penyimpanan BBM yang terpisah,
pastikan bahwa sistem yang ada telah sesuai dengan standard atau persyaratan lainnya.
Do not smoke or allow sparks, flames or other sources of ignition around fuel. Fuel and oil
vapor are explosive.
Jangan merokok, membiarkan percikan api atau sumber pengapian lainnya disekitar bahan bakar.
Uap bahan bakar oil dapat menyebabkan ledakan.
Day Tank: Day tanks provide a readily available supply of fuel directly to the generating
set and should therefore be located within the generator room. The steel base frame of all but
the largest sets are designed with a steel or polyethylene day tank built in with the engine fuel
lines connected. These “base tanks” provide for at least 8 hours operation at full load or
approximately 24 hours if an extended capacity base tank has been filled.
Tangki BBM: Tangki BBM menyediakan suplai BBM langsung ke genset, dan untuk itu tangki harus
diletakkan di dalam ruangan tempat genset berada, kebanyakan tangki berbahan dasar besi, tapi pada
genset yang lebih besar, tangki biasanya berbahan besi atau polyethylene dan terpasang berikut pipa
salurannya. Tangki tersebut dapat dipakai untuk mengoperasikan genset selama 8 jam pada
pembebanan penuh, juga dapat sampai 24 jam penoperasian apabila tangki tersebut telah diperbesar
kapasitasnya.
WARNING!
Never connect a remote fuel system to polyethylene fuel tanks incorporated in the base
frame on smaller generating sets.
Jangan menghubungkan sistem suplai BBM terpisah ke tangki BBM berbahan polyethylene yang
terpasang pada rangka penyanggga atau pada model genset yang lebih kecil.
Bulk Storage Tanks: For extended operation, a separate bulk storage tank is required.
Especially for standby generating sets it is not advisable to depend on regular delivery of fuel.
The emergency that requires use of the standby set may also interrupt the delivery of fuel.
Tangki penimbun BBM: untuk pengoperasian yang lebih lama, tangki penimbunan yang lebih besar
sangat diperlukan, terutama pada genset Standby, sangat tidak disarankan untuk hanya tergantung
kepada sistem supplai BBM yang telah ada. Dalam keadaan darurat yang memerlukan pengaktifan genset
standby. Suplai BBM mungkin terganggu.
The bulk tank should generally be located outside the building where it will be convenient
for refilling, cleaning and for inspection. It should not, however, be exposed to freezing weather
because fuel flow will be restricted as viscosity increases with cold temperatures. The tank may
be located either above or below ground.
Tangki penimbunan umumnya harus diletakkan di luar bangunan, hal itu untuk memudahkan
proses pengisian, pembersihan dan pemeriksaan. Akan tetapi, tangki juga tidak boleh dibiarkan terbuka
pada lingkungan yang dingin, karena hal tersebut dapat menyebabkan terhambatnya aliran BBM, seiring
dinginnya cuaca yang dapat mempengaruhi kekentalan cairan BBM. Tangki dapat diletakan diatas atau
dibawah permukaan tanah.
A vent must be installed on the bulk tank to relieve the air pressure created by filling the
tank or created by evaporation and expansion. It will also prevent a vacuum as the fuel is
- 17 -
4. Installation
consumed. The tank bottom should be rounded and placed on a 2° tilt to assure a concentrated
settling of water and sediment. A sludge drain valve should be installed at low point to allow
removal of water and sediment on regular basis. Underground tanks should have this water and
sediment pumped out regularly.
Tangki penimbunan harus memiliki lubang ventilasi agar dapat melepaskan tekanan udara yang
timbul saat pengisian BBM atau juga karena penguapan, hal tersebut juga dapat mencegah vakumnya
tangki selama proses suplai BBM. Dasar tangki harus melingkar dengan sudut kemiringan 20 untuk
memastikan agar air dan kotoran lainnya terkumpul mengendap dibawah. Kran pembuangan endapan
juga harus terpasang pada titik terendah tangki untuk memudahkan proses pembuangan endapan air
dan kotoran. Endapan tersebut harus dibuang secara rutin dari tangki.
Fuel Lines: The fuel lines can be of any fuel compatible material such as steel pipe or
flexible hoses that will tolerate environmental conditions.
Pipa saluran BBM: pipa saluran BBM dapat memakai pipa besi atau hose fleksibel yang dapat
dipakai pada berbagai kondisi.
WARNING!
Do not use galvanized pipe or fittings for the fuel system.
Jangan menggunakan pipa atau sambungan yang di galvanis pada saluran suplai BBM
Fuel delivery and return lines should be at least as large as fitting sizes on the engine,
and overflow piping should be one size larger. For longer runs of piping or low ambient
temperatures the size of these lines should be increased to ensure adequate flow. Flexible
piping should be used to connect to the engine to avoid damage or leaks caused by engine
vibration.
Ukuran pipa suplai dan return BBM dari tangki harus berukuran minimal sama dengan sambungan
pipa pada mesin, dan pipa salurannya harus satu ukuran lebih besar. Untuk pemakaian pada jangka
waktu yang lama atau pada temperature yang rendah, ukuran pipa saluran harus lebih besar lagi untuk
menjamin kelancaran pasokan BBM. Pipa fleksibel harus digunakan untuk menghindari kerusakan pada
pipa karena getaran mesin.
The fuel delivery line should pick up fuel from a point no lower than 50mm (2”) from the
bottom at the high end of the tank (away from the drain plug).
Posisi pipa pada saat menyedot BBM tidak boleh lebih rendah dari 50mm (2”) dari dasar tangki
(jauh dari lubang keran pembuangan).
Remote Fuel System: Most sets are supplied equipped with a diesel fuel tank in the Base
frame. Certain installations, however, require the addition of remote fuel supplies.
Sistem suplai BBM terpisah : kebanyakan unit genset telah dilengkapi dengan tangki BBM pada
rangka penyangganya, akan tetapi pada beberapa pemasangan genset, diperlukan tambahan berupa
sistem suplai aliran BBM yang terpisah.
4.5. FIRE PRECAUTIONS
When designing the generating set installation the following points should be considered:
Beberapa hal yang harus diperhatikan dalam proses instalasi genset sehubungan dengan
pengamanan terhadap bahaya api atau kebakaran :
• The room should be designed so that there is an easy escape route for operating personnel in
the event of fire within the room.
Denah ruangan harus dirancang dengan memiliki jalur pengamanan dan pintu darurat untuk operator
sebagai antisipasi terrjadinya kebakaran.
• Supply a class BC OR Class ABC fire extinguisher and/or fire extinguishing system.
Alat pemadam kebakaran kelas BC atau kelas ABC harus tersedia di ruangan.
• Gravity operated fire valves, released by temperature operated fusible links mounted above
the engine can be installed in the fuel lines.
- 18 -
4. Installation
Katup pengaman api yang beroperasi dengan gravitasi dan aktif karena temperatur operasi yang
terpasang bersama diatas mesin dapat dipasangkan pada saluran pipa bahan bakar.
4.6. STARTING BATTERIES
WARNING!
Do not smoke or allow sparks, flames or other sources of ignition around batteries.
Hydrogen gas generated by charging batteries is explosive.
Jangan merokok, membiarkan percikan api atau sumber pengapian lainnya disekitar baterei,
karena gas hidrogen yang dihasilkan selama proses pengisian ulang baterei dapat menyebabkan ledakan.
The starting batteries should be located as close as possible to the generating set while
being accessible for servicing. This will prevent electrical losses from long cables that could
affect the engine starting capability of the batteries.
Baterei starter harus diletakkan sedekat mungkin dengan genset dan memudahkan proses
perawatan. Hal ini akan mencegah hilangnya arus listrik karena pemakaian kabel yang panjang dan
mengakibatkan berkurangnya kemampuan baterei untuk menyalakan mesin.
4.7. ELECTRICAL CONNECTION
Onsite electrical installation will generally consist only of connecting the site load to the
generating set output terminals. Only fully qualified and experienced electrical technicians
should carry out electrical installation, service and repair work.
Instalasi kelistrikan dari unit genset di lokasi biasanya hanya menghubungkan kabel dari lokasi
pembebanan ke output terminal pada genset. Hanya teknisi berpengalaman dan memenuhi kualifikasi
yang diperbolehkan melakukan instalasi kelistrikan, perawatan dan proses perbaikan.
WARNING!
Make electrical connections in compliance with relevant Electrical Codes, Standards or
other requirements. This includes requirements about grounding and ground/earth faults.
Setiap koneksi kelistrikan yang dibuat harus sesuai dengan kode, standard electric yang berlaku
atau persyaratan lainnya. Termasuk persyaratan mengenai grounding.
4.7.1 Cabling: Due to movement of generating sets on their vibration mounts, the
electrical connection to the set should be made with flexible cable. This will prevent
transmission of vibrations and possible damage to the alternator or circuit breaker terminals. If
flexible cabling cannot be used throughout the installation then a link box should be installed
close to the set with a flexible connection to the set.
4.7.1.Kabel kelistrikan: karena genset akan menghasilkan getaran pada bantalan peredam
getarnya, koneksi kelistrikan harus menggunakan kabel yang fleksibel. Hal ini untuk mencegah
perambatan getaran yang kemungkinan dapat menyebabkan kerusakan pada alternator atau terminal
circuit breaker. Jika kabel yang fleksibel tidak dapat digunakan, maka kotak sambungan kabel harus
terpasang dekat dengan genset dengan sambungan fleksibel terpasang ke genset.
The cable should be protected by lay in a duct or cable tray. However, the duct or tray
should never be rigidly connected to the generating set. When bending cable, reference must
be made to the recommended minimum-bending radius.
Kabel harus dilindungi dengan memasangkannya pada cable duct atau cable tray. Meski begitu,
cable duct atau tray yang digunakan tidak boleh terpasang kaku ke generator set. Ketika membelokan
kabel, pastikan untuk mengacu kepada sudut minimum pembelokan yang dianjurkan.
The cable must be suitable for the output voltage of the generating set and the rated
current of the set. In determining the size, allowances should be made for ambient
temperature, method of installation, proximity of other cables, etc. When single core cables are
- 19 -
4. Installation
used the gland plates must be of non-ferrous material such as aluminum, brass or non-metallic
material such as tufnol. Alternatively, slots can be cut between gland holes of cables to prevent
circulating (eddy) currents in magnetic gland plates.
Kabel yang digunakan harus sesuai dengan output voltage dan rated current dari genset. Dalam
menentukan ukuran kabel, harus diberikan kelonggaran terhadap suhu lingkungan sekeliling, cara
pemasangan kabel, kedekatan posisi kabel dengan kabel lainnya, dll. Jika menggunakan kabel berinti
tunggal, gland yang dipergunakan harus berbahan non logam seperti aluminium, kuningan atau tufnol.
Sebagai kemungkinan lain, celah pada lubang kabel pada gland harus dipotong untuk mencegah
timbulnya perputaran arus ‘eddy current’ pada plat magnetic gland.
All connections should be carefully checked for integrity. Phase rotation must be checked
for compatibility with the installation. This is vitally important when connection is made to an
automatic transfer switch, or if the machine is to be paralleled.
Semua koneksi kabel harus diperiksa dengan baik. Fasa rotasi juga harus diperiksa kesesuainnya
dengan instalasi yang akan memakai genset. Hal ini sangat penting pada saat dibuat koneksi ke
automatic transfer switch atau pada saat mesin hendak dipasang secara pararel.
4.7.2 Protection: The cables connecting the generating set with the distributing system
are protected by means of a circuit breaker to automatically disconnect the set in case of
overload or short circuit.
4.7.2. Perlindungan: koneksi kabel antara genset dan sistem distribusinya harus dilindungi dalam
arti, koneksi terhadap circuit breaker harus diputuskan pada saat genset kelebihan beban atau terjadi
short circuit.
4.7.3 Loading: When planning the electrical distribution system it is important to ensure
that a balanced load is presented to the generating set. If loading on one phase is substantially
higher than the other phases it will cause overheating in the alternator windings, imbalance in
the phase-to-phase output voltage and possible damage to sensitive 3-phase equipment
connected to the system. Ensure that no individual phase current exceeds the current rating of
the generating set. For connection to an existing distribution system, it may be necessary to
reorganize the distribution system to ensure these loading factors are met.
4.7.3 Pembebanan: pada saat merencanakan pendistribusian beban dari sistem kelistrikan,
sangat penting untuk memastikan pembebanan yang seimbang pada genset. Jika pada pembebanan 1
fasa lebih tinggi dari fasa lainnya, hal tersebut akan menyebabkan kepanasan pada gulungan Alternator.
Keseimbangan pada tegangan output fase ke fase dan kemungkinan dapat merusak peralatan 3 fase
yang sensitif terpasang pada sistem. Pastikan bahwa tidak ada arus fase yang melebihi arus rata-rata
dari genset. Untuk koneksi pada sistem distribusi yang telah tersedia, perlu dilakukan penataan ulang
terhadap sistem distribusi tersebut untuk memastikan bahwa pembebanannya sesuai.
4.7.4 Power Factor: The power factor of the connected load should be determined. Power
factors below 0.8 lagging (inductive) can overload the generator. The set will provide its
kilowatt rating and operate satisfactorily from 0.8 lagging to unity power factor.
4.7.4. Power Factor: Power factor dari koneksi pembebanan harus diketahui, power factor dibawah
0.8 lagging dapat menyebabkan kelebihan beban pada genset. Genset disediakan dengan kilowatt rating
nya dan beroperasi memuaskan dari 0.8 lagging power factor nya.
Particular attention must be given to installations with automatic or manual 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 over voltages. Generally,
whenever the generating set is supplying the load any power factor correction equipment
should be switched off.
Perhatian khusus harus diberikan pada instalasi yang memiliki peralatan pengoreksi power factor
baik automatis maupun manual, seperti kapasitor, untuk memastikan bahwa perubahan pada power
factor tidak terjadi. hal ini dapat menyebabkan ketidakstabilan tegangan dan berakibat pada kerusakan
kelebihan tegangan. Umumnya, setiap kali genset mendapatkan pembebanan, segala peralatan
pengoreksi power factor harus dimatikan.
4.7.5 Grounding Requirements: Regulations vary for different locations. The frame of the
- 20 -
4. Installation
generating set must be positively 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. On the majority of self-contained sets, the ground connection is located inside the
circuit breaker box.
4.7.5 Kebutuhan akan grounding: peraturan mengenai hal ini berbeda-beda di tiap tempat. Rangka
dari genset harus terhubung dengan pasti ke bumi. Karena genset terpasang pada bantalan isolasi
getaran, koneksi ke bumi harus fleksibel untuk menghindari kerusakan akibat getaran yang dihasilkan.
Pada kebanyakan genset, koneksi untuk grounding terletak didalam boks circuit breaker.
Grounds connection cables or straps should have at least full load current carrying
capacity and meet applicable regulations.
Kabel untuk koneksi grounding harus dapat menampung arus kapasitas pembebanan penuh dan
sesuai dengan peraturan yang diterapkan berkenaan dengan hal tersebut.
4.7.6 Alternator Reconnection: Most alternators can be reconnected to suit different
output voltages. The reconnection procedures are given in the Alternator Manual. Ensure that
all other components such as circuit breakers, current transformers, cables and ammeters are
suitable before operating at a difficult voltage.
4.7.6 Koneksi ke Alternator: sebagian besar alternator dapat di koneksi ulang disesuaikan dengan
tegangan output yang berbeda. Prosedur koneksi ulang ini ada pada buku manual alternator. Pastikan
bahwa komponen lain seperti circuit breaker, transformator, kabel dan ammeter yang dipergunakan telah
sesuai sebelum dioperasikan pada tegangan yang berbeda.
4.7.7 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.
4.7.7. Pengoperasian pararel: perlengkapan tambahan harus dipasangkan pada genset standard
yang akan dioperasikan secara pararel dengan genset lain atau dengan pembangkit listrik utama.
4.7.8 Insulation Test before starting the generating set after installation, test the
insulation resistance of the windings. The Automatic Voltage Regulator (AVR) should be
disconnected and the rotating diodes either shorted out with temporary links or disconnected.
Any control wiring must also be disconnected.
4.7.8 Setelah proses instalasi, lakukan test insulasi sebelum mengoperasikan genset. Test tahanan
insulasi pada gulungan Alternator. AVR dan rotating diode harus diputuskan selama melakukan test
tersebut. Semua instalasi kabel kontrol juga harus diputuskan.
A 500V Megger or similar instrument should be used. Disconnect any earth conductor
connected between neutral and earth and megger an output terminal to earth. The insulation
resistance should be in excess of 5M to earth. Should the insulation resistance be less than 5M
the winding must be dried out. See the Alternator Manual for procedures.
Alat 500V megger atau peralatan sejenis lainnya harus dipergunakan untuk melakukan test
tersebut. Putuskan semua penghantar grounding yang terpasang antara kutub netral dan kutub
grounding dan lakukan test pada terminal output ke grounding. Tahanan insulasinya harus lebih besar
dari 5M terhadap kutub bumi, apabila tahanan insulasinya kurang dari 5M, gulungan harus dikeringkan,
lihat buku manual alternator mengenai prosedur pelaksanaannya.
4.8. ACOUSTIC SILENCING
Control of generating set noise is becoming very important in most installations. There is
a range of options available to control the noise level.
Pengendalian tingkat kebisingan dari genset menjadi sangat penting pada kebanyakan proses
instalasi. Terdapat beberapa pilihan untuk mengendalikan tingkat kebisingan suara.
WARNING!
Ear protection must be worn when operating or working around an operating generating
set.
Pelindung telinga harus dikenakan selama mengoperasikan atau bekerja disekitar genset.
- 21 -
4. Installation
4.8.1 Exhaust Silencers: the exhaust silencer will decrease sound levels from the engine.
Varying degrees of sound attenuation are available from different types of silencers. These
levels are often described by terms such as industrial, residential, critical or supercritical.
4.8.1 Exhaust silencer: Exhaust silencer akan mengurangi tingkat suara yang dihasilkan oleh
mesin. Beberapa tingkat peredaman suara dihasilkan dari jenis-jenis silencer yang berbeda. Tingkatan ini
biasa dijelaskan dengan istilah industrial, residential, critical atau supercritical.
4.8.2 Enclosures: Enclosures that is available in either weatherproof or sound attenuating
versions. These enclosures can be designed to meet a specific sound level requirement.
4.8.2 Perlengkapan tambahan: perlengkapan tambahan yang tersedia berupa perlengkapan tahan
cuaca atau peredam suara. Perlengkapan tambahan ini dapat didesain untuk disesuaikan dengan tingkat
suara yang dikehendaki.
4.8.3 Other Sound Attenuation: For installations in buildings there are other types of
equipment such as acoustic louvers, splitter vents and fan silencers, as well as sound absorbing
wall covering that can used to reduce the noise levels of generating sets.
4.8.3 Peralatan peredam suara lainnya: pada instalasi di dalam gedung, ada peralatan jenis lainnya
seperti acoustic louver, splitter vents dan fan silencer, termasuk lapisan penutup dinding yang menyerap
suara dapat dipergunakan untuk mengurangi tingkat kebisingan suara dari genset.
4.9. TOWING (Portable Generating Sets)
4.9.1 Preparing to tow: Inspect all components of the coupling equipment on the towing
vehicle and the generating set for defects such as excessive wear, corrosion, cracks, and bent
metal or loose bolts. Ensure that the towing vehicle is rated for towing a load of at least the
weight of the mobile generating set plus a 10% safety factor.
4.9.1 Persiapan sebelum menggandeng genset: periksa semua komponen dari peralatan
penghubung pada kendaraan penggandeng dan genset terhadap kemungkinan timbulnya kerusakan
seperti kerusakan akbiat pemakaian yang berlebihan, karat, retak, bengkok atau juga baut yang hilang.
Pastikan bahwa kendaraan penggandeng dapat menarik beban minimal seberat genset plus 10% untuk
faktor keamanan.
Couple the towing vehicle to the trailer and ensure the coupling device is engaged, closed
and locked. Attach electrical connector for indicator lights, etc. Attach chains, if provided, by
crossing them under the drawbar and attaching to the towing vehicle. Attach any “breakaway”
safety wire, if fitted.
Hubungkan kendaraan penggandeng ke trailer dan pastikan bahwa bagian penghubung terpasang
dan terkunci dengan baik. Pasangkan kabel koneksi untuk lampu indikator, dll. Pasangkan rantai, jika
tersedia, dengan menyilangkannya dibawah batang penarik dan pasangkan pada kendaraan
penggandeng. Pasangkan kawat pengaman, jika terpasang.
Fully retract the front screw jack, if equipped, and secure with the pin or locking device.
Lock the front castor wheel, if equipped, in the full up position. Ensure that rear stabilizer jacks,
if equipped, are raised and locked.
Tarik penuh sekrup pengangkat bagian depan, jika terpasang, dan amankan posisinya dengan pin
atau alat pengunci posisi. Kunci pengangkat roda depan, jika terpasang, pada posisi penuh ke atas.
Pastikan bahwa penyeimbang bagian belakang terangkat dan terkunci, jika memang terpasang.
Inspect the tires for condition and proper inflation. Check all taillights, if equipped, are
operating properly and that all reflectors are clean and functional.
Periksa kondisi ban dan tekanannya. Jika terpasang, periksa apakah lampu belakang beroperasi
dengnan semestinya dan semua reflector dalam kondis bersih dan berfungsi dengan baik.
Ensure load and grounding/earth cables are disconnected and that all windows, access
doors, and tool box covers are closed, latched and locked. Ensure any external fuel pipes are
disconnected. Release trailer-parking brakes, if equipped, and remove any blocks or chokes
under the wheels.
Pastikan bahwa kabel untuk pembebanan dan grounding telah diputuskan. Pastikan bahwa semua
- 22 -
4. Installation
jendela, pintu dan tutup tool box tertutup rapat dan terkunci. Pastikan bahwa semua pipa eksternal
saluran bahan bakar telah terputus. Lepaskan rem parkir trailer, jika terpasang dan pindahkan semua
balok penahan di bawah roda.
4.9.2 Towing: Whenever towing a mobile generating set, remember that the set may
approach or exceed the weight of the towing vehicle so maneuverability and stopping distance
will be affected.
4.9.2 Proses menggandeng: Ketika menggandeng mobile genset, harap diingat bahwa berat dari
genset dapat mendekati atau bahkan melebihi berat kendaraan penggandengnya, dan hal tersebut akan
berpengaruh pada saat melakukan gerakan dan menentukan jarak sebelum berhenti.
WARNING!
When towing a mobile generating set, observe all Codes, Standards or other regulations
and traffic laws. These include those regulations specifying required equipment and maximum
and minimum speeds.
Ketika menggandeng mobile genset, periksa semua standard dan peraturan yang berlaku dan juga
peraturan lalu lintas. Termasuk didalamnya peraturan yang mengatur tentang perlengkapan yang
diperlukan dan maksimum dan minimum kecepatan yang diperbolehkan.
Ensure brakes, if fitted, are in good order.

Pastikan rem yang terpasang dalam kondisi baik.
Do not permit personnel to ride in or 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
towing vehicle.
Operator dilarang untuk menaiki mobile genset. Operator dilarang untuk menaiki atau berdiri di
atas batang penghubung atau untuk berjalan di atas penghubung antara genset dan kendaraan
penggandeng.
Avoid gradients in excess of 15O (27%) and avoid potholes, rocks or other obstructions
and soft or unstable terrain.
Hindari permukaan yang curam melebihi 15O(27%) dan hindari lubang, bebatuan atau penghalang
lainnya dan juga permukaan yang lunak dan tidak stabil.
Ensure the area behind and under the mobile set is clear before reversing.
Pastikan bahwa areal dibelakang dan dibawah mobile genset bersih sebelum berputar arah.
4.9.3 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 15O (27%).
4.9.3 Parkir: parkirkan genset pada permukaan tanah yang kering dan rata yang dapat menopang
beban berat dari genset. Jika harus parkir pada daerah lereng, parkirkan melintang pada turunan untuk
mencegah terhadap kemungkinan terguling dan tergelincir ke bawah. Jangan memarkirkan genset pada
permukaan lereng lebih dari 15O(27%).
Set the parking brake and block or chock both sides of all wheels. Lower front screw jack,
castor wheel and/or rear stabilizer jacks, as fitted. Unhook chains, if equipped, from the towing
vehicle, disconnected electrical connection, disconnected the coupling device and move the
towing vehicle clear of the mobile generating set.
Pasangkan rem parkir dan pasangkan balok penahan pada kedua sisi semua ban. Turunkan sekrup
pengangkat bagian depan, pengangkat roda depan, penyeimbang bagian belakang, jika terpasang.
Lepaskan rantai pengikat, jika terpasang, dari kendaraan penggandeng, putuskan koneksi kabel lampu
indikator, putuskan alat penghubung dan gerakan kendaraan penggandeng menjauhi mobile genset.
- 23 -
4. Installation
4.10. STORAGE
Long-term storage can have detrimental effects on both the engine and alternator. This
can be minimized by properly preparing and storage the generating set.
Penyimpanan dalam jangka waktu yang lama dapat menimbulkan kerusakan pada mesin maupun
alternator, hal ini dapat dikurangi dengan melakukan persiapan penyimpanan yang tepat.
4.10.1 Engine Storage: The engine should be put through an engine “preservation”
procedure that includes cleaning the engine and replacing all the fluids with new or preserving
fluids. See the Engine Manual for the proper procedure.
4.10.1 Penyimpanan mesin: mesin harus disimpan melalui prosedur pemeliharaan yang meliputi
pembersihan dan penggantian semua cairan, baik itu pelumas ataupun pendingin dengan yang baru atau
berbahan pengawet. Lihat buku manual mesin untuk prosedur yang lebih tepat.
4.10.2 Alternator Storage: When an alternator is in storage, moisture tends to condense
in the windings. To minimize condensation, store the generating set in a dry storage area. If
possible use space heaters to keep the windings dry.
4.10.2 Penyimpanan alternator: pada saat alternator disimpan, uap udara akan mengembun pada
gulungan. Untuk mengurangi pengembunan, simpan genset pada lokasi yang kering, jika mungkin,
gunakan pemanas ruangan untuk menjaga gulungan tetap kering.
After removing the generating set from storage, perform an insulation check. If the
readings are lower than prior to storage, it may be necessary to dry out the windings. See the
Alternator Manual for procedures.
Setelah mengeluarkan genset dari lokasi penyimpanan, lakukan pemeriksaan insulasi. Jika
pembacaan pada alat test lebih rendah dari pada saat sebelum penyimpanan, bagian gulungan pada
alternator perlu dikeringkan. Lihat buku manual alternator untuk prosedur pengeringannya.
If the megger reads below 1 M after drying, the insulation has deteriorated and should be
reconditioned.
Jika pada pembacaan pada tes megger dibawah 1 M setelah pengeringan, berarti isolasinya telah
rusak dan perlu diperbaiki.
4.10.3 Battery Storage: While the battery is stored, it should receive refreshing charges
every 12 weeks (8 weeks in a tropical climate) up to a fully charged condition.
4.10.3 Penyimpanan Baterei: Baterei yang disimpan harus di charge setiap 12 minggu ( 8 minggu
pada iklim tropis) sampai terisi penuh.
- 24 -
5. Operation system
5.1. CONTROL SYSTEM
5.1.1. CONTROL SYSTEM DSC 521 Remote Start Modules
The Control Panel uses DSC 521 Remote Start Modules to monitor the generator system.
The control systems consist of the following items:
Kontrol panel menggunakan modul kendali start DSC 521 untuk memantau pengoperasian genset.
sistem pada kontrol panel terdiri dari :
1) Ammeter
2) Frequency meter
3) Voltmeter
4) DSC 521 Controllers
5) Ammeter Selector Switch
6) Hour run meter
7) Voltmeter Selector Switch
8) Alarm Acknowledge
9) Voltmeter Gauge
10) Buzzer
11) Emergency Stop
12) Spare
13) Oil Pressure Gauge
Applied in D9 engine
14) Water Temperature Gauge
15) EMS Lamp
16) Diagnosis Switch
Applied in D12, D16 EMS engine
17) Diagnosis Button
18) COO Lamp
- 25 -
5. Operation system
2 3 4
14
5
8
10 13
11
15 16 17 18 9 12
Fig 3. A typical Control Panel
5.1.1.1 CONTROL SYSTEM DESCRIPTION
The control systems consist of two major components working together a control panel
and a Modular Case Circuit Breaker (MCCB).
Sistem control pada genset terdiri dari 2 komponen utama yang bekerja bersama, yaitu kontrol
panel dan modular case circuit breaker (MCCB).
Control Panel
The control panel provides a means of starting and stopping the generator 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 coolant temperature.
Menyalakan dan mematikan genset dioperasikan dari Kontrol panel, memantau proses operasi dan
keluarannya, dan proses mematikan genset secara otomatis ketika kondisi kritis terjadi seperti rendahnya
tekanan oli atau tingginya suhu pendingin mesin.
- 26 -
5. Operation system
MCCB
The MCCB serves to protect the alternator by automatically disconnecting the load in the
event of overload or short circuit. It also provides a means of switching the generating set
output.
MCCB berfungsi untuk melindungi alternator dengan memutuskan pembebanan secara otomatis
manakala terjadi pembebanan berlebih atau short circuit. Juga sebagai kenop pemutus dan penghubung
output genset.
Panel equipment
Before starting or running the generating set, the operator should become fully
acquainted with the instruments and controls. The instruments should be observed from time to
time while the generating set is running so that any abnormal readings can be detected before
problems arise.
Sebelum mulai mengoperasikan genset, operator harus sepenuhnya mengerti mengenai instrumen
dan fungsi kendali yang ada pada kontrol panel. Instrumen tersebut harus terus diamati dari waktu ke
waktu selama genset beroperasi, sehingga setiap ada pembacaan yang tidak sesuai pada instrumen
kontrol panel dapat dideteksi sebelum menimbulkan masalah.
Fig 2 shows typical diagrams of each of the control panels. Addition of optional equipment
will add items to the panel so the panel fitted on the generating set may be slightly different
from the typical ones shown. The following descriptions explain the function of each item on
the panels:
Gambar 2 memperlihatkan diagram dari tiap bagian kontrol panel. penambahan dari peralatan
pilihan akan ditambahkan ke panel, sehingga panel yang terpasang pada genset akan terlihat berbeda
dari jenis kontrol panel yang sedang diperlihatkan. Berikut adalah uraian mengenai fungsi dari tiap
bagian dari kontrol panel:
1. Ammeter — An Ammeter that indicates the AC electrical current being delivered which is
dependant on the connected load. A separate reading from each of the phases is possible
using the ammeter selection switch (Item 5) if the meter gives no reading while the
generating set is running; ensure that the AC ammeter selector switch is not in the OFF
position.
1. Ammeter — Ammeter digunakan untuk mengindikasikan aliran arus listrik AC dari genset ke
pembebanan dan tergantung pada beban yang terhubung pada genset. Pembacaan amphere
terpisah dari tiap fase dimungkinkan dengan menggunakan kenop pilihan (item 5) jika ammeter
tidak menunjukkan pembacaan amphere saat genset beroperasi; pastikan bahwa kenop pilihan AC
ammeter tidak pada posisi OFF.
2. Frequency meter — A meter that indicates the output frequency of the generating set. The
engine maintains a relatively constant speed under governor control to provide the proper
operating frequency of 50 Hz or 60 Hz when the generating set is operating at full rated
load. At partial load, the frequency will be slightly higher than normal, depending on the
droop of the governor. In practice, no load frequencies of approximately 52 and 62 Hz for
50 Hz and 60 Hz respectively, are considered normal. The frequencies will fall, as the set is
loaded, to 50 Hz and 60 Hz at full load.
2. Frequency meter — Frekuensi meter digunakan unutk mengindikasikan frekuensi keluaran dari
genset. Mesin akan menjaga untuk dapat terus beroperasi pada kecepatan yang tetap di bawah
kendali engine governor untuk menyediakan frekuensi pengoperasian yang sesuai, yaitu 50Hz atau
60Hz ketika genset beroperasi pada pembebanan penuh. Pada pembebanan sebagian, frekuensi
- 27 -
5. Operation system
yang dihasilkan akan lebih besar dari kondisi normal, hal ini tergantung kondisi engine governor.
Pada prakteknya, frekuensi tanpa pembebanan kira-kira sebesar 52 Hz dan 62 Hz untuk 50 Hz dan
60Hz masing-masing, masih dianggap normal. Frekuensi akan turun saat genset dibebani, ke nilai 50
Hz dan 60 Hz saat pembebanan penuh.
3. Voltmeter — A voltmeter that indicates the AC voltage generated at the alternator output
terminals. The reading indicated on the voltmeter will vary depending on the connections
made inside the alternator terminal box, the setting of the voltage regulator and the
position of the voltmeter selector switch (Item 7). It should not, however, vary while the
set is operating. In the event of alternator excitation failing, the output voltage will fall to
approximately 20 to 40 volts. If the meter gives no reading while the generating set is
running, ensure that the AC voltmeter selector switch is not in the OFF position.
3. Voltmeter — Voltmeter dipergunakan untuk mengindikasikan tegangan AC yang dihasilkan terminal
output alternator. Voltase yang terbaca pada voltmeter akan berbeda tergantung pada koneksi yang
dibuat di dalam terminal boks alternator, penyetelan voltage regulator dan posisi kenop selector
pada voltmeter (item 7). Akan tetapi penunjukan nilai voltase tidak akan berubah-ubah saat genset
beroperasi. Pada saat eksitasi alternator mengalami kegagalan, voltase output yang dihasilkan akan
turun berkisar 20 sampai 40 volt. Jika voltmeter tidak menunjukkan pembacaan voltase pada saat
genset beroperasi, pastikan bahwa kenop selector tidak pada posisi OFF.
4. DSC 521 controller - The DSC 521 control the behavior of the generator set operational
function.
4. DSC 521 controller – DSC 521 berfungsi untuk mengontrol fungsi-fungsi pada pengoperasian dari
genset.
5. Ammeter Selector Switch — A selector switch allowing the operator to select a current
reading from each of the phases. The OFF position allows the ammeter “zero” position
to be checked while the generating set is running.
5. Ammeter Selector Switch – kenop selector ammeter memungkinkan operator untuk memilih
pembacaan arus listrik untuk tiap fasa. Posisi OFF memungkinkan posisi NOL ammeter untuk
diperiksa pada saat genset beroperasi.
6. Hour run meter — A meter that indicates the total number of hours of generating set
operation to aid in maintenance.
6. Hour run meter – mengindikasikan total waktu pengoperasian genset sampai saat memerlukan
pemeliharaan.
7. Voltmeter Selector Switch — A selector switch allowing the operator to select voltage
reading between phases or between a phase and neutral. The OFF position allows the
voltmeter “zero” position to be checked while the generating set is running.
7. Voltmeter Selector Switch – kenop selector voltmeter memungkinkan operator untuk memilih
pembacaan voltase antara tiap fasa ataupun antara fasa dengan kutub netral. Posisi OFF
memungkinkan posisi NOL voltmeter untuk diperiksa pada saat genset beroperasi.
8. Alarm acknowledge – In the case of fault occurs, the buzzer will give a siren. To cancel off
this siren, the alarm acknowledge is pressed. On the other hand, the controller will
continue to indicate the fault till necessary action has been taken.
8. Alarm acknowledge - Pada saat terjadi kesalahan, Buzzer akan memberikan sirine dan untuk
membatalkan sirine, tombol Alarm acknowledge harus ditekan. Sementara itu, controller akan
terus mengindikasikan kesalahan sampai telah diambil tindakan perbaikan terhadap kesalahan
tersebut.
- 28 -
5. Operation system
9. Voltmeter gauge — A voltmeter that indicates the state of charge of the battery. When the
engine is at standstill, the normal battery voltage will be 12 to 14 volts on 12-volt system
and 24 to 28 volts on a 24-volt system. During starting, the needle will drop to about 70%
of normal and oscillate as the engine cranks. Once the engine has started, the needle
should return to its normal value. If the battery-charging alternator is charging correctly,
the voltage reading will always be higher with the generating set running than when it is
stopped.
9. Voltmeter gauge – berfungsi untuk menunjukkan voltase dari baterei. Saat mesin tidak beroperasi,
voltase normal baterei berada pada 12 sampai 14 volt untuk baterei sistem 12 volt dan 24 sampai 28
volt untuk baterei sistem 24 volt. Saat mesin diengkol, jarum penunjuk akan menunjukan nilai
voltase 70% dari voltase normalnya dan terus bergerak saat mesin akan menyala. Jika baterei
charging alternator mengisi baterei dengan benar, pembacaan voltase akan selalu lebih besar pada
saat genset beroperasi dibandingkan saat genset tidak beroperasi.
10. Buzzer — A buzzer gives a continuous siren to alert the operator that there is a fault to
remedy.
10. Buzzer – Buzzer berfungsi untuk memberikan sirine untuk memperingatkan operator bahwa telah
terjadi masalah untuk segera ditangani.
11. Emergency stop — A red lock-down pushbutton that immediately shuts down the
generating set and will inhibit start until the pushbutton has been release by turning it
clockwise. The button normally placed in the right panel next to control panel
11. Emergency stop – tombol tekan berwarna merah yang akan segera menghentikan operasi genset
dan akan mencegahnya dari menyala kembali sampai tombolnya dilepas dengan memutarnya
searah jarum jam. Tombol ini biasanya terletak pada panel sebelah kanan control panel.
12. Spare - For future application requirement.

12. Spare – untuk keperluan aplikasi tambahan dimasa mendatang.
13. Oil pressure gauge — A gauge to monitor engine oil pressure from the moment the engine
is cranked. The proper oil pressure rating should be 3.5 to 5.5 bar on the gauge.
13. Oil pressure gauge – berfungsi untuk memantau tekanan oli pada mesin saat mesin diengkol.
Tekanan oil yang tepat ditunjukan pada 3.5 sampai 5.5 bar di oil pressure gauge.
14. Water temperature gauge — A temperature gauge connected to a sensor in the engine to
monitor engine coolant temperature.
14. Water temperature gauge – gauge ini terhubung ke sensor di mesin untuk memantau suhu
pendingin pada mesin.
15. EMS Lamp – Fault indicator for EMS.

15. EMS Lamp – lampu sinyal indikasi kesalahan untuk EMS.
16. Diagnosis Switch – This switch must be activated before we push the diagnosis button when
we want to read the fault code through EMS Lamp & COO Lamp
16. Diagnosis Switch – saklar ini harus diaktifkan sebelum kita menekan tombol diagnosis jika kita
hendak membaca kode kesalahan melalui lampu EMS dan lampu COO.
17. Diagnosis Button – This button must be push whittin 1 second to read the fault code
through EMS Lamp and COO Lamp.
17. Diagnosis Button – tombol ini harus ditekan selama 1 detik untuk membaca kode kesalahan melalui
lampu EMS dan lampu COO.
- 29 -
5. Operation system
18. COO Lamp – Fault indicator for coordinator.

18. COO Lamp – lampu sinyal indikasi kesalahan untuk coordinator.
5.1.1.2 DSC 521 CONTROL UNIT
The model 521 remote start modules has been designed for front panel mounting fixing is
by 2 springs loaded clip for easy assembly.
Modul remote start 521 telah di desain untuk dapat dipasangkan pada panel muka dengan hanya
menggunakan 2 klip pegas untuk kemudahan proses pemasangannya.
Mounted in a 90 x 90 mm panel cut-out Rear panel layout

terpasang pada potongan panel ukuran 90 x 90 mm Bagian belakang panel
5.1.1.3 ELECTRICAL CONNECTION
Connection to the 521 module are via plug and sockets

Koneksi ke modul 521 menggunakan plug dan soket.
The following describes the connections of the 521 module. See rear panel layout.
Berikut adalah uraian mengenai koneksi dari modul 521, lihat bagian belakang panel.
PLUG “A” 13 WAY

PIN NO DESCRIPTION
1 DC Plant supply input (-ve)
2 DC palnt supply input (+ve)
3 Emergency stop input
4 Fuel relay output
5 Start relay output
6 Auxiliary output relay 1
7 Auxiliary output relay 2
8 Charge fail input/ excitation output
9 Low oil pressure input
10 High engine temp input
11 Auxiliary input 1
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5. Operation system
13 Remote start input
PLUG “B” 10 WAY

PIN NO DESCRIPTION
14 Auxiliary input L1
15 Auxiliary input N
16 DO NOT USE
17 Auxiliary Output 3
18 Auxiliary Input 3
19 Auxiliary Input 4
20 Magnetic Pickup Input (+ve)
21 Magnetic Pickup Input (-ve)
22 Tachometer Output (+ve)
23 Tachometer Output (-ve)
5.1.1.4 OPERATION – AUTOMATIC OPERATION
The module is only activated when turning the selector switch to the AUTO position.
Modul ini hanya berfungsi pada saat tombol pilihan berada pada posisi AUTO.
When a Remote Start signal is applied to the remote start input, the following sequence is
initiated.
Pada saat sinyal remote start dipergunakan pada input remote start, tahap berikut ini akan mulai
berjalan.
The Remote Start Present LED Illuminates.
Lampu indikator remote start akan menyala.
A short delay will allow for false signals.
Akan terjadi penundaan untuk memberikan waktu terhadap sinyal kesalahan yang mungkin terjadi.
After a delay, Fuel Solenoid is energizes, the Start Motor is then engaged.
Setelah beberapa saat, fuel solenoid akan mulai menyala dan mengaktifkan start motor.
The engine is cranked for a pre-set time period and number of attemps. Should there be
fault, the Fail to Start Led will be flashing.
Mesin akan terengkol pada beberapa saat percobaan aktivasi, jika terjadi kesalahan, lampu sinyal
Fail to start akan menyala.
When the process goes smoothly, the start motor will be disengaged and the Safety On
timer is activated. It allows all the necessary auxiliary faults inputs to stabilize without triggering
the fault.
Jika proses berjalan lancar, motor starter akan terputus dan safety timer akan aktif, hal tersebut
akan memberikan waktu pada Auxiliary fault input untuk menstabilkan diri tanpa mengaktifkan sinyal
tanda kesalahan.
Once the engine is running, the Warm Up timer, if selected is initiated, allowing the engine
to stabilize before accepting the load.
Jika Warn up timer dipillih, pada saat mesin mulai menyala, maka timer akan mulai aktif untuk
memberi waktu pada mesin untuk menstabilkan diri sebelum mendapatkan beban.
On removal of the Remote Start signal, the Remote Stop delay timer is initiated, once it
times out the load transfer signal is de-energized, removing the load. The Cooling timer is the
initiated transfer shutting down. Once the cooling timer expires, the Fuel Solenoid is de-
energized, bringing the generator to a stop.
Pada saat melepaskan sinyal remote start, remote start delay timer akan menjadi aktif, dan pada
saat sinyal transfer pembebanan dipadamkan, memindahkan beban, cooling timer akan menjadi aktif
untuk melakukan transfer pemadaman. Saat cooling timer telah melampaui batas waktunya, fuel solenoid
- 31 -
5. Operation system
akan padam dan menghentikan generator.

Should the Remote Start signal be re-activated during the cooling down period, the set will
return on the load after the warming timer has expired.
Jika sinyal remote start harus diaktifkan kembali selama waktu pendinginan, set akan kembali ke
pembebanan setelah waktu pemanasan telah selesai.
5.1.1.5. OPERATION - MANUAL OPERATION

(Without using external start/stop push-button control)
The module is only activated when turning the selector switch to the Manual position.
Modul ini hanya akan aktif jika kita memutar tombol pilihan ke posisi manual.
If the pre-heat output option selected this timer is then intiated, and the auxiliary output
selected is energized.
Pada saat pilihan pre-heat output terpilih, maka timernya akan mulai aktif, maka auxiliary output
terpilih pun akan menyala.
After the delay, Fuel Solenoid is energizes, the Start Motor is then engaged.
Setelah beberapa saat, fuel solenoid akan mulai menyala dan mengaktifkan start motor.
The engine is cranked for a pre-set time period and number of attempts. Should there be
fault, Fail to Start LED will be flashing.
Mesin akan terengkol pada beberapa saat percobaan aktivasi, jika terjadi kesalahan, lampu sinyal
Fail to start akan menyala.
When the process goes smoothly, the start motor will be disengaged and the Safety On
timer is activated. It allows all the necessary auxiliary fault inputs to stabilize without triggering
the fault.
Jika proses berjalan lancar, motor starter akan terputus dan safety timer akan aktif, hal tersebut
akan memberikan waktu pada Auxiliary fault input untuk menstabilkan diri tanpa mengaktifkan sinyal
tanda kesalahan.
Once the engine is running, the Warm up timer, if selected is initiated, allowing the
engine to stabilize before it can be loaded.
Jika Warn up timer dipillih, pada saat mesin mulai menyala, maka timer akan mulai aktif untuk
memberi waktu pada mesin untuk menstabilkan diri sebelum mendapatkan beban.
The generator will run off load, unless a Remote start signal is applied, and if load
transfer has been selected as a control source, the appropriate auxiliary output selected will
active.
Generator akan beroperasi tanpa beban, kecuali jika sinyal remote start difungsikan dan jika
transfer beban telah dipilih sebagai pusat kendali, maka tambahan output pilihan yang sesuai akan
menjadi aktif.
If the remote start signal is removed, the generator will continue to run on load until the
selector switch is turned to auto. The remote stop delay timer will time out, the load is then
disconnected. The generator will then run off load allowing the engine a cooling down period.
Jika sinyal remote start dilepaskan, generator akan terus beroperasi dalam beban sampai tombol
pilihan di pindahkan ke fungsi auto. Timer penunda remote stop akan terlewati dan kemudian beban
akan terputus. Generator akan menurunkan beban dan memberikan waktu pada mesin untuk proses
pendinginan.
Turning the selector to stop de-energizes the fuel solenoid, bringing the generator to a
stop.
Pindahkan tombol pilihan untuk memadamkan fuel solenoid yang akan menghentikan generator.
5.1.1.6. OPERATION – MANUAL OPERATION

(With using external start/stop push-button control)
- 32 -
5. Operation system
If the module has been configured to use external start and stop pushbuttons the
normal ‘manual’ mode of operation is over-ridden.
Jika modul telah dipilih untuk menggunakan tombol start dan stop eksternal, maka fungsi operasi
manual dari modul tidak berlaku.
5.1.1.7. PROTECTIONS
The Led’s will indicate the fault condition and one of the auxiliary outputs if selected to
be a common alarm output, will activate. First up fault is indicated by flashing Led, subsequent
faults which happen simultaneously are indicated by a steady Led, Warnings are also indicated
by a steady Led. Indications are fed directly from the appropriate input and are indicated by a
steady Led, which will be present for as long as the input is active, this feature can be used to
allow the module to operate as an annouciator.
Lampu indikator akan mengindikasikan kondisi terjadinya kesalahan dan juga jika satu dari
beberapa output tambahan yang terpilih sebagai output alarm, akan aktif. Pertama kali terjadi kesalahan
ditandai dengan kilasan lampu indikator, kesalahan berikutnya yang terjadi berkelanjutan ditandai
dengan lampu indikator yang menyala terus, peringatan juga ditandai dengan lampu indikator yang
menyala terus. Indikasi dari kesalahan yang terjadi di berikan langsung dari input yang sesuai dan
ditandai dengan lampu indikator yang menyala pula dan akan terus menyala selama inputnya masih aktif,
dengan fungsi ini, modul dapat berfungsi sebagai pemberitahu kondisi kepada pemakai.
5.1.1.8. WARNING
Warning is self re-setting; once the fault has been removed the input is reset.
Tanda peringatan berikut dapat kembali ke kondisi semula, sesaat setelah kesalahan tersebut
diperbaiki.
Charge fail, if charge alternator voltage fails below the pre-set trip voltage after the end
of safety on timer. The charge fail Led is illuminated.
Charge fail, jika pengisian voltase alternator mengalami kegagalan sebelum melewati voltase
setelan awal setelah safety timer menyala, maka lampu indikator charge fail akan menyala.
Auxiliary inputs, if an auxiliary input has been configured as a warning the appropriate
Led will illuminate.
Input tambahan, jika input tambahan telah dikonfigurasikan sebagai penanda peringatan, lampu
indikator yang sesuai dengan fungsi peringatan tersebut akan menyala.
Oil pressure switch, the 521 will only attemps to crank the engine if the oil pressure is
initially low, (engine at rest, no running). There is also possibility that the oil pressure is faulty if
engine not running. The common alarm Led will illuminate.
Tombol pengontrol tekanan oli, modul 521 hanya akan mencoba untuk mengengkol mesin jika
tekanan oli mesin pada kondisi rendah (mesin dalam kondisi diam, tidak beroperasi). Akan tetapi ada
juga kemungkinan bahawa tekanan oli mengalami kesalahan pada saat mesin tidak beroperasi. lampu
indikator yang sesuai dengan fungsi kesalahan tersebut akan menyala.
5.1.1.9. SHUTDOWNS
Shutdowns are latching and stop the Generator. The selector switch must be turned to
Stop Reset and the fault removed to reset the module.
Shutdown berarti menghentikan operasi genset, saklar pemilih harus dipindahkan ke posisi Stop
dan mengembalikan modul dari kegagalan operasi ke kondisi semula.
Emergency Stop, removal of the +ve DC Supply from Emergency Stop input initiates the
following sequence, firstly it will initiate a controlled shutdown of the Generator and prevent
any attempt to restart the Generator until the Emergency Stop push-button has been reset:
- 33 -
5. Operation system
Secondly it removes the +ve DC supply from both the Fuel Solenoid and Starter Solenoid. This
input is always active when AUTO or MANUAL is selected.
Emergency stop, akan melepaskan kutub +ve suplai arus DC dari Emergency stop input yang
membangkitkan beberapa urutan proses berikut, pertama-tama akan mengendalikan pemadaman genset
dan mencegah segala bentuk percobaan menyalakan genset kembali sampai tombol tersebut telah
dikembalikan ke posisi semula, kemudian akan memutuskan +ve suplai arus DC dari fuel solenoid dan
starter solenoid. Input fungsi ini akan selalu aktif saat genset dalam fungsi Auto dan juga Manual.
Low Oil Pressure, activation of the Low oil Pressure input after the Safety On timer has
expired, initiates a shutdown. The Low Oil Pressure LED will flash.
Low oil pressure, aktivasi input tekanan oli terlalu rendah setelah waktu pada timer lewat dan
menyebabkan pemadaman mesin. Lampu indikator tanda tekanan oli rendah akan menyala.
High Engine Temperature, activation of the High Engine Temperature input after the
Safety On timer has expired, initiates a shutdown. The High Engine Temperature LED will flash.
High engine temperature, aktivasi input suhu mesin terlalu tinggi setelah waktu pada timer lewat
dan menyebabkan pemadaman mesin. Lampu indikator tanda suhu mesin tinggi akan menyala.
Over speed, if the engine speed exceeds the pre-set trip a shutdown is initiated. The Over
speed LED will flash. Over speed is not delayed, it is an immediate shutdown.
Over speed, saat kecepatan mesin menjadi berlebih, hal ini akan menyebabkan pemadaman
mesin, dan lapu indikator tanda kecepatan mesin berlebih akan menyala. Over speed tidak mengalami
penundaan dan akan langsung menyebabkan terjadinya pemadaman mesin.
Fail To Start, if the engine fails to fire after the pre-set number of attempts to crank, the
start sequence is terminated. The Fail to Start LED will flash.
Fail to start, jika mesin gagal menyala setelah beberapa kali percobaan mengengkol mesin,
tahapan proses starter akan terhenti dan lampu indikator kegagalan start akan menyala.
Fail to Stop, if the generator fails to stop after the pre-set time, the Common Alarm LED
will flash. Two conditions must be met to signal that the generator has stopped, Oil Pressure
has gone low, and that no speed is sensed from either Magnetic Pickup or Alternator speed
sensing sources.
Fail to stop, jika genset gagal stop beroperasi setelah beberapa selang waktu, lampu indikator
Common Alarm akan menyala. Dua kondisi berikut mengindikasikan bahwa genset telah padam, yaitu
tekanan oli pada mesin telah rendah dan tidak ada kecepatan terdeteksi baik itu pada Magnetic pickup
ataupun pada sensor pendeteksi kecepatan pada alternator.
Under speed, if the engine speed falls below the pre-set trip after the Safety On timer has
expired a shutdown is initiated: The Common Alarm LED will flash.
Under speed, jika kecepatan mesin menjadi sangat rendah setelah selang waktu pada timer lewat,
hal ini akan menyebabkan mesin padam dan lampu indikator Common Alarm akan menyala.
Sensor Fail, if the speed-sensing signal is lost during cranking, the Generator will
shutdown and the Common Alarm LED will flash.
Sensor fail, jika sensor kecepatan mesin hilang selama proses mengengkol mesin, genset akan
melakukan pemadaman dan lampu indikator Common alarm akan menyala.
- 34 -
5. Operation system
5.1.2. CONTROL SYSTEM EasYgen 320 Woodward
4
2
3
6
Fig 4. typical control panel for D9 engine with woodward controller.
7
1
8
9
10
2
12
11
4
3
6
Fig 5. typical control panel for D12, D16 EMS engine with woodward controller.
- 35 -
5. Operation system
1. EasYgen 320 controller

2. Ammeter
3. Ammeter selector switch
4. Spare
5. Buzzer
6. Emergency button
7. Oil pressure gauge Applied in D9 engine
8. Water temperature gauge
9. EMS lamp
10. Coordinator lamp Applied in D12, D16 EMS engine
11. Diagnosis button
12. Diagnosis switch
1. Easygen 320 controller - The easYgen 320 control the behavior of the generator set
operational function.
1. EasYgen 320 controller – easYgen 320 berfungsi untuk mengontrol fungsi-fungsi pada
pengoperasian dari genset.
2. Ammeter — An Ammeter that indicates the AC electrical current being delivered which is
dependant on the connected load. A separate reading from each of the phases is possible
using the ammeter selection switch (Item 3) if the meter gives no reading while the
generating set is running; ensure that the AC ammeter selector switch is not in the OFF
position.
2. Ammeter — Ammeter digunakan untuk mengindikasikan aliran arus listrik AC dari genset ke
pembebanan dan tergantung pada beban yang terhubung pada genset. Pembacaan amphere
terpisah dari tiap fase dimungkinkan dengan menggunakan kenop pilihan (item 5) jika ammeter
tidak menunjukkan pembacaan amphere saat genset beroperasi; pastikan bahwa kenop pilihan AC
ammeter tidak pada posisi OFF.
3. Ammeter Selector Switch — A selector switch allowing the operator to select a current
reading from each of the phases. The OFF position allows the ammeter “zero” position
to be checked while the generating set is running.
3. Ammeter Selector Switch – kenop selector ammeter memungkinkan operator untuk memilih
pembacaan arus listrik untuk tiap fasa. Posisi OFF memungkinkan posisi NOL ammeter untuk
diperiksa pada saat genset beroperasi.
4. Spare - For future application requirement.

4. Spare – untuk keperluan aplikasi tambahan dimasa mendatang.
5. Buzzer — A buzzer gives a continuous siren to alert the operator that there is a fault to
remedy.
5. Buzzer – Buzzer berfungsi untuk memberikan sirine untuk memperingatkan operator bahwa telah
terjadi masalah untuk segera ditangani.
6. Emergency stop — A red lock-down pushbutton that immediately shuts down the
generating set and will inhibit start until the pushbutton has been release by turning it
clockwise. The button normally placed in the right panel next to control panel
6. Emergency stop – tombol tekan berwarna merah yang akan segera menghentikan operasi genset
dan akan mencegahnya dari menyala kembali sampai tombolnya dilepas dengan memutarnya
searah jarum jam. Tombol ini biasanya terletak pada panel sebelah kanan control panel.
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5. Operation system
7. Oil pressure gauge — A gauge to monitor engine oil pressure from the moment the engine
is cranked. The proper oil pressure rating should be 3.5 to 5.5 bar on the gauge.
7. Oil pressure gauge – berfungsi untuk memantau tekanan oli pada mesin saat mesin diengkol.
Tekanan oil yang tepat ditunjukan pada 3.5 sampai 5.5 bar di oil pressure gauge.
8. Water temperature gauge — A temperature gauge connected to a sensor in the engine to

monitor engine coolant temperature.
8. Water temperature gauge – gauge ini terhubung ke sensor di mesin untuk memantau suhu pendingin
pada mesin.
9. EMS Lamp – Fault indicator for EMS.

9. EMS Lamp – lampu sinyal indikasi kesalahan untuk EMS.
10. COO Lamp – Fault indicator for coordinator.

10. COO Lamp – lampu sinyal indikasi kesalahan untuk coordinator.
11. Diagnosis Button – This button must be push whittin 1 second to read the fault code
through EMS Lamp and COO Lamp.
11. Diagnosis Button – tombol ini harus ditekan selama 1 detik untuk membaca kode kesalahan melalui
lampu EMS dan lampu COO.
12. Diagnosis Switch – This switch must be activated before we push the diagnosis button when
we want to read the fault code through EMS Lamp & COO Lamp
12. Diagnosis Switch – saklar ini harus diaktifkan sebelum kita menekan tombol diagnosis jika kita
hendak membaca kode kesalahan melalui lampu EMS dan lampu COO.
Fig 6. EasYgen 300 back view – terminal arrangement
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5. Operation system
Fig 7. Wiring diagram – easYgen320X
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5. Operation system
Operation and Navigation
Fig 8. Illustrates the front panel/displays, which include push-buttons.
This push-button Is always enabled and will stop the engine when pressed
Tombol ini akan selalu berfungsi dan akan menghentikan mesin jika ditekan
Push-buttons – the push buttons of the front panel are assigned to fixed of the
unit
Tombol tekan – tombol yang terdapat pada bagian depan panel yang berfungsi untuk
mengatur pengoperasian unit.
LEDs – The LEDs indicate operating states of the unit and alarm messages. The
right LED indicates that messages are present in the unit.
LEDs – LEDs mengindikasikan kondisi pengoperasian dari unit dan pesan dari alarm yang
ada. LED yang menyala menandakan pesan dari kondisi yang sedang terjadi pada unit
7 segment LED display – This alphanumerical display is used to display all

measured values, operating parameters, and alarm messages.
7 segment LED display – display alphanumerical ini dipergunakan untuk menampilkan
semua nilai hasil pengukuran, parameter pengoperasian, dan pesan darurat.
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5. Operation system
Operartion and display
Purpose of the Status LEDs
The easYgen has several status LEDs to indicate the operating state. The LEDs indicate the
following conditions:
EasYgen memiliki beberapa status dari LEDs yang mengindikasikan kondisi pengoperasian. LEDs tersebut
mengindikasikan kondisi berikut:
LED 9 : Mains voltage present (only easYgen 350 and 350X)

Keberadaan tegangan induk (hanya pada easYgen 350 dan 350X)
LED 10 : Mains circuit breaker (MCB) closed (only easYgen 350 and 350X)
Circuit breaker induk (MCB) terputus (hanya pada easYgen 350 dan 350X)
LED 11 : Generator circuit breaker (GCB) closed
Circuit breaker generator (GCB) terputus/tidak terhubung.
LED 12 (on) : Generator in operation
Generator sedang beroperasi.
LED 12 (flashing) : Generator voltage and/or frequency are not within the breaker closure limit
Voltase dan atau frekuensi generator tidak dalam batas breaker.
LED 13 (on) : Engine in operation
Mesin sedang beroperasi.
LED 13 (flashing) : Engine in operation, but engine monitoring delay time not yet expired
Mesin sedang beroperasi,tetapi pemantau waktu tunda mesin belum selesai.
LED 14 : Alarm message present
Keberadaan pesan darurat
LED 15 : Genset in automatic operation
Genset dalam sistem pengoperasian secara otomatis
LED 16 : Genset in manual operation
Genset dalam sistem pengoperasian secara manual
LED 17 : Genset stopped
Genset berhenti.
A function test of all LEDs and the seven-segment display may be conducted by pressing the
and button simultaneously.
Test fungsi dari semua LEDs dan display harus dilakukan dengan menekan tombol dan
bersamaan.
Operating the easYgen
¾ When the easYgen control unit is powered up and the genset is not operating, 17 LED is
illuminated and the MCB is closed (only easYgen 350 and 350X).
Ketika easYgen control unit dihidupkan dan genset dalam keadaan tidak beroperasi, 17 LED akan
menyala dan MCB terputus (hanya pada easYgen 350 dan 350X)
¾ The control unit may be started in automatic mode or have the operation mode changed
from automatic to manual by pressing the auto-manual button . LED 15 (automatic)
or LED 16 (manual) will indicate the current mode of operation by the corresponding LED
being illuminated.
Control unit dapat menyala secara otomatis atau dapat dirubah dari model pengoperasian otomatis
ke manual dengan menekan tombol auto-manual . LED 15 (otomatis) atau LED 16 (manual)
akan mengindikasikan model pengoperasian yang sedang beroperasi dengan memperhatikan LED
yang sedang menyala pada saat tersebut.
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5. Operation system
¾ The breaker control button enable the operator to open or close the circuit breaker(s)
depending on the current state of the breaker and the control unit being in manual
operation mode. This button is disabled in automatic operation mode.
Tombol kontrol breaker memungkinkan operator untuk menghubungkan dan memutuskan
circuit breaker tergantung kondisi breaker dan control unit ketika model pengoperasian manual
dijalankan. Tombol ini tidak berfungsi pada saat pengoperasian secara otomatis.
¾ The start/stop engine button will start and stop the engine when the control unit is in
manual operation mode. This button is disabled when the control unit is in automatic
operation mode.
Tombol start/stop mesin akan menyalakan dan mematikan mesin ketika control unit berada
pada model operasi manual. Tombol ini tidak berfungsi pada saat control unit pada model operasi
otomatis.
¾ The stop button is always enabled and when pressed while in the automatic mode
will shut the engine down after the configured cool down period has expired. Pressing this
button twice will shutdown the genset immediately.
Tombol stop akan selalu berfungsi dan pada saat ditekan ketika berada pada model operasi
otomatis, ini akan menghentikan mesin setelah melewati waktu pendinginan. Menekan tombol ini
dua kali akan menghentikan mesin dengan cepat.
¾ Active alarm messages may be acknowledge with the alarm button . Alarm conditions
are indicated when LED 14 is illuminated.
Pesan alarm yang sedang terjadi pada unit dapat diketahui dengan menekan tombol alarm .
kondisi alarm ditandai dengan menyalanya LED 14 .
¾ When the easYgen is in normal operation, the operator may view the monitored parameters
by using the scroll button. the monitored values will be displayed on the 7-segment
display 14 .
ket
ketika easYgen beroperasi secara normal, operator dapat melihat parameter-parameter yang dipantau
dengan menggerakan tombol scroll. Nilai-nilai yang terpantau akan ditampilkan pada layar 14
Acknowledging Alarm Messages
LED 14 will flash when an alarm is active. The alarm message will be displayed in the 7-segment
display 18 . pressing the alarm button will acknowledge the alarm, reset the alarm relay
(if relay is configured for alarm input), and the LED will change from flashing to continuously
illuminated. If more than one fault condition is present, the operator may display these
messages by pressing the scroll button . The alarm may be deleted by pressing and
holding the alarm button a second time until the LED 14 is no longer illuminated. If the
fault condition is still present, the LED 14 will remain illuminated and the unit stays in a locked
mode according to the appropriate alarm condition.
LED 14 akan berkedip ketika alarm aktif. Pesan alarm akan ditampilkan pada display 18 . Tekan tombol
alarm untuk mengetahui alarm yang terjadi tersebut, set ulang alarm relay (jika relay tersusun
sebagai input alarm), dan LED akan berubah dari berkedip terus menjadi menyala. Jika terdapat lebih
dari satu kondisi kesalahan, operator dapat menampilkan semua pesan-pesannya dengan menekan
tombol scroll .alarm dapat dihentikan dengan menekan dan menahan tombol alarm
14 beberapa detik sampai LED 14 tidak lagi menyala.
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5. Operation system
Configuring the easYgen
To enter the configuration mode, press the scroll and alarm buttons simultaneously.
Pressing the scroll button will display the various parameters that may be changed. The
displayed values for the parameters may be changed by pressing and buttons. If
the operator presses and holds these buttons, the rate of change for the value will increase.
After the parameter has been adjusted to the desired value, enter it into the control unit by
pressing the scroll button once. After a parameter has been changed and enetered into
the control unit, the operator may advance to the next parameters by pressing the scroll button
a second time. To exit the configuration mode, press the scroll and alarm
Buttons simultaneously again.
Untuk masuk ke dalam mode konfigurasi, tekan tombol scroll dan alarm bersamaan.
Dengan menekan tombol scroll akan tertampilkan berbagai parameter yang dapat dirubah-rubah.
Nilai yang ditampilkan dapat dirubah dengan menekan tombol dan . Jika operator
menekan dan menahan tombol tersebut, rating perubahan dari nilai tersebut akan bertambah, dan
setelah parameter telah disesuaikan dengan nilai yang dikehendaki, masukan ke dalam control unit
dengan menekan tombol scroll sekali. Setelah parameter dirubah dan dimasukan ke dalam
control unit, operator dapat beranjak ke parameter berikutnya dengan menekan tombol scroll
satu kali. Untuk keluar dari mode konfigurasi, tekan tombol scroll dan alarm
bersamaan sekali lagi.
Display of the operating value
The easYgen-300 series control units are able to display various measured values during
operation depending the respective easYgen model. You may advance trough the single value
display using the scroll button .
The values are displayed numerically, while the engineering unit, source, and phase are coded
in the seven-segment display if applicable. See the example below:
Control unit seri easYgen-300 dapat menampilkan berbagai nilai pengukuran selama pengoperasian
tergantung kepada model easYgen yang dipergunakan. Anda dapat melihatnya melalui nilai yang
tertampilkan dengan menggerakan tombol scroll .
Nilai-nilai tersebut ditampilkan dalam bentuk angka, sementara satuan teknis, sumber dan fasa
dikodekan pada layer display 7 bagian jika tersedia. Lihat contoh berikut dibawah ini:
¾ The first digit (counted from left) indicates what is being measured, (mains, engine, or
generator). The top horizontal segments indicates mains, the middle horizontal segments
indicates engine, and the bottom horizontal segments indicates generator.
Digit pertama (dibaca dari kiri) menunjukkan apa yang sedang diukur pada saat ini, (induk, mesin,
atau generator). Bagian atas sisi horizontal menandakan induk, bagian tengah menandakan mesin
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5. Operation system
dan bagian bawah horizontal menandakan generator.

¾ The second digit indicates the measured phase. The top segment indicates L1, the midlle
horizontal segment indicates L3. if only one line is displayed for phase measurement, a
phase to neutral measurement is displayed. If two lines are displayed, a phase to phase
measure ment is shown.
Digit kedua menunjukkan pembacaan fasa. Bagian atas menunjukkan L1, bagian tengah
menunjukkan L3. jika hanya satu jalur yang ditampilkan untuk pengukuran fasa, pengukuran fasa ke
netral yang ditampilkan. Jika dua jalur yang ditampilkan, berarti pengukuran fasa ke fasa yang
diperlihatkan
¾ Digit 3-6 indicate what the measured value of the displayed parameter is.
Digit 3-6 menunjukkan nilai hasil pengukuran dari parameter-parameter yang ada.
¾ The indicators located at the top left of the first four digits of the display indicate the
engineering unit of measure to be utilized. The indicators are assigned the following
engineering units measure.
Lampu indikator yang terletak pada sebelah kiri atas dari keempat digit pertama display
menunjukkan satuan ukuran teknis yang dipergunakan. Lampu indikator tersebut menetapkan
satuan ukuran teknis berikut.
ª Digit 1 : Operating hours (h)
ª Digit 2 : Revolutions (rpm)
ª Digit 3 : Frequency (Hz)
ª Digit 4 : Voltage (V)
With this information, the example in the figure above reads as follows:
Voltage at generator between phase L2 and N is at 235.0 volts
Digit 1 : Generator
Digit 2 : Measurement between phase L2 and N
Digit 3 to 6 : Numerical Value 235.0
Indicator at digit 4 : Voltage (V)
Dengan informasi tersebut diatas, contoh pada gambar diatas dapat diartikan sebagai berikut:
Voltase pada generator antara fasa L2 dan N yaitu 235.0 volts
Digit 1: generator
Digit 2: pengukuran antara fasa L2 dan N
Digit 3-6: nilai angka 235.0
Indikator pada digit 4: Voltase (V)
Digit 5 and 6 of the display are used to display eight different alarm states. The upper and
lower vertical segment are used to indicate the various alarm states.
Digit 5 dan 6 dari display dipergunakan untuk menampilkan 8 kondisi alarm yang berbeda. Bagian atas
dan bawah dari display dipergunakan untuk mengindikasikan berbagai macam kondisi alarm.
Cycling Through the Displayed Operating Values
If the easYgen is in normal operation, the operator may advance through the different
operating parameter using the scroll button . The parameters are displayed in the order
shown below (some parameters will not display if the related function is disabled or not
available on the control unit):
Pada saat easYgen berada pada operasi normal, operator dapat melihat berbagai parameter
pengoperasian dengan menggunakan tombol scroll . parameter yang ditampilkan diperlihatkan
secara berurutan dibawah ini (beberapa parameter tidak akan tampil jika fungsi terkait tidak diaktifkan
atau tidak tersedia pada control unit tersebut):
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5. Operation system
- 44 -
5. Operation system
Fig 9. Display of operating values
If the scroll button is pressed again, the display returns to generator voltage V12. the
display automatically returns after 180 second to generator voltage V12 being displayed if a
button isn’t pressed.
- 45 -
5. Operation system
Jika tombol scroll ditekan lagi, display akan kembali ke voltase V12 generator. Display secara
otomatis akan kembali ke voltase V12 generator setelah 180 detik jika tombol tersebut tidak ditekan.
J1939 Visualization (320X)
The easYgen 300 with the X package is able to display standard J1939 messages, which are
sent by the engine control to the easYgen via the CAN bus. The values are displayed on the unit
and in LeoPC1. it also possible to display Scania S6 and Deutz EMR2 messages in LeoPC1. the
J1939 visualization can be configured with parameter 90, J1939 device type. If this parameter
is configured to standard, the standard J1939 messages are displayed on the unit immediately
following the operating values as described in the Display of the operating values section.
easYgen 300 dengan paket X dapat menampilkan pesan standard J1939, yang dikirimkan oleh kontrol
mesin ke easYgen melalui CAN bus. Nilai-nilai tersebut ditampilkan pada unit dan pada LeoPC1. Control
unit tersebut juga dapat menampilkan pesan dari mesin Scania S6 dan Deutz EMR2 dalam LeoPC1.
visualisasi J1939 tersusun berupa parameter 90, jenis alat J1939. jika parameter tersebut disusun ke
posisi standard, pesan standard J1939 yang ditampilkan dengan segera mengikuti nilai-nilai dari
parameter operasional seperti ditampilkan pada bagian operating value sebelumnya.
NOTE
Only signals, which are present, will be displayed. If signal is not sent to the control unit, the
display of this value is not shown. If the sent value exceed the specified range, the displayed
value is not defined.
Hanya sinyal yang ada yang akan ditampilkan, jika sinyal tidak terkirim ke control unit, maka tampilan
dari nilai tersebut tidak akan ada. jika nilai yang dikirim melebihi rentang nilai yang telah ditetapkan, nilai
tersebut juga tidak dapat ditampilkan.
The following J1939 messages can be displayed as easYgen. The J1939 messages follow the
operating values and can be viewed in the following order using the scroll button . The
values are updated by pressing the scroll button.
Berikut adalah Pesan dari standard J1939 yang dapat ditampilkan pada easYgen. Pesan standard J1939
mengikuti nilai pengoperasian dan dapat dilihat berdasarkan urutan berikut dengan menggunakan tombol
scroll . nilai-nilai tersebut dapat diperbaharui dengan menekan tombol scroll.
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5. Operation system
- 47 -
5. Operation system
in case of a defective sensor or a broken wire the easYgen-300 displays four dashes instead of
the J1939 value following the respective J1939 identifier.
Jika terjadi kerusakan sensor atau kabel, layar pada easYgen-300 akan menampilkan 4 garis, dan bahkan
tampilan dari nilai J1939 pun mengikuti tampilan diatas berdasarkan identifikasi dari kode pesan J1939
nya.
The above display shows that the engine oil pressure (identifier 9r) sensor is defective or the
cable from the sensor to ECU is unplugged or broken. A defective sensor or a broken wire is
also displayed in LeoPC1. The display appearing in this case is described under J1939 Protocol
Description.
Layar diatas menampilkan bahwa engine oil pressure (diidentifikasikan sebagai 9r) sensor mengala\mi
kerusakan atau kabel dari sensor ke ECU terputus atau juga rusak. Sensor atau kabel yang rusak juga
dapat ditampilkan pada LeoPC1. Tampilan yang muncul dalam hal ini seperti diuraikan pada protocol
J1939.
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5. Operation system
6. Maintenance
5.3. LOAD TRANSFER PANELS
When the generating set is installed to automatically provide standby power in the event
of mains failure, a load transfer panel is required. This transfer panel is designed to sense when
the mains have failed, signal the generating set to start, switch the load from the failed mains
to the generating set and then switch it back the mains are re-established.
Panel transfer beban diperlukan pada genset yang terpasang secara otomatis sebagai penyedia
sumber tenaga listrik cadangan, pada saat terjadi kerusakan pada suplai tenaga listrik utama. Panel
transfer ini didesain untuk mendeteksi kegagalan yang terjadi pada sumber listrik utama, dan memberi
sinyal pada genset untuk segera menyala dan memindahkan beban dari sumber listrik utama ke genset
dan memindahkannya kembali setelah sumber listrik utama telah kembali normal.
Function of a Load Transfer Panel

Fungsi dari panel transfer beban
6.1 GENERATING SET MAINTENANCE
A good maintenance program is the key to long generating set life. Qualified technicians
should only carry out maintenance and service task. Records of this work should be kept to aid
in developing an efficient maintenance program.
Program perawatan yang baik merupakan kunci untuk menjaga umur pakai unit genset. Program
perawatan dan perbaikan tersebut harus dilakukan oleh Teknisi berkualifikasi. Tindakan-tindakan dalam
program tersebut harus selalu didokumentasikan untuk mengembangkan dan menjaga efisiensi program
perawatan.
In general, the generating set should be kept clean. Do not permit liquids such as fuel or
oil film to accumulate on any internal or external surfaces or on, under or around any acoustic
material, if fitted. Wipe down surfaces using an aqueous industrial cleaner. Do not use
flammable solvents for cleaning purposes.
Secara umum, genset harus selalu dijaga kebersihannya. Jangan sampai cairan seperti lapisan
- 49 -
5. Operation system
6. Maintenance
bahan bakar atau oli menggenang pada permukaan dasar genset, atau cerukan disela-sela mesin yang
dapat menampung cairan. Bersihkan permukaan tersebut menggunakan pembersih kelas industri
berbahan dasar air, jangan membersihkan menggunakan larutan yang mudah terbakar.
Any acoustic material with a protective covering that has been torn or punctured should
be replaced immediately to prevent accumulation of liquids or oil film with in the material.
Bagian peredam atau tutup pelindung yang telah rusak terkoyak atau berlubang, harus segera
diganti untuk mencegah masuk dan terkumpulnya air atau oli pada bagian tersebut.
6.2 PREVENTIVE MAINTENANCE
Depending on the application of the generating set, requirement for preventative

maintenance requirements associated with the engine are detailed in the Engine Manual, which
should be reviewed in conjunction with this section. Maintenance intervals for the engine may
be more frequent than those shown in this section.
Keperluan untuk melakukan perawatan pencegahan pada genset harus disesuaikan dengan uraian
yang terdapat pada buku manual tentang mesin dan sesuai dengan aplikasinya sebagai genset. Rentang
waktu perawatan mesin kemungkinan harus lebih sering dibandingkan dengan uraian yang tertulis pada
bagian tersebut.
6.3 ALTERNATOR PREVENTIVE MAINTENANCE
There is no routine maintenance required on the alternator, however periodic inspection

of the alternator winding condition and periodic cleaning is recommended. See Alternator
Maintenance, and Alternator Manual.
Alternator tidak memerlukan perawatan secara rutin, namun pemeriksaan rutin terhadap kondisi
gulungan alternator harus dilakukan, dibersihkan jika memang perlu. Lihat uraian pada bagian perawatan
alternator.
6.4 ENGINE PREVENTIVE MAINTENANCE
See the Engine Manual provided with this manual for information on regular maintenance
required to keep the engine operating efficiently.
Lihat uraian pada buku manual pengoperasian mesin Untuk informasi mengenai perawatan rutin
dan diperlukan unutk menjaga agar mesin dapat tetap beroperasi secara efisien.
6.5. REMOVAL OF ENGINE AND/OR ALTERNATOR
The following procedures should be used for removal of the engine and/or alternator.
Berikut adalah prosedur yang harus dilakukan pada saat melepaskan mesin dan atau
alternator.
1. Isolate and disconnect electrical power supply to auxiliary equipment such as a water
heater.
Isolasi dan putuskan semua suplai arus listrik ke peralatan elektronik seperti pemanas air.
2. Isolate the battery charger supply. Disconnect the battery (negative lead first) and remove
if necessary.
Isolasi baterei, putuskan kutub baterei (kutub negatif terlebih dahulu) dan lepaskan semuanya jika
diperlukan.
2. If the generating set is equipped with a canopy, remove the fixing bolts on each side,
disconnect the exhaust system and then remove the canopy.
Jika genset dilengkapi dengan canopy, lepaskan baut pada sekeliling canopy dan lepaskan sistem
pembuangan gasnya lalu canopy.
3. Isolate and disconnect the control panel and remove together w/ stand from the generating
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5. Operation system
6. Maintenance
set, ensuring that all cables have been adequately identified to facilitate reconnection.
Isolasi dan putuskan kabel yang terhubung antara control panel ke genset, pastikan semua kabel
telah teridentifikasi untuk memudahkan proses koneksi ulang kabel.
5. If the engine and alternator are both to be removed, they may be lifted out as one unit
using the lifting eyes provided on both the engine and alternator. First, the bolts holding the
engine/alternator to the base frame have to be removed.
Jika mesin dan alternator akan dilepas bersamaan, keduanya harus diangkat bersamaan sebagai satu
unit menggunakan lifting eyes yang terpasang pada sisi mesin dan alternator, setelah baut yang
menahan mesin dan alternator ke rangka penyangga dilepaskan.
6.5.1. Engine Removal Only
1. If only the engine is to be removed, the wiring loom should first be removed from the
engine.
Jika hanya mesin yang akan dilepaskan, rangkaian kabel yang terpasang pada mesin harus
dilepaskan terlebih dahulu.
2. If the alternator is fitted with only one set of feet, then the front end of the alternator will
have to be firmly supported before removing the engine.
Jika alternator hanya memiliki satu kaki penyangga, maka bagian depan alternator harus disangga
terlebih dahulu sebelum melepaskan mesin dari alternator.
3. Remove the bolts holding the engine to the base. It may also be advantageous to loose the
alternator mounting bolts.
Lepaskan baut yang menahan mesin ke rangka penyangga, akan lebih mudah apabila baut yang
menahan alternator juga dilonggarkan.
4. Remove the alternator fan guards.
Lepaskan pelindung kipas alternator.
5. Support the rotor assembly using a sling or wooden supports taking care not to damage the
fan.
Sangga bagian rotor mesin menggunakan sling atau bantalan kayu penyangga untuk melindungi
kipas dari kerusakan.
6. Remove the bolts between the flexible coupling and the engine flywheel.
Lepaskan baut yang menghubungkan fleksibel coupling dan flywheel mesin.
7. Support the rear of the engine using an overhead crane or similar device.
Sangga bagian belakang mesin dengan menggunakan overhead crane atau peralatan sejenis.
8. Remove the coupling housing bolts.
Lepaskan baut rumah coupling.
9. The engine is now moved forward unit it is clear of the alternator and may be lifted away
from the base.
Kemudian geser mesin menjauhi alternator untuk kemudian diangkat menjauh dari rangka
penyangga.
6.5.2. Alternator Removal Only
1. If the alternator only is to be removed, the rear of the engine must be firmly supported.
Jika hanya alternator yang akan dilepaskan, bagian belakang mesin harus disangga dengan baik.
2. Remove the wiring loom.
Lepaskan rangkaian kabel.
3. Remove the bolts holding the alternator to the base frame. Loosen the engine bolts as well.
Lepaskan baut yang menahan alternator ke rangka penyangga dan longgarkan baut penahan mesin.
4. Remove the alternator fan covers and support the rotor and the front of the alternator.
Ensure that the rotor is positioned with a pole at the bottom centerline. This is to avoid any
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5. Operation system
6. Maintenance
damage to the bearing or exciter by limiting the rotor movement to that of the air gap.
Lepaskan cover kipas alternator dan support rotor serta bagian depan dari alternator.Pastikan rotor
di posisikan dengan sebuah lubang di garis tengah bagian dasar. Ini untuk menghindari beberapa
kerusakan bearing atau exiter dengan membatasi pergerakan rotor terhadap celah udara
5. Uncouple the alternator from the engine.
Lepaskan alternator dari mesin.
6. Support the alternator using a sling or similar device and slide the complete alternator back
on the base before lifting.
Sangga alternator menggunakan sling atau peralatan sejenis lainnya dan geser alternator ke
belakang sebelum diangkat dari rangka penyangga.
6.6. RADIATOR MAINTENANCE
General Notes: Corrosion in the radiator can be a prime cause of failure. This is prompted
by air in the water. Always ensure pipe connections are free of leaks and bleed air from top of
the radiator regularly to keep the system “air free”.
Catatan: korosi pada radiator dapat menjadi penyebab utama timbulnya kerusakan. Hal ini
disebabkan masuknya udara ke dalam air radiator. Pastikan selalu bahwa pipa sambungan terbebas dari
kebocoran dan masuknya udara dari bagian atas radiator secara teratur, untuk menjaga sistem terbebas
dari udara luar.
Radiators should not be left standing in a partially filled condition. Radiators left partly
filled with water will suffer much more rapidly from the effects of corrosion. For an inoperative
generating set, either drain the radiator completely or ensure that it is maintained full.
Wherever possible, radiators should be filled with distilled or naturally soft water, dosed with
suitable corrosion inhibitors.
Radiator tidak boleh dibiarkan dalam kondisi terisi sebagian dari kapasitasnya. Radiator yang hanya
terisi air sebagian akan mempercepat timbulnya korosi pada radiator. Pada genset yang tidak
dioperasikan, air radiator harus dikosongkan dan selalu dalam perawatan. Jika memungkinkan, radiator
harus diisi dengan air murni dengan tambahan larutan pencegah korosi didalamnya.
WARNING!
Radiator coolant is normally very hot and under pressure. Do not work on the radiator
or remove any guarding while the fan is in motion.
Coolant pada radiator biasanya sangat panas dan bertekanan. Jangan bekerja disekitar radiator
atau melepaskan pelindung selama kipas masih berputar.
6.6.1. External Cleaning:
In dusty or dirty conditions, the radiator fins can become blocked with loose debris,
insects, etc. and this fouling will have an effect on the performance of the radiator.
Pada kondisi yang kotor dan berdebu, kisi-kisi radiator mungkin terhalangi oleh kotoran, serangga,
dll. Dan hal ini dapat mempengaruhi kinerja radiator secara keseluruhan.
For regular removal of light deposits, use a low-pressure steam jet. More deposits that
are difficult may need a detergent with a low-pressure hot water hose. Spray steam jet or water
from the ‘front of the radiator towards the fan. Spraying in the opposite direction will force
debris further into the core. Covering the engine/alternator during this process will keep them
clean.
Untuk perawatan teratur terhadap lapisan kotoran, gunakan steam jet bertekanan rendah, dan Untuk
lapisan kotoran yang tebal dan susah dihilangkan, gunakan deterjen dan semprotan hose air panas
bertekanan rendah. Semprot kisi radiator menggunakan steam jet atau air panas dari bagian depan kisi
radiator kearah kipas. Penyemprotan pada arah yang berlawanan akan menambah kotoran lebih masuk
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5. Operation system
6. Maintenance
ke dalam kisi radiator. Tutupi mesin dan alternator selama proses pembersihan ini.
Stubborn deposits, which cannot be removed by the above method, may require removal
of the radiator and immersion in a heated alkali degreasing solution for about 20 minutes and
then washing off with a hot water hose.
Untuk lapisan kotoran yang tidak dapat dihilangkan dengan kedua metode diatas. Radiator
perlu dilepaskan dan di rendam dalam larutan alkali yang dipanaskan selama 20 menit. Dan kemudian
dicuci sampai bersih menggunakan semprotan hose air panas.
6.6.2. Internal Cleaning:
If, due to leaky joints for instance, indiscriminate topping-up with hard water has been
carried out for sometime, or if the generating set has been run without inhibitors the system
may become fouled by scale.
Radiator akan dipenuhi dengan kerak apabila ada kebocoran pada sambungannya atau karena
pengisian dengan air yang tidak bersih atau jika radiator dioperasikan tanpa menambahkan larutan
pencegah karat kedalamnya.
To descale the radiator, use the following procedure:
Berikut adalah prosedur untuk menghilangkan kerak di dalam radiator :
1. Drain the water system and disconnect and blank off the pipe connections to the engine.
Kosongkan air dari radiator dan putuskan pipa yang terhubung antara radiator dan mesin.
2. Prepare a 4% solution of inhibited acid solvent and fresh water. Add the acid to the water,
never vice versa.
Siapkan larutan asam 4% dan air murni, tuang asam ke air, jangan sebaliknya.
3. Allow several minutes for mixing, and then heat the solution to 49° C (120° F) maximum.
Biarkan beberapa menit agar larutan tercampur benar, lalu panaskan sampai suhu maksimum 490C
(1200F).
4. Run the solution slowly into the radiator via the filler cap or branch in the manifold.
Effervescence will occur. When it ceases, fill the radiator completely with the heated
solvent.
Tuang pelan-pelan larutan ke dalam radiator melalui lubang pengisian atau atau cabang pipa
pengisian lainnya. Akan timbul buih busa. Ketika berhenti, tuang semua larutan yang telah
dipanaskan ke dalam radiator.
5. Allow to stand for several minutes; then drain the solvent back into the original container
through the bottom manifold or drain plug.
Biarkan beberapa menit, kemudian kosongkan larutan dari radiator ke tempat larutan semula melalui
lubang pembuangan yang berada dibagian bawah radiator.
6. Examine the interior of the headers. If scale remains, repeat the process outlined above
with the solvent strength increased to 8%.
Periksa bagian dalam radiator, jika kerak masih ada, ulangi proses diatas dengan menambahkan
konsentrasi larutan sampai 8%.
7. After descaling the acid solution has to be neutralized as follows:
Fill the mixing container with fresh water, heat to boiling point then add common washing
soda crystals at the following strength: 0.5 kg soda to 20 liters water. Fill the radiator with
this solution; drain it back into the container.
Setelah proses pembersihan kerak selesai, sisa larutan asam di dalam radiator harus dinetralisasi
dengan proses berikut :
Tuang air bersih ke tempat larutan, panaskan sampai mendidih, kemudian tambahkan soda kristal
pembersih dengan komposisi : 0,5 Kg soda untuk setiap 20 liter air. Tuang larutan tersebut ke dalam
radiator, dan kosongkan kembali ke dalam tempat larutan semula.
8. Flush the radiator in this manner several times, finally leaving the radiator full for at least an
hour. Drain until empty and wash out the radiator with hot fresh water.
Bilas radiator dengan air bersih beberapa kali, kemudian biarkan radiator terisi air bersih selama
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5. Operation system
6. Maintenance
minimal 1 jam. Kosongkan air dari radiator dan bilas kembali dengan air panas.
9. Before putting the radiator into service again, fill with water and apply a test pressure equal
to twice that of the working pressure. Examine carefully for any leaks, which may have
been revealed by descaling.
Sebelum dioperasikan kembali, isi radiator dengan air dan periksa tekanan radiator sampai dengan 2
kali tekanan pengoperasiannya. Periksa terhadap kemungkinan kebocoran yang dapat sebabkan
proses pembersihan kerak.
10. Prior to decommissioning, the coolant must be closed with any necessary corrosion
inhibitors and/or the correct proportion of antifreeze.
Sebelum dioperasikan ulang, air radiator harus ditambahkan coolant atau laurtan pendingin , larutan
pencegah karat dan atau larutan pencegah pembekuan.
6.7. BATTERY DESCRIPTIONS AND MAINTENANCE
6.7.1. Battery Description
The battery is an assembly of “cells” containing a number of plates, immersed in an

electrically conductive fluid. The electrical energy from the battery comes from chemical
reactions taking place with in the cells. These reactions are reversible, which means that the
battery can be repeatedly charged, and discharge.
Baterei terdiri dari “Cell” yang berupa beberapa plat tipis yang direndam dalam larutan
berpenghantar lisrtik. Tenaga listrik yang dihasilkan dari baterei berasal dari reaksi kimia yang terjadi
pada cell. Reaksi ini dapat dibalik, yang berarti baterei dapat terus diisi ulang atau dikosongkan tenaga
listriknya.
6.7.2. Electrolyte
The electrically conductive fluid, called electrolyte, in a lead-acid battery is a diluted

sulphuric acid solution, it aids the chemical reactions occurring at the plates and it acts as the
carrier for the electrical current.
Larutan penghantar listrk yang disebut elektrolisa ini, pada baterei timbal berupa cairan asam
sulfat yang membantu proses kimia yang terjadi pada plat dan bertindak sebagai pembawa arus listrik.
6.7.3. Battery Maintenance
WARNING!
Wear an acid resistant apron and face shield or goggles when servicing the battery. In
case of electrolyte spilled on skin/clothing, flush immediately with large quantities of
water.
Kenakan pelindung muka atau kaca mata dan apron anti larutan asam ketika melakukan
perawatan pada baterei. Jika terjadi tumpahan elektrolisa dan mengenai kulit atau kain, cuci
secepatnya dengan air.
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5. Operation system
6. Maintenance
Battery acid is highly caustic and may

splash into eyes.
During filling or charging, explosive gases
+ - may develop.
Metal object between battery terminals
cause short circuiting.
Risk of explosion, burning and
short-circuiting.
NO naked flames, No electrical sparks.
Do not smoke.
Wear rubber gloves, protective goggles
and protective clothing.
Before starting work, provide clean water
for washing.
If battery filling gets into eyes, rinse
immediately with water and seek medical
attention.
Do not place metal objects on battery.
6.7.4. Filling
The battery will often be shipped dry. Pre-mixed electrolyte of the correct specific gravity
will have to be added.
Baterei biasanya dikirim dalam kondisi kering. Campuran Elektrolisa diisikan kemudian pada
kapasitas yang sesuai.
Remove the vent plugs and fill each cell with the electrolyte until the level is 8mm above
the top edge of the separators. Allow the battery to stand for 15 minutes. Check and adjust the
level as necessary.
Lepaskan tutup ventilasi dan isi tiap cell dengan elektrolisa sampai 8mm di atas batas atas sekat
pemisah. Biarkan baterei selama 15 menit, lalu periksa kembali ketinggian larutan.
6.7.5. Initial Charging
Within 1 hour of filling, the battery must be charged for 4 hours. This will ensure that the
acid is sufficient mixed within the battery. Failure to give this charge at this time may impair the
capacity of the battery.
1 jam setelah pengisian elektrolisa, baterei harus di charge selama 4 jam. Hal ini untuk memastikan
bahwa larutan asam telah tercampur benar di dalam baterei. Kekeliruan saat pengisian awal ini akan
berdampak pada kapasitas penyimpanan pada baterei.
6.7.6. Topping
Normal operation and charging of the battery will cause some of the water to evaporate.
This will require occasional topping up of the battery.
Pengoperasian dan pengisian ulang baterei akan menyebabkan penguapan air pada larutan
baterei, untuk itu diperlukan pengisian ulang terhadap cairan tersebut.
Clean the battery first to avoid contamination and remove the vent plugs. Add distilled
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5. Operation system
6. Maintenance
water, until the level is 8mm above the separators. Replace vent plugs.
Pertama bersihkan baterei untuk menghindari kontaminasi, lalu lepaskan tutup ventilasinya.
Tuang air murni ke dalam baterei sampai batas 8mm diatas sekat pemisah.
6.8. CHARGING BATTERY
WARNING!
Always ensure battery charging is carried out in a well-ventilated area away from sparks
and naked flames.
Pastikan proses pengisian ulang baterei dilakukan pada ruangan yang memiliki cukup ventilasi dan
jauh dari percikan api.
Never operate a battery charger where unprotected from rain and snow. The charger
should never be used near water.
Jangan melakukan proses charging baterei jika tidak terlindungi pada saat hujan atau salju.
Charger tidak boleh digunakan dekat air.
Always switch the charger off prior to disconnecting the battery.
Matikan charger terlebih dahulu sebelum memutuskan hubungan dengan baterei.
The engine driven alternator and or a static battery charger, if fitted, should maintain the
batteries in a charged state. However, if the battery has recently been filled or recharging is
required the battery may be disconnected from the generating set and connected to an external
battery charger.
Mesin yang dijalankan oleh alternator dan atau baterei charger statis, harus dijaga agar baterei
nya selalu dalam kondisi penuh. Namun demikian, jika telah sering di charge, baterei mungkin perlu di
charge menggunakan baterei charger eksternal dan diputuskan sementara dari genset selama
melakukannya.
6.8.1. Charger and battery Connections
The battery charger should be connected to suitable mains supply (13 Amps minimum)
using a plug connected as indicated below.
Charger baterei harus terhubung ke suplai listrik utama (minimal 13 Amps) dengan koneksi kabel
seperti ditunjukkan dibawah ini.
Mains Connection
Live Brown Lead
Neutral Blue Lead
Earth Green/Yellow Lead
Also ensure that the battery terminals are connected as indicated below:
Pastikan bahwa terminal baterei terhubung seperti ditunjukan dibawah ini:
Battery Connection
Positive (+) Terminal
Negative (-) Terminal
Connect the batteries to the charger as per the following chart:

Hubungkan baterei ke charger seperti gambar berikut ini:
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6. Maintenance
7. Commissioning
+ - + - + - + -
Series
+ -
Single Battery
+ - + -
Parallel Battery
+ - + -
12 Volt System
Series/Parallel
24 Volt System
7.1. COMMISSIONING
The purpose of this Commission Specification is to give guidance in the site testing of the
generating set and its associated equipment.
Perlunya spesifikasi commissioning berikut ini adalah untuk memberikan panduan selama
melakukan test di lokasi genset berada dan peralatan terkait lainnya.
Site testing, or Commissioning, is carried out after the installation of the equipment has
been completed. In most generating set cases, this would include all other building services and
installed equipment required by the generating set itself to be completed. The procedure should
also be carried out if the generating set has been withdrawn from service for extensive
maintenance or repair, in order to establish that it has been restored to full working order.
Pemeriksaan ditempat atau commissioning, dilakukan setelah proses pemasangan peralatan genset
telah lengkap. Pada kebanyakan proses instalasi, hal tersebut termasuk pelayanan penataan instalasi di
dalam bangunan dan instalasi peralatan yang diperlukan untuk melengkapi genset tersebut. Prosedur
tersebut juga harus dilakukan untuk genset yang akan dirawat atau diperbaiki lebih lanjut, untuk
mengembalikan genset ke kondisi awalnya.
A copy of the Commissioning Sheet is available for the Engineer carrying out the
Commissioning, prior to his visit to site.
Kopi lembar commissioning dipersiapkan oleh teknisi untuk melakukan proses commissioning,
sebelum kunjungannya ke lokasi test.
Commissioning is a proving test of the generating set system, including all its ancillaries,
on site under the conditions that it will be asked to operate in during its working life. As these
conditions will rarely be ideal it follows therefore that there will be several significant differences
between Works Testing and Commissioning.
Commissioning adalah test yang dilakukan dilokasi untuk membuktikan bahwa genset dapat
beroperasi dengan baik, termasuk didalamnya pengoperasian semua peralatan tambahan, hal ini
dilakukan dalam keadaan genset yang beroperasi. Dan pada prakteknya, Kemungkinan akan ditemui
bahwa kondisi tersebut tidak ideal sebagai mana mestinya, oleh karena itu ada beberapa perbedaan
mendasar antara test pengoperasian dan commissioning.
In the absence of any other specific instructions when carrying out the Commissioning of
the generating set this Commission Specification should be referred to and allowed.
Apabila ada instruksi khusus yang diberikan selama melakukan proses commissioning pada genset
untuk pengoperasian genset ke depannya, hal tersebut harus diikuti dan disesuai dengan petunjuk yang
diberikan.
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6. Maintenance
7. Commissioning
7.2. PRELIMINARY CHECKS BEFORE STARTING GENERATORS
Before Commissioning can be carried out, the following static checks must carry out by
the commissioning engineer and his assistant.
Sebelum proses commissioning dilakukan, beberapa proses pemeriksaan harus dilakukan oleh
teknisi commissioning dan asistennya.
7.2.1. Damage
The generator and any other associated equipment should be checked for any sign of
damage sustained during the assembly and moving into the test cell. Any such damage should
be noted. Trained engineer can also do repair and rectified, otherwise the manufacturer must
be notified.
Generator dan perlengkapan tambahan lainnya harus diperiksa terhadap semua tanda kerusakan
yang kemungkinan terjadi pada saat proses perakitan atau mobilisasi unit genset. Segala bentuk
kerusakan harus dicatat. Teknisi terlatih dapat melakukan perbaikan langsung ditempat atau dengan
memberitahukan pihak pabrikan.
7.2.2. Generator base
Ensure the generator is level by checking the base skid and position the anti-vibration
mount or the neoprene - dampening pad.
Pastikan bahwa generator berada pada tempat yang datar dengan memeriksa rangka penyangga
dan posisi dudukan peredam getaran yang terpasang.
7.2.3. Exhaust System
The exhaust system should be correctly connected, properly routed & adequately
supported. The exhaust system is usually isolated from the effects of the engine vibration by a
flexible connection or bellow fitted closely to the engine exhaust manifold as possible. Attention
should be paid to the exhaust outlet to ensure the fumes are discharged safely, and that they
cannot be drawn back into the engine room or into a ventilation system. The amount of heat
radiated & conducted from the exhaust system should also be taken into account, especially if it
is routed anywhere near any inflammable material.
Sistem pembuangan gas harus terhubung dengan benar, memiliki saluran yang sesuai dan
tersangga dengan baik. Sistem pembuangan biasanya terisolasi dari getaran mesin dengan menggunakan
sambungan fleksibel yang terpasang sedekat mungkin dengan manifold mesin. Harus diperhatikan agar
asap keluar dengan aman dari pipa keluaran dan tidak tertarik kembali ke dalam ruangan mesin atau ke
sistem ventilasi udara. Radiasi panas yang dirambatkan dari sistem pembuangan juga harus diperhatikan,
terutama jika saluran pembuangannya berada dekat bahan yang mudah terbakar.
7.2.4. Lubricants
The engine sump, and any make up system, should be filled with the correct grade of
lubricant to the required level. This also applied to any gearboxes or gear drive fitted.
Bak oli pada mesin dan sistem pelumasan lainnya harus diisi pelumas dengan jenis dan volume
yang sesuai. Hal ini juga berlaku pada gearbox dan gear drive yang terpasang.
7.2.5. Coolant
The cooling system, unless an air cool system is employed, should be filled to the required
level with the correct grade of anti-freeze. Unless otherwise specified the mixture should be
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6. Maintenance
7. Commissioning
30%-33% anti-freeze the remainder is water. The cooling system should be filled with care to
avoid the formation of air lock.
Pada sistem pendingin, terkecuali memakai sistem pendingin udara, maka harus diisi larutan anti
beku dengan volume dan jenis yang sesuai. Kecuali telah dijelaskan sebelumnya, campuran dari larutan
anti beku berkisar 30%-33% dan sisanya adalah air. Sistem pendingin harus diisi dengan hati-hati untuk
mencegah terperangkapnya udara dalam ruang pendingin.
7.2.6. Fuel System
The service tank should be filled, with the correct grade of fuel. The fuel should to be
checked to ensure its not contaminated with water or dirt. The fuel lines, both the supply and
return, and all other fuel pipe connection should be checked for leaks or restrictions.
Tangki BBM harus terisi sampai batas pengisian yang sesuai. BBM juga harus diperiksa terhadap
kemungkinan kontaminasi air atau kotoran lainnya. Saluran suplai bahan bakar dan pipa sambungannya
harus diperiksa terhadap kemungkinan kebocoran atau terjadinya sumbatan.
7.2.7. Service Tank
The service tank should be positioned to provide the fuel within the engine’s
requirements. That is a positive head of fuel without excessive pressure, or negative fuel head
but within the capacity of the fuel lift pump. Any air that may be trapped in the system should
be bled off prior to any start attempt.
Tangki BBM harus diletakkan sedemikian rupa agar dapat menyuplai BBM kepada mesin dengan
baik. Tidak terlalu tinggi sehingga menyebabkan tekanan yang berlebih pada sistem suplai bahan bahan,
juga tidak terlalu rendah, sehingga masih memungkinkan bahan bakar terpompa ke mesinb. Udara yang
terperangkap dalam sistem saluran harus dikeluarkan sebelum mulai menjalankan genset.
7.2.8. Ventilation
There should be adequate ventilation into the engine room for both cooling and air
combustion purposes. The airflow should be unobstructed, and all air intakes and air cleaner
should be clear. The hot air outlet should also be unobstructed, and should be ducted away so
that the hot gases cannot be drawn back into the engine room via the air intake system. Any
hot air should also be discharged safely and away from any public area.
Ruangan tempat mesin berada harus memiliki ventilasi yang baik untuk mengalirkan udara
pendingin dan pembuangan. Aliran udara tidak boleh terhambat, semua saluran masuk udara dan
saluran pembersih tidak boleh terhalangi. Keluaran udara panas juga tidak boleh terhambat, dan harus
dialirkan keluar agar udara panas tidak terhisap kembali ke dalam ruangan mesin. Semua emisi udara
yang panas harus dilepaskan dengan aman dan jauh dari lingkungan umum.
7.2.9. Cabling
All cables, especially those between the Control panel and ATS box. Should be checked for
size and suitability. Termination should be light and secure, and of the correct type and polarity.
Terhadap semua kabel, terutama kabel sambungan antara control panel dan kotak ATS, harus
diperiksa ukuran dan kesesuaian kabelnya. Kabel harus dihubungkan dengan baik dan aman, sesuai jenis
dan kutubnya.
7.2.10. Insulation & Continuity test
Should be carried out on all wiring prior to applying any power, voltage or current. All live
connections of a dangerous voltage must be protected to prevent danger from electric shock.
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6. Maintenance
7. Commissioning
Pemeriksaan terhadap insulasi dari instalasi kabel harus dilakukan baik terhadap voltase maupun
arus listrik. Semua koneksi beraliran listrik harus terlindungi untuk mencegah bahaya kejutan arus listrik.
7.2.11. Earth
All the company equipment is provided with suitable earth point to allow common bonding
of all such equipment. This should then be connected to a permanent earth point. The provision
of this permanent earth electrode or mat is the responsibility of the electrical contractor.
Semua peralatan yang dibuat telah diperlengkapi dengan kutub grounding yang dapat dipakai
bersama pada peralatan sejenis. Kutub tersebut harus dihubungkan ke kutub grounding bumi yang
permanen. Penyedia elektroda kutub bumi ini menjadi tanggung jawab pihak kontraktor kelistrikan.
7.2.12. Batteries
The batteries supplied with the generator should be of the correct size, type and voltage.
The cell should be fully charged, with the electrolyte at the correct level.
Baterei yang dipakai pada genset harus menggunakan jenis, tipe dan voltase yang tepat. Sel
baterei harus dalam kondisi penuh dengan tingkat elektrolisa yang tepat.
7.2.13. Engine Control
The linkages of the governor and speed adjuster of the engine should be checked for
cleanliness and freedom of movement. All protection and shutdown devices, mechanical and
electrical, should be checked for correct operation.
Sambungan antara engine governor dan speed adjuster harus diperiksa kebersihan dan
kebebasan gerakannya. Semua pelindung dan bagian pemutus, bagian mekanik dan kelistrikan harus
diperiksa apakah beroperasi dengan benar.
7.2.14. Alternator Insulation Test (Megger Test)
Prior to continuous running of the generator, the insulation of the resistance of the
alternator must be checked. Each phase should be individually meggered to earth, the minimum
value being 50 mega ohms.
Sebelum mengoperasikan genset, insulasi dari tahanan alternator harus diperiksa, tiap fasa harus
diperiksa memakai test megger ke bumi, dan minimal nilai pembacaan pada alat test sebesar 50 mega
ohms.
7.2.15. Safety
All protective covers and guards should be in place and securely fitted. All necessary
warning labels or hazard indicator should be fitted where they can be clearly seen.
Semua tutup pelindung harus berada pada tempatnya dan benar-benar terpasang. Label
peringatan atau indikator bahaya harus terpasang pada tempat yang mudah terlihat.
7.2.16. Cranking of Engine
After preliminary check of generator, the following must be complied before cranking the
generator.
Setelah melakukan pemeriksaan awal pada genset, hal berikut harus dilakukan sebelum
mengengkol genset.
Ensure that TWO engineer must be present during the first crank of the engine. The
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6. Maintenance
7. Commissioning
electrical engineer will crank the engine for 3 seconds without starting the engine while the
mechanical engineer check the engine for any unusual noise and sound at the coupling area.
Pastikan bahwa 2 teknisi mengawasi saat pertama kali mesin diengkol. Teknisi elektrik akan
mengengkol mesin selama 3 detik tanpa menyalakan mesin, sementara teknisi mekanik memeriksa mesin
terhadap suara-suara yang tidak biasa pada area kopel mesin dan alternator.
Repeat the process for the second and third crank to confirm that the coupling and the
other external moving parts are in order.
Ulangi proses dua sampai 3 kali percobaan mengengkol untuk memastikan bahwa area kopel dan
bagian mekanis lainnya telah sesuai dengan semestinya.
7.2.17. Function test
Start engine and proceed with the function test. Adjust the speed and the voltage
required by the customer. With the generator running at normal speed and voltage, but not on
load, test must be made by simulation to check the function and circuit operation of all
shutdown and warning protective devices and their associated indicator and alarms.
Nyalakan mesin dan lanjutkan dengan melakukan tes fungsional. Setel kecepatan dan voltase
sesuai permintaan pelanggan. Dengan beroperasi pada kecepatan dan voltase normal tanpa
pembebanan, test harus dilakukan dengan membuat simulasi untuk memeriksa fungsi dan operasional
sirkuit dari bagian pelindung dan pemutus tegangan termasuk alarm dan bagian indikator lainnya.
The following recordings must be made, where applicable, of the settings of any
adjustable devices.
Hal berikut dibawah ini harus didokumentasikan, ketika melakukan penyetelan terhadap setiap
peralatan, jika memang diterapkan.
1) Engine high temperature protection.
Perlindungan terhadap temperature mesin yang tinggi.
2) Engine low oil pressure protection
Perlindungan terhadap tekanan oli yang rendah.
3) Battery charger (float) voltage
Voltase dari baterei.
4) Over speeding protection
Perlindungan terhadap kecepatan mesin yang berlebih.
5) Voltage sensing units.
Sensor voltase.
6) Any other protection device as require by customer
Peralatan pengaman lain sesuai permintaan pelanggan.
Note: The above process must be carried out as required by manufacturer. Various
incidents and damages have occurred due to carelessness of assembly staff &
design.
Proses di atas harus dilakukan sebagaimana dipersyaratkan oleh pihak pabrikan, untuk
mengantisipasi kejadian ataupun kerusakan yang mungkin terjadi karena kecerobohan
selama proses assembly atau kesalahan desain.
After the function test, continue to run the generator for about 10 minutes. Stop the
generator and later check the engine coolant and lubricant etc. Top up coolant and lubricant if
required.
Setelah melakukan test fungsional, lanjutkan untuk terus mengoperasikan genset selama 10 menit.
Matikan genset untuk kemudian memeriksa pelumasan dan pendingin mesin, dll. Tambahkan pelumas
dan larutan pendingin jika diperlukan.
- 61 -
6. Maintenance
7. Commissioning
7.3. PRELIMINARY DATA RECORDS
The following data should be recorded on the Commissioning Report.

Data berikut ini harus didokumentasikan pada commissioning report.
Generator set / Serial No
Model genset / nomor serial
Engine Model / Serial No
Model mesin / nomor seri
Alternator Model I Serial No
Model alternator / nomor seri
Date of Commissioning
Tanggal pelaksanaan commissioning
Company Name
Nama perusahaan
Address
Alamat
Genset Location
Lokasi genset
Any other general notes that the Commission Engineer considers necessary
Catatan umum lainnya yang dianggap perlu oleh teknisi pelaksana commissioning.
7.4. OBSERVATION DURING COMMISSIONING
Close observation must be kept during the Commissioning for any abnormalities in the
operation of the generator. Wherever possible these abnormalities should be corrected, they
should clearly noted on the report.
Proses commissioning harus benar-benar mengamati terhadap kondisi-kondisi abnormal yang
mungkin terjadi selama pengoperasian generator. Jika memungkinkan, kondisi abnormal ini harus dapat
diperbaiki dan dituliskan dengan jelas dalam laporan.
The generator itself should not exhibit any of the following:
Selama dioperasikan, generator tidak boleh menunjukkan gejala berikut:
1. Excessive vibration
Getaran yang berlebihan
2. Fuel, oil coolant leaks
Kebocoran bahan bakar, oli dan coolant
3. Excessive heat, smell or noise
Panas, bau dan suara yang berlebihan
If there are any deviations required from the design specification of the generator or
associated equipment, they should be noted on the Commissioning Sheet. This may include the
removal or addition of equipment to apply with site conditions, modifications to interface with
equipment supp!ied by others, etc.
Jika ada penyimpangan yang terjadi karena permintaan spesifikasi desain dari generator atau
perlengkapan terkait, hal tersebut harus dituliskan pada lembar commissioning. Hal tersebut termasuk
penambahan atau pengurangan perlengkapan yang disesuaikan dengan kondisi lokasi genset, modifikasi
dengan perlengkapan yang disediakan oleh pihak ketiga.
Any modifications, omissions deviations, defects or other factors that affect the final
product as received by the customer should be reported back to the Company through the
proper channels.
Terhadap setiap modifikasi, penyimpangan yang terabaikan, kerusakan atau hal lain yang dapat
berdampak terhadap kondisi barang yang diterima oleh pelanggan, harus dilaporkan kembali kepada
pihak pabrikan melalui jalur yang tepat.
- 62 -
6. Maintenance
7. Commissioning
COMMISSIONING SHEET
GENERATOR SET DATA
Generator Set Model / Serial No : ____________________ / ____________________
Engine Model / Serial No : _______________ / _______________

Alternator Model / Serial No : _______________ / _______________
Date of Commissioning : ______________________
V Inspection Passed
END USER DATA X Refer to Comments
N/A Not Applicable
Company Name : _________________________________________________________

Address : _________________________________________________________
Genset Location : _________________________________________________________
Duty: Standby I Prime Volts: __________V Rating: ___________kVA

Phase: _________ Frequency: __________Hz
Fuel System _____ Manual Availability _____

Water Level and Additives _____ Load Test _____
Lube Oil Level _____ Exhaust System _____
Battery Terminals and Wiring _____ Cooling System _____
Belt Tension _____ Jacket Water/Oil Heater _____
Radiator and Alternator Guards _____ Crankcase Breather System _____
Electrical Instruments _____ Air Filtration System _____
Engine Instruments _____ Vibration _____
Engine Temperature _____ 0C Mains Fail System _____
Engine Oil Pressure _____ Bar Panel Functional Check _____
Earth Connections _____ Changeover Panel Functional _____
Electrical Connections Power _____ Main Circuit Breaker Functional _____
Electrical Connections Control _____ Fuse and Fuse Rating _____
Alarm and Shutdown Devices _____ Phase Rotation _____
Comments:
_____________________________________________________________________________
_____________________________________________________________________________
_____________________________________________________________________________
_____________________________________________________________________________
IT IS THE DUTY AND RESPONSIBILITY OF THE END USER TO ENSURE ALL OILS ARE AS
PER MANUFACTURER’S RECOMMENDATION AND A SERVICE PERIOD IS ESTABLISHED
AND ADHERED TO AS FAILURE TO DO SO COULD RESULT IN WARRANTY BECOMING
INOPERATIVE.
Machine satisfactorily commissioned and handed over subject to comments:

Distributor Name: _______________ Signature: _______________ Date: ______________
End User Signature: ___________________
- 63 -
6. Maintenance
8. Fault Finding
8.1. INTRODUCTION
Faults occur most frequently in plants when maintenance has been in adequate or when
the plant is incorrectly operated.
Kerusakan biasa terjadi pada lokasi genset dimana genset kurang mendapat perawatan atau tidak
dioperasikan dengan benar.
It is thus advisable to follow the operation and maintenance instructions in the manual to
ensure a long and trouble-free working life for the plant.
Untuk itu sangat disarankan untuk selalu mengikuti manual instruksi perawatan dan pemeliharaan
genset untuk memastikan bahwa genset dapat beroperasi dengan semestinya.
When faults do occur, always follow the safety instructions in the front of this manual.
Ketika terjadi masalah, pastikan untuk selalu mengikuti intruksi keselamatan yang terdapat pada
bagian depan buku manual ini.
Before embarking on the detailed faultfinding, a check on the following may reveal the
cause of a fault or make the fault finding simpler.
sebelum berlanjut ke detail penelusuran permasalahan, pemeriksaan pada hal-hal berikut akan
mempermudah proses penelusuran permasalahan yang terjadi.
1) Fuel level correct

kecukupan bahan bakar sesuai.
2) Lubricating oil level correct
Kecukupan oli pelumasan sesuai.
3) Battery conditions
Kondisi baterei.
4) Radiator core clear from obstructions
Kisi-kisi radiator bebas dari kotoran penghalang.
5) Panel connections secured
Panel terhubung dengan baik.
- 64 -
6. Maintenance
8. Fault Finding
8.2. FAULT FINDING FOR DSC MODULES
SYMPTOM POSSIBLE REMEDY

GEJALA TINDAKAN
Unit is inoperative Select AUTO on the front panel. Check the battery and
Unit tidak beroperasi wiring to the unit. Check the DC supply. Check the DC
fuse.
Pilih AUTO pada panel. Periksa baterai dan instalasi kabel ke
unit. Periksa suplai arus DC. Periksa sekering DC
Units shuts down Check DC supply voltage is not above 35 Volts or below 8
Unit tiba-tiba mati Volts Check the operating temperature is not above
55°C. Check the DC fuses.
Periksa suplai voltase DC tidak diatas 35 Volt atau dibawah 8
Volt. Periksa temperatur operasi tidak diatas 55°C. Periksa
sekering DC
Units locks out on Emergency If an Emergency Stop Switch is not fitted, ensure that a
Stop positive is connected to the Emergency Stop input. Check
Unit terkunci pada Emergency emergency stop switch is functioning correctly. Check
Stop wiring is not open circuit.
Jika Emergency Stop tidak terpasang, pastikan kabel positif
terpasang ke in put Emergency Stop. Periksa tombol Emergency
Stop itu bekerja dengan baik. Periksa instalasi kabel tidak
terbuka
Intermittent sensor fault Ensure that Magnetic pick-up screen is only connected at
Sinyal sensor yang menyala one end; if connected at both ends this enables the
sebentar-sebentar screen to act as an aerial and will pick up random
voltages.
Pastikan sekat magnet hanya terhubung hanya pada 1 ujung,
jika terhubung dengan kedua ujung ini dapat membuat sekat
menjadi penerima dan akan mengambil voltase secara acak
Low oil pressure fault operates Check engine oil pressure. Check oil pressure switch and
after engine has fired wiring. Check configured polarity is correct.
Tekanan oli rendah setelah mesin Periksa tekanan oli mesin. Periksa saklar tekanan oli dan
menyala instalasi kabelnya. Periksa kutub-kutubnya
High engine temperature fault Check engine temperature. Check switch and wiring.
operates after engine has fired Check configuration of input i.e. Normally Open or
Temperatur mesin tinggi setelah Normally Closed.
mesin menyala Periksa temperatur oli. Periksa switch dan instalasi kabelnya.
Periksa susuna input N/O atau N/C
Shutdown fault operates Check relevant switch and wiring of illuminated fault LED.
Peringatan tanda unit mati Check configuration of input.
menyala Periksa kenop dan rangkaian kabel yang berhubungan dengan
fungsi tersebut dan rangkaian kabel lampu tanda kesalahan.
Periksa konfigurasi input.
Warning fault operates Check relevant switch and wiring of illuminated fault LED.
peringatan tanda kesalahan telah Check configuration of input.
terjadi menyala Periksa kenop dan rangkaian kabel yang berhubungan dengan
fungsi tersebut dan rangkaian kabel lampu tanda kesalahan.
Periksa konfigurasi input.
Fail to start is activated after Check wiring of fuel solenoid. Check fuel. Check battery
pre-set number of multi supply. Check battery supply is present on the Fuel output
attempts to start of the module. Check the speed-sensing signal is present
- 65 -
6. Maintenance
8. Fault Finding
Kegagalan menyalakan genset on the 521 inputs. Refer to engine manual.

setelah beberapa kali percobaan. Periksa rangkaian kabel ke solenoid bahan bakar, periksa bahan
bakar, periksa suplai arus baterei, periksa bahwa ada suplai
arus baterei pada output modul bahan bakar, periksa bahwa
sinyal sensor kecepatan mesin ada pada input modul 521,
tindakan lanjutan merujuk ke buku manual operasi mesin.
Continuous starting of Check that there is no signal present on the Remote Start
generator when in AUTO input. Check configured polarity is correct.
Genset starter terus-menerus Periksa bahwa tidak ada sinyal pada input remote start. Periksa
saat dalam fungsi AUTO bahwa konfigurasi kutubnya telah benar terpasang.
Generator fails to start on Check Start Delay timer has timed out. Check signal is on
receipt of Remote Start signal Remote Start input.
Genset tidak bisa menyala karena Periksa bahwa timer penunda start telah lewat. Periksa sinyal
tidak menerima sinyal start. input dari remote start.
Pre-heat inoperative Check wiring to engine heater plugs. Check battery
Fungsi pre heat tidak beroperasi supply. Check battery supply is present on the Pre-heat
output of module. Check pre-heat has been selected in
the configuration menu.
Periksa rangkaian kabel ke katup pemanas mesin, periksa
baterei suplai, periksa apakah ada suplai arus dari baterei ke
output modul pre heat. Periksa bahwa pilihan pre heat telah
terpilih pada konfigurasi menu.
Starter motor inoperative Check Wiring to starter solenoid. Check battery supply.
Starter motor tidak beroperasi Check battery supply is present on the Starter output of
module. Ensure that the Emergency Stop input is at +ve.
Periksa rangkaian kabel ke starter solenoid, periksa suplai arus
baterei, periksa apakah suplai arus baterei ada pada modul
output starter. Pastikan bahwa input untuk emergency stop
adalah +.
Engine runs but generator will Check Warm Up timer has timed out. Check configuration
not take load to ensure output has been selected to give Load Transfer.
Mesin berjalan, tetapi beban yang Periksa apakah timer warm up telah lewat, periksa
diberikan pada genset tidak konfigurasinya untuk memastikan bahwa output telah terpilih
tercapai. untuk transfer pembebanan.
8.3. IF THE ENGINE DOES NOT CRANK
1. Check battery voltage. If it is low, charge the battery. Investigate the battery charger (if
fitted).
1. Periksa voltase aki, Jika lemah, charge baterai tersebut, Periksa baterei chargernya (jika terpasang).
2. Check the fuse. If open circuit replace the fuse, ensuring that the rating is correct and
investigate the cause of the fuse blowing (short circuit to earth).
2. Periksa sekering, Jika terjadi hubungan langsung, segera ganti dengan sekering yang baru dan
pastikan spesifikasi sekeringnya sesuai dan periksa sebab-sebab sekering terputus.
3. Check ‘the start contactor, which may be open circuit, have a short circuit to earth or have
contacts, which fail to close. If the start contactor is faulty, replace it.
3. Periksa Kontak Start, kemungkinan mengalami sirkuit terbuka, terhubung langsung dengan kutub
bumi atau masih kontak walau sudah terputus. Jika kontaktor tersebut mengalami kerusakan, segera
diganti.
4. Check the starter motor carefully. It may be faulty or it may be jamming when it attempts to
engage the flywheel ring gear.
4. Periksa stater motornya dengan seksama. Mungkin terjadi kerusakan atau macet waktu
- 66 -
6. Maintenance
8. Fault Finding
menggerakkan roda gigi flywheel-nya
8.4. ENGINE CRANKS BUT DOES NOT FIRE
1. Check the fuel level in the service tank. If empty, fill the tank with the correct fuel, and
bleed the system.
1. Periksa level bahan bakar pada tangki. Jika kosong, isi dengan bahan bakar yang sesuai.
2. Check that the fuel lines are not broken and that there is no air in the fuel System. If so,
repair and bleed the system as necessary.
2. Periksa apakah saluran bahan bakar bocor dan tidak ada udara dalam sistem, jika hal itu terjadi
segera perbaiki.
3. Ensure the Control Switch is set at off before carrying out the following test:
3. Pastikan Saklar Kontrol di posisikan “off” sebelum di tes seperti berikut:
Disable the starter by removing the power supply cable.
Turn the key-switch to START and check that the run solenoid moves the fuel rack to the
correct position.
Matikan starter dengan melepaskan kabel powe supply
Putar kunci ke posisi START dan cek apakah tuas solenoid bergerak ke posisi yang benar.
4. Move the fuel linkage (if fitted) manually. If it is jammed, investigate and do necessary
remedy.
4. Gerakan pipa sambungan bahan bakar secara manual, Jika macet, periksa dan lakukan perbaikan.
5. Check the continuity of the run solenoid. If fault, replace the respective item.
5. Periksa kontinuitas pergerakan solenoid, jika tidak, ganti dengan yang baru.
NOTE: RECONNECT THE STARTER CABLE TO THE CORRECT TERMINAL

SAMBUNG KEMBALI KABEL STATER KE TERMINAL YANG TEPAT
6. Please, refer to the engine handbook and investigate the causes of poor starting
performance.
6. Gunakan buku manual mesin dan periksa penyebab starting mesin yang buruk itu.
8.5. GENERATOR SET DOES NOT START AUTOMATICALLY ON MAINS FAILURE

(MAINS FAIL SETS ONLY)
1. Does the set start under manual control.

1. Apakah unit dapat hidup dengan cara manual.
2. Check the wiring from the panel to the remote start/run contact.
2. Periksa instalasi kabel dari panel ke kontak start/run.
3. Replace the control unit.
3. Ganti kontrol unit.
8.6. LOW OIL PRESSURE PROTECTION CIRCUIT OPERATES
1. Check the oil level in the sump and replenish if necessary.

1. Periksa level oli dan tambahkan oli jika diperlukan.
2. Start the plant and observe the oil pressure gauge. Does the oil pressure increase on
starting? If not, consult the engine handbook and investigate the gauge and lubrication
system.
2. Hidupkan unit dan perhatikan petunjuk tekanan oli, Apakah tekanan oli bertambah pada waktu start?
Jika tidak, baca buku manual engine dan periksa pengukur dan sistem pelumasan.
3. Disconnect the wires to the trip switch. Does the generator now shutdown on starting? If so,
- 67 -
6. Maintenance
8. Fault Finding
then replace the trip switch.

3. Lepaskan kabel saklar pemutus. Apakah generator mati saat dihidupkan? Jika mati, sambungkan lagi
kabel tersebut.
4. If the trip switch is working properly, then try changing the control unit.
4. Jika saklar pemutus masih bekerja dengan baik, coba ganti kontrol unitnya
8.7. ENGINE HIGH TEMPERATURE PROTECTION CIRCUIT OPERATES
1. Check that the airflow through the radiator module and around the generator set is not
restricted.
1. Periksa aliran udara yang melalui modul radiator dan sekeliling radiator, pastikan tidak terhalang.
2. Disconnect the cable from the engine temperature sensor and start the generator. Does the
protection circuit still operate? (If NO, check the temperature trip switch and wiring)
2. Lepaskan kabel sensor temperatur mesin dan hidupkan generator. Apakah sirkuit pengaman masih
berfungsi? (Jika tidak, periksa saklar pengatur temperatur dan kabel-kabel yang terkoneksi
dengannya).
3. Please, refer to the engine handbook and investigate the cause of overheating.
3. Gunakan buku manual engine dan periksa sebab-sebab kelebihan panas (overheating).
4. If there is no fault found, try changing the control unit.
4. Jika tidak ada kesalahan yang ditemukan, coba ganti control unit tersebut
8.8. GENERATOR SET STARTS ON MAINS FAILURE BUT DOES NOT GO ON LOAD
(MAINS FAIL SETS ONLY)
1. Check the fuse in the circuit breaker coil circuit. If fused, investigate the cause of its failure
and replace the fuse.
Periksa sekering pada sirkuit kumparan breaker.Jika terpasang, periksa sekering tersebut lalu pasang
kembali
2. Check for loose cables or wiring. If loose, do necessary remedy.
Periksa kabel-kabel atau wiring yang longgar,Jika longgar, perbaiki.
- 68 -
6. Maintenance
8. Fault Finding
8.9. ENGINE FAULT FINDING TABLE
The engine fault finding table will be describe in the enclosure at the end of this operation
manual.
No illustration intented for this section
- 69 -
OPERATION MANUAL
BRUSHLESS A.C. GENERATOR

Brushless A.C. Generator Operation Manual
6. Maintenance
1. Introduction
1. INTRODUCTION
This Operation Manual describes necessary instructions and cautions on how to handle
with this product and how to use it in safe manner.
Before using this product, you should first read this manual thoroughly and understand its
contents sufficiently.
Nonconformity to the instructions or cautions in this operation manual may lead to serious
accident.
As for the details of the related devices such as generator panel, AVR, distribution panel,
engine and so on, refer to their respective operation manual.
CARELESS USE OF THIS MACHINE MAY LEAD TO SERIOUS INJURY OR DEATH.
OPERATORS AND MAINTENANCE SERVICE WORKERS SHOULD READ THIS
OPERATION MANUAL THOROUGHLY BEFORE OPERATION, INSPECTING AND
MAINTAINING THIS MACHINE.
THIS MANUAL SHOULD BE KEPT NEAR THIS MACHINE FOR REFERENCE FOR ALL
OPERATORS TO LOOK IN TO IT PERIODICALLY.
• DO NOT OPERATE THE MACHINE UNTIL YOU ARE SUFFICIENTLY FAMILIAR

WITH THE EXPLANATIONS INCLUDED IN THIS OPERATION MANUAL.
• KEEP THIS OPERATION MANUAL ALWAYS NEAR THE MACHINE TO READ

IT REPEATEDLY.
• WHEN TO TRANSFER THE MACHINE, ALSO TRANSFER THIS OPERATION

MANUAL TO A NEW OWNER.
• IN THE EVENT OF LOSS OR DAMAGE OF THIS OPERATION MANUAL, ASK US

OR OUR AGENT FOR A NEW COMPLETE COPY OF THE MANUAL.
• DO NOT MODIFY THE MACHINE AT YOUR OWN CIRCUMSTANCE.

INSTRUCTIONS ON SAFETY ARE DESCRIBED IN THE NEXT PAGE
IN THIS OPERATION MANUAL, PLEASE UNDERSTAND THAT THE PRODUCT TYPE

IN ILLUSTRATION MAY DIFFER FROM THAT YOU USE.
- 70 -
6. Maintenance
2. Safety
2. SAFETY
To understand better the safety labels used in this product and its operation manual,
safety messages are classified as follows:
This indication is used in the case where
misoperation may cause a dangerous situation,
lead to serious personal injury or death.
This indication is used in the case where

misoperation may cause a dangerous situation,
lead to personal middle-class or slight injury or
physical damage to properties.
By the way, even some particulars listed under label may lead to serious results in
accordance with conditions. Observe all the instructions and cautions listed under both Warning
and Caution labels.
It is difficult for our company to forecast danger in operation and maintenance under all
the circumstances. Therefore, the warnings and cautions specified in this operation manual do
not cover all the ones for safety.
In the case to carry out any operation or maintenance other than specified in this
operation manual, those operators to do so are responsible for their results.
2.1. Cautions on Safety

2.1.1. Cautions on Safety in Transportation
• LOADING AND UNLOADING WORK MAY BE DANGEROUS, THEREFORE

PAY SUFFICIENT ATTENTION.
• SELECT A TRANSPORTATION VEHICLE CAREFULLY IN CONSIDERATION

OF THE PRODUCT WEIGHT AND VEHICLE LOADAGE.
• AT LOADING AND UNLOADING WORK, USE THE SUSPENDING LUG ATTACHED

TO THIS PRODUCT. IN ADDITION, DO NOT USE THE SUSPENDING LUG AT THE
CASE OF COMPLETE GENERATOR SET.
WHEN TO ENGAGE THE CRANE HOOK TO THE SUSPENDING LUG,

MAKE SURE THAT THE HOOK IS ENGAGED SECURE.
DISCONNECTION OF THE HOOK MAY CAUSE A SERIOUS PERSONAL
INJURY OR DAMAGE.
- 71 -
6. Maintenance
2. Safety
KEEP A DISTANCE FROM THE MACHiNE FOR FEAR OF ITS DROPPING

DOWN OR FALLING DOWN.
WHEN TO LOAD THIS PRODUCT WITH A FORKLIFT, PAY SUFFICIENT

ATTENTION TO THE PRODUCT WEIGHT AND STABILITY OF IT WHILE
LIFTED UP.
IF THE ALLOWABLE LOADAGE OF FORKLIFT IS EXCEEDED, OR THE
PRODUCT IS LIFTED IN UNSTABLE STATUS, THE PRODUCT MAY DROP
DOWN, CAUSING A SERIOUS PERSONAL INJURY OR DAMAGE.
AFTER LOADING THE PRODUCT, FIX IT SECURELY WITH WIRE ROPE,

FIXATION METAL FITTING, SQUARE BAR AND THE LIKES. OTHERWISE,
PERSONAL INJURY OR DAMAGE MAY RESULT.
AFTER LOADING THE PRODUCT, PROTECT THE PRODUCT WITH

APPROPRIATE COVER. OTHERWISE, DAMAGE BY RAIN, DIRT OR
DUST MAY RESULT.
2.1.2. Cautions on Safety in Installation and before Operation
DO NOT USE THE MACHINE IN EXPLOSIVE ATMOSPHERE. OTHERWISE,

PERSONAL INJURY OR FIRE MAY RESULT
DO NOT USE THE MACHINE IN STORMY ATMOSPHERE OR OUTDOOR.

OTHERWISE, CURRENT LEAKAGE, PERSONAL INJURY OR FIRE MAY
RESULT.
- 72 -
6. Maintenance
2. Safety
CHECK THE TERMINAL NUMBER, PHASE, CONNECTION AND WRONG

WIRING ARE CORRECT. OTHERWISE, ELECTRIC SHOCK OR FIRE MAY
RESULT.
CHECK THE CONNECTION AND ACTION OF THE PROTECTIVE DEVICE. OTHERWISE,

PERSONAL INJURY OR FIRE MAY RESULT.
KEEP THE PRODUCT AWAY FROM OPEN FIRE. OTHERWISE, PERSONAL

INJURY OR FIRE MAY RESULT. BY THE WAY, MAKE SURE THE INSTALLATION
PLACE OF AN EXTINGUISHER BEFORE OPERATION.
AVOID THE USE OF THIS PRODUCT UNDER THE AMBIENT

ENVIRONMENTAL CONDITIONS OTHER THAN SPECIFIED. OTHERWISE,
ELECTRIC SHOCK, PERSONAL INJURY OR DAMAGE MAY RESULT.
THE AMBIENT ENVIRONMENTAL CONDITIONS ARE SPECIFIED BY
RESPECTIVE CLASSIFICATION, STANDARDS AND SPECIFICATIONS.
MAKE SURE THAT THE PHASE ROTATION IS CORRECT BEFORE OPERATION.

SOME KINDS OF LOADS MAY CAUSE PERSONAL INJURY OR DAMAGE ON DEVICE.
KEEP A SAFE MAINTENANCE SPACE. OTHERWISE, ELECTRIC SHOCK

OR PERSONAL INJURY MAY RESULT.
DO NOT RIDE ON OR HUNG FROM THE PRODUCT. OTHERWISE, PERSONAL

INJURY MAY RESULT.
- 73 -
6. Maintenance
2. Safety
MAKE SURE THAT THE NECESSARY INSULATION RESISTANCE IS

OBTAINED BEFORE OPERATION. OTHERWISE, CURRENT LEAKAGE OR
PERSONAL INJURY MAY RESULT.
IN MEASURING INSULATION RESISTANCE, DO NOT CONTACT THE

TERMINAL. OTHERWISE, ELECTRIC SHOCK MAY RESULT.
DO NOT PLACE ANYTHING THAT MAY PREVENT VENTILATION AROUND

THE PRODUCT AT LEAST MORE THAN 50M. OTHERWISE, PERSONAL
INJURY, FIRE, OR DAMAGE MAY RESULT.
2.1.3. Cautions on Safety in Operation, Inspection, and Maintenance
DURING THE ROTATION OF THE PRODUCT, NEVER TOUCH THE

ROTATING PORTION. THERE IS A FEAR OF PERSONAL INJURY,
THEREFORE, ARRANGE A SAFETY GUARD OVER EXPOSED ROTATING
PORTION.
• WHEN TO COME NEAR THE PRODUCT OR INSPECT IT, AVOID WEARING

CLOTH THAT MAY TOUCH OR BE CAUGHT IN ITS ROTATING PORTION OR
HOT LINE PORTION. OTHERWISE, ELECTRIC SHOCK OR PERSONAL
INJURY MAY RESULT.
• BE SURE TO WEAR PROTECTIVE CLOTH SUCH AS A HELMET, SAFETY
SHOES, GLOVES 114 NECESSARY WORK.
DO NOT WORK IN HOT LINE CONDITION. BE SURE TO TURN THE

MACHINE OFF BEFORE WORKING. OTHERWISE, ELECTRIC SHOCK MAY
RESULT.
- 74 -
2. Safety
3. Qualification of Operator
IN INSPECTION, BE SURE TO CHECK EACH PHASE TERMINAL FOR

LOOSENESS OR DISCONNECTION. OTHERWISE, PERSONAL INJURY OR
FIRE MAY RESULT.
AVOID THE USE OF THIS PRODUCT UNDER LOAD OTHER THAN RATED.
OTHERWISE, PERSONAL INJURY, FIRE, OR DAMAGE MAY RESULT.
(IN ADDITION, EACH LOAD SHOULD BE ADDED EQUALLY TO EACH
PHASE.)
BECAUSE THE STATOR FRAME GETS VERY HOT DURING OPERATION,

DO NOT TOUCH IT. OTHERWISE, A BURN MAY RESULT.
MAKE SURE THAT THE NECESSARY INSULATION RESISTANCE IS

OBTAINED. OTHERWISE, CURRENT LEAKAGE OR PERSONAL INJURY
MAY RESULT.
IN MEASURING INSULATION RESISTANCE, DO NOT CONTACT THE

TERMINAL. OTHERWISE, ELECTRIC SHOCK MAY RESULT.
2.1.4. Disposal
WHEN TO DISPOSE THIS PRODUCT, DO SO AS A GENERAL INDUSTRIAL

WASTE.
3. QUALIFICATION OF OPERATOR
1) If the generator is used on board a ship, qualified marine engineers and other persons
who have been authorized by engineering institutes are allowed to operate the
generator.
2) If the generator is used on land, qualified chief engineers for electric machines or other
- 75 -
3. Qualification of Operator
4. General Identification
persons who are authorized by engineering institutes are allowed to operate the
generator, or should be an expertised person.
4. GENERAL IDENTIFICATION
1. Damper bar 9. Field core for exciter 17. Rotor coil

2. Coil Supporter 10. Field coil for exciter 18. Fan
3. Ventilation cover 11. End bracket 19. Coupling plate
4. Ball bearing 12. Lead wire 20. Fan boss,Coupling boss
5. Bearing shield 13. Frame 21. Shaft
6. Rotating rectifier 14. Stator core 22. Ventilation cover
7. Armature core for exciter 15. Rotor core
8. Armature coil for exciter 16. Stator coil
- 76 -
5. Mechanical Constructions
6. Initial Inspection and Coupling
5. MECHANICAL CONSTRUCTIONS
• STATOR
The stator frame is fabricated with mild steel plate or cast iron of round construction
which is designed to provide rigidity and strength so as to resist excessive mechanical and
electrical shocks.
The armature core is made of high quality silicon steel plates each coated with insulating
film for preventing eddy current, which are positioned along the internal surface of the frame.
The exciter field core is made of special steel plates capable of retaining high residual voltage.
• ROTOR
The rotor shaft is made of high quality carbon steel, and is designed and manufactured to
be mechanically durable. The rotor is a salient revolving field type with the main field core
made from special steel plates having superior magnetic characteristics. The field core ele-
ments, exciter rotor, rotary rectifier and cooling fan are integrated above the same shaft.
• BEARINGS
The long-life sealed ball bearing which prevents the grease, from escaping and the
entrance of foreign matter.
• VENTILATION
Cooling is provided by the cooling fan of the rotor through suction ports and exhausted
through outlet ports. Every machine conforms to the cooling code IC 01 of OS.
• ENCLOSURE
Every machine conforms to BS 4999, Part 20, which is screen protected or drip-proof
type.
Standard with connection box IP21
With terminal box IP21
With leading wire plate IP20
Options for drip-proof protection type IP22 is available at extra cost. (To be manufactured
at your request)
• CONNECTION BOX
The cable drawer attached to the external side of the connection box should be drawn
toward easy direction to process when using.
In case of the terminal box, the standard position of the external cable drawer viewed
from an anti-coupling side is on the right side.
6. INITIAL INSPECTION AND COUPLING
6.1. INITIAL INSPECTION

In case that the generator is stored for a long time, the storage place should be kept
clean, dry and ventilated. After warehousing the generator for a long time, check the insulative
resistance of the coils in accordance with this manual, Item 9—2, before operation and make
sure that there is no abnormal sound and overheating during operation. Especially in case of
generator for emergency, we recommend you to use the space heater (optional) in order to
keep the insulation of coils in a good condition.
- 77 -
6. Initial Inspection and Coupling
7. Excitation System
6.2. COUPLING WITH PRIME MOVER

T 7 series single bearing type generators make the centering possible with direct coupling
easily. If necessary then, insert an adjusting liner under the generator legs to obtain a level.
Coupling bolts are different depending on engine. For the bolt size and tightening torque,
inquire the engine maker or the related maker. Lamination plate for coupling is attached to
generator; Its tightening bolt size and tightening torque are shown in Table 1.
6.3. GROUNDING
The generator frame should be grounded surely based on generator set. Neutral terminal
used for neutral wiring is provided with generator, 3-phase 4-wire. The neutral line is not
connected with the generator frame.
Generator Model Tightening bolt No. of bolt Tightening torque

18B, 18GS. 18G M 10x1.5 x25 6 440kg—cm
2OCL, 20DL. M 12X1.75X25 8 740kg—cm
22DL, 25BL M16x2 x30 8 1 800kg—cm
Note) Tightening bolt material is SCM435 (111)

[Table 1.]
7. EXCITATION SYSTEM
Excitation system for T 7 series generator controls a part of power from main armature by
means of Automatic Voltage Regulator (AVR) as shown in Fig. 1, and supplies D.C. power to
exciter field. After D.C. power was supplied to exciter field, output from exciter armature is
supplied to main field coils by way of 3-phase bridge rotary rectifier.
AVR : Automatic Voltage regulator

Ex : Exciter
Si : Rotating rectifier
Fig.1. Block diagram for T7 series excitation system
ROTARY RECTIFIER AND SURGE SUPPRESSOR

The rotary rectifier assembly functions as 3-phase full wave rectification of output from
exciter armature and supplies it to the main field coil. To protect the diodes from big
instantaneous voltage surge, the surge absorber is provided with the rectifier unit.
- 78 -
8. Characteristics
9. Standard Voltage Selection Tables
8. CHARACTERISTICS
8.1. VOLTAGE REGULATION

Generator terminal voltage regulation is within ±1.5% of the rated voltage in lagging
power factor, 1.0 to 0.8, when the load is varied gradually from no load to full load. This value
includes the temperature drift and rotating variation.
8.2. RESPONSE
After supplying a load instantaneously, the generator voltage should be restored to the
steady condition in accordance with BS4999 Part 40, grade VR2.1 1 to VR223.
8.3. VOLTAGE STABILITY

In constant load and engine speed, voltage stability remains ±0.25% of the rated voltage.
8.4. MOTOR STARTING

The generator is capable of enduring up to 150% of the rated current for 15 seconds.
8.5. PHASE ROTATION

Phase sequence is T1-T2-T3 (U-V-W) is a counter-clock wise rotation of generator viewed
from the anti-coupling side.
9. STANDARD VOLTAGE SELECTION TABLES
8.1. FOR 18 B ~ 25 B L
Standard voltage selection tables of T7 series 3-phase 4-wore / 3-phase 12-wire A.C.
generator and connection diagram of T7 series 3-phase 12-wire A.C. generator are shown as
follow.
Model Winding connection Freq Voltage
18 B ~ 25 B L 3-phase 4 wire 60 Hz 480/277 460/266 440/254
Series star 50 Hz 415/240 400/231 380/219
18 B ~ 25 B L 3-phase 4-wire 60 Hz 240/139 230/133 220/127
Parallel star 50 Hz 208/120 200/115 190/110
18 B Single phase 60 Hz 240/120
Parallel zig-zag 50 Hz 230/115 200/100
3-phase 4 wire series 3-phase 4-wire parallel single phase 2 or 3 wire

Star star parallel zig-zag
Fig.5. Wiring for the 12 lead wire generator
- 79 -
10. Optional Equipments
11. Operation
10. OPTIONAL EQUIPMENTS
10.1 For 18 B ~ 25 B L
For T 7 series AC generator, the following optional equipments are available.
1) EXTERNAL VOLTAGE ADJUSTS RESISTOR (HT):

Available for remote control of voltage on the switch board distant from the generator set
in parallel operation (See AVR manual and parts list.)
2) SPACE HEATER:
For emergency generator which is not used for a long time or the generator which may
get wet with moisture (Coil heating type heater is available by supplying parts hut element type
one is made to order.)
3) TACHO GENERATOR:
Available for detection of generator speed (Made to order).
4) AIR FILTER:
For generator installed at sandy place. In use of air filter, derate the generator output to
90% of the rated output as the air absorption of the generator varies. To prevent the loading of
air filter; clean it periodically. The loading of air filter causes overheat. (Made to order)
5) THERMISTOR:
When the temperature of the main armature coil exceeds the specified value, the
thermistor gives a signal. (Made to order)
6) REMEDY FOR MOISTURE AND SALTY DAMAGE:

When the generator is used near sea or at damp place. (Made to order)
7) EXCITATION SUPPORT SYSTEM

T 7 series A.C. generator cannot have the sustained short-circuit current as a
standard but can have it flow over 250% of the rated current with excitation support
system provided (Made to order).
8) CHOPPER SYSTEM AVR (Model: DST)
11. OPERATION
11.1. STARTING
For generator starting, make sure of the followings.
a) Make sure that each wiring is correct.
b) Make sure that there is no obstacle to ventilate near the air inlet and outlet.
c) Make sure that there is no foreign matters inside the generator.
- 80 -
11. Operation
12. Maintenance
d) Make sure that the circuit breaker is switched OFF.
After making sure of these points described above, start the generator in accordance with
the following procedure.
1) Start the engine in accordance with Service Manual for Engine and gradually
accelerate the engine speed up to the rated speed. Make sure that there is no
abnormal sound or vibration.
2) The voltage arises due to increase in generator speed. After making sure that each
interphase voltage is balanced, set the voltage and frequency to the rated level.
3) After making sure that the generator runs well during no-load operation, switch the
circuit breaker ON to start the load operation.
VOLTAGE ADJUSTMENT
The generator has been adjusted to obtain the optimum characteristic at order voltage at
the shop. If the voltage is different a little and the order voltage varies, adjust the voltage with
Voltage Adjust provided on AVR. When the external voltage adjust resistor (HT) is provided, set
up the HT in the center of generator to set to the rated voltage with Voltage Adjust provided on
AVR.
11.2. RUNNING
During operation, check the followings.
a) Abnormal vibration and sound

b) Load
c) Voltage, current and frequency
d) Temperature
e) Circumstance:
Keep it clean and clear to ventilate in circumference of air inlet and outlet for cooling
the generator, because insufficient cooling causes the overheat of generator.
When 3-phase generator is used at single phase load, each phase current should be
balanced. In addition, allowable unbalanced load is followed by Data Sheet.
11.3. STOPPING
After making the running generator in no-load condition by removing the generator loud
In turn, stop the engine in accordance with the Engine Manual.
12. MAINTENANCE
Normally, it is enough to inspect the bearings, but in the case where the generator has
not been used for a long time, check the insulation resistance. Next, the inspection method for
all sections is explained.
12.1. BEARING INSPECTION

For bearing inspection, make sure that there is no abnormal sound during normal running
- 81 -
11. Operation
12. Maintenance
and that there is no overheatIng. Grease resupply is not necessary for generators using the
double seal type ball bearings.
For the grease, use Kyodo Oil MULTEMP SAL or equivalent product. Also, both types of
bearings are expendable parts, so replace them with new parts after 20,000 hours of running.
(Concerning the replacement method, consult item 12.4. 1 “Bearing replacement”).
12.2. INSULATION RESISTANCE MEASUREMENT METHOD

In the case that the generator has not been used for a long time, check the insulation
resistance of each lead wire at 600 V megger. Usually it is enough to check only the stator
winding. At this time, in order to prevent damage to the AVR, disconnecting connector.
It the measured insulation resistance value is above 2 MΩ there is no problem, but in the
event it is lower than that, check to see if the inside of the generator is dirty or wet. In the
event that dust has accumulated, blow it out with dry compressed air. Wipe off oil stains with a
cloth. When the generator Is damp, dry it and check it again.
12.3. ROTATING RECTIFIER ASSEMBLY INSPECTION
Normally, there is practically no need to pay attention to the rotating rectifier assembly.
Periodically clean off its dust and oil stains. In the unlikely event that it is necessary to replace
the diode elements and surge absorber elements, consult Item, 12.4. 2) “Replacement of parts
for the rotating rectifier assembly” and item 12.4.3) “Rotating rectifier assembly detailed
structure figure”
12.4. PARTS REPLACEMENT METHOD
1) BEARING REPLACEMENT
(See 1. GENERAL IDENTIFICATION)
(A) In order to replace the bearing (2), first remove the bearing shield (7) on the anti-
coupling side.
When the bearing shield is removed, be careful not to damage the lead wires. In
addition, since there is a risk that when the bearing shield is being removed, the rotor
may fall and damage the Ex. rotor or the Ex. stator, remove it by lifting it up and let it
down gently.
The faucet length of bearing shield (7) is 3 mm,
[Fig. 8]
- 82 -
11. Operation
12. Maintenance
(B) Using bearing puller, extract the bearings from the shaft.
Bearing puller Ball bearing Exciter armature
Rotating rectifier assembly
[Fig. 9]
(c) When fitting new bearing, place a steel pipe to the inner race surface, and fit the
bearing by tapping it lightly with a hammer.
(Note) At this time, absolutely no strength must be applied to outer race of bearing.
2) REPLACEMENT OF ROTARY RECTIFIER PARTS
(a) In order to replace the parts of the rotating rectifier assembly, extract the generator
rotor from the generator frame. However, for generators from 18 B ~ 25 B L
replacements is possible by just removing the bearing shield.
(b) The sequence for extracting the generator rotor is as follows.
(1) Remove the generator from the engine and transfer it to the work location.
(2) Remove the bearing shield (refer to Item 12, 12.4),
(3) Using an auxiliary shaft, extract towards the coupling side, as shown in the rough
figure on following page.
(4) Place the remove rotor on a stand, and be sure to cover it with a vinyl or cloth mat.
Also, pay attention that no other objects touch the rotor winding, etc.
(5) When extracting the rotor, bring the shaft centers of both the rotor and stator into
line so they do not come into contact. In particular, both end portions have been
bound with special tape in order to bind the coil end, so be careful not to allow
them to come into contact with the stator.
(c) In order to test whether the rotating rectifier assembly diode elements are good or not,
first disconnect the A.C. side lead wires and the D.C. side lead wires coming from the
exciter which is connected to the rotating rectifier assembly, and also disconnect the
lead to the diode elements and measure the resistance between the nnode and cathode
of each diode with a tester.
=caution=
Make the time the soldering Iron is in contact with the diode elements as short as
possible.
- 83 -
11. Operation
12. Maintenance
(Fig.10 Extracting the Generator Rotor]
If the resistance value of the diode element in forward direction is near 0Ω and the
reverse direction resistance value shows infinity, it is good, but if this is not the case, the
diode element is defective and must be replaced. When installing diode elements, it is
essential not to tighten them with excessive strength. If they are over tightened, the
diode elements will be damaged.
The specified fastening torque for each diode element is as in the table below.
Model Diode Element Diode type Fastening Torque

Part model
18 B ~ 22 D L S I D 01 – 09 K 17 Kg-cm
E R D 51 – 09 J
25 B L S I E 01 – 12 K 40 Kg-cm
E R E 51 – 12 J
“J” type diode elements for the J (+) side of the rotating rectifier assembly, and “K” type
diode elements for the K (-) side, are fastened. The method for checking each type with a
ohmmeter is as follow. ( Normal condition ).
Fig. 11-1 “K” type checking method.
- 84 -
11. Operation
12. Maintenance
Fig. 11-2 “J” type checking method.
(D) In order to test wether the rotating rectifier assembly surge absorber elements are good
or not, first disconnect all lead wires as described item 12-4. 2). C). and measure the
resistance across surge absorber elements with a tester. Good surge absorber element
have approximately 10~30KΩ, but if resistance reading are near 0Ω surge absorber
element is defective and must be replaced, also inspect outside view of surge absorber
and replace new one of it is cranked. In addition, when installing surge absorber
elements, apply super bond to the bolts.
3) ROTATING RECTIFIER ASSEMBLY DETAILED STRUCTURE FIGURE
T7 series generator of the rotating rectifier assembly, and figures 12-1 show detail
drawing
Surge absorber
Diode (J)
Diode (K)
Exciter rotor lead Conductive Ring (K)

(AC side)
Lock washer
Conductive ring (J)
Generator rotor lead

(DC side)
Sleeve
Fig. 12-1 (18 B ~ 25 B L)
- 85 -
13. Trouble Shooting
14. Service Information
13. TROUBLE SHOOTING
No Symptom Problem cause Remedy

1 Only a few volts are 1. Disappeareance of remaining magnetism 1. Carry out field flashing.
output of the ex. Field. 2. Check the insulation of all
2. Disconnection or short circuit of winding. winding and check the
3. Defective AVR. resistance value.
4. Defective revolving rectifier assembly 3. Check the AVR.
element 4. Replace diode element.
2 Voltage low 1. Incorrect wiring (GEN, AVR). 1. Re-check the winding
2. Too low speed. connection.
3. Overloaded. 2. Check the engine.
4. Defective AVR. 3. Reduce the load.
4. Check the AVR.
3 Voltage dip when on 1. Starting of big motor or spot welding 1. About 15% voltage dip is no
load machine. problem.
2. Defective diode on revolving rectifier. 2. Change diode.
F(+) F(-) terminal voltage will show very
high value when one of the diode is
defective.
4 Voltage high 1. Incorrect wiring (GEN, AVR). 1. Re-check the winding
2. Too high speed. connections.
3. Defective AVR. 2. Check the engine.
3. Check the AVR.
5 Fluctuation voltage 1. Loosening of each lead wire. 1. Re-tighten.
2. Irregular speed of engine. 2. Check the engine.
3. Poor AVR adjustment. 3. Check the AVR.
4. External noise. 4. Filter.
6 Abnormal sound or 1. Foundation uneven. 1. Check the ground level.
vibration 2. Poor mounting. 2. Check the mounting section.
3. Misaligned coupling. 3. Check the coupling section.
4. Defective bearing. 4. Replace the bearing.
14. SERVICE INFORMATION
We are confident that you will have no problem if you use our Brushless A.C. generator
in accordance with this manual. When the generator had any trouble, investigate the cause of
trouble as per trouble shooting. If you could not solve the problem on the generator, please
contact us or our agency after making sure the following items, the more correct and detailed
description on check items below makes the finding of cause of the generator trouble easy and
makes the speedy solution of trouble and good customer service possible.
- 86 -
13. Trouble Shooting
14. Service Information
SERVICE INFORMATION
DATE CLIENT Address
TEL NO.
GENERATOR MODEL GENERATOR Serial No.
AVR MODEL AVR Serial No.
COMMISSIONING DATE Running Hour
Symtomp No output Voltage low Controlable Uncontrolable V
of Voltage high Controlable Uncontrolable V Voltage dip when on load
trouble Fluctuating voltage V ~ V Others
When problem Engine starting time Engine stopping time When on load / off load Continual operation
occurred Other's
What kind Single phase load D.C. motor Welding sets AC/DC converter
of load Other's
O
Near sea High temperature C Moisture % Sand
Circumstance Outdoor Indoor Chemical gas Thunder
Other's
Running Voltage KW
condition Current P.F
before trouble Hz Other's
Agency
- 87 -
OPERATION MANUAL
AUTOMATIC VOLTAGE REGULATOR
DST-100-2FA
Automatic Voltage Regulator (AVR) Operation Manual
1. Introduction
2. Safety
1. INTRODUCTION
This instruction manual describes necessary instruction and caution on how to handle this
product, and how to use it in safe manner.
Before use, please read this manual carefully, and well familiarize yourself with the
product so that you can handle and use it properly.
Failure to observe any instructions in this manual may result in a serious accident.
Careless handling or use of the product may lead to an accident causing a serious injury
or death. All persons in charge of operation or maintenance should read this manual
attentively before proceeding to operation, maintenance, or inspection. Keep this manual
near the product so that the operators can read it whenever necessary.
Don’t use the product before you become thoroughly familiar with it.
Always keep this manual near the product so that you can refer to it whenever necessary.
If you transfer the product, don’t forget to hand over this manual, too.
Never modify the product at your own discretion.
Safety matter is described page 2 to 3 in this manual.
Figures shown in this manual may not perfectly represent your AVR
2. SAFETY
To understand better the safety labels used in this product and ~ts operation manual,
safety messages are classified as follows:
This indication is used in the case where misoperation may

cause a dangerous situation, lead to serious personal injury or
death.
This indication is used in the case where misoperation may cause

a dangerous situation, lead to personal middleclass or slight injury
or physical damage to properties.
By the way, even some particulars listed under

! label may lead to
serious results in accordance with conditions. Observe all the instructions and cautions listed
under both Warning and Caution labels.
It is difficult for our company to forecast danger in operation and maintenance under all
the circumstances. Therefore, the warnings and cautions specified in this operation manual do
not cover all the ones for safety.
- 88 -
1. Introduction
2. Safety
In the case to carry our any operation or maintenance other than specified in this
operation manual, those operators to do so are responsible for their results.
2.1 SAFETY PRECAUTION

2.1.1 CAUTION ABOUT INSTALLATION AND WIRING.
Don’t use the AVR under any environmental conditions other than those specified.
Should install service and operate by suitable operators and engineers to prevent
personal injury or physical damage to properties.
2.1.2 PRECAUTION TO BE TAKEN BEFORE OPERATION.
Do not execute measurement of insulation resistance and resist pressure

test for AVR.
When you execute measurement of insulation resistance and resist pressure
test for generating set, you should execute it after take AVR connector off from
generating set.
If you execute wrong test, you will break components in AVR.
2.1.3 PRECAUTIONS TO BE TAKEN DURING OPERATION.
Don’t touch any part except adjustment part during operation.

Never touch any terminals of the AVR during operation. Touching a terminal
during operation may cause an electric shock or injury.
CAUTION ABOUT MMNTENANCE AND INSPECTION.
Don’t proceed to maintenance or inspection before turning off the generator

driving unit, otherwise you may get a shock.
You should hold case portion of AVR, when carrying AVR for maintenance or
inspection. Don’t hold connector portion or electric wire, it will be cause such as
damage or disconnection by fall accident.
- 89 -
1. Introduction
3. Product Description
3. PRODUCT DESCRIPTION
3.1 CHARACTERISTIC
The DST-100-2FA, Automatic Voltage Regulator (AVR) is suitable for TAIYO brushless A.C.
Generators (5OHz/6OHz).
The AVR is provided over excitation shutdown protection to prevent this AVR break down
to shut off over exciting current and frequency characteristic (V/Hz characteristic).
3.2. SPECIFICATIONS FOR AVR/DST-100-2FA
General specification of this AVR, refer the table 1-1.

Wiring for connection, refer the outline drawing 2-1.
Table 1-1 General specification
Input sensing power Voltage 173V~220V~240V

Frequency 5OHz/6OHz
Phase Single (Line to line)
AC Input power Voltage lOOV~127V~l39V
Frequency 5OHz/GOHz
Phase Single (Line to neutral)
DC Output power Voltage 85% of power input voltage
Cont. Current 3A maximum continuous
Current Max. 9A forcing 1~5 seconds at 25 degree OC
Forcing
Field resistance minimum 15 ohms
Voltage adjust range Minimum ±5% of nominal voltage
Temperature drift Within ±0.02% / degree C
Voltage build-up Self-building up at over 6V (power input voltage)
Ambient temperature —20 degree C ~ +50 degree C
Operating temperature —20 degree C ~ +60 degree C
Storage temperature —20 degree C ~ +70 degree C
VOLT I Hz characteristic 57Hz in 60Hz operation mode
47Hz in 50Hz operation mode
Exterior connection method Connector joint
Vibration countermeasure Mold packing
Outside dimensions 148mm (L) x 41mm (W) x 84mm (H)
Weight 0.48 kg
- 90 -
1. Introduction
4. Outline Drawing
4. OUTLINE DRAWING
Fig. 2.1 – Outline drawing
- 91 -
1. Introduction
5. Installation
5. INSTALLATION
5.1 MOUNTING
This AVR can be installed to horizontality and perpendicularity direction. In case of

perpendicularity direction, fetch side of AVR connector should be done to below direction, install
AVR to appropriate position of generator or control panel with small vibration. (Refer the
drawing 2-1)
Electric wire from AVR should be fixed and installed position to avoid disconnection by
vibration.
5.2 EXCITATION CIRCUIT
(1) Excitation terminal of AVR shall be connected as follows: (Refer the drawing6-1--6-3)
[1] Connector/9-pin, terminal number “4”(wire color : Yellow) should be connected to the
generator, exciter field terminal “J”.
[2] Connector/9pin, terminal number “5”(wire color: Green) should be connected to the
generator, exciter field terminal “IC’.
(2) When field resistance of excitation circuit is less than 15 ohms, and exciting current of full
load does not exceed maximum rating value of AVR, adjust the total amount value of
resistance equivalent to appropriate capacity should be more than 15 ohms, and connector
terminal of AVR shall connect to generator terminal J and K with series.
5.3. A.C INPUT POWER / INPUT SENSING POWER CIRCUIT AND AUXILIARY
POWER.
(1) A.C input power and input sensing power of AVTR shall be connected as follows:
A.C input power / input sensing power is supplied from the generator output.
A.C input power and input sensing power terminal consist of 3 terminals, one of this
terminal is common use terminal of A.C input power and input sensing power.
(Refer the drawing 6.1~6.3)
1) Common use terminal of A.C input power and input sensing power.Connector/9-pin,
terminal number “l”(wire color: Light brown) should be connected to the generator
terminal number “3”.
2) The other terminal of A.C input power. Connector/9-pin, terminal number “2”(wire
color : Red) should be connected to the generator terminal number “4”.
3) The other terminal of input sensing power. Connector/9-pin, terminal number
“3”(wire color: Orange) should be connected to the generator terminal number
“E3”.
(2) Auxiliary power should be connected as follows:
1) Connector/9-pth, terminal number “7”(wire color : Purple) should be open-circuit.
2) Connector/9-pin, terminal number “8”(wire color: Gray) should be open-circuit.
(3) Adjustment field of A.C input power is from 100V to 127V and from 127V to 139V (A.C
voltage).
- 92 -
1. Introduction
5. Installation
5.4 INTERNAL VOLTAGE ADJUST CONTROL AND EXTERNAL VOLTAGE ADJUST

RHEOSTAT
(1) Internal voltage adjust control (VOLT.ADJ) is used for adjustment of the generator output
voltage.
(2) The terminal for connection of external voltage adjust rheostat is equipped on AVR.
[1] In case of not use external voltage adjust rheostat.(Refer the drawing 6.1~6.3)
Jumper wire should be connected as follows. Generator output voltage increases when
turn internal voltage adjust control (VOLT.ADJ) to clockwise.
(a) In case of 60Hz specification.
Connector/6-pin, terminal number “1”(wire color Light brown) and connector/6-
pin, terminal number “2”(wire color : Red) should be connected by jumper wire.
(b) In case of 50Hz specification.
Connector/6-pin, terminal number “1”(wire color: Light brown) and connector/B-
pin, terminal number “3”(wire color: Orange) should be connected by jumper wire.
[2] In case of using external voltage, adjust rheostat. (Refer the drawing 6.1~6.3)
HT (below 2000 ohms and more than 2 watt) should connect as follows.
Besides, if jumper wire is connecting, you should connect HT after removing jumper
wire.
Connector/6-pin, terminal number “1”(wire color : Light brown) and connector/B-
pin, terminal number “2”(wire color: Red) should be connected to HT.
Connector/6-pin, terminal number “1”(wire color: Light brown) and connector/6-
pin, terminal number “3”(wire color: Orange) should be connected to HT.
5.5. SELECTION AND ADJUSTMENT FOR V/Hz CHARACTERISTIC AND “CORNER

FREQUENCY”.
V/Hz characteristic control voltage rise until frequency setting will be started, and is used
to improve start characteristic of load. (Refer the drawing 3.1)
(1) To acquire V/Hz characteristic, connect as follows: (Refer the drawing 6.1~6.3)
[1] In case of setting “corner frequency (57Hz)” at 60Hz specification.
Connector/6-pin, terminal number “4”(wire color : Yellow) and terminal number
“5”(wire color: Green) should be connected by jumper wire.
[2] In case of setting “corner frequency (47Hz)” at 50Hz specification. Connector/6-pin,
terminal number “4”(wire color : Yellow) and terminal number “5”(wire color : Green)
should be open (open circuit).
(2) “Corner frequency” of each specification is adjusted by V/Hz adjustment knob (V.F.ADJ),
and “corner frequency point” is decrease, when you turn adjustment knob to clockwise.
[1] In case of changing set point of adjustment knob (V.F.ADJ).
(a) Full turn the adjustment knob (V.F.ADJ) to clockwise direction before alternator
starting.
(b) Adjust rated voltage by internal voltage adjustment knob after alternator
starting.
(c) Adjust the engine rotating speed and “corner frequency” to require alternator
frequency.
(d) ”Corner frequency” is set by turning V/Hz adjustment knob (V.F.ADJ) to
counterclockwise direction until output voltage begin to drop.
- 93 -
1. Introduction
5. Installation
Fig. 3.1 V/Hz Characteristic
5.6. STABILITY ADJUSTMENT KNOB
Internal stability adjustment knob can adjust response speed of generator output voltage
in load effect.
(1) When turn stability adjustment knob (STAB.ADJ) to clockwise direction, response
speed is blunt and value of voltage overshoot is small (stability orientation).
(2) When turn stability adjustment knob (STAB.ADJ) to counterclockwise direction,
response speed is quick and value of voltage overshoot is big (instability orientation).
5.7. OVEREXCITATION PROTECTION
When only flow over excitation current by wrong wiring to detection input of AVIR or
disconnection and imperfect contact, Circuit protector (CPR) for protecting AVIR damage is built
in AVR’s power input. (Refer the drawing 2.1)
When flow excessive current to AVR’s power input, CPR will be trip. White push-button of
CPR upside will remain condition to be pushed up approx. 1mm. (Refer the drawing 3.3)
- 94 -
5. Installation
6. Operation
When release CPR trip, you should stop the generator set. And you should push back
white button with finger as same height CPR top face after removing to be flowed cause
of over excitation current. This time, you feel sense a finger-top with small sound such
“click”. (Refer the drawing 3.2) If you strongly push back CPR’s white button with pen
point (etc), CPR will be broken. Please do not absolutely carry it out.
Fig. 3.2 In case of CPR is in normal operation
Fig. 3.3 In case of CPR is trip
6. OPERATION
6.1. GENERAL
The following operation method mentions for DST-1002FA type A’S/B.

You should execute the following step before setting up system. When abnormality
occurred in generation voltage, you should confirm it according to “chapter 8 Troubleshooting”.
Do not execute measurement of insulation resistance and resist pressure test

for AVR.
When you execute measurement of insulation resistance and resist pressure
test for generating set, you should execute it after take AVR’s connector
off from generating set.
If you execute wrong test, you will be break components in AVR.
6.2. PRELIMINARY SET UP
Confirm matching AVR’s specification with generating set.

Confirm connection of AVR’s wiring as follows:
(1) External voltage adjustment resistor (HT : less than 2kohm, more than 2W)
connection.
[1] In case of using HT.
- 95 -
5. Installation
6. Operation

Should connect HT to connector/6-pin, terminal number “1”(wire color: Light
brown) and connector/6-pin, terminal number “2”(wire color : Red).
Should connect HT to connector/G-pin, terminal number “1”(wire color : Light
brown) and connector/6-pin, terminal number “3”(wire color : Orange).
[2J In case of no using HT.
Should connect jumper wire between connector/6-pin, terminal number
“1”(wire color: Light brown) and connector/6-pin, terminal number “2”(wire
color : Red).
Should connect jumper wire between connector/S-pin, terminal number
“1”(wire color: Light brown) and connector/6-pin, terminal number “3”(wire
color: Orange).
(2) Adjust white line of AVR’s external voltage adjustment resistor knob (HT) to center
position.
(3) Setting V/Hz.
Connector/S-pin, terminal number “4”(wire color : Yellow) and connector/6-pin,
terminal number “5”(wire color : Green) should be connected by jumper wire.
Connector/6-pin, terminal number “4”(wire color : Yellow) and connector/6-pin,
terminal number “5”(wire color: Green) should be connected open(open circuit).
(4) Check the AVR connects with generating set justly.
6.3. SYSTEM SETUP
(1) Execute preliminary set up.

(2) Start the prime mover and increase the speed to the rated value. Voltage will be built
up.In case of no voltage built up, confirm the following items.
[1] When minimum residual voltage of power supply is less than 6V, you should
execute initial excitation according to “Section 6.4 of Chapter 6”.
[2] Check the alternator’s connection, short circuit, and overload.
(3) Check the alternator’s output voltage.
[1] In case of using external voltage adjustment resistor (HT less than 2kohm, more
than 2W), beforehand adjust HT’s dial to the center position.
[2] Slowly turn AVR’s internal voltage adjustment control (VOLT.ADJ) to clockwise
direction until alternator’s output voltage will become rated voltage.
[3] Confirmation of voltage adjustment range by HT.
Slowly turn the HT, confirm that alternator output voltage can adjust with range
more than ± 5% of rated voltage.
(4) Check AVR at normal operation and normal load.
Voltage regulation is less than ± 1.5% by full load from no load. When voltage
regulation becomes out of this range and problem occurred by operation, you should
confirm following items.
[1] Voltage drop by the load depends on speed fluctuation from no load to full load,
there is the case that corner frequency is set highly. You should increase to full
load at rated voltage by using V/Hz adjustment control (V. F.ADJ) and you
should set corner frequency.
- 96 -
6. Operation
7. Maintenance
[2] Check whether electrical insulation is correctly executed on wire of AVR or load
and all wires is correctly connected.
[3] Check the load balance is keeping equilibrium.
(5) When you find abnormality on operation besides above (2), (3) and (4), confirm
according to “Chapter 8 Trouble shooting”.
6.4. INITIAL EXCITATION
When you initially use AVR, there may be a case that polarity of residual magnetism is not
correct or magnet capacitance is not enough.
When there is no output from alternator after starting, stop the prime mover and execute
following steps.
Do not absolutely perform initial excitation to remain installing AVR during prime mover
operation.
(1) Take off AVR from generating set during prime mover stopping, directly connect direct
current (DC12V or DC24V) source that is not grounded and resistor to alternator’s
terminal “J” and “K”.
Select and connect the series resistor to supply the necessary exciting current at
8O% ~ 100% of alternator’s rated voltage during no load.
(2) Apply direct-current power source voltage for three seconds.
(3) Measure alternator’s terminal voltage after starting prime mover.
[1] If minimum residual voltage of power supply is more than 6V, voltage settlement
is adequate.
[2J If minimum residual voltage of power supply is less than 6V, execute initial
excitation again.
Fig. 4.1 Initial excitation.
7. MAINTENANCE
7.1. DAILY INSPECTION
Check it regularly whether there are not the accumulation of dust and the moisture.
Check the all wires are surely connected to AVR, is not stained and is rightly insulated.
- 97 -
7. Maintenance
8. Trouble Shooting
7.2. TEST FOR AVR UNIT
(1) Connect the circuit like the “Fig. 5.1” and confirm electric bulb is less than 100W at
100V.
(2) Fully turn the internal voltage adjustment control (VOLT.ADJ) or external voltage
adjustment knob (HT: less than 2kohm, more than 2W) to counterclockwise
direction.
(3) Supply power-source of 100V, 5OHz/GOHz to AVR.
(4) Electric-bulb, which is connected to AVR, continues turn off.
(5) Slowly turn internal voltage adjustment control (VOLT.ADJ) to clockwise. Electric-
bulb will turn on at setting point. If electric-bulb is staying light on or light off after
fine adjustment from this point, you can judge AVR normal.
Fig. 5.1 Unit test equipment
8. TROUBLE SHOOTING
8.1. TROUBLESHOOTING
When abnormality occurred with alternator voltage, check AVR according to

troubleshooting. This AVR is configuration to prevent a little malfunction and it consists of mold
stowing for confidence improvement. When it was broken, replace to the brand new AVR.
- 98 -
7. Maintenance
8. Trouble Shooting
8.1.1. IN CASE OF ELECTRICITY IS NOT GENERATED.
Phenomenon Cause Measure

1. No Voltage built up 1.1. Residual voltage is low 1.1. Execute initial excitation.
(refer the section 6.4)
1.2. Wrong wiring or disconnection. 1.2. Repair the wiring
1.3. Overloaded 1.3. Cut down the loads
1.4. AVR failure 1.4. Replace AVR
8.1.2. IN CASE OF GENERATION VOLTAGE IS LOW

1. CPR is tripping after 1.1. Wrong wiring or disconnection 1.1. Repair wiring
voltage built up
2. programmed voltage 2.1. HT set up failure 2.1. Adjust HT
is mismatched 2.2. VOLT. ADJ setup failure 2.2. Adjust VOLT. ADJ
3. Voltage changes with 3.1. V/Hz setup failure 3.1.Adjust V/Hz
engine speed 3.2. HT disconnection 3.2.HT repair or replacement
3.3. Imperfect contact of connector part 3.3.Repair connector part
4. CPR tripping after 4.1. Overloaded 4.1. Cut down the loads
load issuance 4.2. Voltage detection part disconnection 4.2. Repair wires or connector
or imperfect contact part
4.3. Alternator abnormality 4.3. Investigate alternator
4.4. AVR abnormality 4.4. Replace AVR
5. Adjustment inability 5.1. AVR abnormality 5.1. Replace AVR
8.1.3. IN CASE OF GENERATION VOLTAGE IS HIGH

1. Programmed voltage 1.1. HT set up failure 1.1. Adjust HT
is mismatched 1.2. VOLT. ADJ set up failure 1.2. Adjust VOLT. ADJ
2. Adjustment inability 2.1. AVR abnormality 2.1. Replace AVR
8.1.4. IN CASE OF GENERATION VOLTAGE IS HIGH

1. Unstable at low 1.1. Irregularity of engine rotation 1.1. Adjust engine
speed rotation
2. Voltage is unstable in 2.1. STAB. ADJ set up failure 2.1. Adjust STAB. ADJ
specified range
3. Adjustment inability 3.1. Interference with engine or governor 3.1. Adjust engine, governor or
3.2. AVR abnormality STAB. ADJ
3.2. Replace AVR
- 99 -
7. Maintenance
8. Trouble Shooting
8.1.5. IN CASE OF CARRIAGE RETURN IS SLOW AFTER LOAD ISSUANCE

1. Rotation recovery is 1.1. Overloaded 1.1. Measure current and check
slow 1.2. Engine abnormality specification
1.2. Adjust engine
2. Voltage recovery is 2.1. STAB. ADJ set up failure 2.1. Adjust STAB. ADJ
slow
8.1.6. IN CASE OF VOLTAGE FLUCTUATION IS BIG

1. Voltage fluctuation is 1.1. V-belt skids 1.1. Adjust tightening of V-belt
big in load issuance 1.2. Issuance or interrupting capacity is 1.2. Measure current and check
big specification
1.3. STAB. ADJ set up failure 1.3. Adjust STAB. ADJ
1.4. V/Hz Set up failure 1.4. Adjust V/Hz
1.5. Alternator abnormality 1.5. Investigate alternator
2. Adjustment inability 2.1. AVR failure 2.1. Replace AVR
- 100 -
7. Maintenance
9. Connection Diagram
9. CONNECTION DIAGRAM
Fig. 6.1 400V Class 3 phase 4 wire star connection
- 101 -
7. Maintenance
Fig. 6.2 200V Class 3 phase 4 wire star connection
- 102 -
7. Maintenance
Fig. 6.3 200V Class / 100V Class single phase zig zag connection
- 103 -
Enclosure
7. Maintenance
No illustration intented for this section
- 104 -
1 2 3 4 5 6 7 8 9 10 11 12
ALL DIMENSION IN mm
UNLESS OTHERWISE STATED
A TO LOAD A
R Y B N
TO DEEP SEA 521K
B B
ENGINE CONTROLLER
ST
HOUR RUN
3P 800AMP MCCB
STC COUNTER
W/S NEUTRAL LINK HZ
HR
FREQUENCY METER
C A 15 45 - 65HZ C
49 A 1 F1 2A
045 45
R
6
A 2
R3
F2 2A
046 46
Y
8
A 3 F3 2A
047 47 V1
B V1
A 4 TBE-1 V
48 48 V2
N V2
D D
AC VOLTMETER
VOLTMETER SWITCH 0 - 500V
P2
A 5
61
R
P1 P2
3 X CT A 6 62
E CLASS 1 15VA Y E
P1 P2
A 7 63 A1
B
P1
A 8 A
64 A2
N
A 9
E AC AMMETER
AMMETER SWITCH
800/5A
F F
Brown Brown VT1 A 23 VT1
3
1 1 2K OHM WP5W
(MOUNTED ON MCCB BOX)

4 Red Red POTENTIOMETER
AVR (DST-100-2FA)
2 2
Orange Orange VT3 A 24 VT3
(MOUNTED INSIDE PANEL BOX)
E3
3 3
J Yellow Yellow
4 4
DIESEL GENERATOR
380/220V 3P 4W G K
5
Green Green
5
50HZ 0.8PF Purple
G ~ 7 G
Grey
8
ENGINEERING DEPT. TITLE : AC SCHEMATIC DIAGRAM FOR SCANIA PROJ. REF
H H
DRAWN ANTONI APPROVED MODEL FPS PROJ. NO -
-
DATE 29 JUN '05 SCALE NTS PROJECTION DWG. NO DSE521/FPS/AC1 PAGE : 03/ 05 REV AMENDMENTS DATE
1 2 3 4 5 6 7 8 9 10 11 12
1 2 3 4 5 6 7 8 9 10 11 12
ALL DIMENSION IN mm
A TO LOAD A
R Y B N
TO WOODWARD
B B
CONTROLLER
ST
3P 630AMP MCCB
STC
W/S NEUTRAL LINK
C A 15 C
49 A 1 F1 2A
045 45 45 46 47 48
6
A 2
R3
F2 2A
046 46
8
A 3 F3 2A
047 47
A 4 TBE-1
48 48
D D
P2
A 5
61
R
P1 P2
3 X CT A 6 62
E CLASS 1 15VA Y E
P1 P2
A 7 63 A1
B
P1
A 8 A
64 A2
N
A 9
E AC AMMETER
AMMETER SWITCH
800/5A
F F
3
1 1 2K OHM WP5W

AVR (DST-100-2FA)
2 2
E3
3 3
J Yellow Yellow
4 4
DIESEL GENERATOR
380/220V 3P 4W G K
5
Green Green
5
50HZ 0.8PF Purple
G ~ 7 G
Grey
8
ENGINEERING DEPT. TITLE : AC SCHEMATIC DIAGRAM FOR SCANIA D9 - SOLENOID (WOODWARD) PROJ. REF
H H
DRAWN ANTONI APPROVED MODEL FPS PROJ. NO -
-
DATE 18 AUG '05 SCALE NTS PROJECTION DWG. NO 320X/FPS/AC1 PAGE : 03 / 05 REV AMENDMENTS DATE
1 2 3 4 5 6 7 8 9 10 11 12
H

ALL DIMENSION IN mm
ENGINEERING DEPT.
1
1
E
TBE-3
BATTERY BANK
1
E 22
6A 1P MCB1
2
1
1
01
2
2
ES
1
20A 1P MCB2
DATE
DRAWN
TITLE :
3
SYSTEM ON AUX RELAY
2 7 2 1
04
R2
FROM PROJ. NO : DSE521/FPS/AC1

SYSTEM ON AUX RELAY
2 7
29 JUN '05
DC SCHEMATIC DIAGRAM FOR SCANIA D9 - SOLENOID

ANTONI
ALTERNATOR SUPPLY
R2A
14
5
STARTER AUX RELAY
2 7
45
3
3
R1
COMMON FAULT AUX
15
6
RELAY 2 7
48
SCALE
APPROVED
R3
R5
7
BUZZER
8 5 +
28
7
-
BZ
DEEP SEA 521 ENGINE CONTROLLER

ALARM MUTE AUX RELAY
8 6 2 7
4
4
29
CBZ R5
ALARM MUTE PUSH

NTS
BUTTON 4 3
E
8
TO CHARGING ALTERNATOR
D+
8
CHARGE FAIL SIGNAL
8
PROJECTION
MODEL
LOW OIL PRESS. BYPASS R2A

5
5
SIGNAL 8 5
E
5
LOW OIL PRESS. SIGNAL

OP
(DIRECT FROM SWITCH)

9
4
E
6
FPS
HIGH WATER TEMP. SIGNAL

10
WT

10
MSR
13
AUTO START SIGNAL

6
6
16 15
13
TBM-2
TBM-1
DWG. NO
PROJ. NO
11
E 12
-
DSE521/FPS/CL1
7
7
COOLANT LOW LEVEL
CLL
12
SIGNAL
12
E
R2
3
TO FUEL SOLENOID HOLD

FPS
SIGNAL 3 1
32
E
8
8
R1
2
TO FUEL SOLENOID PULL

FPS
SIGNAL 6 8
34
PAGE :
E
-
R1
4
PROJ. REF
SMC
TO STARTER RELAY
3 1
33
01 / 05
9
9
DCV
DC VOLTMETER
E 10
TO OIL PRESSURE SENSOR

96
3
REV
R2
OPG
OIL PRESSURE GAUGE

6 8
03
E 11
10
10
TO WATER TEMPERATURE
SENSOR
97
WATER TEMPERATURE
WTG
AMENDMENTS
GAUGE
E 20

OPS
(+)
1
2
11
11
12
12
DATE
-
H
A
H

ALL DIMENSION IN mm
ENGINEERING DEPT.
1
1
E
TBE-3
BATTERY BANK
1
E 22
6A 1P MCB1
2
1
2
1
01
2
2
ES
1
20A 1P MCB2
DATE
DRAWN
TITLE :
13
11
SYSTEM ON AUX RELAY
13
11
2 7 2 1
TBS-1
TBS-2
04
R2
2
SYSTEM ON AUX RELAY
2 7
18 AUG '05
15
DC SCHEMATIC DIAGRAM FOR SCANIA D9 - SOLENOID (WOORWARD)
ANTONI
R2A
15
14
3
3
STARTER AUX RELAY
14
2 7
R1
COMMON FAULT AUX

SCALE
APPROVED
RELAY 2 7
R3
12
BUZZER
12
+
33
-
45
BZ
WOODWARD 320X CONTROLLER

4
4
E
ALTERNATOR SUPPLY
8
31
D+
NTS
46
CHARGE FAIL SIGNAL
29
47
LOW OIL PRESS. BYPASS R2A
PROJECTION
MODEL
SIGNAL 8 5
E
35
5
48
OP
5
5
16

16
4
E
6

17
WT

17
FPS
MSR
18
AUTO START SIGNAL

6
6
16 15
18
TBM-2
TBM-1
DWG. NO
PROJ. NO
E 12
-
320X/FPS/CL1
7
7
COOLANT LOW LEVEL
CLL
20
SIGNAL
20
E
R2
3
TO FUEL SOLENOID HOLD

FPS
8
8
SIGNAL 3 1
32
E
R1
2
PAGE :
TO FUEL SOLENOID PULL

FPS
-
SIGNAL 6 8
34
PROJ. REF
R1
4
01 / 05
SMC
TO STARTER RELAY
3 1
33
9
9
REV
E 10

96
10
10
R2
OPG
OIL PRESSURE GAUGE

6 8
03
E 11
AMENDMENTS
TO WATER TEMPERATURE
SENSOR
97
WATER TEMPERATURE
WTG
GAUGE
11
11
E 20

OPS
(+)
1
2
12
12
DATE
-
H
A
1 2 3 4 5 6 7 8 9 10 11 12
ALL DIMENSION IN mm
A TO LOAD A
R Y B N
TO DEEP SEA 521K
B B
ENGINE CONTROLLER
ST
HOUR RUN
3P 800AMP MCCB
STC COUNTER
W/S NEUTRAL LINK HZ
HR
FREQUENCY METER
C A 15 45 - 65HZ C
49 A 1 F1 2A
045 45
R
6
A 2
R3
F2 2A
046 46
Y
8
A 3 F3 2A
047 47 V1
B V1
A 4 TBE-1 V
48 48 V2
N V2
D D
AC VOLTMETER
P2
A 5
61
R
P1 P2
3 X 800/5A CT A 6 62
E CLASS 1 15VA Y E
P1 P2
A 7 63 A1
B
P1
A 8 A
64 A2
N
A 9
E AC AMMETER
AMMETER SWITCH
800/5A
F F
3
1 1 2K OHM WP5W

AVR (DST-100-2FA)
2 2
E3
3 3
J Yellow Yellow
SCANIA DC16 43A 4 4
DIESEL GENERATOR
380/220V 3P 4W
G K
5
Green Green
5
Purple
G 50HZ 0.8PF ~ 7 G
Grey
8
ENGINEERING DEPT. TITLE : AC SCHEMATIC DIAGRAM FOR SCANIA D16 - EMS PROJ. REF
H H
DRAWN ANTONI APPROVED MODEL - PROJ. NO -
-
DATE 29 JUN '05 SCALE NTS PROJECTION DWG. NO -
ED-05000-003-00 PAGE : 01 / 01 REV AMENDMENTS DATE

1 2 3 4 5 6 7 8 9 10 11 12
1 2 3 4 5 6 7 8 9 10 11 12
ALL DIMENSION IN mm
A TO LOAD A
R Y B N
TO WOODWARD
B B
CONTROLLER
ST
3P 800AMP MCCB
STC
W/S NEUTRAL LINK
C A 15 C
49 A 1 F1 2A
045 45
6
A 2
R3
F2 2A
046 46
8
A 3 F3 2A
047 47
A 4 TBE-1
48 48
D D
P2
A 5
61
R
P1 P2
3 X 800/5A CT A 6 62
E CLASS 1 15VA Y E
P1 P2
A 7 63 A1
B
P1
A 8 A
64 A2
N
A 9
E AC AMMETER
AMMETER SWITCH
800/5A
F F
3
1 1 2K OHM WP5W

AVR (DST-100-2FA)
2 2
E3
3 3
J Yellow Yellow
SCANIA DC16 43A 4 4
DIESEL GENERATOR
380/220V 3P 4W
G K
5
Green Green
5
Purple
G 50HZ 0.8PF ~ 7 G
Grey
8
H H
-
DATE 08 JUL '05 SCALE NTS PROJECTION DWG. NO -

1 2 3 4 5 6 7 8 9 10 11 12
H

ALL DIMENSION IN mm
ENGINEERING DEPT.
1
1
E1
TBE-3
BATTERY BANK
1
E 22
6A 1P MCB1
2
1
1
01
1
ES 20A 1P MCB2
2
2
4
3
SYSTEM ON AUX RELAY
DATE
DRAWN
2 7 2 1
3
TITLE :
04
R2
2
SYSTEM ON TIMER
(TIME SET 5 SEC.) 2 7
ALTERNATOR SUPPLY
T1
29 JUN '05
DC SCHEMATIC DIAGRAM FOR SCANIA D12 - EMS
14
ANTONI
45
E5
3
3
SMC
15
5
TO STARTER RELAY
48
COMMON FAULT AUX
SCALE
APPROVED
6
RELAY 2 7
6
R3
R5
7
BUZZER
8 5
28
7
- +
BZ
DEEP SEA 521 CONTROLLER

4
4
8 6 2 7
29
NTS
CBZ R5
ALARM MUTE PUSH

BUTTON 4 3
E8
PROJECTION
MODEL
L
8
CHARGE FAIL SIGNAL
8
5
5
10
(DIRECT FROM COO.)

C6
(DIRECT FROM COO.)

-
T1
OIL PRESSURE SIGNAL

9
8 5
C15
1T
6
6
DIAGNOSIS SWITCH NOT
11
NO NO
11
DWG. NO
PROJ. NO
OFF SIGNAL
MSR
13
AUTO START SIGNAL

16 15
13
TBM-2
TBM-1
12
-
E 14
E 12
7
7
COOLANT LOW LEVEL
CLL
18
18
SENSOR
OIL PRESSURE SIGNAL
(DIRECT FROM COO.)

C11
R2
8
8
OPG
OIL PRESSURE GAUGE

6 8
03
WATER TEMPERATURE SIGNAL

PAGE :
(DIRECT FROM COO.)

C10
-
PROJ. REF
WATER TEMPERATURE
WTG
GAUGE
01 / 01
9
9
DCV
DC VOLTMETER
REV
10
10
AMENDMENTS
11
11
O4
DC SOURCE TO DWG. NO : ED-05000-003-00

12
12
DATE
A
1 2 3 4 5 6 7 8 9 10 11 12
ALL DIMENSION IN mm
A A
ALTERNATOR SUPPLY
BATTERY BANK CAN BUS
FROM DWG. NO : ED-05000-001-00
TBCB-1
TBCB-2
E 1 E 22
1 01
B B
20A 1P MCB2
6A 1P MCB1
TBE-3
2 2
04 O4
C C
8
1
R1
ES
6
2
2 11 15 45 46 47 48 C21 C45
2 11 15 33 31 29 35 39 40

WOODWARD CONTROLLER 320X
D D
1 13 14 12 3 17 16 19 18 20
1 13 14 12 3 C6 C15 19 18 20
TBM-1
E 12
NO
15
+
MSR
BZ
CLL
T1
1T
E 33 E
-
NO
16
8
E 8 E 5
E 14
TBM-2
L
7
7
F F
R1
T1
R2
R3
SMC
2
2
1


SYSTEM ON AUX RELAY

OIL PRESSURE SIGNAL
(DIRECT FROM COO.)
(DIRECT FROM COO.)
COOLANT LOW LEVEL

CHARGE FAIL SIGNAL
COMMON FAULT AUX
AUTO START SIGNAL

TO STARTER RELAY
TO STARTER RELAY
(TIME SET 5 SEC.)
SYSTEM ON TIMER
G G
OFF SIGNAL
SENSOR
BUZZER
RELAY
ENGINEERING DEPT. TITLE : DC SCHEMATIC DIAGRAM FOR SCANIA D12 - EMS (WOODWARD) PROJ. REF
H H
-
PAGE : 01 / 01 REV AMENDMENTS DATE
1 2 3 4 5 6 7 8 9 10 11 12
H

ALL DIMENSION IN mm
DC CONTROL SOURCE FROM DWG. NO : ED-05000-002-00
ENGINEERING DEPT.
1
1
E
E 20
04
1
2
TBCP-4 TBCP-1
NETGATIVE (GROUND)
P2
P1
POSITIVE SOURCE
(MOUNTED ON ENGINE SIDE)

1/1
1/1
04/1
04/1
E
E 21
3
TBCP-4 TBCP-2
2
2
NETGATIVE (GROUND)
P7
P6
POSITIVE SOURCE
1/2
1/2
04/2
04/2
DATE
DRAWN
E 10
E
EMS
TITLE :
R2
4
CAN HIGH SIGNAL IGNITION SOURCE
P3
P9
(GOLD PLATED) (CLOSE TO ACTIVATED)
C32
3 1
E
9
CAN LOW SIGNAL
29 JUN '05
P10
ANTONI
(GOLD PLATED)
3
3
P49
P21
CAN LOW SIGNAL TBCB-1
C21
04
SCALE
APPROVED
TBCP-3
1T
IGNITION SOURCE
P45
P7
CAN HIGH SIGNAL TBCB-2
(CLOSE TO ACTIVATED)
C45
C32
NO NO
1596 OHM±1%
4
4
P29
NETGATIVE (GROUND)
P1
R
1
C29
TBCP-5 TBR-1
RESISTOR 1596 OHM±1%
NTS
NOMINAL SPEED SW. 1
P13
P48
(CLOSE TO 1500RPM)
C13
C48
TBCP-5 TBR-2
N/U
5K OHM POTENTIOMETER
NOMINAL SPEED SW. 1
P24
P36
PROJECTION
MODEL
CLOSE TO 1800RPM)
C24
TBS-1
SPEED FINE TUNE
5
5
TORQUE LIMIT SW. 1 N/U P54
P60
POTENTIOMETER
C54
TBS-2 (MOUNTED IN PANEL BOX)
TORQUE LIMIT SW. 2 N/U
P40
P28
C28
-
TBS-3
ES
EMERGENCY STOP SIGNAL

N/U ENGINE SHUTDOWN
P57
P51
(CLOSE TO ACTIVATED) 4 3 OVERRIDE SIGNAL

C51
C57
6
6
DROOP/ISOCRONE SIGNAL
P30
DWG. NO
PROJ. NO
(CLOSE TO ISOCRONE)
C30
TBCP-6
SPEED & TORQUE CONTROL N/U

P34
(COLSE TO TORQUE)
COO COORDINATORS I/O
ENGINE COOLANT LEVEL

P61
-
7
7
TBM-3
ED-05000-003-00
P52
GROUND
C52
TBCP-6
OIL PRESS. GAUGE SIGNAL

P11
(DIRECT TO GAUGE)
C11
WATER TEMP. GAUGE SIGNAL

P10
(DIRECT TO GAUGE)
8
8
C10

P15
PAGE :
(DIRECT TO 521)
C15
-
PROJ. REF

P6
(DIRECT TO 521)
C6
01 / 01
ENGINE RUN STATUS N/U

9
9
P4
SIGNAL
EMS DIAGNOSIS FLASH

P2
CODE LAMP X2 X1
C2
DL 1D
REV
DIAGNOSIS REQUEST
P12
SIGNAL 4 3
C12
10
10
COO DIAGNOSIS FLASH

X2 X1 CODE LAMP
CDL
N/U
AMENDMENTS
LAMP TEST REQUEST

P9
SIGNAL
N/U ENGINE COOLANT LOW

LEVEL LAMP
11
11
NOTE: N/U = NOT IN USE
12
12
DATE
A
H

ALL DIMENSION IN mm
ENGINEERING DEPT.
1
1
E
E 20
04
1
2
TBCP-4 TBCP-1
NETGATIVE (GROUND)
P2
P1
POSITIVE SOURCE

1/1
1/1
04/1
04/1
E
E 21
3
TBCP-4 TBCP-2
2
2
NETGATIVE (GROUND)
P7
P6
POSITIVE SOURCE
1/2
1/2
04/2
04/2
DATE
DRAWN
E 10
E
EMS
TITLE :
R2
4
P3
P9
C32
3 1
E
9
CAN LOW SIGNAL
08 JUL '05
P10
ANTONI
(GOLD PLATED)
3
3
P49
P21
C21
04
SCALE
APPROVED
TBCP-3
1T
IGNITION SOURCE
P45
P7
C45
C32
NO NO
1596 OHM±1%
4
4
P29
NETGATIVE (GROUND)
P1
R
1
C29
TBCP-5 TBR-1
NTS
NOMINAL SPEED SW. 1
P13
P48
(CLOSE TO 1500RPM)
C13
C48
TBCP-5 TBR-2
N/U
NOMINAL SPEED SW. 1
P24
P36
PROJECTION
MODEL
CLOSE TO 1800RPM)
C24
TBS-1
SPEED FINE TUNE
5
5
P60
POTENTIOMETER
C54
P40
P28
C28
-
TBS-3
ES

N/U ENGINE SHUTDOWN
P57
P51

C51
C57
6
6
P30
DWG. NO
PROJ. NO
(CLOSE TO ISOCRONE)
C30
TBCP-6

P34
(COLSE TO TORQUE)

P61
-
7
7
TBM-3
ED-05000-003-00
P52
GROUND
C52
TBCP-6
P11
P10
8
8
P15
PAGE :
(DIRECT TO 521)
C15
-
PROJ. REF

P6
(DIRECT TO 521)
C6
01 / 01

9
9
P4
SIGNAL
EMS DIAGNOSIS FLASH

P2
CODE LAMP X2 X1
C2
DL 1D
REV
DIAGNOSIS REQUEST
P12
SIGNAL 4 3
C12
10
10
COO DIAGNOSIS FLASH

X2 X1 CODE LAMP
CDL
N/U
AMENDMENTS
LAMP TEST REQUEST

P9
SIGNAL

LEVEL LAMP
11
11
12
12
DATE
A
1 2 3 4 5 6 7 8 9 10 11 12
ALL DIMENSION IN mm
A TO LOAD A
R Y B N
TO DEEP SEA 521K
B B
ENGINE CONTROLLER
ST
HOUR RUN
3P 800AMP MCCB
STC COUNTER
W/S NEUTRAL LINK HZ
HR
FREQUENCY METER
C A 15 45 - 65HZ C
49 A 1 F1 2A
045 45
R
6
A 2
R3
F2 2A
046 46
Y
8
A 3 F3 2A
047 47 V1
B V1
A 4 TBE-1 V
48 48 V2
N V2
D D
AC VOLTMETER
P2
A 5
61
R
P1 P2
3 X 800/5A CT A 6 62
E CLASS 1 15VA Y E
P1 P2
A 7 63 A1
B
P1
A 8 A
64 A2
N
AC AMMETER
AMMETER SWITCH
800/5A
F F
3
1 1 2K OHM WP5W

AVR (DST-100-2FA)
2 2
E3
3 3
J Yellow Yellow
SCANIA DC16 43A 4 4
DIESEL GENERATOR
380/220V 3P 4W
G K
5
Green Green
5
Purple
G 50HZ 0.8PF ~ 7 G
Grey
8
H H
DRAWN ANTONI APPROVED MODEL EMS PROJ. NO -
-
DATE 29 JUN '05 SCALE NTS PROJECTION DWG. NO ED-05000-003-05 PAGE : 03 / 06 REV AMENDMENTS DATE
1 2 3 4 5 6 7 8 9 10 11 12
1 2 3 4 5 6 7 8 9 10 11 12
ALL DIMENSION IN mm
A TO LOAD A
R Y B N
TO WOODWARD
B B
CONTROLLER
ST
3P 800AMP MCCB
STC
W/S NEUTRAL LINK
C A 15 C
49 A 1 F1 2A
045 45
6
A 2
R3
F2 2A
046 46
8
A 3 F3 2A
047 47
A 4 TBE-1
48 48
D D
P2
A 5
61
R
P1 P2
3 X 800/5A CT A 6 62
E CLASS 1 15VA Y E
P1 P2
A 7 63 A1
B
P1
A 8 A
64 A2
N
A 9
E AC AMMETER
AMMETER SWITCH
800/5A
F F
3
1 1 2K OHM WP5W

AVR (DST-100-2FA)
2 2
E3
3 3
J Yellow Yellow
SCANIA DC16 43A 4 4
DIESEL GENERATOR
380/220V 3P 4W
G K
5
Green Green
5
Purple
G 50HZ 0.8PF ~ 7 G
Grey
8
H H
-

1 2 3 4 5 6 7 8 9 10 11 12
H

ALL DIMENSION IN mm
ENGINEERING DEPT.
1
1
E1
TBE-3
BATTERY BANK
1
E 22
6A 1P MCB1
2
1
1
01
1
ES 20A 1P MCB2
2
2
4
3
SYSTEM ON AUX RELAY
DATE
DRAWN
2 7 2 1
3
TITLE :
REF TO DWG NO : ED-05000-003-00

04
R2
2
SYSTEM ON AUX RELAY
2 7
ALTERNATOR SUPPLY
R2A
29 JUN '05
SYSTEM ON TIMER
14
ANTONI
(TIME SET 5 SEC.) 2 7
45
E
T1
5
3
3
SMC
15
5
TO STARTER RELAY
48
COMMON FAULT AUX
SCALE
APPROVED
6
RELAY 2 7
6
R3
R5
7
BUZZER
8 5
28
7
- +
BZ
DEEP SEA 521 CONTROLLER

4
4
8 6 2 7
29
NTS
CBZ R5
ALARM MUTE PUSH

BUTTON 4 3
E8
PROJECTION
MODEL
L
8
CHARGE FAIL SIGNAL
8
5
5
10
(DIRECT FROM COO.)

C6
(DIRECT FROM COO.)

EMS
T1
OIL PRESSURE SIGNAL

9
8 5
C15
1T
6
6
11
NO NO
11
DWG. NO
PROJ. NO
OFF SIGNAL
MSR
13
AUTO START SIGNAL

16 15
13
TBM-2
TBM-1
12
ED-05000-001-05
E 14
E 12
7
7
COOLANT LOW LEVEL
CLL
18
18
SENSOR
E 13
OIL PRESSURE SIGNAL
(DIRECT FROM COO.)

C11
R2
8
8
OPG
OIL PRESSURE GAUGE

6 8
03
WATER TEMPERATURE SIGNAL

PAGE :
(DIRECT FROM COO.)

C10
-
PROJ. REF
WATER TEMPERATURE
WTG
GAUGE
01 / 06
9
9
DCV
DC VOLTMETER
E
R2A
6
REV
D+
CHARGE SIGNAL 6 8
03A
10
10
AMENDMENTS
11
11
O4

12
12
DATE
A
1 2 3 4 5 6 7 8 9 10 11 12
ALL DIMENSION IN mm
A A
ALTERNATOR SUPPLY
BATTERY BANK CAN BUS
FROM DWG. NO : ED-05000-001-00
TBCB-1
TBCB-2
E 1 E 22
1 01
B B
20A 1P MCB2
6A 1P MCB1
TBE-3
2 2
04 O4
C C
8
1
R1
R2
ES
6
2
2 11 15 45 46 47 48 C21 C45
2 11 15 33 31 29 35 39 40

WOODWARD CONTROLLER 320X
D D
1 13 14 12 3 17 16 19 18 20
1 13 14 12 3 C6 C15 19 18 20
TBM-1
E 12 E 13
NO
15
+
MSR
BZ
CLL
T1
1T
33 03A
E E
-
NO
16
8
E 8 E 5 E 6
E 14
TBM-2
L D+
7
7
F F
R1
T1
R2
R3
SMC
2
2
1

SYSTEM ON AUX RELAY

OIL PRESSURE SIGNAL
(DIRECT FROM COO.)
(DIRECT FROM COO.)
COOLANT LOW LEVEL

CHARGE FAIL SIGNAL
COMMON FAULT AUX
AUTO START SIGNAL

TO STARTER RELAY
TO STARTER RELAY
(TIME SET 5 SEC.)
SYSTEM ON TIMER
CHARGE SIGNAL
G G
OFF SIGNAL
SENSOR
BUZZER
RELAY
ENGINEERING DEPT. TITLE : DC SCHEMATIC DIAGRAM FOR SCANIA D16 - EMS (WOODWARD) PROJ. REF
H H
-
PAGE : 01 / 01 REV AMENDMENTS DATE
1 2 3 4 5 6 7 8 9 10 11 12
H

ALL DIMENSION IN mm
ENGINEERING DEPT.
1
1
E
E 20
04
1
2
TBCP-4 TBCP-1
NETGATIVE (GROUND)
P2
P1
POSITIVE SOURCE

1/1
1/1
04/1
04/1
E
E 21
3
TBCP-4 TBCP-2
2
2
NETGATIVE (GROUND)
P7
P6
POSITIVE SOURCE
1/2
1/2
04/2
04/2
DATE
DRAWN
E 10
E
EMS
TITLE :
R2
4
P3
P9
C32
3 1
E
9
CAN LOW SIGNAL
29 JUN '05
P10
ANTONI
(GOLD PLATED)
3
3
P49
P21
C21
04
SCALE
APPROVED
TBCP-3
1T
IGNITION SOURCE
P45
P7
C45
C32
NO NO
1596 OHM±1%
4
4
P29
NETGATIVE (GROUND)
P1
R
1
C29
TBCP-5 TBR-1
NTS
NOMINAL SPEED SW. 1
P13
P48
(CLOSE TO 1500RPM)
C13
C48
TBCP-5 TBR-2
N/U
NOMINAL SPEED SW. 1
P24
P36
PROJECTION
MODEL
CLOSE TO 1800RPM)
C24
TBS-1
SPEED FINE TUNE
5
5
P60
POTENTIOMETER
C54
P40
P28
C28
EMS
TBS-3
ES

N/U ENGINE SHUTDOWN
P57
P51

C51
C57
6
6
P30
DWG. NO
PROJ. NO
(CLOSE TO ISOCRONE)
C30
TBCP-6

P34
(COLSE TO TORQUE)

P61
ED-05000-002-05
7
7
TBM-3
P52
GROUND
C52
TBCP-6
OIL PRESS. GAUGE SIGNAL

P11
(DIRECT TO GAUGE)
C11
WATER TEMP. GAUGE SIGNAL

P10
(DIRECT TO GAUGE)
8
8
C10

P15
PAGE :
(DIRECT TO 521)
C15
-
PROJ. REF

P6
(DIRECT TO 521)
C6
02 / 06

9
9
P4
SIGNAL
EMS DIAGNOSIS FLASH

P2
CODE LAMP X2 X1
C2
DL 1D
REV
DIAGNOSIS REQUEST
P12
SIGNAL 4 3
C12
10
10
COO DIAGNOSIS FLASH

X2 X1 CODE LAMP
CDL
N/U
AMENDMENTS
LAMP TEST REQUEST

P9
SIGNAL

LEVEL LAMP
11
11
12
12
DATE
A
H

ALL DIMENSION IN mm
ENGINEERING DEPT.
1
1
E
E 20
04
1
2
TBCP-4 TBCP-1
NETGATIVE (GROUND)
P2
P1
POSITIVE SOURCE

1/1
1/1
04/1
04/1
E
E 21
3
TBCP-4 TBCP-2
2
2
NETGATIVE (GROUND)
P7
P6
POSITIVE SOURCE
1/2
1/2
04/2
04/2
DATE
DRAWN
E 10
E
EMS
TITLE :
R2
4
P3
P9
C32
3 1
E
9
CAN LOW SIGNAL
08 JUL '05
P10
ANTONI
(GOLD PLATED)
3
3
P49
P21
C21
04
SCALE
APPROVED
TBCP-3
1T
IGNITION SOURCE
P45
P7
C45
C32
NO NO
1596 OHM±1%
4
4
P29
NETGATIVE (GROUND)
P1
R
1
C29
TBCP-5 TBR-1
NTS
NOMINAL SPEED SW. 1
P13
P48
(CLOSE TO 1500RPM)
C13
C48
TBCP-5 TBR-2
N/U
NOMINAL SPEED SW. 1
P24
P36
PROJECTION
MODEL
CLOSE TO 1800RPM)
C24
TBS-1
SPEED FINE TUNE
5
5
P60
POTENTIOMETER
C54
P40
P28
C28
-
TBS-3
ES

N/U ENGINE SHUTDOWN
P57
P51

C51
C57
6
6
P30
DWG. NO
PROJ. NO
(CLOSE TO ISOCRONE)
C30
TBCP-6

P34
(COLSE TO TORQUE)

P61
-
7
7
TBM-3
ED-05000-003-00
P52
GROUND
C52
TBCP-6
P11
P10
8
8
P15
PAGE :
(DIRECT TO 521)
C15
-
PROJ. REF

P6
(DIRECT TO 521)
C6
01 / 01

9
9
P4
SIGNAL
EMS DIAGNOSIS FLASH

P2
CODE LAMP X2 X1
C2
DL 1D
REV
DIAGNOSIS REQUEST
P12
SIGNAL 4 3
C12
10
10
COO DIAGNOSIS FLASH

X2 X1 CODE LAMP
CDL
N/U
AMENDMENTS
LAMP TEST REQUEST

P9
SIGNAL

LEVEL LAMP
11
11
12
12
DATE
A
ENCLOSURE
CONTENTS OF ENGINE FAULT FINDING
Abnormal wear (liner, piston rings, etc) ………………………………………… i-8

Black smoke on starting ………………………………………………………… i-3
Black smoke when running/under load ………………………………………… i-2
Blue smoke ………………………………………………………………………… i-3
Cold engine ………………………………………………………………………… i - 21
Compressed air system ………………………………………………………… i - 27
Coolant loss ………………………………………………………………………… i - 21
Coolant/water in oil ………………………………………………………………… i-4
Delivery pipe fracture ……………………………………………………………… i - 13
Engine difficult to start …………………………………………………………….. i - 13
Engine heater ……………………………………………………………………… i - 22
Engine speed hunting …………………………………………………………….. i - 11
External coolant leakage …………………………………………………………. i - 25
External corrosion on cylinder liner ……………………………………………... i - 13
External fuel leakage ……………………………………………………………… i - 25
External oil leakage ……………………………………………………………….. i - 24
Fluid stroke …………………………………………………………………………. i - 14
Fuel in the oil ……………………………………………………………………….. i-3
High exhaust temperature ………………………………………………………… i - 23
High fuel consumption …………………………………………………………….. i - 18
High oil consumption ………………………………………………………………. i - 17
High oil pressure (engine warmed up) …………………………………………… i-7
High oil temperature ……………………………………………………………….. i - 22
High system voltage ……………………………………………………………….. i - 24
Hot engine …………………………………………………………………………... i - 20
Knocking/noise ……………………………………………………………………… i - 15
Low charge air pressure …………………………………………………………… i - 23
Low compression …………………………………………………………………… i - 18
Low engine output ………………………………………………………………….. i - 18
Low fuel pressure …………………………………………………………………… i - 24
Low oil pressure …………………………………………………………………….. i-5
Low system voltage …………………………………………………………………. i - 24
Oil in coolant …………………………………………………………………………. i-4
Oil pressed out via crankcase ventilation …………………………………………. i - 26
Polluted coolant ………………………………………………………………………. i - 22
Thermostat hunting, 14-series engine ……………………………………………... i - 15
Turbocharger breakdown ……………………………………………………………. i - 26
Vibration ……………………………………………………………………………….. i-9
White smoke …………………………………………………………………………… i-1
White smoke, water vapor …………………………………………………………… i–1
White smoke
Effect Cause Trouble shooting Action
- If possible: reduce
engine speed or put the
The white smoke starts engine under load
Incompletely burnt to turn blue and disap- - Install a white smoke
Cold engine
fuel pears when the engine is limiting device
warmed up (exhaust brake)
- Install flame heater
- Install an engine heater
Injection timing too late
Inlet valve does not open
properly. Valve adjust-
ment disturbed
Disconnect one delivery pipe at a time and listen
Too much fuel in for changes in the engine sound.
relation to air at low
combustion temper- Broken delivery valve
atures spring, uncontrolled
! WARNING!
injection Be careful when disconnecting the delivery

pipes as the pressure is extremely high and
could cause injury
Leaky injector, drip-

ping?
White smoke, water vapour

Test pressure (air
Leaky charge air cooler
0.5 bar, liquid 4 bar)
Leaky cylinder head
gasket The fault is also present
Cracked water-cooled when the engine is hot
Water in the com- exhaust manifold
bustion chamber
If the fault is hard to trace:
Cracked cylinder head Change all cylinder heads for exchange cylinder
(not cracks between heads.
valve seats). (Or test pressurize all cylinder heads. Heat the cyl-
inder heads before pressurizing them.)
Crack in cylinder liner
i-1
Black smoke when running/under load
“Adjusted” injection
Check the lead seal - Test in test bench
pump, attempt to boost
Injection timing too late
Inlet valve does not open
properly. Valve adjust-
ment disturbed
for changes in the engine sound.
Broken delivery valve

spring, uncontrolled
! WARNING!
injection Be careful when disconnecting the delivery

could cause injury
Too much fuel in
relation to air at high
Leaky injector, drip-
combustion temper-
ping?
atures
Nozzle tip jams
Incorrect spray pattern
from nozzle
More than 1 washer
under injector
Check charge air pres-
Fault in turbo
sure
Clogged air filter
High exhaust counter-
See page ( i - 23 )
pressure
Worn intake valves
Clogged intake port
i-2
Black smoke on starting
Open the cover
(RQ/RQV) or hexagon
(RSV) on the governor
and check with a finger
on the control rod that it - Take the pump to a
Engine difficult to
Binding control rack goes to the maximum Bosch workshop for
start
stop bracket. repair
(This applies to engines
without a smoke limiter
on the governor hous-
ing.)
Blue smoke
Oil coating past piston
rings
Check for oil in the
Oil leakage in turbo-
intake manifold after the
charger
turbocharger
Damaged piston cooling - Change damaged
nozzles nozzles
Petrol in diesel oil
Fuel in the oil

- Normally about 1% of
Unburnt fuel passes the
fuel in the lubricating
piston
oil per 200 h
Defective injector
Internal leakage in injec-
Dilution of oil in
tion pump (worn pump
sump
element or crack in
pump housing)
Worn/broken O-ring at
feed pump pushrod
Frequent cold starts
Cont.
i-3
Fuel in oil, cont.
Check “blow-by” in crankcase
Correct value for new engine: 0 - +10 mm wc
Dilution of oil in Worn engine
(flow rate 60 - 100 l/min.)
sump Closed crankcase ventilation: -50 - +20 mm wc
Intake valve not opening
Oil in coolant
Test pressurize the oil cooler
Oil cooler leaks when Note: classed oil cooler, test pressurized: 10 bar oil
engine is running on the oil side, 0.5 bar air on the water side,
immersed in water 25 - 27 °C
Defective cylinder head
gasket
Crack in cylinder head
(not cracks between If the fault is hard to trace:
valve seats). Change all cylinder heads for exchange cylinder
(On 11-series engines: heads.
look for cracks between (Or test pressurize all cylinder heads. Heat the cyl-
the water jacket and oil inder heads before pressurizing them.)
duct.)
Coolant/water in oil
Oil cooler leaks when Test pressurize the oil
engine is not running cooler, see above
Leaky O-rings at cylin-
Leakage in telltale hole? - Change liner seals
der liner
water is condensed in
Dilution of oil in crankcase ventilation
sump and runs down into the
sump
14-series engine:
Clogged drain hole in
coolant pump in combi-
nation with leaking
pump seal
i-4
Coolant/water in oil, cont.
Crack in cylinder head Run the engine until
warm.
Crack in water jacket on Remove the oil sump
cylinder block/cylinder and all side covers.
head. (Coolant runs Test pressurize the cool- - Change the cylinder
down through the push- ing system. head for a exchange
rod hole.) If coolant seeps out cylinder head
behind side covers or at - If no leakage can be
the camshaft bearing found, change all cylin-
Crack in water jacket on there is probably a crack der heads for exchange
cylinder head. (Coolant in one of the cylinder cylinder heads
runs down via the oil heads.
duct for rocker arm As a rule it is possible to
Dilution of oil in lubrication.) see which cylinder head
sump or heads are leaking.
Cracked water-cooled
exhaust manifold
Leakage in charge air Test pressure (air
cooler core 0.5 bar, liquid 4 bar)
- Install a self-closing
cover on the exhaust
Water enters via the pipe
exhaust/intake system - Position the air cleaner
so that water cannot
run into it
Low oil pressure

Take a reading of the oil pressure on warmed-up
engine using a mechanical pressure gauge directly
on the engine:
Defective sensor/instru- Minimum 1 bar at 800 r/min.
ment Maximum 6 bar > 800 r/min.
Obs! Single-speed engines must not be tested
at 800 r/min. Risk of damage to the flexi-
ble coupling
Gauge shows low - 1 shim = 0.2 bar
Incorrectly adjusted oil (screw adjustment on
pressure relief valve 14-series engines)
Broken spring in oil Max. oil pressure 2 bar - Check/remedy
relief valve (14-series
engines, earlier version) at 2000 r/min relief valve
The piston in the oil

relief valve has jammed
in open position
Cont.
i-5
Low oil pressure, cont.
Crankshaft bear- - Change to bearings of
ing/main bearing of
wrong size has been fit- Max.
also
oil pressure 2 bar
when engine cold
the correct size. Check
the bearing seats before
ted on reground crank- assembly
shaft
Excessive play in big-
end and main bearings
If the bushing slides all
the way out of the bear-
ing seat, the oil pressure
Seizing in camshaft warning lamp will come
bearings on.
The engine throws out
oil through the crank-
case ventilation
Piston cooling nozzle
has come loose
Seizing in the bearing on Oil pressure can be

engine power take-off increased ~ 1 bar when
ED140 (14-series engine) the power take-off is
under load
Loosened oil duct plugs
Gauge shows low at camshaft bearing
pressure seats, under Pressure drops to 0 bar
the protection plate in
the V (14-series engine)
Suction pipe to oil pump
has come loose, the
pump sucks air
Engine too hot
Extremely low lubricat- - Choose a viscosity that

ing oil viscosity is suitable for the ambi-
ent temperature
- Change rotor if bush-
Worn bushings or loose ing is worn oval
shaft in oil cleaner - Change worn/dam-
aged shaft
Broken O-ring on
cyclone part of oil
cleaner
Defective oil pump drive
Internal leakage in oil Check that the oil

cleaner cleaner is correctly
assembled
Cont.
i-6
Low oil pressure, cont.
Loosened guide plates in
the oil cooler prevent
passage of the oil
Worn/damaged oil pump
Plug in cylinder block
under the relief valve
Gauge shows low has come loose (11-
pressure series engine)
Clogged oil cooler
Seized/worn bearings in Pressure varies when
compressed air compres- compressor
sor, see also page 30 charges/relieves
Loose screws in timing
gear’s intermediate gear
The main oil duct (to
Oil pressure at
Gauge indicates low piston cooling nozzles)
idling/low engine speed
pressure at maxi- plug in the rear of the
is not affected since the
mum speed but not engine has come loose
delivery valve closes at
at idling speed (also at front of engine,
3 bar
9-series engine)
Oil valve sleeve screwed
- Tighten the oil valve
No oil pressure at out of oil pump housing Check that the oil
sleeve
idling speed (gives “by-pass” and valve sleeve is correctly
- If damaged, change the
(14-series engine) disables the overflow fitted
sleeve
valve)
High oil pressure (engine warmed up)

Take a reading of the oil pressure on the warmed-
up engine using a mechanical pressure gauge
directly on the engine:
Defective sensor/instru- Minimum 1 bar at 800 r/min.
ment Maximum 6 bar > 800 r/min.
Gauge indicates Note! Single-speed engines must not be tested
high pressure at 800 r/min. Risk of damage to the
flexible coupling
- Choose a viscosity that
Oil viscosity too high is suitable for the ambi-
ent temperature
Cont.
i-7
High oil pressure (engine warmed up), cont.
- 1 shim = 0.2 bar
Incorrectly adjusted oil
(screw adjustment on
relief valve
14-series engines)
Piston in oil relief valve
Gauge indicates
jammed in closed posi-
high pressure
tion
Valve in oil duct to pis-
ton cooling nozzles is
binding
Abnormal wear (liner, piston rings, etc.)

Unclean induction air
Wear ridge (ring travel
due to inadequate filter- - Fit a more efficient air
shoulder) at piston top
ing (wrongly dimen- filter
dead centre
sioned air filter)
Unclean intake air due to
leakage in intake piping
Wrong grade of oil, pol-
ishing damage
Changing of filters and
oil has been neglected
Short service life
Low coolant tempera-
ture (cold engine)
- Change the fuel
- Change to oil with a
Excessive sulphur con-
higher base number
tent in fuel
- Shorter oil change
intervals
Defective injector
(causes oil film to be
washed off)
i-8
Vibration, no driven components engaged
Wrong injection timing
Broken delivery valve Disconnect one delivery pipe at a time and listen
spring for changes in the engine sound.
! WARNING!
Individual injectors not Be careful when disconnecting the delivery
operating pipes as the pressure is extremely high and
could cause injury
Fan imbalance
Flywheel has come
loose
Crankshaft hub loosened
Abnormally worn main
bearings
Vibration or unusual
noise at
1500 - 1700 r/min Defective vibration
damper
Drive belts run off
pulleys
Compressor operates
Only when com-
with excessive counter-
pressed air compres-
pressure (e.g. clogged
sor is charging, worst
piping/air dryer) or
at about 1000 r/min,
excessively high safety
see also page 30
valve opening pressure
Alignment fault Check engine alignment
Unsuitable rubber sus- - Change to rubber ele-
pension and location of ments of different
same hardness
Movement at engine - Reinforce the engine
Weak engine bed
attachment points bed
i-9
Vibration when the clutch or reverse gear is engaged
Imbalance in driven unit - Balance the unit
Imbalance in clutch
Inadequate alignment
- Carry out alignment
between engine and Check alignment
more accurately
driven unit
Unsuitable suspension
of engine or driven unit
Movement at attachment - Reinforce the engine
Weak engine bed
points bed
Defective flexible - Change rubber ele-
coupling between ment in flexible cou-
clutch/reverse gear and pling (consumption
driven unit item)
Unsuitably mounted - Reposition the engine
propeller shaft, e.g. or driven unit so that
excessive deflection the propeller shaft’s
angle or excessive devi- working range is in
ation in parallelism accordance with rec-
between flanges ommendations
Propeller shaft too long
and weak
Vibration when alternator is in operation

Imbalance in generator
Dismantle the coupling. Assemble the coupling
Imbalance in coupling
halves rotated half a turn relative to each other
Bearing damage in alter-
nator
Defective flexible cou- - Change the rubber ele-
pling between engine ment or type of cou-
and alternator pling
Fault in reduction gear
i - 10
Engine speed hunting - single-speed engines with RQ governor
Play in flexible cou-
Apply a light load, at a - Change the rubber ele-
pling between engine
load of about 20 kW the ment/check the cou-
and alternator (worn
hunting disappears pling hub and flange
coupling)
- Choose a coupling
without play, e.g.
Play in new coupling
Scania standard cou-
pling
Not enough flywheel
- Mount extra flywheel
mass in the driven unit,
mass
e.g. alternator
Hunting when Skew engine brackets

engine is running (engine suspension) - Change to harder rub-
under light load could under unfavoura- ber elements for the
(15 - 20 kW) or ble circumstances engine/alternator sus-
no-load conditions worsen engine speed pension
hunting
Incorrect injection tim-
ing
for changes in the engine sound.
Individual injectors not ! WARNING!

operating
Be careful when disconnecting the delivery
could cause injury
Engine speed hunting - single-speed engines with RSV governor

The RSV governor - Change the injection
Engine speed hunt- should not nowadays be pump delivery valves
ing at 4-5% speed used for single-speed (1-hole or 2-hole) for
droop operation (except on 9- 0-hole valves
series engines)
i - 11
Governor incorrectly - Tighten the idling
adjusted spring and adjust
engine speed
Engine speed hunt-
ing at idling Below 700 r/min the - Fit a weaker starter
standard starter spring, spring, part number
282 544 (Bosch 1 424 268 866
650 006) is too strong (Bosch 1 424 650 056)
i - 12
Delivery pipe fractures
No clamping
Carelessly handled
delivery pipe
Internal cavitation in
Fit 0-hole delivery
delivery pipe
valves for single-speed
Note: Single-pipe sys-
operation
tem is not permitted
External corrosion on cylinder liner

- Clean the cooling sys-
Unsuitable corrosion tem and fill up with
protection agent, glycol coolant as described in
or water in coolant the maintenance
instructions
Engine difficult to start

Leakage in suction pipe
The highest fuel level in
the tank is lower than the
feed pump. A longer - Install a ”daily supply
Air in fuel system standstill (days) the fuel tank” at a higher loca-
in the suction pipe may tion than the feed pump
run back to the tank
because of a leaky over-
flow valve
Leaky overflow valve
Low battery voltage
- Starting aids are not
Ambient temperature normally needed at
too low temperatures above
-15 °C
Oil viscosity too high
Paraffin precipitation in
the fuel
Cont.
i - 13
Engine difficult to start, cont.
Blocked intake or
exhaust system
No fuel
Stop lever in stop posi- - Check the stop
tion solenoid and links
Faulty injector
Open the cover
(RQ/RQV) or hexagon
(RSV) on the governor
Control rack/pump ele- and check with a finger
ment will not go into the on the control rod that it - Take the pump to a
cold start position. goes to the maximum Bosch workshop for
Binding control stop bracket. repair
rack/pump element (This applies to engines
without smoke limiter
on the governor hous-
ing.)
- Preheat the engine
combustion chambers
by running the starter
motor with the stop
control in stop position
for about 15 seconds.
Then start in the usual
way.
Fluid stroke
Test pressure (air
Leaky charge air cooler
0.5 bar, liquid 4 bar)
Starter motor not Leaky cylinder head
powerful enough to gasket
pull the piston over
the compression If the fault is hard to trace:
stroke (if the engine Change all cylinder heads for exchange cylinder
fires a connecting Crack in cylinder head heads.
rod could be bent) (Or test pressurize all cylinder heads. Heat the cyl-
inder heads before pressurizing them.)
Crack in cylinder liner
Cont.
i - 14
Fluid stroke
- Install a self-closing
cover on the exhaust
Starter motor not Water has entered the
pipe
powerful enough to engine via the
- Position the air cleaner
pull the piston over exhaust/intake system
so that water cannot
the compression run into it
stroke (if the engine
fires a connecting Crack in water-cooled
rod could be bent) exhaust manifold
Injector open
Thermostat hunting, 14-series engine

- Fit an external thermo-
Piping between thermo-
stat
stat housing and radia-
- Try drilling 2 holes,
tor too long (more than
∅ 2.5 mm, in the ther-
0.5 m)
mostat disc
Knocking/noise
Timing gears incor-
rectly meshed
Exhaust valves close Check the valve timing,
The crankshaft gear has
too late and strike see “Service data,
come loose
the piston crowns engines”
Valve mechanism not
operating
Disturbances in the sup-
Rapidly increasing
ply of lubricant for the
valve clearances
rocker arms
Loosened big end cap - Tighten to the torque
The piston strikes
(wrong tightening torque specified in the Work-
the cylinder head
after repair) shop manual
Foreign objects in the
piston crown
Cont.
i - 15
Knocking/noise, cont.
Piston seizure (may be
caused by clogged pis-
ton cooling nozzles)
Worn collets on exhaust
valves
Incorrectly adjusted Disconnect one delivery pipe at a time and listen
injection pump for changes in the engine sound.
Broken upper pis- Broken delivery valve ! WARNING!

ton rings spring (after-injection)
Be careful when disconnecting the delivery
could cause injury
Connecting rod bearing

seizure
Faulty injector (seized,
worn, incorrect or
cracked tip, fatigued
spring)
Incorrectly adjusted
injector
More than 1 washer
under injector
Fuel leakage in flame Check whether it leaks. (Take out the flame start
start and run the engine with fuel pipe connected)
Loosened big end cap
Injection timing
Check the injection tim-
extremely advanced,
ing
Melting damage on 30 °BTDC or more
piston crown
Incorrectly adjusted
injector
i - 16
High oil consumption
Piston ring seizure
Combustion tempera-
Piston seizure
ture too high?
Cylinder seizure
Liner wear Unclean intake air?
Carbon polishing
(in patches)
Poor grade of oil?
Piston ring wear
Piston rings stuck
Tapered piston rings fit-
ted wrong way
Individual piston rings broken = incorrectly fitted
Several upper rings broken = start spray used
Broken piston rings wrongly, wrong injection timing (too early)
Several intermediate rings broken = worn rings or
grooves
Check the clearance
between valve and
Blue smoke under guide.
load Worn valve guides
High exhaust tempera-
ture?
Poor grade of oil?
Oil level too high?
Check whether oil is
Defective shaft seals in
present in the compres-
turbocharger
sor or intake manifold
Clogged air filter
Excessive vacuum in the Measure the vacuum
air intake before the tur- (max. 500 mm wc)
bocharger Check the air filter
Oil viscosity too low
Deformed/incorrectly
directed piston cooling
nozzles
External leakage
Leakage in seawater-
cooled oil cooler (11-
series marine engines)
i - 17
High fuel consumption
Faulty injector
Low charge air pressure
Check in a pump test
bench that the amount
Adjusted injection pump
(Q-mm3/stroke) corre-
sponds to specification
Manner of driving, oper-
ating/load conditions
Low compression
Worn engine Check the compression
Broken piston rings
Incorrectly adjusted/
defective valves
Hydrostatic lock/bent
connecting rod
Take compression readings on a hot engine, with
all injectors removed, at starter motor speed
Readings not taken cor- Check cylinders 1 - 6, then cylinder 1 again
rectly Check that starter motor speed does not drop
Correct reading: 20 - 30 bar
Max. 3 bar difference between cylinders
Low engine output

Check the feed pump and overflow valve for leak-
age as described in the workshop manual
Low fuel supply pres-
Look for leakage in the suction pipe between tank
sure (below 0.3 bar)
and feed pump
Clogged fuel filter/Paraffin precipitation in fuel
Faulty injector
Fuel too hot
Cont.
i - 18
Low engine output, cont.
Incorrect fuel specifica- Check density and vis-
tion cosity
Low charge air pressure Check charge air pressure
Abnormal pressure drop Check

500 mm
the vacuum before the turbocharger, max.
wc
in intake piping Check the air filter
Worn engine Correct value for new engine: 0 - +10 mm wc
(flow rate 60 - 100 l/min.)
Worn crankcase ventilation: -50 - +20 mm wc
Take compression read-
Leaky valves ings and compare those
of the different cylinders
Check that the governor
starts deregulating at the
Incorrectly adjusted intended speed
governor/throttle control Check that the throttle
control goes to the maxi-
mum stop bracket
Check the temperature
Intake air temperature of the air before the
too high engine.
Above +25 °C reduces
engine power
Take a reading, recom-
Exhaust counterpres- mended counterpres-
sure too high sure:
500 mm wc,
max. 1000 mm wc
Intake counterpressure See “Low charge air
too high pressure”, page 26
Incorrectly adjusted Check in a pump test
injection pump bench
Blocked fuel consump-
tion gauge
Binding injector Injector’s nozzle nut

tightened too hard
Exhaust brake/white
smoke limiter throttle in
closed position
i - 19
Hot engine
Defective sensor/instru- Check

(120
that sensor and instrument suit each other
and 150 °C)
ment Check with a separate instrument
Low coolant level
Clogged seawater filter
Clogged freshwater/sea- - Clean the cooling sys-

water cooling system tem internally and
externally
Pressure cap not operat- Test pressurize
ing
Impeller on freshwa-
Instrument shows ter/seawater pump worn
high temperature or damaged
Incorrect cam/worn
cover on seawater pump
Restriction in coolant
flow, e.g. pieces of rub-
ber from seawater
impeller
Cooling capacity too Take a reading of the
low cooling capacity
Gas leakage (causes loss
of coolant)
Defective thermostats Check opening tempera-

ture of thermostats
Drive belts slip or pump
wheel loose on pump
shaft
- Vent at the cooling sys-
tem’s highest point
Reduced coolant Air pockets in engine’s - Check that the ventila-
flow outer cooling circuit tion piping to the
expansion tank is not
clogged
Excessive pressure drop Check with forcibly
in the external cooling opened thermostats
system
Clogged radiator
Cont.
i - 20
Hot engine, cont.
Circulation of cooling Check by taking temper-
air ature readings
Cavitation damaged
impeller in coolant
pump
Leakage in charge air
cooler
Cold engine
Check that sensor and instrument match each other
Defective sensor/instru-
(120 and 150 °C)
ment
Check with a separate instrument
Thermostat jammed in Check operation of ther-
open position mostat
- Fit a thermostat fan
Instrument indi- - Fit a smaller fan
Low power output at
cates low tempera- - Install a KLAFFO radiator shutter
low ambient temperature
ture NOTE: NOT A RADIATOR BLIND
(large external cooling
Risk of fan blade breakage
surface)
- Reduce the air flow
- Reduce fan/coolant pump gear ratio
Large leakage flow in
thermostat housing
(9- and 11-series marine
engines)
Coolant loss
gasket (external leakage)
External leakage
Turbocharging pressure
Coolant pressed out
enters cooling system Test pressure
of radiator on DSI
via leaking charge air (air 0.5 bar, liquid 4 bar)
engines
element
Cont.
i - 21
Coolant loss, cont.
If the fault is hard to trace:
Crack in cylinder head Change all cylinder heads for exchange cylinder
(not cracks between heads.
White smoke when valve seats) (Or test pressurize all cylinder heads. Heat the cyl-
engine hot indicates inder heads before pressurizing them.)
water vapour Grey oil = Coolant in oil
Locate the leak by removing the oil sump and pres-
Cracked cylinder liner
surizing the cooling system while turning the
engine over by hand
Polluted coolant
Faulty inhibitor - Clean the cooling sys-
tem and fill it with
Overdosed corrosion coolant as described in
inhibitor the maintenance
instructions
Engine heater
Incorrect mixture or type
- Clean the cooling sys-
of glycol and/or corro-
tem and fill it with
Boiler scale on sion inhibitor
coolant as described in
engine heater Anti-freeze with phos-
the maintenance
phate-based inhibitor
instructions
must not be used
The heater is not
designed for continuous
Short service life engagement. Suitable
temperature for thermo-
stat control = 40 - 60 °C
High oil temperature

- Defective sen- Check with separate
- Instrument indi- sor/instrument instrument
cates too high tem-
perature - Poor water flow in oil
cooler
i - 22
High exhaust temperature
Check the lead seal,
Adjusted injection pump - Test in test bench
check CRO if necessary
Check the injection tim-
ing
Check type, opening
Nozzle drips pressure and general
condition
Take a reading, recommended counterpressure:
High exhaust counter- 500 mm wc, max. 1000 mm wc
pressure Check silencer, spark arrester, length and inside
diameter of exhaust pipe
High inlet air tempera-
ture
Clogged air filter

Dirty/damaged tur-
bine/compressor wheel - Check/clean
in turbocharger
Leakage between turbo-
charger and cylinder - Check/change gaskets
head
Bearing seizure in turbo- - Recondition/change
Check bearing play
charger turbocharger
Check the vacuum
Clogged air filter before the turbocharger,
max. 500 mm wc
Take a reading, recommended counterpressure:
High exhaust counter- 500 mm wc, max. 1000 mm wc
pressure Check silencer, spark arrester, length and inside
diameter of exhaust pipe
High fuel temperature
i - 23
Low fuel pressure
Clogged fuel filter
Defective overflow
valve
Defective feed pump
Air leakage in suction
pipe
High pressure drop in
suction pipe
Low system voltage

Broken alternator drive
belt
Slipping alternator drive
belt
(Normal charging
voltage: Batteries in poor condi-
27 - 28 V) tion
Alternator fault
Voltage regulator fault
Battery charger fault
High system voltage

(Normal charging Voltage regulator fault
voltage:
27 - 28 V) Battery charger fault
External oil leakage

Crankcase pressure too Correct value for new engine: 0 - +10 mm wc
high (flow rate 60 - 100 l/min.)
Closed crankcase ventilation: -50 - +20 mm wc
Cont.
i - 24
External oil leakage, cont.
Leaky crankshaft seal
Leakage at liner seal via
overflow hole in cylin-
der block
gasket
Leakage in manifold
Low load
joint
External fuel leakage

Damaged injector and
injection pump connec-
tions/gaskets
Defective pulsation
damper
Leakage at high engine
- Change to Bosch over-
Blocked overflow valve speed and low power
flow valve (with ball)
output
External coolant leakage

Leakage in cylinder liner
seal
- Change to hoses of bet-
Cold leakage ter quality (preferably
silicone hoses)
gasket
Check at the water pump
Water pump leakage
housing’s telltale hole
Leakage at charge air
cooler connection
Cont.
i - 25
External coolant leakage, cont.
Check that the self-vent-
Loss of coolant in ing valve is not situated
stationary installa- Coolant pressed out of higher than the highest - Change the valve or fit
tions with self-vent- expansion tank coolant level and that air a manual air screw
ing valves is not drawn in through
the valve
Oil pressed out via crankcase ventilation

Hole in piston crown Increases when white
smoke limiting device is
Bearing seizure in turbo- engaged or exhaust
charger brake applied
Oil seepage via pistons -
liner
Oil seepage in air com-
pressor
Turbocharger breakdown
Excessive bearing play
in turbocharger
Loss of power Lubrication piping
between turbocharger
- Check the connections
and filter incorrectly
connected
i - 26
Compressed air system
Too much carbon in
compressor cylinder Empty the compressed
head or discharge air tank, retain the air in
piping connected compressed
air components. - If charging time
Exhaust valves leak Run the engine at exceeds specified val-
Worn pistons and cylin- 1200
Compressor does r/min and note the ues:
not maintain suffi- ders time it takes for the com- - Rectify leakage, if any
cient pressure in the pressor to discharge: - Check/rectify pressure
system 3 - 3.5 min.
Leaking/jammed intake series engines for 9/11- regulator
valves with - Check/rectify compres-
90-110 dm3 tank capac- sor
Defective pressure regu- ity
lator 2.5 - 3 min. for 14-series
engine with 90-110 dm3
Leakage in compressed tank capacity
air piping
Too much carbon in
compressor cylinder
head or discharge piping
Check/rectify compres-
Worn big end/main sor as described in the
bearings Workshop Manual
Noise Worn pistons and cylin-
ders
Compressor gear loose
on shaft, see also
“Knocking/noise”,
page 18
Worn pistons and cylin-
ders
Compressor allows
passage of oil, see Piston rings fitted
also “High oil con- wrongly
sumption”, page 20
Overpressure in engine
crankcase.
Defective seals on dis-
charge pistons
Compressor does Discharge mechanism
not discharge binding
Defective pressure regu-
lator
Check operation of air
Moisture/oil in com- Air dryer not working dryer, change desiccant.
pressed air system properly If desiccant is oily, see
“Compressor allows
passage of oil” above
i - 27
NOTE
NOTE
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USER’S NAME : …………………………………………………………………………

USER’S ADDRESS : …………………………………………………………………………

TELEPHONE NO. : …………………………………………………………………………

GENERATOR SET MODEL : …………………………………………………………………………

GENERATOR SET SERIAL NO. : ...………………………………………………………………………

ENGINE MODEL : …………………………………………………………………………

ENGINE SERIAL NO. : …………………………………………………………………………

ALTERNATOR MODEL : …………………………………………………………………………

ALTERNATOR SERIAL NO. : …………………………………………………………………………

DEALER’S NAME : …………………………………………………………………………

CONTACT PERSON : …………………………………………………………………………

DEALER’S ADDRESS : …………………………………………………………………………

TELEPHONE NO. : …………………………………………………………………………

CONTENTS OF BRUSHLESS A.C. GENERATOR OPERATION MANUAL

CONTENTS OF AUTOMATIC VOLTAGE REGULATOR (AVR) OPERATION MANUAL

I. AC & DC Schematic Diagram

SCANGEN GENERATOR SET

2.1. GENERATING SET SAFETY GUIDE

BEFORE OPERATING THE GENERATING SET, ENSURE THAT THE FOLLOWING

2.2. FIRST AID IN CASE OF ELECTRIC SHOCK

NOTE: DO NOT GIVE LIQUIDS UNTIL THE VICTIMS IS COMPLETELY CONSCIOUS.

If, after 5 or 6 effective inflations of the victim’s lungs, there is:

2.3. EXTERNAL CARDIAC MASSAGE

2.4. CORRECT PROCEDURE FOR HANDLING ELECTROSTATIC SENSITIVE DEVICES

2.5. WARNING - DANGEROUS VOLTAGE

2.6. CAUTION — NOISE

2.7. CHEMICAL SAFETY

2.8. FIRE AND EXPLOSION

2.9. MECHANICAL SAFETY

2.10. ELECTRICAL SAFETY

3.1. GENERAL DESCRIPTION

4.1. INSTALLATION AND MOUNTING THE GENERATOR SET

Fig 1. Show typical installation when wind prevailing exhausts system.

Site installation for generator set

Fig 2. Silencer position

4.3.1. Other exhaust design criteria are as follow:

4.4. FUEL SYSTEM

4.5. FIRE PRECAUTIONS

4.6. STARTING BATTERIES

4.7. ELECTRICAL CONNECTION

4.8. ACOUSTIC SILENCING

4.9. TOWING (Portable Generating Sets)

Ensure brakes, if fitted, are in good order.

5.1. CONTROL SYSTEM

5.1.1. CONTROL SYSTEM DSC 521 Remote Start Modules

Fig 3. A typical Control Panel

5.1.1.1 CONTROL SYSTEM DESCRIPTION

12. Spare - For future application requirement.

15. EMS Lamp – Fault indicator for EMS.

18. COO Lamp – Fault indicator for coordinator.

5.1.1.2 DSC 521 CONTROL UNIT

Mounted in a 90 x 90 mm panel cut-out Rear panel layout

5.1.1.3 ELECTRICAL CONNECTION

Connection to the 521 module are via plug and sockets

PLUG “A” 13 WAY

PLUG “B” 10 WAY

5.1.1.4 OPERATION – AUTOMATIC OPERATION

Engine Model / Serial No : _ / _

Duty: Standby I Prime Volts: V Rating: _kVA

Fuel System _ Manual Availability _