About Mahindra

Congratulations on becoming a proud owner of Mahindra Generator. We welcome you to the

Mahindra family.

We are a federation of companies divided into 10 business sectors. Befitting our size, we operate in 20
key industries, providing insightful and ingenious solutions that are global in their ramifications. Our
companies act as a federation, with an optimum balance of entrepreneurial independence and synergy.
From Mobility to Rural Prosperity and IT, from Financial Services to Clean Energy and Business
Productivity, we’re empowering enterprise everywhere. Headquartered in Mumbai, India, we have an
operational presence in over 100 countries and employ more than 200,000 people. And though we
operate across vast geographies, our governing spirit of "Rise" binds us as one Mahindra, dictating that
we empower people everywhere to not only chart new frontiers, but to conquer them too.

We are the world’s largest tractor brand by volume, India’s largest utility vehicle manufacturer, and
several of our businesses enjoy leadership positions in the industries in which they operate. We remain
committed to investing in technology, growing our global presence and maintaining our leadership
position.
 About Mahindra Powerol
Mahindra entered the field of Power Generation with the brand name of Mahindra Powerol in 2001-02.
Starting FY 2002, the business has grown exponentially to become a Rs. 1,000 crore business in FY 2009-
10. Today, engines from Mahindra Powerol are powering Diesel Generator sets from 5 kVA to 320 kVA.

Since inception, Mahindra Powerol has made rapid strides in the Indian genset industry within a very
short span of time. Mahindra Powerol DG sets are the first choice of telecom majors like Reliance Jio,
Indus Towers, Bharti Infratel, Viom Networks, American Tower, Telesonic Networks, Etisalat,
Ooredoo,Tata Tele, Vodafone, Nokia, BSNL and MTNL across India and globally.

Besides Telecom, Mahindra Powerol DG sets are powering customers from a diverse cross-section of
industries and segments like Banks, Building & Construction, Public Sector Units, Hospitals, Hotels,
Homes and Manufacturing units in India and in Global markets.

Mahindra Powerol has been awarded with the prestigious Deming Prize in 2014. The Deming Prize is a
global quality award instituted by Union of Japanese Scientists & Engineers (JUSE) that recognizes
businesses that have successfully implemented Total Quality Management (TQM).

Powerol engines have unique features like:

▪ Fuel efficient engines
▪ Over 400 sales and service touch points
▪ Easy finance schemes available
▪ Low vibration and noise levels

Mahindra Powerol takes care of the entire value chain of customers. This not only covers areas like
personalized transportation of the DG sets, Installation & Commissioning etc., but also encompasses the
Annual and Comprehensive Maintenance Contracts at the other end of the spectrum.

Engines are also suitable for various industrial applications like cranes, compressors, forklifts, rice mills
and concrete mixers. Recently Powerol has launched Rice Mill & Marine engines.

Mahindra Powerol engines and diesel generator sets are certified for the stringent noise and exhaust
emission norms made mandatory by the CPCB (Central Pollution Control Board, India).
 CONTACT DETAILS

HEAD OFFICE

In the very unlikely event of you not receiving prompt attention from our field force,
following are the contact numbers of our managers for your assistance.

Address of Head Office :

Mahindra & Mahindra Ltd.
Powerol Business, Powerol Building, Gate No. 2
Akurli Road, Kandivali (E), Mumbai – 400 101, India
Visit us at: mahindrapowerol.com

Contact no at Head Office:

(+91 22 66483824)
(+91 22 66483959)

AFRICA SAARC
Contact no: Contact no:
(+234 8024435585) (+91 22 67504093)
(+91 22 67503959) (+91 22 66483824)

MIDDLE-EAST
Contact no:

(+971 56 415 0826)

Important note:

The information contained within this publication is given with our best intensions and are believed to be correct at the time of going
to the press. Our policy is one of continued development and we reserve the right to amend any technical information with or
without prior notice.
Whilst every effort is made to ensure the accuracy of the particulars contained within this publication the Manufacturer, Sales Dealer
or Service dealer shall in any circumstances not be held liable for any inaccuracy or the consequences thereof.
WARRANTY POLICY
Dear Customer,
Thank you for your purchasing “MAHINDRA POWEROL GENERATOR”. Kindly read the complete document to
avail the warranty on your Generator.

Standard Manufacturer’s Warranty General Warranty Terms:

“The manufacturer’s warranty is applicable for 18 months from the date of The warranty is not applicable or will
shipment from our works OR 12 months from the date of installation and be void in the event of....
commissioning OR 1200 hours of operation, whichever occurs first. 1. Is applicable only if the Generator
is installed according to our correct
installation procedure.
2. Is not covered for accidental or
Extended Warranty intentional damage, including
Mahindra Powerol offers extended warranty through its distributors which vandalism, improper maintenance,
can be availed at nominal charges. Kindly select the option by “✔” or damage by chemicals, misuse or
neglect, or the defects in any
1 Year or 1200 hours of operation products which have been altered
outside the company’s works or
2 Years or 2400 hours of operation which have been let out on hire.
3. Natural disaster, such as fire,
earthquake, acid rain, etc. will not
On-line Warranty Registration (To be done by Powerol Distributor): be covered
4. Defects/damage caused by
Please get your product registered immediately within 7 days of the
normal wear and tear.
date of purchase for availing warranty. On-line warranty services are 5. If the identification marks of
applicable only for product purchased from Authorised Mahindra which have been altered or
Distributor. removed.
6. Loaded beyond the
To complete this on-line warranty registration process, please fill in recommended power ratings.
your personal details as well as complete Generator information by 7. Misapplication, not as per
logging to www.powerolglobeconnect.com recommended specifications and
condition of use.
8. If the Diesel Generator is not used
properly or for any other purpose
Customer Information for which it is not meant for such
as welding, etc.
▪ Customer Name: 9. If the Diesel Generator is exposed
during running condition to the
▪ Organization: conditions beyond operating norms
▪ Address: like excess heat / temperature,
Altitude, improper installation etc.
▪ Contact Number: 10. Improper mounting and
coupling of driven units.
▪ Email id: 11. Use of spurious parts and non-
▪ kVA Rating/Engine Model: recommended Lubricants and
Coolant.
▪ Generator Serial No.: 12. If regular Preventive
Maintenance Service is not
▪ Engine Serial No: carried out through Mahindra
▪ Date of commissioning:

▪ Contact No:
Customer’s Seal & Signature Distributor’s Seal & Signature
▪ Email Address:
For▪ detailed Warranty terms
kVA Rating/Engine and condition, please turn over leaf
Model:
▪ DG Serial No:
▪ Engine Serial No:
▪ Date Of Commissioning:
Warranty will be null & void if:

 Generator & Engine registration is not done on web portal.

 Genuine Mahindra spares parts are not used &/or procured from Mahindra Authorized Partner in the
country.
 Recommended engine oil & coolant are not used during the preventive maintenance.
 Preventive maintenance is not carried as per the recommended maintenance schedule.
 Any alteration done / design changes without the approval of the company.
 Product used in overloaded condition, operational abuse / use of adulterated fuel / sabotage & in
case of theft etc.
 Unauthorized repair work.
 Any tampering or wrong adjustment done in the systems
 Shifting of generators from one site to another site OR one country to another country, without
intimation to Mahindra Powerol / Authorized Distributor.
 Cannibalizing of generator components from one generator to another generator.
 Generators are stored for long time without preservation process as explained in the Owner’s
Manual.
 For resale of Mahindra Powerol Generator or if the Generator purchased second hand.
 Proprietary parts are not manufactured by Mahindra Powerol, such as Fuel Injection Pumps,
Batteries, Starter motor, electrical equipment and instruments etc. The warranty terms of respective
suppliers will be applicable.

Care to be taken by Purchaser for availing Warranty:

The company’s liability under this warranty is dependent upon the strict observance by the purchaser, of the
following provisions:

The purchaser at the time of installation shall sign, complete and return the installation form.
Under all operating conditions, adequate ventilation will be provided to the generator.

Repairs and replacement will be performed by the Mahindra Powerol’s Authorized Distributors only, following
delivery of the product by the purchaser to the distributor’s place of business, or on the site of commissioning,
as agreed.

This warranty shall not apply if the product or any part thereof is repaired or altered otherwise in accordance
with Mahindra Powerol’s standard repair procedure or by any person other than Mahindra Powerol’s
Authorized Distributor or their branch distributor or their service centres in any way.

The purchaser shall at all times during the operation of the Generator, use only those brands of oils, lubricants
and parts, which are recommended & approved by Mahindra Powerol.

The judgment of Mahindra Powerol or its Authorized Distributors in all cases of claims shall be final and
conclusive and the purchaser will agree to accept its decisions on all questions as to defects and to exchange of
part or parts. After the expiration of six days from the dispatch of notification of Mahindra Powerol’s or its
Authorized Distributors decision, the part or parts submitted may be scrapped or returned carriage forward by
the company or its Authorized Distributor.

Claims arising from this warranty will be recognized only if they are notified in writing to Mahindra Powerol’s
Authorized Distributor concerned or to Mahindra Powerol without delay, after the defect has been
ascertained.

Mahindra Powerol reserves the right to make changes in design or introduce any improvement or add any part
on products at any time without incurring any obligation to install the same on products previously sold.
WARRANTY POLICY
Dear Customer,
Thank you for your purchasing “MAHINDRA POWEROL GENERATOR”. Kindly read the complete document to
avail the warranty on your Generator.

Standard Manufacturer’s Warranty General Warranty Terms:

“The manufacturer’s warranty is applicable for 18 months from the date of The warranty is not applicable or will
shipment from our works OR 12 months from the date of installation and be void in the event of....
commissioning OR 1200 hours of operation, whichever occurs first. 13. Is applicable only if the Generator
is installed according to our correct
installation procedure.
14. Is not covered for accidental or
Extended Warranty intentional damage, including
Mahindra Powerol offers extended warranty through its distributors which vandalism, improper maintenance,
can be availed at nominal charges. Kindly select the option by “✔” or damage by chemicals, misuse or
neglect, or the defects in any
1 Year or 1200 hours of operation products which have been altered
outside the company’s works or
2 Years or 2400 hours of operation which have been let out on hire.
15. Natural disaster, such as fire,
earthquake, acid rain, etc. will not
On-line Warranty Registration (To be done by Powerol Distributor): be covered
16. Defects/damage caused by
Please get your product registered immediately within 7 days of the
normal wear and tear.
date of purchase for availing warranty. On-line warranty services are 17. If the identification marks of
applicable only for product purchased from Authorised Mahindra which have been altered or
Distributor. removed.
18. Loaded beyond the
To complete this on-line warranty registration process, please fill in recommended power ratings.
your personal details as well as complete Generator information by 19. Misapplication, not as per
logging to www.powerolglobeconnect.com recommended specifications and
condition of use.
20. If the Diesel Generator is not used
properly or for any other purpose
Customer Information for which it is not meant for such
as welding, etc.
▪ Customer Name: 21. If the Diesel Generator is exposed
during running condition to the
▪ Organization: conditions beyond operating norms
▪ Address: like excess heat / temperature,
Altitude, improper installation etc.
▪ Contact Number: 22. Improper mounting and
coupling of driven units.
▪ Email id: 23. Use of spurious parts and non
▪ kVA Rating/Engine Model: recommended Lubricants and
Coolant.
▪ Generator Serial No.: 24. If regular Preventive
Maintenance Service is not
▪ Engine Serial No: carried out through Mahindra
▪ Date of commissioning:

▪ Contact No:
Customer’s Seal & Signature Distributor’s Seal & Signature
▪ Email Address:
For▪ detailed Warranty terms
kVA Rating/Engine and condition, please turn over leaf
Model:
▪ DG Serial No:
▪ Engine Serial No:
▪ Date Of Commissioning:
Warranty will be null & void if:

 Generator & Engine registration is not done on web portal.

 Genuine Mahindra spares parts are not used &/or procured from Mahindra Authorized Partner in the
country.
 Recommended engine oil & coolant are not used during the preventive maintenance.
 Preventive maintenance is not carried as per the recommended maintenance schedule.
 Any alteration done / design changes without the approval of the company.
 Product used in overloaded condition, operational abuse / use of adulterated fuel / sabotage & in
case of theft etc.
 Unauthorized repair work.
 Any tampering or wrong adjustment done in the systems
 Shifting of generators from one site to another site OR one country to another country, without
intimation to Mahindra Powerol / Authorised Distributor.
 Cannibalizing of generator components from one generator to another generator.
 Generators are stored for long time without preservation process as explained in the Owner’s
Manual.
 For resale of Mahindra Powerol Generator or if the Generator purchased second hand.
 Proprietary parts are not manufactured by Mahindra Powerol, such as Fuel Injection Pumps,
Batteries, Starter motor, electrical equipment and instruments etc. The warranty terms of respective
suppliers will be applicable.

Care to be taken by Purchaser for availing Warranty:

The company’s liability under this warranty is dependent upon the strict observance by the purchaser, of the
following provisions:

The purchaser at the time of installation shall sign, complete and return the installation form.
Under all operating conditions, adequate ventilation will be provided to the generator.

Repairs and replacement will be performed by the Mahindra Powerol’s Authorized Distributors only, following
delivery of the product by the purchaser to the distributor’s place of business, or on the site of commissioning,
as agreed.

This warranty shall not apply if the product or any part thereof is repaired or altered otherwise in accordance
with Mahindra Powerol’s standard repair procedure or by any person other than Mahindra Powerol’s
Authorized Distributor or their branch distributor or their service centres in any way.

The purchaser shall at all times during the operation of the Generator, use only those brands of oils, lubricants
and parts, which are recommended & approved by Mahindra Powerol.

The judgment of Mahindra Powerol or its Authorized Distributors in all cases of claims shall be final and
conclusive and the purchaser will agree to accept its decisions on all questions as to defects and to exchange of
part or parts. After the expiration of six days from the dispatch of notification of Mahindra Powerol’s or its
Authorized Distributors decision, the part or parts submitted may be scrapped or returned carriage forward by
the company or its Authorized Distributor.

Claims arising from this warranty will be recognized only if they are notified in writing to Mahindra Powerol’s
Authorized Distributor concerned or to Mahindra Powerol without delay, after the defect has been
ascertained.

Mahindra Powerol reserves the right to make changes in design or introduce any improvement or add any part
on products at any time without incurring any obligation to install the same on products previously sold.
 Table of Contents
1. KNOW YOUR GENERATOR 1
2. BEST FEATURES OF YOUR GENERATOR 3
3. TECHNICAL SPECIFICATIONS OF ENGINE 4
4. INSTALLATION 5
4.1 Location 5
4.2 Foundation 6
4.3 Ventilation 6
4.4 Lifting/ Unloading of Generating Sets 7
4.5 Roof Top Installation 7
4.6 Exhaust Piping 8
4.7 Engine Breather Vents 8
4.8 Electrical Connections/Cabling 9
4.9 Load Cable selection Chart 11
4.10 Earthing 12
4.11 Design of a standard Earth Pit 13
4.12 EARTH PLATE AND EARTH STRIP SIZE 14
5. KNOW YOUR MAHINDRA ENGINE 15
5.1 Engine Numbering System 15
5.2 Storage 15
5.3 Using After Storage 16
6. PREPARING ENGINE FOR WORK 17
6.1 Inspection before Starting Engine 17
7. PREVENTIVE MAINTENANCE 20
7.1 Regular Maintenance to Be Done By the Customer 21
7.2 Air Intake System 21
7.3 Turbocharger 23
7.4 Cooling System 25
7.5 Lubrication System 28
7.6 Fuel System 29
7.7 Exhaust System 30
7.8 Electrical System 30
8. CHECKING OF SENSORS 31
8.1 Checking of HWT 31
8.2 Checking of RWL (Float type) 31
8.3 Checking of RWL (without Float type) 31
8.4 Checking of LLOP (Pressure Switch) 32
8.5 Oil Pressure Sensor cum Switch 32
9. SPECIFICATIONS 34
9.1 Lubricating Oil 34
9.2 Fuel Specifications 34
9.3 Coolant 34
10. SAFETY PRECAUTIONS AND DO’S / DON’TS 35
11. CONTROLLERS 37
11.1 DeepSea 4521 37
 Owner’s Manual

1. KNOW YOUR GENERATOR

Special Features

Features:

▪ Weather proof Galvanized Iron Canopy, Ideal for outdoor sites.

▪ Tamper proof powder coated pad locks with single key for all doors.
▪ Tamper proof Cast door hinges.
▪ Legs provided to prevent water accumulation underneath the base frame, ensures ease of
cleaning, easy to lift with Fork Lift.
▪ Removable drawer type fuel tank.
▪ Compact design with larger door spans for better access.
▪ Easy to refill Coolant and Lube Oil (from top of Canopy).
▪ Residential type Silencer (inside). Tail Pipe and Silencer with heat resistant paint.
▪ Fire retardant Foams used for sound attenuation as well as safety.
▪ Fuel efficient diesel engines with better weight to power ratio and compact size.
▪ Less vibration and low sound level.
▪ Designed to meet the latest environmental norms.

-1-
 Owner’s Manual

Generator Name Plate

Generator Name Plate

Generator model designation

-2-
 Owner’s Manual

2. BEST FEATURES OF YOUR GENERATOR

TECHNICAL SPECIFICATIONS OF GENERATOR SET

Standard Power
8 11 17 22 28 33 44 55 69 82.5
Rating,
(6.6) (8.8) (13.2) (17.6) (22) (26.4) (35.2) (44) (55.2) (66)
kVAe (kWe)
Continuous
7.5 10 15 20 25 30 40 50 62.5 75
Power Rating,
(6) (8) (12) (16) (20) (24) (32) (40) (50) (60)
kVAe (kWe)
2185 2185 3255 3305 4375 4445 4575 4725 4905 41035
Engine Model
GM GM GM GM GM GM GM GM GM GM
Maximum Load,
11 15 23 31 38 46 61 77 96 114
Amperes
Rated Load,
10 14 21 28 35 42 56 70 87 105
Amperes
Power Factor 0.8
ALTERNATOR SPECIFICATIONS
Make Mahindra/Leroy Somer
Type Brushless, Single bearing, Self-exciting
230 (1 Phase) /
Voltage, volts 415 (3 Phase)
415 (3 Phase)
Rpm / Frequency,
1500 / 50
hz
Voltage
±1% (7.5 to 20 kVA), ±0.5% (25 to 75 kVA)
Regulation
Enclosure Type IP 23
Class of Insulation H Class
Standard Manual Control Panel with Digital Engine Safety & Measurement Controller
CONTROL PANEL
(AMF Panel - as per specific requirement / application)
ACOUSTICS SPECIFICATIONS
Acoustics
Made from specially procured CRCA sheet using CNC machines for precision fit & finish, powder
Enclosure
coated
(Canopy)
75dBA @ 1 meter distance (as per the stringent testing guidelines of Central Pollution Control
Noise level, dB
Board, India)
Exhaust Silencer Inside Canopy
Length, mm 2150 2150 2500 2500 3100 3000
Width, mm 1030 1030 1030 1030 1150 1150
1405, 1650,
(w/d (w/d (w/d (w/d
Height, mm 1350 1350 (w/d 1405 1455 (w/d
1680) 1680) 1700) 1760)
1700) 2135)
Weight, kg 750 800 850 900 1000 1050 1100 1200 1250
Standby Power: Standby power is defined as the maximum power available during a variable electric power sequence, under the
stated operating conditions, for which a generating set is capable of delivering in the event of a utility power outage or under test
conditions for up to 500 hours of operation per year under average of 70% load. Overloading is not permissible
Prime Power: Prime power is defined as being the maximum power which the generator set is capable of delivering continuously
whilst supplying a constant electrical load when operated for an unlimited number of hours per year under the agreed operating
conditions with maintenance intervals and procedures being carried out as prescribed by the manufacturer.

Notes: All outputs stated are based at NTP in accordance with ISO 8528 standards. Please contact Mahindra Distributor to assess if any
derate is required
- Engine Governing is as per IS 10000 standards
- Fuel Consumption is @ 75% load and based on diesel having specific gravity of 0.85 and conforming to IS 1460 standards
- Fuel consumption tolerance is +5%
- All information given in this leaflet is intended for general purpose only. Due to continuous improvement policy, Mahindra reserves
the right to amend details and specifications without prior notice & liability
- Illustrations do not necessarily show the product in its standard form

TC = Turbo Charged, TCI = Turbo Charged Intercooled

-3-
 Owner’s Manual

3. TECHNICAL SPECIFICATIONS OF ENGINE

-4-
 Owner’s Manual

4. INSTALLATION

Proper installation and commissioning of a Generator is very important to achieve better up time
and safety.

Importance of proper installation of DG set:

a. Improved reliability & durability
b. Better fuel economy
c. Easy serviceability
d. High up time of Generator set
e. Better working conditions

The complete installation must comply with state / central and other applicable statutory
regulations.

4.1 Location
Selecting the right location for Generator is very important part of installation procedure. Consider
the following points:

▪ Canopy Generators can be

placed in open not in
closed room.

▪ While placing the

Generator on the
foundation, consider
natural wind flow. Ensure
no obstruction to natural
wind flow. Ensure the
direction of natural wind
flow and generator fan
wind throw is the same.

▪ It is recommended to leave
minimum 1 meter space
around all sides of
Generator. It facilitates
ease of service.

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 Owner’s Manual

4.2 Foundation

Inadequate foundation may lead to excessive vibration resulting in leakages, failure of the auto-
electrical and safety system, coupling or other engine parts. Ensure cement concrete foundation of
adequate size made ready before placing Generator.

▪ Length and breadth of the foundation should be minimum 300 mm more than the Generator.
▪ The foundation should be at least 100-150 mm above the ground. It helps to maintain
cleanliness of the Generator.
▪ Depth of the foundation should be 600 mm (if the soil is loose the depth may have to be
increased. It is advised to consult a structural engineer for designing the foundation).
▪ Surface of the foundation should be levelled. Use a ‘Sprit Level’ to measure the flatness of the
surface (should be 1 water level.)

4.3 Ventilation
Improper ventilation will result in overheating which may lead to higher consumption of fuel.

▪ Ensure that the openings provided

for fresh air inlet & outlets are not
blocked. If they are blocked the heat
generated inside the canopy and the
fumes dissipated by the engine,
alternator and its accessories will not
be removed. The Generator will also
not get fresh air for combustion. This
will affect the performance of the
Generator.
▪ The exhaust gases should go out
without any obstruction. Take care
that the exhaust gases do not enter
into other’s premises, doors, windows etc.

-6-
 Owner’s Manual

▪ Generator should be located away from polluted atmosphere like acidic fumes, cement dust,
stone dust etc. wherever possible. In case this is not possible, heavy duty air cleaner is a must for
such installations. Heat exchanger cooled system is recommended for such installations as
radiator gets clogged in dusty atmosphere.
▪ For humid/coastal atmospheric applications, anti condensation heaters are mandatory for
alternator.

4.4 Lifting/ Unloading of Generating Sets

▪ For Centre lifting – Provision for

Generator lifting is provided at the
centre in canopy roof. Load/ Unload
the generator using suitable capacity
crane.
▪ Ensure the DG set is placed exactly at
the centre of foundation so that
uniform gap is maintained at all the
sides of the Generating Sets from the
foundation.

4.5 Roof Top Installation

▪ Structure of the roof area should be
suitable for the entire weight, size and shape of the enclosure.
▪ Floating floor of the structural steel platform across the building main columns can be a one
of the solution.
▪ Ensure using AVMs and also other installation techniques so that vibrations are not
transmitted to the building.

It is recommended that the control cubicle containing change over contractor be located as close to
the building's incoming EB supply as possible.

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 Owner’s Manual

4.6 Exhaust Piping

Exhaust piping is required to direct exhaust gases to non-confined

areas & reduce the noise to tolerable levels.

▪ The exhaust piping run through to roof top should be through

sound attenuated ducting.

▪ To avoid excessive back pressure on engine, ensure the exhaust

piping length as short as possible. Excessive back pressure will
result in poor engine performance.

▪ Ensure smooth minimum number of bends.

▪ Calculate the total equivalent length of the

exhaust piping and accordingly increase the
diameter of the pipe. (From 5 to 15 meters,
increase inner diameter by 20%. From 15 to 25
meters, increase inner diameter by 40%).

4.7 Engine Breather Vents

▪ Crankcase gases should be piped outside the canopy so that oil fumes don't accumulate on
the engine / radiator. Oil fumes affect appearance, performance of radiator & early chocking
of air cleaners.

▪ Vent tube/ hose should continuously slope downwards to avoid oil accumulation.

√ Breather Pipe should be routed to mix

the ‘blow-by’ gas with Fan air flow.
[Pipe is not visible outside Canopy]

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 Owner’s Manual

4.8 Electrical Connections/Cabling

▪ Ensure that only qualified electricians carry out this work.
▪ All electrical work should be carried out in accordance with local rules / codes or regulations.
▪ Use flexible cable to avoid vibrations and possible damages to the alternator or circuit
breaker terminals.
▪ Support the cables so that weight of the cable should not fall on alternator/ base rail.
▪ Ensure cable is laid in a duct or on cable tray, minimise the bending radius.

Cable Tray

▪ Use only recommended cable sizes suitable for applied voltage and current.
▪ Crimped cables should be connected to alternator and control panel through cable glands.

Use insulating tape in the

crimped cables.
Use only crimped cables

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 Owner’s Manual

▪ Overheating due to lose thumbing, undersized cables causes most of the electrical failures.
For proper terminal connection, the contact area must be adequate. Strictly avoid loose
thumbing / undersize cables.

▪ It is highly recommended to
use a Transfer Switch
between the Generator and
Load.

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 Owner’s Manual

4.9 Load Cable selection Chart

-11-
 Owner’s Manual

4.10 Earthing
The Generating set and all associated equipment, control and switch gear panels must be earthed
before the set is put into operation. Earthing should be done in accordance with the local
regulations.

NOTE: Improper Earthing may lead to major accident, even loss of life. It may lead to equipment
failure because of lightening, Generator may catch fire due to lack of Earthing.

▪ Four number of earth pits are

recommended for our Generators.

▪ Neutral earth pits and Body earth pits

should be located at opposite side of
the Generator.

▪ 2 earth pits for the Body.

One from canopy/base rail.
Other from Alternator body.

▪ 2 separate earth pits for the

Neutral.

▪ Connect the two Body earth

plates to form a body earth grid.
Similarly, connect two Neutral
earth plates to form a neutral
earth grid.

▪ Body and Neutral earth pits

should never be interconnected.

▪ Engine and Alternator is

separated from the base rail by
AVM pads. Therefore earthing
must be done on engine /
alternator body and not on base
rail.

Copper or GI strips of suitable size may be used for Earthing. Please note that for normal soil, earth
resistance should not exceed 1 ohm. Ensure that Earthing checks are conducted once every year.

-12-
 Owner’s Manual

4.11 Design of a standard Earth Pit

-13-
 Owner’s Manual

4.12 EARTH PLATE AND EARTH STRIP SIZE

Generating Set 3-PHASE EARTH PITS SIZE G.I.PLATE EARTH STRIP SIZE

10kVA 300×300×5 mm 25×3 mm

15kVA 300×300×5 mm 25×3 mm

20kVA 300×300×5 mm 25×3 mm

25kVA 300×300×5 mm 25×3 mm

30kVA 300×300×5 mm 25×5 mm

35kVA 400×400×5 mm 25×5 mm

40kVA 400×400×5 mm 25×5 mm

45kVA 400×400×5 mm 25×5 mm

50kVA 400×400×5 mm 35×5 mm

62.5kVA 400×400×5 mm 35×5 mm

82.5kVA 600×600×5 mm 40×5 mm

100kVA 600×600×5 mm 40×5 mm

125kVA 600×600×5 mm 40×5 mm

140kVA 600×600×5 mm 40×5 mm

160kVA 600×600×5 mm 50×5 mm

180kVA 600×600×5 mm 50×5 mm

250kVA 600×600×5 mm 50×5 mm

320kVA 600×600×5 mm 50×5 mm

380kVA 750×750×5 mm 70×5 mm

500kVA 750×750×5 mm 70×5 mm

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 Owner’s Manual

5. KNOW YOUR MAHINDRA ENGINE

5.1 Engine Numbering System

Model Designation:
▪ The engine model is punched on name
plate in column “MODEL”.
▪ The first one digit indicates number of
cylinder of engine (3) i.e. 3 cylinder
engine.
▪ Next two digits indicate HP of engine (30)
i.e. Engine power is 30HP.
▪ Remaining last digit is the unique number
(5) i.e. it is Mahindra Unique Number.
▪ First alphabet indicates the application
(G) i.e. it is Geneset application.
▪ Last alphabet indicates the location of
manufacturing (M) i.e. Mumbai.

5.2 Storage

HOW TO STORE:
If the Generator is to be kept out of service for some time, it should be stored in a dry place. If the
storage period is more than one month, follow the procedure below:
▪ Drain the Fuel Tank, Feed Pump and Fuel Filters.
▪ Disconnect the Fuel Return Pipe at the Fuel Tank and connect a suitable tubing to allow
excess fuel to drain into a container. Fill the system with calibrating oil of 1.5 litres.
▪ Drain the lubricating oil from the crankcase sump and fill to normal level with rust
preventive oil
▪ Run the engine for 1.5 minutes. Shut down the engine.
▪ Drain the calibrating oil from the fuel tank only.
▪ Seal the fuel system with same quantity of calibrating oil in it.
▪ Remove air cleaner hose from the manifold of the engine and spray rust preventive through
the air intake while the engine is being turned.
▪ Drain the crankcase sump and the cooling system.
▪ Plug all orifices with expose the internal parts of the engine to the atmosphere. Detach
additional weights from Engine, if any.
▪ Remove batteries and store in a cool dry place, keep topped up and fully charged.

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5.3 USING AFTER STORAGE:

▪ Install the battery, be sure it is fully charged.
▪ Check the Fan and Charging Alternator belt tension.
▪ Drain the rust preventive oil from engine and oil filter and fill the crankcase with specified oil
and refit the oil filter.
▪ Service the Air Cleaner.
▪ Fill the fuel tank with clean fuel.
• Start the engine and run it at low speed. Observe all gauges and be sure they are functioning
properly and reading normal. Ensure there is no evidence of oil or water leakage.

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6. PREPARING ENGINE FOR WORK

(New or Overhauled Engine - Check for installation as per guideline provided)

6.1 Inspection before Starting Engine

General
▪ Check Engine accessory mounting for damage/looseness. Correct as required.
▪ Check Engine & coupling alignment.
▪ Check crankshaft end play &record.
▪ Check belts tension & adjust if necessary.

Cooling System
▪ Check coolant level in radiator as well as
recovery bottle.
▪ Ensure 'Mahindra Plus Coolant' is filled.
▪ Recovery bottle to be topped up only upto
max mark.
▪ Cap of recovery bottle should be securely
fixed.
▪ Check all hose pipes for proper connections.
▪ Ensure radiator cap is fixed &securely tight
at all the time.
▪ Check radiator mounting bolts for tightness.
▪ Check gap between cowl & fan & correct if
necessary.

Air System
▪ Check air cleaner for dents/damages
▪ Check air piping for Sealing, proper support & tightening of hose clamps.
▪ Check air cleaner mounting bolts for tightness
▪ Check engine breather vent. Extend vent outlet away from air cleaner, radiator.
▪ Ensure that the breather pipe is not bent or twisted.
▪ If any discrepancy noticed as mentioned above, the Air Cleaner need to be replaced.

Exhaust
▪ Check for exhaust bellow - proper fitment.
▪ Exhaust pipe properly supported
▪ Silencer location, bends, diameter of exhaust pipe. Rain water protection is proper.

Battery / Electrical System

▪ Check Battery electrolyte daily. (Not required for Dry battery).
▪ Add only distilled water inside the battery. Do not use tap water.
▪ Check all electrical instruments, gauges, meters are connected properly.
▪ Check for battery cable size & tightness.

State of Charge Specific Gravity Voltage – 12V

100% 1.265 12.7
75% 1.225 12.4
50% 1.190 12.2
25% 1.155 12.0
Discharged 1.120 11.90

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Fuel System
▪ Drain sediments from fuel tank and. If required
flush the fuel tank.
▪ Drain water from Water Separator. When the
float reaches the RED line, loosen the Drain Plug
and drain out the accumulated water.
▪ Check all pipe / hose connections are securely
tight.
▪ Clean fuel and a clean supply of air are essential
for efficient and prolonged engine life. Ensure
no sediments can enter at the time of pouring
the fuel in the tank.
▪ Remove

Bleeding the Fuel System:

WATER SEPARATOR
The air must be completely bled from the fuel system so
that the engine operates suitably.

1. Do not use your hand to check for leaks. Use piece of cardboard or paper to search for
leaks.
2. Stop engine and relieve pressure before connecting or disconnecting lines.
3. Tighten all connections before pressurizing lines.
4. If any fluid is injected into the skin, obtain medical attention immediately or else,
gangrene may result.

▪ Crank the engine at low rpm.

▪ Ensure engine should not start.
▪ Loosen the fuel feed pump (hand primer) cap
screw and start pumping to ensure air bubbles
coming out from bleed screws.
▪ Tighten the feed pump cap screw.

▪ Loosen air bleeding screw '3' on primary filter

and operate hand primer on fuel feed pump to
free fuel of air. Retighten bleeding screw.
▪ Loosen air bleeding screw '3' on secondary filter
and operate hand primer on fuel feed pump to
free fuel of air. Re-tighten bleeding screw.

1.Drain Plug, 2.Central Bolt, 3.Bleeding Screw,

4.Primary Filter, 5.Secondary Filter

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Lubrication System

Before you start a new or an overhauled engine, attend to the points given below:

▪ Fill engine oil through oil filling neck (1).

▪ Check Engine oil level in sum up to maximum
mark on dipstick.

Priming the Lubrication System:

After filling recommended engine oil, crank the engine

at least for 15 seconds with fuel shut off conditions.
Check that oil has reached up to all points in tappets.
(Remove tappet cover to check).

Key Points to be noted:

▪ The Oil capacity of the fuel pump is max.400ml

▪ Use same grade of oil used for engine lubrication (15W40 CH4).
▪ Always replaced the oil in the fuel pump, if the FIP is not used for more than 6 months.
▪ Use genuine oil only in fuel system.

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7. PREVENTIVE MAINTENANCE

Maintenance is the key to lower operating costs. A diesel engine requires regularly scheduled
maintenance to keep it running efficiently.

Maintenance Schedule

A Good Maintenance Schedule depends on Engine Application. Actual operating environment of the
engine governs the maintenance schedule. Some checks have to be performed more often under
heavy dust or other special conditions.

Preventive Services to be carried out as per hours / months, whichever is earlier, from date of commissioning

# Description 100 Hr / 300 Hr / 600 Hr / 900 Hr / 1200 Hr 1500 Hr 1800 Hr 2100 Hr 2400 Hr 2700 Hr 3000 Hr 3300 Hr 3600 Hr
15 Day 3 6 9 / 12 / 15 / 18 / 21 / 24 / 27 / 30 / 33 / 36
Month Month Month Month Month Month Month Month Month Month Month Month

Engine oil
1 (CH4 15 W Replace Replace Replace Replace Replace Replace Replace Replace Replace Replace Replace Replace Replace
40)
Replace Replace Replace Replace Replace Replace Replace Replace Replace Replace Replace Replace
2 Lube oil filter Replace

Primary fuel Replace Replace Replace Replace Replace Replace Replace Replace Replace Replace Replace Replace
3 Replace
filter
Secondary Replace Replace Replace Replace Replace Replace Replace Replace Replace Replace Replace Replace
4 Replace
fuel filter
Air cleaner
5 element Replace Replace Replace
(outer)
Air cleaner
6 element Replace
(inner)
Coolant
7 Replace Replace Replace
Replacement
Radiator
8 Flushing
Flushing
NOTE:
1. Recommended engine oil 15W40 - CH4
2. Maintenance schedule for dry type air cleaner element has been provided. However replacement of air cleaner element will depend on the dust condition at the site as being indicated
by the vacuum indicator. Failure to replace air cleaner element appropriately may result in reduced performance & life of the diesel Engine.
3. Generator rating 7.5 kVA to 25 kVA - There is only Safety Air cleaner element, Cleaning is not recommended on this filter, hence it is recommended to replace this element every 1200
Hours of operation or one year, whichever comes first.

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7.1 Regular Maintenance to Be Done By the Customer

JOB ACTIVITY 10 HRS 50 HRS
AIR CLEANER
Air cleaner connection / hose Check *
FUEL SYSTEM
Fuel tank sediments Drain * *
Fuel tank breather Check *
Feed pump filter Clean *
Fuel pump oil Check *
Leakage Check * *
COOLING SYSTEM
Coolant Level Check & top up * *
Hoses Check * *
Fan belt & belt tension Check & adjust *
LUBRICATING SYSTEM
Oil level (if required top up) Check * *
ELECTRICAL
Electrolyte level Check *
Battery terminal Clean *
Vent Clean *

7.2 Air Intake System

Air Cleaner (dry type)

The engine draws a large volume of air into the combustion chambers and the important function of
the air cleaner is to purify this air so that no dust or chaff etc. enters the engine. To remove these
impurities it is most important that the air cleaner should have regular maintenance. It can then
continually and efficiently protect the engine from dust and other harmful substances which would
otherwise enter the engine and cause abrasion and excessive wear.

The air cleaner comprises of the following parts:

Body Air-Cleaner
These serves as the main frame for housing all
parts associated with the air cleaner system.

Cyclopack or built-in Pre-Cleaner

The coarse dust particles are separated by the
curved blades of the cyclopack and get
collected in
the dust collector.

Paper element filter

This screens the fine impurities. This has to be
cleaned by compressed air during every
service or earlier if required. The filter should
be replaced after every 1000 hours or earlier if
required.

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Safety Cartridge
Safety Cartridge fits inside the paper element filter. It is a safeguard against uncontrolled dust entry
into engine due to paper filter element rupture and also when the paper element is removed for
cleaning.
Cleaning of safety cartridge is not recommended. It is to be replaced. Change Safety Cartridge once
for every third change of paper element.

Dust Collection Bowl

It collects the dust and releases it automatically.

Service Indicator
Mechanical service indicator is mounted on intake pipe. Visibility of red band in transparent window
shows choking of air cleaner element. In this condition or at every 300 hrs, clean the paper element.
If the red band persists after cleaning change the element.

Cleaning of Air Cleaner – SERVICE INSTRUCTIONS

▪ Open the steel clamps given on air cleaner body.

Remove the bowl by opening four wire clamp given
on its body.
▪ Take out paper element along with safety cartridge.
Take care that dust is not spilled inside air intact.
▪ Separate the paper element from safety cartridge.
▪ If safety cartridge is very dirty then replace it by new
one. Never clean safety cartridge.

▪ Clean the paper element by blowing compressed air

from inside to outside. Ensure no damage to the
paper element.
▪ After cleaning the paper element, check paper
element for any crack or hole by putting an electric
bulb inside the element and check from outside. If
found damaged change it by new one.

▪ Remove the rubber dust unloader from air cleaner

and clean and refit it.
▪ Assemble the safety cartridge and then paper element
on air cleaner body.
▪ Assemble the bowl on body and ensure dust unloader
is towards down.
▪ Put the clamps back. Ensure all clamps are properly
fitted, if any clamp is found loose, replace it by new
one.
▪ Put the steel clamp on filter body.
▪ Ensure that all the joints of air cleaner are air tight.
▪ Press reset button on service indicator.

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7.3 Turbocharger
The Turbocharger makes use of thermal energy of engine exhaust gases to run a turbine which in
turn drives a compressor to force air under pressure into the inlet manifold.

Operation Recommended
▪ Idle the engine for one minute after
starting, and before stopping the engine.
This is to ensure adequate lubricating oil
supply to the Turbocharger unit.
▪ The Turbocharger needs to be pre-oiled
after any change or any service involves oil
draining. Whenever the engine has not
been used for a long period or operated at
low ambient temperatures crank the engine
a few times before allowing it to start. Then
start the engine and allow it to idle for a
few minutes to establish full oil circulation
and pressure operating at higher speeds.
▪ Avoid long periods of engine idling. Low turbocharger shaft rotating speed may lead to oil
and blow by-pass gas to seep past the seal into the turbine or the compressor.

Maintenance
▪ Engine oil has to be changed regularly.
▪ Maintenance work has to be carried out regularly.
▪ Check all turbocharger connections. Connection must be leak proof.
▪ When carrying out maintenance work on engine, close the opening on turbocharger
connecting parts removed to prevent entry of dirt or foreign objects.
▪ When fitting the turbocharger to the engine fill the central housing with clean oil and before
fitting make sure that all pipes are connected to the turbocharger.
▪ Check the engine breather system. If you suspect any malfunctioning of the turbocharger,
inform to the nearest service dealer.
▪ If the Turbocharger shaft axial play exceeds 0.004 inch and radial play exceeds 0.016 inch it
needs servicing,

Useful Tips
▪ Turbocharger is matched with a particular engine in association with the engine
manufacturer. Therefore, the specification stipulated by the engine manufacturer should not
be changed.
▪ Tampering of Fuel Injection Equipment is prohibited as it may result in engine as well as
Turbocharger damage.
▪ Changes in boost pressure control of the Turbocharger (where applicable) may result in
engine damage.
▪ Use only the oil filter and oil grade recommended by the engine manufacturer.
▪ Use only the Intercooler (where applicable) recommended by the engine manufacturer.
▪ Changes in exhaust system are not recommended.
▪ Ensure proper functioning of exhaust brake, if fitted.
▪ Use original gaskets and connecting pipes.

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DO’S AND DON’T’S FOR SATISFACTORY FUNCTIONING OF TURBOCHARGER

DO’S
▪ Regular change of engine oil I oil filters according to engine manufacturer's specification.
▪ Regular change / cleaning of air filter element according to engine manufacturer's
specification.
▪ Check for oil pressure at engine idling condition. Minimum oil pressure to be as per engine
manufacturers' recommendation during idling.
▪ Idle the engine for 60 seconds after starting the engine.
▪ Idle the engine for 60 seconds before switching off the engine.
▪ Periodic cleaning of crankcase breather IS necessary to allow free flow of oil from
turbocharger outlet.
▪ Regularly check all air, oil and exhaust connections for leaks and abnormal dust / oil carbon
build up.

DON’TS
▪ Don't run the engine with low oil pressure.
▪ Don't put the engine under full load immediately after starting.
▪ Don't switch off the engine under full load.
▪ Don't run the engine with damaged oil feed & drain pipes.
▪ Don't run with damaged / faulty connections from the air cleaner to the turbocharger and
turbocharger to the inlet manifold.
▪ Don't run with damaged / faulty connections to the turbocharger turbine inlet from turbine
outlet

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7.4 Cooling System

WARNING: The cooling system is under pressure, it is dangerous to remove the radiator cap
while the system is hot. Always turn the cap slowly at the first step and allow pressure to
escape before removing the cap completely. To avoid personal injury be sure to stop the
engine before working on radiator.

To ensure an even temperature, the cylinder head and cylinder walls of the Engine are cooled by
coolant. This coolant is in turn cooled in the radiator. Coolant is circulated from the radiator to the
Engine and back through the radiator by means of a water pump. The flow of the coolant is
regulated by a thermostat. Below layout shows the coolant path.

Rust Prevention
To prevent rust formation in sleeve cylinder, water pump, cylinder block, Radiator tube & other
parts of cooling system, “Power Supercool” coolant is recommended. Continuous usage of the
solution will ensure increased efficiency & increase life of the cooling system. During repair if for any
reason coolant is to be removed, collect the solution in clean vessel & refill it after repair. Please
replace coolant after every 1200 hrs. or 1 year whichever occurs earlier. Use clean water for mixing
the coolant.

Hose Connections
• Inspect the hoses for cracks & damages. Replace if necessary.
• Check clips are tight &no leakage.
• Replace Coolant. Flush the cooling system at 1000 hrs. or one year, whichever is earlier.

Fresh Water Pump

The water pump is provided with bearing which will last the normal life of the pump, no adjusting or
greasing is required for bearing.

Thermostat
This device prevents water circulating through the Radiator until the engine reaches its operating
temperature. With the thermostat closed, the water circulates only through the engine block. It is
important that the thermostat is in good working order. If it is defective, do not attempt to repair it,
replace with new When installing a new thermostat, ensure the valve is facing upward, towards the
radiator connection.

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Flushing of Cooling System

Draining the System

There are two drain taps which must be opened, one is to the left hand said of the crankcase and
one on the bottom tank of the radiator.
To speed up the draining, the radiator filler cap should be removed. Ensure that the drains are not
clogged. When the water has drained completely, close the taps.

IMPORTANT: Do not run the Engine when the cooling system is empty, and do not add cold water
or cold antifreeze solution if the engine is hot.

Cleaning out Dirt and Sludge

Fill the cooling system with a solution of 1.36 kgs. of ordinary caustic soda to 10.19 liters of water.
Operate the Engine until the water is hot. Drain, flush with clean water and refill.
The system should be kept filled with clean water with a rust inhibitor or anti-freeze solution till the
time of use. Fill with coolant with engine operation.

Hose Connections
Check periodically to ensure all the connections are in good order and the clips are tight. A leaking
hose connection results in loss of coolant and thus Engine efficiency.

Radiator Core
Over heating may be caused by bent or clogged radiator fins. If the spaces between the radiator fins
become clogged, clean them with forced air or water. When straightening bent fins be careful not to
damage the tubes or to break the bond between the fins and tubes.

IMPORTANT: Do not run the Engine without Thermostat Value.

Service Instructions
▪ Fill the Radiator with recommended coolant till the neck of the top tank.
▪ Check the coolant level in recovery bottle &
top up if necessary.
▪ Do not use muddy water for radiator as it
may chokes/corrodes the cooling system.
▪ Blow compressed air through the radiator
fins to remove foreign material.
▪ Coolant level should be up to the Max mark
on the recovery bottle.
▪ To prepare the coolant, add 4 litre clean
water with 1 litre of Power kool coolant.
▪ If the Fan blade is found in bent or damaged
condition, replace the fan.
▪ If the fan belt is found loose, tighten it.
▪ Inspect the hoses for cracks & damages.
Replace if necessary. Check clips are
tightened.

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BELT TENSION ADJUSTMENT PROCEDURE:

FOR MDI ENGINES (2185GM, 3255GM, 3305GM,

4375GM, 4445TCGM, 4575TCIGM)

Turn the engine until the Set Screw can be

Flange
reached. Loosen the set screw.
Screw the flange towards the fan belt to tighten
or away from the fan belt to slacken. [Use a C-
Spanner.]
When the tension is correct lock the flange by
set screw. Screw

USING THE C-SPANNER

▪ Remove the lock nut and screw from the

water pump pulley hub. C-SPANNER
▪ Place the spanner over the water pump
pulley flange.
▪ Align the grooves provided on the spanner
with ribs on the water pump pulley flange.
▪ Rotate the spanner clockwise / anti-
clockwise
▪ for tightening / loosening fan belt
respectively.
▪ Retighten the lock screw and nut in nearest
groove.

FOR NEF ENGINES (4725GM, 4905GM, 41035GM)

Loosen the Adjusting Bolt in the alternator

bracket. Lock the bolt in correct location. Alternator
Press the belt with thumb at the middle Bracket
between two pulleys, without much effort belt
should move half inch approximately.

Adjusting Bolt

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7.5 Lubrication System

To prevent excessive friction and heat generation between any two surfaces in relative motion with
respect to each other, an oil or lubricant film is required in between the two.

Lubricant oils mainly have the following additives:

▪ Anti oxidation additive : for avoiding the risk of burning of oil due to sparks.
▪ Anti corrosion of Rust : for preventing corrosion, scaling &rust formation. Preventive additive
▪ Detergent additive : for removing &cleaning carbon deposits &other impurities.
▪ Anti foaming additive : for preventing foaming or bubble formation on oil surface.

Oil change Intervals

Oil change interval is very important factor in preserving integrity of an engine. Lubricating oil
contamination is the direct result of engine operation & load factor involved. The amount of
contamination generated depends on the amount of the fuel, the engine consumes. At each oil
change the filters must be replaced. (For details of oil change intervals, check the PREVENTIVE
MAINTENANCE SCHEDULE, Page No.23)

NOTE: If the lubricating oil is drained from the oil pan to make
an engine repair, new oil must be used. Do not use oil after it
has been drained from the oil pan.

Daily Checking
▪ Check engine oil level before starting the engine by means
of dipstick gauge.
▪ Top up if found below low level.

NOTE: Do not check oil level when engine is running. Shut

down the engine and wait for 10 minutes, then check the oil
level.

Oil and Oil Filter Change

▪ Remove the locking plug and rotate the handle to OPEN
position.
▪ Collect the Oil in flat tray, if metal particles are observed on
Drain Plug or in the oil then check the engine thoroughly.
▪ After draining the oil refit the Locking Plug then rotate the
handle to CLOSE position.
▪ Remove the oil filter with the help of filter removing tool.
▪ Install a new filter by simply rotating it to the filter head.
The filter must be hand tightened. Do not over tighten
otherwise the filter O Ring may get damaged.
▪ To refill oil, first remove the Breather Cap then put the tube
inside the breather hole. Pour oil from the funnel on top (if
provided). Always use recommended grade of oil.
▪ After refilling oil, do not forget to fix the cover of the tube.

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7.6 Fuel System

Providing clean and adequate supply of fuel to the engine is the prime function of the fuel system.

Service Instructions:

▪ Drain the sediment from fuel filter

from the drain plugs.
▪ Do not permit dirt to get into fuel
tank.
▪ Do not forget to securely tighten the
fuel filling cap after refuelling.
▪ Do not let the fuel tank become
empty. It the tank becomes fully
empty air can enter into the fuel
system necessitating air bleeding
before starting the engine.
▪ Be careful not to spill fuel during
refuelling. If it spills, wipe if off immediately or it may cause fire.
▪ Do not use pesticide/chemical cans for storing fuel. Store fuel in a clean container. Dirty fuel
will cause severe damage to the FIP.

CAUTION: Be sure to stop the engine before refuelling.

Cleaning the Feed Pump Filter

▪ Remove the feed pump bowl by rotating

the knob anticlockwise.
▪ Remove the filter and clean the bowl as
well as the filter in diesel.
▪ While fitting the filter make sure that the
spring is pointing downwards.
▪ Ensure the O ring sits properly.

Draining water from Water Separator

▪ Check for water level in the Water Separator and

drain water when the float reaches the red line.
▪ Rotate the Knob anti clockwise to drain water.
Close the knob when water is drained out.

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7.7 Exhaust System

The Exhaust System is designed to remove the exhaust gases from the Engine into the atmosphere.

CAUTION: Do not run the engine with disconnecting the silencer.

Service Instruction
Silencer is required to be cleaned if the back pressure exceeds to 70 mm of Hg.

7.8 Electrical System

Maintaining the electrical system in good working order will enable the alternator to provide the
battery with the flow of current needed to keep it fully charged thus ensuring maximum efficiency of
the electrical devices.

Battery Maintenance

Keeping the battery fully charged not only adds to its life but makes it available for instant use when
needed.

CAUTION:
1. When the alternator is charging, an explosive gas is produced inside the battery. Therefore
always check the electrolyte level when the engine is not running.
2. Do not run the engine without battery.
3. Do not keep any exposed flame and do not smoke while checking the battery.
4. Before working on any part of the electrical system, disconnect the battery. Do not re connect
the cable until all electrical work is complete. This will prevent short circuits and damage to
electrical unit.
5. Do not allow acid to come into contact with the skin or clothing. Wear protective goggles.

When replacing the Battery the earth cable must be connected to the negative terminal and the
battery cover secured in its correct position.

▪ Keep the battery clean and dry. After cleaning ensure vent holes are open.
▪ Clean the terminals (+ -) with emery cloth if it is corroded.
▪ Wash the battery top with warm water & soda.
▪ Ensure cleaning solution does not enter the cell through the vent holes.
▪ After cleaning ensure that all vent holes are open.
▪ When reconnecting ensure good contact of the terminals. Tighten clamping bolts firmly.
▪ Apply petroleum jelly on terminals.

Checking Specific Gravity of Electrolyte:

Check the specific gravity of Electrolyte with a hydrometer five min. after adding
distilled water.

SPECIFIC GRAVITY (Kg/Ltr) STATE OF CHARGE

NORMAL TROPICS
1.280 1.230 Fully charged.
1.200 1.112 Half charged / recharging.
1.120 1.080 Discharge / Charge up immediately.

Battery care in Winter

▪ Cold Starting requires a good state of charge of battery.
▪ Lowering the starting limit temperatures by 4-5° is possible by raising the battery
▪ Temp at about + 20°C. This is achieved by removing the battery & storing it is warm room.

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8. CHECKING OF SENSORS

8.1 Checking of HWT

▪ Put Generating Set in Manual
mode
▪ Remove the wiring connector
of the HWT
▪ Connect with Body to check if
the wiring connection of HWT
is OK.

To separately check the HWT sensor, its resistance value HWT MULTIMETER
should be checked by a multimeter. sensor

With temperature increase the resistance decreases. In

the normal condition the sensor should show very high
resistance (Around 750 Ohm’s). If the sensor shows low
resistance or continuity at normal temperature, then the
sensor is faulty. (66 ohm’s @ 100 deg cen)

8.2 Checking of RWL (Float type)

▪ Remove the RWL from radiator.
▪ Check the float for free movement. Clean dirt if found.
▪ Dip the float in pot of water, and check the movement of the
float.
▪ Check continuity when the float is at the bottom, OK if
continuity is found.
▪ Check continuity when the float is at the top, OK if no
continuity is found.

8.3 Checking of RWL (without Float type)

▪ Remove the RWL from radiator connect the +VE & -VE pins with a
12V battery.
▪ Dip the RWL unit in a pot of water.
▪ Check continuity between +VE & Controller Input pins. Unit is OK if
no continuity is found.
▪ Remove the RWL unit from the water pot.
▪ Check continuity between +VE & Controller Input pins. Unit is OK if
continuity is found.

Green
(Controller input)
Red
(+VE)
Black
(-VE)

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8.4 Checking of LLOP (Pressure Switch)

Checking in Idle condition (Engine Off Condition)

▪ Bulb of the continuity tester should glow at point NC and C.
▪ Bulb of the continuity tester should not glow at point NO and
C.

Checking by engine starting (Engine Running )

▪ Bulb of the continuity tester should not glow at point NC and –
C.
▪ Bulb of the continuity tester should glow at point NO and – C.

8.5 Oil Pressure Sensor cum Switch

Checking the Switch

Ground (BLACK) Multimeter

Condition
Display
Engine stopped Continuity
‘W’ – Switch (BLUE)
Engine running Discontinuity

Checking the Sensor

Check resistance value at various pressure.

Ground (BLACK) BAR RESSITANCE

(P) (R) Ohm
0 10
1 30
5 95

‘T’ – Sensor (YELLOW)

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NOTE: Do not interchange the position of the NUTS. They should be placed at their respective terminals as
mentioned in the picture.

There are ventilation holes at the centre.

SERVICE INSTRUCTIONS
This area should be kept clean.
• Tighten the VDO sensor with a
19mm A/F Spanner
• Maximum allowable tightening
torque is 30 NM.
• Allowable torque for the Nut at
Terminal end is 1NM.

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9. SPECIFICATIONS

9.1 Lubricating Oil

Lubricating oil has a limited working life after which the effects of time, condensation, engine heat and by
products of combustion will combine to reduce its lubricating properties rapidly.
It is incorrect to use Lubricating Oil for more than the specified period. The intervals between lubricant
changes detailed in this manual have been determined after prolonged tests and have been proved the most
suitable for normal operation. In extremely arduous conditions, however, it may be necessary to reduce
these periods and this point should be discussed with Mahindra or with authorised service dealers .

Recommended Lubricating Oil

Mahindra recommends the use of POWERGEN EXCEL or equivalent grade of – API CH4/SJ SAE 15W40 oil.

Do not inter mix different brands / grades of oil as two different brand of oil may not be compatible
with each other. It is therefore recommended that the brand which is used for initial fill should only
be used for top up.

9.2 Fuel Specifications

The performance of the engine depends upon supply of clean & correct grade of fuel. The fuel injection
equipment manufactured to very close tolerance & slightest amount of dirt in fuel can cause wear on the
injection equipment. Always use clean High Speed Diesel having a sulphur content of below 1%.

The following specifications are approved:

IS - 1460
BS - 2869 – A1 & A2 (In case ofA2, note sulphur content)
Din - 51601
ASTMP - 975 – 8P: ID 2D

Winter Grade Fuel

At low temperature waxing may occur and clog the fuel system thus causing operational troubles. In the case
of ambient temperature below 100C, use Winter Grade diesel fuel.

9.3 Coolant

Mahindra recommends use of Powerkool coolant.

In summer: Mix 1 Litre Powerkool with 4 Litre Demineralized water/Soft water.

In winter: Use 100% Powerolkool, do not mix with water (for sub-zero temperature upto -10o C).

Storage of engine with only fresh water in engine cooling system should be avoided at ambient temperature
below 5°C. This may cause cracks in the engine components. If the engine is to be transported from normal
ambient areas to Low ambient temperature (below + 5°C) the complete cooling system should be drained and
refilled with suitable coolant as mentioned above.

Coolant Preparation (for ambient temperature above 0o C)

Mix 1 Litre Powerkool (1 bottle) with 4 Litre soft Do not pour coolant and water directly into the
water. Now 5 Litre of usable Coolant is ready Radiator.

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 Owner’s Manual

10.SAFETY PRECAUTIONS AND DO’S / DON’TS

The following precautions are suggested to help prevent accidents.
A careful operator is the best operator. Most accidents can be avoided by observing certain precautions. Read
and take the following precautions before operating the Engine to prevent accidents. Engine should be
operated only by those who are responsible and instructed to do so.

The Engine
1. Read the Owner’s Manual carefully before using the Engine. Lack of operating knowledge can lead to
accident.
2. Replace of missing, illegible or damaged safety decals.
3. Keep safety decals clean of dirty and grease.

Servicing the Engine

1. Keep the Engine in good operating condition for your safety. An improperly maintained Engine can be
hazardous.
2. The cooling system operates under pressure which is controlled by the Radiator cap. It is dangerous to
remove the cap while the system is hot. First turn the cap slowly to stop and allow the pressure to
escape before removing the cap entirely.
3. Do not smoke while refuelling the Tank. Keep away any type of open flame.
4. The fuel in the injection system is under high pressure can penetrate the skin. Unqualified persons
should not remove or attempt to adjust a pump, injector, nozzle or any part of the fuel injection
system. Failure to follow these instructions can result in serious injury.
5. Keep open flame away from battery to prevent fire or explosions.

Diesel Fuel
1. Keep the fuel injection equipment clean and properly maintained.
2. Under no circumstances should gasoline, alcohol or blending fuels be added to diesel fuel. These
combinations can create an increased fire or explosive hazard. Such blends are more explosive than
pure gasoline in a closed container, such as a fuel tank. DO NOT USE THESE BLENDS.
3. Never remove the fuel cap or refuel while the Engine is running.
4. Do not smoke while refuelling or when standing near fuel tank.
5. Maintain control of the fuel filter pipe when filling the tank.
6. Do not fill the fuel tank to capacity. Allow some room for expansion.
7. Wipe up spilled fuel immediately.
8. Always tighten the fuel cap securely.
9. Do not keep equipment near open fire.
10. Never use fuel for cleaning purposes.

DO’S - for Better Performance

▪ Ensure that all safety shields are in place and in good condition.
▪ Read all operating instructions before commencing to operate Engine.
▪ Carry out all maintenance tasks without fail.
▪ Keep the air cleaner clean and the oil at the correct level.
▪ Ensure that the correct grade of lubricating oils is used and that they are replenished and changed at
the recommended intervals.
▪ Fit new sealing rings when the filter elements are changed.
▪ Watch the oil pressure gauge or warning light and investigate any abnormality immediately.
▪ Keep the radiator filled with recommended coolant mixture. In cold weather use anti-freeze mixture.
Drain the system only in an emergency and fill before starting the Engine.
▪ Ensure that electrical system, instrument & battery are in good working condition. Ensure to charge
battery regularly.
▪ Keep all fuel in clean storage and use a filter when filling the tank.
▪ Attend to minor adjustments and repairs as soon as necessity is apparent. When in doubt, consult
Mahindra authorised service dealer.
▪ Allow the Engine to cool before removing the radiator filler cap and adding water. Remove the
radiator cap slowly.

DON'TS – for Safe Operation

▪ Operate the Engine with the air cleaner or pre-cleaner disconnected.

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 Owner’s Manual

▪ Tamper with the fuel injection pump. If the seal is broken the warranty becomes void.
▪ Allow the Engine to run idle for a long period
▪ Run the Engine if it is not firing on all cylinders.
▪ Refuel while the Engine is running.
▪ Use cloth for filtering Diesel, as minute cloth threads might mix up in fuel & effect the performance of
F.I.P / Engine.
▪ Allow to fill water, Diesel or oil over starter motor.
▪ Wash an Engine attached with alternator without first covering the alternator with polythene bag.

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 Owner’s Manual

11.CONTROLLERS

11.1 DeepSea 4521

BUTTON & LED IDENTIFICATION – DSE 4520 / 4521

RUNNING IN MANUAL MODE:

To run the Generator in Manual mode, first the Manual/Start Mode button should be pressed.
If ‘protected start’ is disabled, the start sequence begins immediately. (* The ‘protected start’ can
be selected or de-selected via DSE Configuration Suite Software.)
If ‘Protected Start’ is enabled, the Waiting in Manual Mode icon is displayed and the LED above
the Manual/Start Mode button flashes to indicate Waiting in Manual Mode.
The Manual/Start Mode button must be pressed once more to begin the start sequence.

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

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

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