operation manual - Yanmar Genset - Taiyo Generator

OPERATION MANUAL 

SCANGEN 

DIESEL GENERATOR 

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USER INFORMATION 

USER’S NAME 

USER’S ADDRESS 

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TELEPHONE NO. 

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GENERATOR SET MODEL 

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

ENGINE MODEL 

ENGINE SERIAL NO. 

ALTERNATOR MODEL 

ALTERNATOR SERIAL NO. 

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DEALER’S NAME 

CONTACT PERSON 

DEALER’S ADDRESS 

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TELEPHONE NO. 

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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


SCANGEN GENERATOR SET 

SG SERIES

7. Maintenance 

1. Introduction 

Generator Set Operation Manual 


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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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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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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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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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: 

‣ No improvement in the color of face and lips 

‣ No construction of the dilated pupils of the eyes. 

‣ No pulse to be felt in the neck or elsewhere: 

Jika setelah 5 atau 6 kali pemompaan pada paru-paru korban, dan: 

‣ Tidak ada perubahan pada warna kulit muka dan bibir korban 

‣ Pupil mata korban tidak mengembang 

‣ 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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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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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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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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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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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 -


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 -




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 -




Roof 

Outlet 

Engine 

Exhaust 

Manifold 

Silencer is hang 

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 -




• 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 60 0 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 

60 0 . 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 -




(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 -




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 2 0 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 -




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 -




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 -




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. 

set. 

WARNING! 

Ear protection must be worn when operating or working around an operating generating 

Pelindung telinga harus dikenakan selama mengoperasikan atau bekerja disekitar genset. 

- 21 -




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 -




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 15 O (27%) and avoid potholes, rocks or other obstructions 

and soft or unstable terrain. 

Hindari permukaan yang curam melebihi 15 O (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 15 O (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 15 O (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 -




4.10. 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. 

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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 

14) Water Temperature Gauge 

Applied in D9 engine 

15) EMS Lamp 

16) Diagnosis Switch 

17) Diagnosis Button 

Applied in D12, D16 EMS engine 

18) COO Lamp 

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2 

3 

4 

1 

7 

5 

14 

8 

6 

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 -




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 -




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 -




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 -




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 

terpasang pada potongan panel ukuran 90 x 90 mm 

Rear panel layout 

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 

- 30 -




11 

12 

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 deenergized, 

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 -




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 -




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 -




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 -




5.1.2. CONTROL SYSTEM EasYgen 320 Woodward 

1 

2 

4 

3 

6 

5 

Fig 4. typical control panel for D9 engine with woodward controller. 

1 

7 

8 

9 

11 

2 

3 

10 

12 

4 

6 

5 

Fig 5. typical control panel for D12, D16 EMS engine with woodward controller. 

- 35 -




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. 

- 36 -




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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Fig 7. Wiring diagram – easYgen320X 

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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. 

right 

LEDs – The LEDs indicate operating states of the unit and alarm messages. The 

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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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 

bersamaan. 

dan 

Operating the easYgen 

‣ 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) 

‣ 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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ket 




‣ 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. 

‣ 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. 

‣ 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. 

‣ 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 . 

‣ 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 . 

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. 

- 41 -




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: 

‣ 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 

- 42 -




dan bagian bawah horizontal menandakan generator. 

‣ 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 

‣ 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. 

‣ 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. 

Digit 1 : Operating hours (h) 

Digit 2 : Revolutions (rpm) 

Digit 3 : Frequency (Hz) 

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): 

- 43 -




- 44 -




Fig 9. Display of operating values 

If the scroll button is pressed again, the display returns to generator voltage V 12 . the 

display automatically returns after 180 second to generator voltage V 12 being displayed if a 

button isn’t pressed. 

- 45 -




Jika tombol scroll ditekan lagi, display akan kembali ke voltase V 12 generator. Display secara 

otomatis akan kembali ke voltase V 12 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. 

- 46 -




- 47 -




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. 

- 48 -




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. 

6.1 GENERATING SET MAINTENANCE 

Function of a Load Transfer Panel 

Fungsi dari panel transfer beban 

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 -




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 

- 50 -




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 

- 51 -




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 

- 52 -




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 49 0 C 

(120 0 F). 

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 

- 53 -




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. 

- 54 -




+ - 

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 

- 55 -




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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7. Commissioning 


+ - + - 

Single Battery 

+ - 

Parallel Battery 

12 Volt System 

+ - + - 

Series 

+ - + - 

+ - + - 

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. 

- 57 -




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 

- 58 -




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. 

- 59 -




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 

- 60 -




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 -




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 -




COMMISSIONING SHEET 

GENERATOR SET DATA 

Generator Set Model / Serial No : ____________________ / ____________________ 

Engine Model / Serial No 

Alternator Model / Serial No 

Date of Commissioning 

Company Name 

Address 

Genset Location 

END USER DATA 

: _______________ / _______________ 

: _______________ / _______________ 

: ______________________ 

V Inspection Passed 

X Refer to Comments 

N/A Not Applicable 

: _________________________________________________________ 

: _________________________________________________________ 

: _________________________________________________________ 

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 _____ 0 C 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 -


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 -




8.2. FAULT FINDING FOR DSC MODULES 

SYMPTOM 

GEJALA 

Unit is inoperative 

Unit tidak beroperasi 

Units shuts down 

Unit tiba-tiba mati 

Units locks out on Emergency 

Stop 

Unit terkunci pada Emergency 

Stop 

Intermittent sensor fault 

Sinyal sensor yang menyala 

sebentar-sebentar 

POSSIBLE REMEDY 

TINDAKAN 

Select AUTO on the front panel. Check the battery and 

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 

Check DC supply voltage is not above 35 Volts or below 8 

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 

If an Emergency Stop Switch is not fitted, ensure that a 

positive is connected to the Emergency Stop input. Check 

emergency stop switch is functioning correctly. Check 

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 

Ensure that Magnetic pick-up screen is only connected at 

one end; if connected at both ends this enables the 

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 

operates after engine has fired 

Temperatur mesin tinggi setelah 

mesin menyala 

Shutdown fault operates 

Peringatan tanda unit mati 

menyala 

Warning fault operates 

peringatan tanda kesalahan telah 

terjadi menyala 

Fail to start is activated after 

pre-set number of multi 

attempts to start 

Check engine temperature. Check switch and wiring. 

Check configuration of input i.e. Normally Open or 

Normally Closed. 

Periksa temperatur oli. Periksa switch dan instalasi kabelnya. 

Periksa susuna input N/O atau N/C 

Check relevant switch and wiring of illuminated fault LED. 

Check configuration of input. 

Periksa kenop dan rangkaian kabel yang berhubungan dengan 

fungsi tersebut dan rangkaian kabel lampu tanda kesalahan. 

Periksa konfigurasi input. 

Check relevant switch and wiring of illuminated fault LED. 

Check configuration of input. 

Periksa kenop dan rangkaian kabel yang berhubungan dengan 

fungsi tersebut dan rangkaian kabel lampu tanda kesalahan. 

Periksa konfigurasi input. 

Check wiring of fuel solenoid. Check fuel. Check battery 

supply. Check battery supply is present on the Fuel output 

of the module. Check the speed-sensing signal is present 

- 65 -




Kegagalan menyalakan genset 

setelah beberapa kali percobaan. 

Continuous starting of 

generator when in AUTO 

Genset starter terus-menerus 

saat dalam fungsi AUTO 

on the 521 inputs. Refer to engine manual. 

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. 

Check that there is no signal present on the Remote Start 

input. Check configured polarity is correct. 

Periksa bahwa tidak ada sinyal pada input remote start. Periksa 

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 

Fungsi pre heat tidak beroperasi 

Starter motor inoperative 

Starter motor tidak beroperasi 

Check wiring to engine heater plugs. Check battery 

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. 

Check Wiring to starter solenoid. Check battery supply. 

Check battery supply is present on the Starter output of 

module. Ensure that the Emergency Stop input is at +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 -




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 -




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 -




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 -


BRUSHLESS A.C. GENERATOR



Brushless A.C. Generator Operation Manual 

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 -


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 -


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 -


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 -


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 

2. Coil Supporter 

3. Ventilation cover 

4. Ball bearing 

5. Bearing shield 

6. Rotating rectifier 

7. Armature core for exciter 

8. Armature coil for exciter 

9. Field core for exciter 

10. Field coil for exciter 

11. End bracket 

12. Lead wire 

13. Frame 

14. Stator core 

15. Rotor core 

16. Stator coil 

17. Rotor coil 

18. Fan 

19. Coupling plate 

20. Fan boss,Coupling boss 

21. Shaft 

22. Ventilation cover 

- 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 elements, 

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 

7. EXCITATION SYSTEM 

Note) Tightening bolt material is SCM435 (111) 

[Table 1.] 

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 

Ex 

Si 

: Automatic Voltage regulator 

: Exciter 

: 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 

Parallel zig-zag 

60 Hz 

50 Hz 

240/120 

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 



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 



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 anticoupling 

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 



(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) 

(b) 

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. 

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 



(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 

Part model 

18 B ~ 22 D L S I D 01 – 09 

E R D 51 – 09 

25 B L S I E 01 – 12 

E R E 51 – 12 

Diode type 

K 

J 

K 

J 

Fastening Torque 

17 Kg-cm 

40 Kg-cm 

“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 



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 

Diode (J) 

Surge absorber 

Diode (K) 

Exciter rotor lead 

(AC side) 

Conductive Ring (K) 

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 

output 

1. Disappeareance of remaining magnetism 

of the ex. Field. 

2. Disconnection or short circuit of winding. 

3. Defective AVR. 

4. Defective revolving rectifier assembly 

element 

2 Voltage low 1. Incorrect wiring (GEN, AVR). 

2. Too low speed. 

3. Overloaded. 


3 Voltage dip when on 

load 

1. Starting of big motor or spot welding 

machine. 

2. Defective diode on revolving rectifier. 

F(+) F(-) terminal voltage will show very 

high value when one of the diode is 

defective. 

4 Voltage high 1. Incorrect wiring (GEN, AVR). 

2. Too high speed. 


5 Fluctuation voltage 1. Loosening of each lead wire. 

2. Irregular speed of engine. 

3. Poor AVR adjustment. 

4. External noise. 

6 Abnormal sound or 

vibration 

14. SERVICE INFORMATION 

1. Foundation uneven. 

2. Poor mounting. 

3. Misaligned coupling. 

4. Defective bearing. 

1. Carry out field flashing. 

2. Check the insulation of all 

winding and check the 

resistance value. 

3. Check the AVR. 

4. Replace diode element. 

1. Re-check the winding 

connection. 

2. Check the engine. 

3. Reduce the load. 


1. About 15% voltage dip is no 

problem. 

2. Change diode. 

1. Re-check the winding 

connections. 



1. Re-tighten. 



4. Filter. 

1. Check the ground level. 

2. Check the mounting section. 

3. Check the coupling section. 

4. Replace the bearing. 

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 -


14. 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 

trouble 

When problem 

occurred 

What kind 

of load 

Circumstance 

Running 

condition 

before trouble 

Agency 

SERVICE INFORMATION 

Voltage high Controlable Uncontrolable V Voltage dip when on load 

Fluctuating voltage V ~ V Others 

Engine starting time Engine stopping time When on load / off load Continual operation 

Other's 

Single phase load D.C. motor Welding sets AC/DC converter 

Other's 

Near sea High temperature 

O C Moisture % Sand 

Outdoor Indoor Chemical gas Thunder 

Other's 

Voltage 

KW 

Current 

P.F 

Hz 

Other's 

- 87 -


AUTOMATIC VOLTAGE REGULATOR 

DST-100-2FA


2. Safety 

Automatic Voltage Regulator (AVR) Operation Manual 

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 -


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 -


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. 

Forcing 

9A forcing 1~5 seconds at 25 degree O C 

Field resistance 

Voltage adjust range 

Temperature drift 

Voltage build-up 

Ambient temperature 

Operating temperature 

Storage temperature 

VOLT I Hz characteristic 

Exterior connection method 

Vibration countermeasure 

Outside dimensions 

Weight 

minimum 15 ohms 

Minimum ±5% of nominal voltage 

Within ±0.02% / degree C 

Self-building up at over 6V (power input voltage) 

—20 degree C ~ +50 degree C 



57Hz in 60Hz operation mode 

47Hz in 50Hz operation mode 

Connector joint 

Mold packing 

148mm (L) x 41mm (W) x 84mm (H) 

0.48 kg 

- 90 -


4. Outline Drawing 


4. OUTLINE DRAWING 

Fig. 2.1 – Outline drawing 

- 91 -




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 -




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/Bpin, 

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/Bpin, 

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 -




5.6. STABILITY ADJUSTMENT KNOB 

Fig. 3.1 V/Hz Characteristic 

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 -


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 

6. OPERATION 

6.1. GENERAL 

Fig. 3.3 In case of CPR is trip 

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 -


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 



[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. 

7. MAINTENANCE 

7.1. DAILY INSPECTION 

Fig. 4.1 Initial excitation. 

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 -




7.2. 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. Electricbulb 

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. 

8. TROUBLE SHOOTING 

8.1. TROUBLESHOOTING 

Fig. 5.1 Unit test equipment 

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 -




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 

engine speed 

3.1. V/Hz setup failure 

3.2. HT disconnection 

3.3. Imperfect contact of connector part 

3.1. Adjust V/Hz 

3.2. HT repair or replacement 

3.3. Repair connector part 

4. CPR tripping after 

load issuance 

4.1. Overloaded 

4.2. Voltage detection part disconnection 

or imperfect contact 

4.3. Alternator abnormality 

4.4. AVR abnormality 

4.1. Cut down the loads 

4.2. Repair wires or connector 

part 

4.3. Investigate alternator 

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 

3.2. AVR abnormality 

3.1. Adjust engine, governor or 

STAB. ADJ 

3.2. Replace AVR 

- 99 -




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 

slow 

2.1. STAB. ADJ set up failure 2.1. Adjust STAB. ADJ 

8.1.6. IN CASE OF VOLTAGE FLUCTUATION IS BIG 


1. Voltage fluctuation is 

big in load issuance 

1.1. V-belt skids 

1.2. Issuance or interrupting capacity is 

big 

1.3. STAB. ADJ set up failure 

1.4. V/Hz Set up failure 

1.5. Alternator abnormality 

1.1. Adjust tightening of V-belt 

1.2. Measure current and check 

specification 

1.3. Adjust STAB. ADJ 

1.4. Adjust V/Hz 

1.5. Investigate alternator 

2. Adjustment inability 2.1. AVR failure 2.1. Replace AVR 

- 100 -


9. Connection Diagram 


9. CONNECTION DIAGRAM 

Fig. 6.1 400V Class 3 phase 4 wire star connection 

- 101 -




Fig. 6.2 200V Class 3 phase 4 wire star connection 

- 102 -




Fig. 6.3 200V Class / 100V Class single phase zig zag connection 

- 103 -


Enclosure 

No illustration intented for this section 

- 104 -

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AVR (DST-100-2FA) 

(MOUNTED ON MCCB BOX) 

5 

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4 

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3 

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VT3 

A 24 

VT3 

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(MOUNTED INSIDE PANEL BOX) 

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POTENTIOMETER 

1 

2K OHM WP5W 

Brown 

Brown 

VT1 

A 23 

VT1 

AMMETER SWITCH 

800/5A 

AC AMMETER 

N 

A2 

A 

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A1 

CLASS 1 15VA 

Y 

3 X CT 

P1 

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P2 

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0 - 500V 

AC VOLTMETER 

N V2 

48 

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V 

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V1 

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V1 

8 

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R3 

46 

6 

R 

45 

49 

A 15 

45 - 65HZ 

FREQUENCY METER 

STC 

W/S NEUTRAL LINK 

3P 800AMP MCCB 

HOUR RUN 

COUNTER 

HZ 

HR 

ST 

ENGINE CONTROLLER 

TO DEEP SEA 521K 

R Y B N 

TO LOAD 

UNLESS OTHERWISE STATED 

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VT3 

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Red 

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POTENTIOMETER 

1 

2K OHM WP5W 

Brown 

Brown 

VT1 

A 23 

VT1 


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CLASS 1 15VA 

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3 X CT 

P1 

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P2 

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49 

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TITLE : DC SCHEMATIC DIAGRAM FOR SCANIA D9 - SOLENOID 

PROJ. REF 

SYSTEM ON AUX RELAY 


STARTER AUX RELAY 

COMMON FAULT AUX 

RELAY 

BUZZER 

ALARM MUTE AUX RELAY 

ALARM MUTE PUSH 

BUTTON 

TO CHARGING ALTERNATOR 

CHARGE FAIL SIGNAL 

LOW OIL PRESS. BYPASS 

SIGNAL 

LOW OIL PRESS. SIGNAL 

(DIRECT FROM SWITCH) 

HIGH WATER TEMP. SIGNAL 


AUTO START SIGNAL 

COOLANT LOW LEVEL 

SIGNAL 

TO FUEL SOLENOID HOLD 

SIGNAL 

TO FUEL SOLENOID PULL 

SIGNAL 

TO STARTER RELAY 

DC VOLTMETER 

TO OIL PRESSURE SENSOR 

OIL PRESSURE GAUGE 

TO WATER TEMPERATURE 

SENSOR 

WATER TEMPERATURE 

GAUGE 


(+) 

1 

2 7 

R2 

2 7 

R2A 

2 7 

R1 

2 7 

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R5 

8 

5 

8 

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OP WT 

D+ 

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SMC 

OPS 

4 

3 

E 8 

E 5 E 6 

TBM-2 

E 3 

E 

2 

E 4 

CLL 

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E 10 E 11 

E 20 

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2 7 

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33 

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DCV OPG WTG 

DEEP SEA 521 ENGINE CONTROLLER 

2 3 

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45 48 

03 

3 

ES 

2 

1 

R2 

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1 

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6 8 

R1 

3 1 

R2 

6 8 

2 

TBE-3 

6A 1P MCB1 

20A 1P MCB2 

04 

1 01 

E 1 

E 22 

FROM PROJ. NO : DSE521/FPS/AC1 

ALTERNATOR SUPPLY 

BATTERY BANK 



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TITLE : DC SCHEMATIC DIAGRAM FOR SCANIA D9 - SOLENOID (WOORWARD) 

PROJ. REF 



STARTER AUX RELAY 


RELAY 

BUZZER 



LOW OIL PRESS. BYPASS 

SIGNAL 







SIGNAL 

TO FUEL SOLENOID HOLD 

SIGNAL 

TO FUEL SOLENOID PULL 

SIGNAL 




TO WATER TEMPERATURE 

SENSOR 


GAUGE 


(+) 

1 

2 7 

R2 

2 7 

R2A 

2 7 

R1 

2 7 

R3 

OP WT 

D+ 

FPS 

FPS 

SMC 

OPS 

E 8 

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R2A 

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OPG WTG 

WOODWARD 320X CONTROLLER 

2 11 

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48 

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ES 

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TBS-2 

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6A 1P MCB1 

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BATTERY BANK 



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50HZ 0.8PF 

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SCANIA DC16 43A 

A F1 2A 

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5 

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3 

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VT3 

A 24 

VT3 

2 


Red 

Red 

POTENTIOMETER 

1 

2K OHM WP5W 

Brown 

Brown 

VT1 

A 23 

VT1 


800/5A 

AC AMMETER 

N 

A2 

A 

B 

A1 

3 X 800/5A CT 

CLASS 1 15VA 

Y 

P1 

R 

P2 


0 - 500V 

AC VOLTMETER 

N V2 

48 

V2 

V 

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V1 

47 

V1 

8 

Y 

R3 

46 

6 

R 

45 

49 

A 15 

45 - 65HZ 


STC 



HOUR RUN 

COUNTER 

HZ 

HR 

ST 



R Y B N 

TO LOAD 



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K 

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A 3 

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VT3 

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POTENTIOMETER 

1 

2K OHM WP5W 

Brown 

Brown 

VT1 

A 23 

VT1 


N 

A2 

B 

A1 

3 X 800/5A CT 

CLASS 1 15VA 

Y 

P1 

R 

P2 

48 

47 

8 

R3 

46 

6 

45 

49 

A 15 

STC 



ST 

CONTROLLER 

TO WOODWARD 

R Y B N 

TO LOAD 



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ENGINEERING DEPT. TITLE : DC SCHEMATIC DIAGRAM FOR SCANIA D12 - EMS 

PROJ. REF 


SYSTEM ON TIMER 

(TIME SET 5 SEC.) 



RELAY 

BUZZER 



BUTTON 




(DIRECT FROM COO.) 



OIL PRESSURE SIGNAL 

DIAGNOSIS SWITCH NOT 

OFF SIGNAL 



SENSOR 




WATER TEMPERATURE SIGNAL 



GAUGE 

DC VOLTMETER 

1 

2 7 

R2 

2 7 

T1 

SMC 

2 7 

R3 

R5 

8 

5 

8 6 

CBZ 

4 3 

L 

E 5 

E 8 

E 14 

TBM-2 

28 29 

- + 

BZ 

2 7 

R5 

T1 

8 

5 

1T 

NO 

MSR 

CLL 

NO 

16 15 

8 C6 C15 11 13 

18 

TBM-1 

E 12 

C11 C10 

1 4 5 6 7 

1 4 5 6 7 

8 10 9 

11 13 

12 

18 

OPG WTG DCV 

DEEP SEA 521 CONTROLLER 

DC SOURCE TO DWG. NO : ED-05000-003-00 

2 3 

14 15 

2 

3 

45 48 

03 

ES 

2 

1 

R2 

6 

8 

04 

O4 

6A 1P MCB1 

20A 1P MCB2 

2 

2 

TBE-3 

E 1 

E 22 

1 01 

BATTERY BANK 




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ENGINEERING DEPT. TITLE : 

DC SCHEMATIC DIAGRAM FOR SCANIA D12 - EMS (WOODWARD) 

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BUZZER 


RELAY 









OFF SIGNAL 



SENSOR 


1 

2 7 

R2 

2 7 

T1 

2 7 

R1 

2 7 

R3 

L 

SMC 

E 8 

E 14 

E 5 

TBM-2 

- + 

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T1 

8 

5 

1T 

NO NO 

MSR 

16 15 

CLL 

33 

1 13 14 12 3 C6 C15 19 18 

20 

TBM-1 

E 12 

2 11 

15 

33 31 

1 13 14 12 

WOODWARD CONTROLLER 320X 

3 17 16 

19 18 

20 


29 

35 

39 40 

2 

11 

15 45 46 

47 

48 

C21 C45 

ES 

2 

1 

R1 

6 

8 

04 

O4 

6A 1P MCB1 

20A 1P MCB2 

2 

2 

TBE-3 

E 1 

E 22 

1 01 

TBCB-1 

TBCB-2 


BATTERY BANK 

CAN BUS 

FROM DWG. NO : ED-05000-001-00 



1 2 

3 4 

5 6 

7 8 

9 10 

11 

12 

A 

B 

C 

D 

E 

F 

G 

H

- 

- 

- 

- 

A 

B 

C 

D 

E 

F 

G 

H 

1 2 

3 4 

5 

6 

7 8 

9 

10 

11 12 

DATE 

29 JUN '05 

SCALE 

NTS 

PROJECTION 

DWG. NO 

ED-05000-003-00 

PAGE : 01 / 01 

REV 

AMENDMENTS 

DATE 

DRAWN 

ANTONI 

APPROVED 

MODEL 

PROJ. NO 


PROJ. REF 

NOTE: N/U = NOT IN USE 

NETGATIVE (GROUND) 


CAN HIGH SIGNAL 

(GOLD PLATED) 

CAN LOW SIGNAL 

(GOLD PLATED) 




NOMINAL SPEED SW. 1 

(CLOSE TO 1500RPM) 


CLOSE TO 1800RPM) 

TORQUE LIMIT SW. 1 

(CLOSE TO ACTIVATED) 



EMERGENCY STOP SIGNAL 


DROOP/ISOCRONE SIGNAL 

(CLOSE TO ISOCRONE) 

SPEED & TORQUE CONTROL 

(COLSE TO TORQUE) 

ENGINE COOLANT LEVEL 


GROUND 

OIL PRESS. GAUGE SIGNAL 

(DIRECT TO GAUGE) 

WATER TEMP. GAUGE SIGNAL 



(DIRECT TO 521) 



ENGINE RUN STATUS 

SIGNAL 

EMS DIAGNOSIS FLASH 

CODE LAMP 

DIAGNOSIS REQUEST 

SIGNAL 

LAMP TEST REQUEST 

SIGNAL 

1 

TBCB-1 

TBCB-2 

N/U 

N/U 

TBCP-4 

TBCP-4 

N/U 

N/U 

N/U 

N/U 

DC CONTROL SOURCE FROM DWG. NO : ED-05000-002-00 

1/1 

1/2 

C21 C45 

TBCP-5 

TBCP-5 

TBCP-6 

TBM-3 

TBCP-6 

X2 X1 

DL 

4 

4 

E 2 

E 3 

ES 

3 

1D 

E 10 E 9 

3 

1/1 1/2 

1 

C13 C51 C30 C52 C11 C10 C15 C6 C2 C12 

P2 P7 P9 P10 

P21 

P45 

P1 

P13 

P36 

P60 

P40 

P51 P30 P34 P61 P52 P11 P10 P15 P6 P4 

P2 P12 

P9 

(MOUNTED ON ENGINE SIDE) 

COO COORDINATORS I/O 

EMS 

P1 P6 P3 

P49 

P7 

P29 

P48 

P24 

P54 

P28 

P57 

04 

C32 

C29 C48 

C24 C54 C28 C57 

04/1 04/2 

N/U 

E 20 E 21 E 4 

TBCP-3 

TBR-1 

TBR-2 

TBS-1 

TBS-2 

TBS-3 

04/1 04/2 

C32 

3 

NO 

R 

R2 

1 

1596 OHM±1% 

N/U 

TBCP-1 

TBCP-2 

1T 

NO 

X2 X1 

CDL 

5K OHM POTENTIOMETER 

04 

POSITIVE SOURCE 


IGNITION SOURCE 




RESISTOR 1596 OHM±1% 

SPEED FINE TUNE 

POTENTIOMETER 

(MOUNTED IN PANEL BOX) 

ENGINE SHUTDOWN 

OVERRIDE SIGNAL 

COO DIAGNOSIS FLASH 

CODE LAMP 

ENGINE COOLANT LOW 

LEVEL LAMP 



1 

2 

3 4 

5 6 

7 8 

9 10 

11 12 

A 

B 

C 

D 

E 

F 

G 

H

- 

- 

- 

- 

A 

B 

C 

D 

E 

F 

G 

H 

1 2 

3 4 

5 

6 

7 8 

9 

10 

11 12 

DATE 

08 JUL '05 

SCALE 

NTS 

PROJECTION 

DWG. NO 

ED-05000-003-00 

PAGE : 01 / 01 

REV 

AMENDMENTS 

DATE 

DRAWN 

ANTONI 

APPROVED 

MODEL 

PROJ. NO 


PROJ. REF 





(GOLD PLATED) 


(GOLD PLATED) 




















GROUND 






SIGNAL 


CODE LAMP 


SIGNAL 


SIGNAL 

1 

TBCB-1 

TBCB-2 

N/U 

N/U 

TBCP-4 

TBCP-4 

N/U 

N/U 

N/U 

N/U 


1/1 

1/2 

C21 C45 

TBCP-5 

TBCP-5 

TBCP-6 

TBM-3 

TBCP-6 

X2 X1 

DL 

4 

4 

E 2 

E 3 

ES 

3 

1D 

E 10 E 9 

3 

1/1 1/2 

1 

C13 C51 C30 C52 C15 C6 C2 C12 

P2 P7 P9 P10 

P21 

P45 

P1 

P13 

P36 

P60 

P40 

P51 P30 P34 P61 P52 P11 P10 P15 P6 P4 

P2 P12 

P9 



EMS 

P1 P6 P3 

P49 

P7 

P29 

P48 

P24 

P54 

P28 

P57 

04 

C32 

C29 C48 

C24 C54 C28 C57 

04/1 04/2 

N/U 

E 20 E 21 E 4 

TBCP-3 

TBR-1 

TBR-2 

TBS-1 

TBS-2 

TBS-3 

04/1 04/2 

C32 

3 

NO 

R 

R2 

1 

1596 OHM±1% 

N/U 

TBCP-1 

TBCP-2 

1T 

NO 

X2 X1 

CDL 


04 









POTENTIOMETER 





CODE LAMP 


LEVEL LAMP 



1 

2 

3 4 

5 6 

7 8 

9 10 

11 12 

A 

B 

C 

D 

E 

F 

G 

H

- 

- 

A 

B 

C 

D 

E 

F 

G 

H 

1 

2 

3 

4 

5 

6 

7 

8 9 

10 

11 

DATE 

29 JUN '05 

SCALE 

NTS 

PROJECTION 

DWG. NO 

ED-05000-003-05 

PAGE : 03 / 06 

REV 

AMENDMENTS 

DRAWN 

ANTONI 

APPROVED 

MODEL 

EMS 

PROJ. NO 



PROJ. REF 

8 

Grey 

380/220V 3P 4W 

50HZ 0.8PF 

7 

Purple 



A F1 2A 

F2 2A 

F3 2A 

1 

045 

K 

G ~ 

5 

A 2 

046 

A 3 

047 

A 4 

TBE-1 

A 5 

61 

P2 

A 6 

62 

P1 

P2 

A 7 

63 

P1 

A 8 

64 

3 

1 

4 

2 

E3 

3 

J 

4 

Green 

Yellow 

Orange 



5 

Green 

4 

Yellow 

3 

Orange 

VT3 

A 24 

VT3 

2 


Red 

Red 

POTENTIOMETER 

1 

2K OHM WP5W 

Brown 

Brown 

VT1 

A 23 

VT1 


800/5A 

AC AMMETER 

N 

A2 

A 

B 

A1 

3 X 800/5A CT 

CLASS 1 15VA 

Y 

P1 

R 

P2 


0 - 500V 

AC VOLTMETER 

N V2 

48 

V2 

V 

B 

V1 

47 

V1 

8 

Y 

R3 

46 

6 

R 

45 

49 

A 15 

45 - 65HZ 


STC 



HOUR RUN 

COUNTER 

HZ 

HR 

ST 



R Y B N 

TO LOAD 



1 2 3 4 5 6 7 8 9 10 11 

12 

DATE 

12 

A 

B 

C 

D 

E 

F 

G 

H

- 

- 

- 

- 

A 

B 

C 

D 

E 

F 

G 

H 

1 

2 

3 

4 

5 

6 

7 

8 9 

10 

11 

DATE 

08 JUL '05 

SCALE 

NTS 

PROJECTION 

DWG. NO 

ED-05000-003-00 

PAGE : 01 / 01 

REV 

AMENDMENTS 

DRAWN 

ANTONI 

APPROVED 

MODEL 

PROJ. NO 



PROJ. REF 

8 

Grey 

380/220V 3P 4W 

50HZ 0.8PF 

7 

Purple 



A F1 2A 

F2 2A 

F3 2A 

1 

045 

K 

G ~ 

5 

A 2 

046 

A 3 

047 

A 4 

TBE-1 

A 5 

61 

P2 

A 6 

62 

P1 

P2 

A 7 

63 

P1 

A 8 

64 

A 9 

E 

3 

1 

4 

2 

E3 

3 

J 

4 

Green 

Yellow 

Orange 



5 

Green 

4 

Yellow 

3 

Orange 

VT3 

A 24 

VT3 

2 


Red 

Red 

POTENTIOMETER 

1 

2K OHM WP5W 

Brown 

Brown 

VT1 

A 23 

VT1 


N 

A2 

B 

A1 

3 X 800/5A CT 

CLASS 1 15VA 

Y 

P1 

R 

P2 

48 

47 

8 

R3 

46 

6 

45 

49 

A 15 

STC 



ST 

CONTROLLER 

TO WOODWARD 

R Y B N 

TO LOAD 



1 2 3 4 5 6 7 8 9 10 11 

A 

AC AMMETER 

800/5A 

12 

DATE 

12 

A 

B 

C 

D 

E 

F 

G 

H

- 

- 

A 

B 

C 

D 

E 

F 

G 

H 

1 2 

3 4 

5 6 

7 8 

9 10 

11 12 

DATE 

29 JUN '05 

SCALE 

NTS 

PROJECTION 

DWG. NO 

ED-05000-001-05 

PAGE : 01 / 06 REV 

AMENDMENTS 

DATE 

DRAWN 

ANTONI 

APPROVED 

MODEL EMS 

PROJ. NO 


PROJ. REF 







RELAY 

BUZZER 



BUTTON 









OFF SIGNAL 



SENSOR 




WATER TEMPERATURE SIGNAL 



GAUGE 

DC VOLTMETER 


CHARGE SIGNAL 

1 

2 7 

R2 

2 7 

R2A 

2 7 

T1 

SMC 

2 7 

R3 

R5 

8 

5 

8 6 

CBZ 

4 3 

L 

D+ 

E 5 

E 8 

E 14 

E 6 

TBM-2 

28 29 

- + 

BZ 

2 7 

R5 

T1 

8 

5 

1T 

NO 

MSR 

CLL 

NO 

16 15 

8 C6 C15 11 13 

TBM-1 

E 12 

18 

E 13 

C11 C10 

1 4 5 6 7 

1 4 5 6 7 

8 10 9 

11 13 

12 

18 

OPG WTG DCV 

DEEP SEA 521 CONTROLLER 

03A 


2 3 

14 15 

2 

3 

45 48 

03 

ES 

2 

1 

R2 

6 

8 

R2A 

6 8 

04 

O4 

6A 1P MCB1 

20A 1P MCB2 

2 

2 

TBE-3 

E 1 

E 22 

1 01 

BATTERY BANK 

REF TO DWG NO : ED-05000-003-00 




1 2 

3 4 

5 6 

7 8 

9 10 

11 

12 

A 

B 

C 

D 

E 

F 

G 

H

- 

- 

- 

A 

B 

C 

D 

E 

F 

G 

H 

1 2 

3 4 

5 6 

7 8 

9 10 

11 12 

DATE 

08 JUL '05 

SCALE 

NTS 

PROJECTION 

DWG. NO 

PAGE : 01 / 01 REV 

AMENDMENTS 

DATE 

DRAWN 

ANTONI 

APPROVED 

MODEL - 

PROJ. NO 

ENGINEERING DEPT. TITLE : 

DC SCHEMATIC DIAGRAM FOR SCANIA D16 - EMS (WOODWARD) 

PROJ. REF 





BUZZER 


RELAY 









OFF SIGNAL 



SENSOR 



CHARGE SIGNAL 

1 

2 7 

R2 

2 7 

T1 

2 7 

R1 

2 7 

R3 

L 

D+ 

SMC 

E 8 

E 14 

E 5 

E 6 

TBM-2 

- + 

BZ 

T1 

8 

5 

1T 

NO NO 

MSR 

16 15 

CLL 

33 

03A 

1 13 14 12 3 C6 C15 19 18 

TBM-1 

E 12 

20 

E 13 

2 11 

15 

33 31 

1 13 14 12 

WOODWARD CONTROLLER 320X 

3 17 16 

19 18 

20 


29 

35 

39 40 

2 

11 

15 45 46 

47 

48 

C21 C45 

ES 

2 

1 

R1 

6 

8 

R2 

6 8 

04 

O4 

6A 1P MCB1 

20A 1P MCB2 

2 

2 

TBE-3 

E 1 

E 22 

1 01 

TBCB-1 

TBCB-2 


BATTERY BANK 

CAN BUS 

FROM DWG. NO : ED-05000-001-00 



1 2 

3 4 

5 6 

7 8 

9 10 

11 

12 

A 

B 

C 

D 

E 

F 

G 

H

- 

- 

A 

B 

C 

D 

E 

F 

G 

H 

1 2 

3 4 

5 

6 

7 8 

9 

10 

11 12 

DATE 

29 JUN '05 

SCALE 

NTS 

PROJECTION 

DWG. NO 

ED-05000-002-05 

PAGE : 02 / 06 

REV 

AMENDMENTS 

DATE 

DRAWN 

ANTONI 

APPROVED 

MODEL 

EMS 

PROJ. NO 


PROJ. REF 





(GOLD PLATED) 


(GOLD PLATED) 




















GROUND 

OIL PRESS. GAUGE SIGNAL 


WATER TEMP. GAUGE SIGNAL 







SIGNAL 


CODE LAMP 


SIGNAL 


SIGNAL 

1 

TBCB-1 

TBCB-2 

N/U 

N/U 

TBCP-4 

TBCP-4 

N/U 

N/U 

N/U 

N/U 


1/1 

1/2 

C21 C45 

TBCP-5 

TBCP-5 

TBCP-6 

TBM-3 

TBCP-6 

X2 X1 

DL 

4 

4 

E 2 

E 3 

ES 

3 

1D 

E 10 E 9 

3 

1/1 1/2 

1 

C13 C51 C30 C52 C11 C10 C15 C6 C2 C12 

P2 P7 P9 P10 

P21 

P45 

P1 

P13 

P36 

P60 

P40 

P51 P30 P34 P61 P52 P11 P10 P15 P6 P4 

P2 P12 

P9 



EMS 

P1 P6 P3 

P49 

P7 

P29 

P48 

P24 

P54 

P28 

P57 

04 

C32 

C29 C48 

C24 C54 C28 C57 

04/1 04/2 

N/U 

E 20 E 21 E 4 

TBCP-3 

TBR-1 

TBR-2 

TBS-1 

TBS-2 

TBS-3 

04/1 04/2 

C32 

3 

NO 

R 

R2 

1 

1596 OHM±1% 

N/U 

TBCP-1 

TBCP-2 

1T 

NO 

X2 X1 

CDL 


04 









POTENTIOMETER 





CODE LAMP 


LEVEL LAMP 



1 

2 

3 4 

5 6 

7 8 

9 10 

11 12 

A 

B 

C 

D 

E 

F 

G 

H

- 

- 

- 

- 

A 

B 

C 

D 

E 

F 

G 

H 

1 2 

3 4 

5 

6 

7 8 

9 

10 

11 12 

DATE 

08 JUL '05 

SCALE 

NTS 

PROJECTION 

DWG. NO 

ED-05000-003-00 

PAGE : 01 / 01 

REV 

AMENDMENTS 

DATE 

DRAWN 

ANTONI 

APPROVED 

MODEL 

PROJ. NO 


PROJ. REF 





(GOLD PLATED) 


(GOLD PLATED) 




















GROUND 






SIGNAL 


CODE LAMP 


SIGNAL 


SIGNAL 

1 

TBCB-1 

TBCB-2 

N/U 

N/U 

TBCP-4 

TBCP-4 

N/U 

N/U 

N/U 

N/U 


1/1 

1/2 

C21 C45 

TBCP-5 

TBCP-5 

TBCP-6 

TBM-3 

TBCP-6 

X2 X1 

DL 

4 

4 

E 2 

E 3 

ES 

3 

1D 

E 10 E 9 

3 

1/1 1/2 

1 

C13 C51 C30 C52 C15 C6 C2 C12 

P2 P7 P9 P10 

P21 

P45 

P1 

P13 

P36 

P60 

P40 

P51 P30 P34 P61 P52 P11 P10 P15 P6 P4 

P2 P12 

P9 



EMS 

P1 P6 P3 

P49 

P7 

P29 

P48 

P24 

P54 

P28 

P57 

04 

C32 

C29 C48 

C24 C54 C28 C57 

04/1 04/2 

N/U 

E 20 E 21 E 4 

TBCP-3 

TBR-1 

TBR-2 

TBS-1 

TBS-2 

TBS-3 

04/1 04/2 

C32 

3 

NO 

R 

R2 

1 

1596 OHM±1% 

N/U 

TBCP-1 

TBCP-2 

1T 

NO 

X2 X1 

CDL 


04 









POTENTIOMETER 





CODE LAMP 


LEVEL LAMP 



1 

2 

3 4 

5 6 

7 8 

9 10 

11 12 

A 

B 

C 

D 

E 

F 

G 

H

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 

Incompletely burnt 

fuel 

Too much fuel in 

relation to air at low 

combustion temperatures 

Cold engine 

Injection timing too late 

Inlet valve does not open 

properly. Valve adjustment 

disturbed 

Broken delivery valve 

spring, uncontrolled 

injection 

The white smoke starts 

to turn blue and disappears 

when the engine is 

warmed up 

- If possible: reduce 

engine speed or put the 

engine under load 

- Install a white smoke 

limiting device 

(exhaust brake) 

- Install flame heater 

- Install an engine heater 

Disconnect one delivery pipe at a time and listen 

for changes in the engine sound. 

! 

WARNING! 

Be careful when disconnecting the delivery 

pipes as the pressure is extremely high and 

could cause injury 

Leaky injector, dripping? 

White smoke, water vapour 


Water in the combustion 

chamber 

Leaky charge air cooler 

Leaky cylinder head 

gasket 

Cracked water-cooled 

exhaust manifold 

Cracked cylinder head 

(not cracks between 

valve seats). 

Crack in cylinder liner 

Test pressure (air 

0.5 bar, liquid 4 bar) 

The fault is also present 

when the engine is hot 

If the fault is hard to trace: 

Change all cylinder heads for exchange cylinder 

heads. 

(Or test pressurize all cylinder heads. Heat the cylinder 

heads before pressurizing them.) 

i - 1

Black smoke when running/under load 


“Adjusted” injection 

pump, attempt to boost 

Injection timing too late 

Inlet valve does not open 

properly. Valve adjustment 

disturbed 

Check the lead seal 

- Test in test bench 

Too much fuel in 

relation to air at high 

combustion temperatures 


spring, uncontrolled 

injection 

Leaky injector, dripping? 

Nozzle tip jams 

Incorrect spray pattern 

from nozzle 

More than 1 washer 

under injector 

Fault in turbo 

Clogged air filter 

High exhaust counterpressure 

Worn intake valves 

Clogged intake port 



! 

WARNING! 




Check charge air pressure 

See page ( i - 23 ) 

i - 2

Black smoke on starting 


Engine difficult to 

start 

Binding control rack 

Open the cover 

(RQ/RQV) or hexagon 

(RSV) on the governor 

and check with a finger 

on the control rod that it 

goes to the maximum 

stop bracket. 

(This applies to engines 

without a smoke limiter 

on the governor housing.) 

- Take the pump to a 

Bosch workshop for 

repair 

Blue smoke 


Oil coating past piston 

rings 

Oil leakage in turbocharger 

Damaged piston cooling 

nozzles 

Petrol in diesel oil 

Check for oil in the 

intake manifold after the 

turbocharger 

- Change damaged 

nozzles 

Fuel in the oil 


Dilution of oil in 

sump 

Unburnt fuel passes the 

piston 

Defective injector 

Internal leakage in injection 

pump (worn pump 

element or crack in 

pump housing) 

Worn/broken O-ring at 

feed pump pushrod 

Frequent cold starts 

- Normally about 1% of 

fuel in the lubricating 

oil per 200 h 

Cont. 

i - 3

Fuel in oil, cont. 



sump 

Worn engine 

Intake valve not opening 

Check “blow-by” in crankcase 

Correct value for new engine: 0 - +10 mm wc 

(flow rate 60 - 100 l/min.) 

Closed crankcase ventilation: -50 - +20 mm wc 

Oil in coolant 


Oil cooler leaks when 

engine is running 

Defective cylinder head 

gasket 

Crack in cylinder head 


valve seats). 

(On 11-series engines: 

look for cracks between 

the water jacket and oil 

duct.) 

Test pressurize the oil cooler 

Note: classed oil cooler, test pressurized: 10 bar oil 

on the oil side, 0.5 bar air on the water side, 

immersed in water 25 - 27 °C 



heads. 



Coolant/water in oil 



sump 

Oil cooler leaks when 

engine is not running 

Leaky O-rings at cylinder 

liner 

water is condensed in 

crankcase ventilation 

and runs down into the 

sump 

14-series engine: 

Clogged drain hole in 

coolant pump in combination 

with leaking 

pump seal 

Test pressurize the oil 

cooler, see above 

Leakage in telltale hole? - Change liner seals 

i - 4

Coolant/water in oil, cont. 



sump 


Crack in water jacket on 

cylinder block/cylinder 

head. (Coolant runs 

down through the pushrod 

hole.) 

Crack in water jacket on 

cylinder head. (Coolant 

runs down via the oil 

duct for rocker arm 

lubrication.) 

Cracked water-cooled 


Leakage in charge air 

cooler core 

Water enters via the 

exhaust/intake system 

Run the engine until 

warm. 

Remove the oil sump 

and all side covers. 

Test pressurize the cooling 

system. 

If coolant seeps out 

behind side covers or at 

the camshaft bearing 

there is probably a crack 

in one of the cylinder 

heads. 

As a rule it is possible to 

see which cylinder head 

or heads are leaking. 



- Change the cylinder 

head for a exchange 

cylinder head 

- If no leakage can be 

found, change all cylinder 

heads for exchange 

cylinder heads 

- Install a self-closing 

cover on the exhaust 

pipe 

- Position the air cleaner 

so that water cannot 

run into it 

Low oil pressure 


Gauge shows low 

pressure 

Defective sensor/instrument 

Incorrectly adjusted oil 

relief valve 

Broken spring in oil 

relief valve (14-series 

engines, earlier version) 

The piston in the oil 

relief valve has jammed 

in open position 

Take a reading of the oil pressure on warmed-up 

engine using a mechanical pressure gauge directly 

on the engine: 

Minimum 1 bar at 800 r/min. 

Maximum 6 bar > 800 r/min. 

Obs! Single-speed engines must not be tested 

at 800 r/min. Risk of damage to the flexible 

coupling 

Max. oil pressure 2 bar 

at 2000 r/min 

- 1 shim = 0.2 bar 

(screw adjustment on 

14-series engines) 

- Check/remedy 

relief valve 

Cont. 

i - 5

Low oil pressure, cont. 



pressure 

Crankshaft bearing/main 

bearing of 

wrong size has been fitted 

on reground crankshaft 

Excessive play in bigend 

and main bearings 

Seizing in camshaft 

bearings 

Piston cooling nozzle 

has come loose 

Seizing in the bearing on 

engine power take-off 

ED140 (14-series engine) 

Loosened oil duct plugs 

at camshaft bearing 

seats, under 

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 lubricating 

oil viscosity 

Worn bushings or loose 

shaft in oil cleaner 

Broken O-ring on 

cyclone part of oil 

cleaner 

Defective oil pump drive 

Internal leakage in oil 

cleaner 

Max. oil pressure 2 bar 

also when engine cold 

If the bushing slides all 

the way out of the bearing 

seat, the oil pressure 

warning lamp will come 

on. 

The engine throws out 

oil through the crankcase 

ventilation 

Oil pressure can be 

increased ~ 1 bar when 

the power take-off is 

under load 

Pressure drops to 0 bar 

Check that the oil 

cleaner is correctly 

assembled 

- Change to bearings of 

the correct size. Check 

the bearing seats before 

assembly 

- Choose a viscosity that 

is suitable for the ambient 

temperature 

- Change rotor if bushing 

is worn oval 

- Change worn/damaged 

shaft 

Cont. 

i - 6

Low oil pressure, cont. 


Loosened guide plates in 

the oil cooler prevent 

passage of the oil 

Worn/damaged oil pump 


pressure 

Gauge indicates low 

pressure at maximum 

speed but not 

at idling speed 

No oil pressure at 

idling speed 

(14-series engine) 

Plug in cylinder block 

under the relief valve 

has come loose (11- 

series engine) 

Clogged oil cooler 

Seized/worn bearings in 

compressed air compressor, 

see also page 30 

Loose screws in timing 

gear’s intermediate gear 

The main oil duct (to 

piston cooling nozzles) 

plug in the rear of the 

engine has come loose 

(also at front of engine, 

9-series engine) 

Oil valve sleeve screwed 

out of oil pump housing 

(gives “by-pass” and 

disables the overflow 

valve) 

Pressure varies when 

compressor 

charges/relieves 

Oil pressure at 

idling/low engine speed 

is not affected since the 

delivery valve closes at 

3 bar 

Check that the oil 

valve sleeve is correctly 

fitted 

- Tighten the oil valve 

sleeve 

- If damaged, change the 

sleeve 

High oil pressure (engine warmed up) 


Gauge indicates 

high pressure 


Oil viscosity too high 

Take a reading of the oil pressure on the warmedup 

engine using a mechanical pressure gauge 

directly on the engine: 

Minimum 1 bar at 800 r/min. 

Maximum 6 bar > 800 r/min. 

Note! Single-speed engines must not be tested 

at 800 r/min. Risk of damage to the 

flexible coupling 

- Choose a viscosity that 

is suitable for the ambient 

temperature 

Cont. 

i - 7

High oil pressure (engine warmed up), cont. 


Gauge indicates 

high pressure 

Incorrectly adjusted oil 

relief valve 

Piston in oil relief valve 

jammed in closed position 

Valve in oil duct to piston 

cooling nozzles is 

binding 

- 1 shim = 0.2 bar 

(screw adjustment on 

14-series engines) 

Abnormal wear (liner, piston rings, etc.) 


Short service life 

Unclean induction air 

due to inadequate filtering 

(wrongly dimensioned 

air filter) 

Unclean intake air due to 

leakage in intake piping 

Wrong grade of oil, polishing 

damage 

Changing of filters and 

oil has been neglected 

Low coolant temperature 

(cold engine) 

Excessive sulphur content 

in fuel 

Defective injector 

(causes oil film to be 

washed off) 

Wear ridge (ring travel 

shoulder) at piston top 

dead centre 

- Fit a more efficient air 

filter 

- Change the fuel 

- Change to oil with a 

higher base number 

- Shorter oil change 

intervals 

i - 8

Vibration, no driven components engaged 


Wrong injection timing 


spring 

Individual injectors not 

operating 



! 

WARNING! 




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 

Only when compressed 

air compressor 

is charging, worst 

at about 1000 r/min, 

see also page 30 

Compressor operates 

with excessive counterpressure 

(e.g. clogged 

piping/air dryer) or 

excessively high safety 

valve opening pressure 

Alignment fault 

Unsuitable rubber suspension 

and location of 

same 

Weak engine bed 

Check engine alignment 

Movement at engine 

attachment points 

- Change to rubber elements 

of different 

hardness 

- Reinforce the engine 

bed 

i - 9

Vibration when the clutch or reverse gear is engaged 


Imbalance in driven unit 

Imbalance in clutch 

Inadequate alignment 

between engine and 

driven unit 

Unsuitable suspension 

of engine or driven unit 

Weak engine bed 

Defective flexible 

coupling between 

clutch/reverse gear and 

driven unit 

Unsuitably mounted 

propeller shaft, e.g. 

excessive deflection 

angle or excessive deviation 

in parallelism 

between flanges 

Propeller shaft too long 

and weak 

Check alignment 

Movement at attachment 

points 

- Balance the unit 

- Carry out alignment 

more accurately 

- Reinforce the engine 

bed 

- Change rubber element 

in flexible coupling 

(consumption 

item) 

- Reposition the engine 

or driven unit so that 

the propeller shaft’s 

working range is in 

accordance with recommendations 

Vibration when alternator is in operation 


Imbalance in generator 

Imbalance in coupling 

Bearing damage in alternator 

Defective flexible coupling 

between engine 

and alternator 

Fault in reduction gear 

Dismantle the coupling. Assemble the coupling 

halves rotated half a turn relative to each other 

- Change the rubber element 

or type of coupling 

i - 10

Engine speed hunting - single-speed engines with RQ governor 


Play in flexible coupling 

between engine 

and alternator (worn 

coupling) 

Play in new coupling 

Not enough flywheel 

mass in the driven unit, 

e.g. alternator 

Apply a light load, at a 

load of about 20 kW the 

hunting disappears 

- Change the rubber element/check 

the coupling 

hub and flange 

- Choose a coupling 

without play, e.g. 

Scania standard coupling 

- Mount extra flywheel 

mass 

Hunting when 

engine is running 

under light load 

(15 - 20 kW) or 

no-load conditions 

Skew engine brackets 

(engine suspension) 

could under unfavourable 

circumstances 

worsen engine speed 

hunting 

Incorrect injection timing 

Individual injectors not 

operating 

- Change to harder rubber 

elements for the 

engine/alternator suspension 



! 

WARNING! 




Engine speed hunting - single-speed engines with RSV governor 


Engine speed hunting 

at 4-5% speed 

droop 

The RSV governor 

should not nowadays be 

used for single-speed 

operation (except on 9- 

series engines) 

- Change the injection 

pump delivery valves 

(1-hole or 2-hole) for 

0-hole valves 

i - 11

Engine speed hunting 

at idling 

Governor incorrectly 

adjusted 

Below 700 r/min the 

standard starter spring, 

282 544 (Bosch 1 424 

650 006) is too strong 

- Tighten the idling 

spring and adjust 

engine speed 

- Fit a weaker starter 

spring, part number 

268 866 

(Bosch 1 424 650 056) 

i - 12

Delivery pipe fractures 


No clamping 

Carelessly handled 

delivery pipe 

Internal cavitation in 

delivery pipe 

Note: Single-pipe system 

is not permitted 

Fit 0-hole delivery 

valves for single-speed 

operation 

External corrosion on cylinder liner 


Unsuitable corrosion 

protection agent, glycol 

or water in coolant 

- Clean the cooling system 

and fill up with 

coolant as described in 

the maintenance 

instructions 

Engine difficult to start 


Air in fuel system 

Leakage in suction pipe 

The highest fuel level in 

the tank is lower than the 

feed pump. A longer 

standstill (days) the fuel 

in the suction pipe may 

run back to the tank 

because of a leaky overflow 

valve 

Leaky overflow valve 

Low battery voltage 

Ambient temperature 

too low 

Oil viscosity too high 

Paraffin precipitation in 

the fuel 

- Install a ”daily supply 

tank” at a higher location 

than the feed pump 

- Starting aids are not 

normally needed at 

temperatures above 

-15 °C 

Cont. 

i - 13

Engine difficult to start, cont. 


Blocked intake or 

exhaust system 

No fuel 

Stop lever in stop position 


Faulty injector 

Control rack/pump element 

will not go into the 

cold start position. 

Binding control 

rack/pump element 

Open the cover 

(RQ/RQV) or hexagon 

(RSV) on the governor 

and check with a finger 

on the control rod that it 

goes to the maximum 

stop bracket. 

(This applies to engines 

without smoke limiter 

on the governor housing.) 

- Check the stop 

solenoid and links 

- Take the pump to a 

Bosch workshop for 

repair 

- 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 


Starter motor not 

powerful enough to 

pull the piston over 

the compression 

stroke (if the engine 

fires a connecting 

rod could be bent) 

Leaky charge air cooler 

Leaky cylinder head 

gasket 


Crack in cylinder liner 





heads. 



Cont. 

i - 14

Fluid stroke 


Starter motor not 

powerful enough to 

pull the piston over 

the compression 

stroke (if the engine 

fires a connecting 

rod could be bent) 

Water has entered the 

engine via the 

exhaust/intake system 

Crack in water-cooled 


Injector open 

- Install a self-closing 

cover on the exhaust 

pipe 

- Position the air cleaner 

so that water cannot 

run into it 

Thermostat hunting, 14-series engine 


Piping between thermostat 

housing and radiator 

too long (more than 

0.5 m) 

- Fit an external thermostat 

- Try drilling 2 holes, 

∅ 2.5 mm, in the thermostat 

disc 

Knocking/noise 


Exhaust valves close 

too late and strike 

the piston crowns 

Rapidly increasing 

valve clearances 

The piston strikes 

the cylinder head 

Timing gears incorrectly 

meshed 

The crankshaft gear has 

come loose 

Valve mechanism not 

operating 

Disturbances in the supply 

of lubricant for the 

rocker arms 

Loosened big end cap 

(wrong tightening torque 

after repair) 

Foreign objects in the 

piston crown 

Check the valve timing, 

see “Service data, 

engines” 

- Tighten to the torque 

specified in the Workshop 

manual 

Cont. 

i - 15

Knocking/noise, cont. 


Piston seizure (may be 

caused by clogged piston 

cooling nozzles) 


Worn collets on exhaust 

valves 

Broken upper piston 

rings 

Incorrectly adjusted 

injection pump 


spring (after-injection) 



! 

WARNING! 




Melting damage on 

piston crown 

Connecting rod bearing 

seizure 

Faulty injector (seized, 

worn, incorrect or 

cracked tip, fatigued 

spring) 


injector 

More than 1 washer 

under injector 

Fuel leakage in flame 

start 

Loosened big end cap 

Injection timing 

extremely advanced, 

30 °BTDC or more 


injector 

Check whether it leaks. (Take out the flame start 

and run the engine with fuel pipe connected) 

Check the injection timing 

i - 16

High oil consumption 


Blue smoke under 

load 

Piston ring seizure 

Piston seizure 

Cylinder seizure 

Liner wear 

Carbon polishing 

(in patches) 

Piston ring wear 

Piston rings stuck 

Tapered piston rings fitted 

wrong way 

Broken piston rings 

Worn valve guides 

Oil level too high? 

Defective shaft seals in 

turbocharger 


Excessive vacuum in the 

air intake before the turbocharger 

Oil viscosity too low 

Deformed/incorrectly 

directed piston cooling 

nozzles 

External leakage 

Leakage in seawatercooled 

oil cooler (11- 

series marine engines) 

Combustion temperature 

too high? 

Unclean intake air? 

Poor grade of oil? 

Individual piston rings broken = incorrectly fitted 

Several upper rings broken = start spray used 

wrongly, wrong injection timing (too early) 

Several intermediate rings broken = worn rings or 

grooves 

Check the clearance 

between valve and 

guide. 

High exhaust temperature? 

Poor grade of oil? 

Check whether oil is 

present in the compressor 

or intake manifold 

Measure the vacuum 

(max. 500 mm wc) 

Check the air filter 

i - 17

High fuel consumption 



Low charge air pressure 

Adjusted injection pump 

Manner of driving, operating/load 

conditions 

Check in a pump test 

bench that the amount 

(Q-mm 3 /stroke) corresponds 

to specification 

Low compression 


Worn engine 

Broken piston rings 

Incorrectly adjusted/ 

defective valves 

Hydrostatic lock/bent 

connecting rod 

Readings not taken correctly 

Check the compression 

Take compression readings on a hot engine, with 

all injectors removed, at starter motor speed 

Check cylinders 1 - 6, then cylinder 1 again 

Check that starter motor speed does not drop 

Correct reading: 20 - 30 bar 

Max. 3 bar difference between cylinders 

Low engine output 


Low fuel supply pressure 

(below 0.3 bar) 


Fuel too hot 

Check the feed pump and overflow valve for leakage 

as described in the workshop manual 

Look for leakage in the suction pipe between tank 

and feed pump 

Clogged fuel filter/Paraffin precipitation in fuel 

Cont. 

i - 18

Low engine output, cont. 


Incorrect fuel specification 

Check density and viscosity 

Low charge air pressure Check charge air pressure 

Abnormal pressure drop 

in intake piping 

Worn engine 

Leaky valves 



governor/throttle control 

Intake air temperature 

too high 

Exhaust counterpressure 

too high 

Intake counterpressure 

too high 


injection pump 

Blocked fuel consumption 

gauge 

Binding injector 

Exhaust brake/white 

smoke limiter throttle in 

closed position 

Check the vacuum before the turbocharger, max. 

500 mm wc 

Check the air filter 




Worn crankcase ventilation: -50 - +20 mm wc 

Take compression readings 

and compare those 

of the different cylinders 

Check that the governor 

starts deregulating at the 

intended speed 

Check that the throttle 

control goes to the maximum 

stop bracket 

Check the temperature 

of the air before the 

engine. 

Above +25 °C reduces 

engine power 

Take a reading, recommended 

counterpressure: 

500 mm wc, 

max. 1000 mm wc 

See “Low charge air 

pressure”, page 26 

Check in a pump test 

bench 

Injector’s nozzle nut 

tightened too hard 

i - 19

Hot engine 


Instrument shows 

high temperature 

Reduced coolant 

flow 


Low coolant level 

Clogged seawater filter 

Clogged freshwater/seawater 

cooling system 

Pressure cap not operating 

Impeller on freshwater/seawater 

pump worn 

or damaged 

Incorrect cam/worn 

cover on seawater pump 

Restriction in coolant 

flow, e.g. pieces of rubber 

from seawater 

impeller 

Cooling capacity too 

low 

Gas leakage (causes loss 

of coolant) 

Defective thermostats 

Drive belts slip or pump 

wheel loose on pump 

shaft 

Air pockets in engine’s 

outer cooling circuit 

Excessive pressure drop 

in the external cooling 

system 

Clogged radiator 

Check that sensor and instrument suit each other 

(120 and 150 °C) 

Check with a separate instrument 

Test pressurize 

Take a reading of the 

cooling capacity 

Check opening temperature 

of thermostats 

Check with forcibly 

opened thermostats 


internally and 

externally 

- Vent at the cooling system’s 

highest point 

- Check that the ventilation 

piping to the 

expansion tank is not 

clogged 

Cont. 

i - 20

Hot engine, cont. 


Circulation of cooling 

air 

Cavitation damaged 

impeller in coolant 

pump 

Leakage in charge air 

cooler 

Check by taking temperature 

readings 

Cold engine 


Instrument indicates 

low temperature 


Thermostat jammed in 

open position 

Low power output at 

low ambient temperature 

(large external cooling 

surface) 

Large leakage flow in 

thermostat housing 

(9- and 11-series marine 

engines) 

Check that sensor and instrument match each other 

(120 and 150 °C) 

Check with a separate instrument 

Check operation of thermostat 

- Fit a thermostat fan 

- Fit a smaller fan 

- Install a KLAFFO radiator shutter 

NOTE: NOT A RADIATOR BLIND 

Risk of fan blade breakage 

- Reduce the air flow 

- Reduce fan/coolant pump gear ratio 

Coolant loss 


Coolant pressed out 

of radiator on DSI 

engines 


gasket (external leakage) 

External leakage 

Turbocharging pressure 

enters cooling system 

via leaking charge air 

element 

Test pressure 

(air 0.5 bar, liquid 4 bar) 

Cont. 

i - 21

Coolant loss, cont. 


White smoke when 

engine hot indicates 

water vapour 



valve seats) 

Cracked cylinder liner 



heads. 



Grey oil = Coolant in oil 

Locate the leak by removing the oil sump and pressurizing 

the cooling system while turning the 

engine over by hand 

Polluted coolant 


Faulty inhibitor 

Overdosed corrosion 

inhibitor 


and fill it with 



instructions 

Engine heater 


Boiler scale on 

engine heater 

Short service life 

Incorrect mixture or type 

of glycol and/or corrosion 

inhibitor 

Anti-freeze with phosphate-based 

inhibitor 

must not be used 

The heater is not 

designed for continuous 

engagement. Suitable 

temperature for thermostat 

control = 40 - 60 °C 


and fill it with 



instructions 

High oil temperature 


- Instrument indicates 

too high temperature 

- Defective sensor/instrument 

- Poor water flow in oil 

cooler 

Check with separate 

instrument 

i - 22

High exhaust temperature 


Adjusted injection pump 


Nozzle drips 


High inlet air temperature 



Check the lead seal, 

check CRO if necessary 

Check the injection timing 

Check type, opening 

pressure and general 

condition 

- Test in test bench 

Take a reading, recommended counterpressure: 

500 mm wc, max. 1000 mm wc 

Check silencer, spark arrester, length and inside 

diameter of exhaust pipe 



Dirty/damaged turbine/compressor 

wheel 

in turbocharger 

Leakage between turbocharger 

and cylinder 

head 

Bearing seizure in turbocharger 



High fuel temperature 

Check bearing play 

Check the vacuum 

before the turbocharger, 

max. 500 mm wc 

- Check/clean 

- Check/change gaskets 

- Recondition/change 

turbocharger 

Take a reading, recommended counterpressure: 

500 mm wc, max. 1000 mm wc 

Check silencer, spark arrester, length and inside 

diameter of exhaust pipe 

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 


(Normal charging 

voltage: 

27 - 28 V) 

Broken alternator drive 

belt 

Slipping alternator drive 

belt 

Batteries in poor condition 

Alternator fault 

Voltage regulator fault 

Battery charger fault 

High system voltage 


(Normal charging 

voltage: 

27 - 28 V) 

Voltage regulator fault 

Battery charger fault 

External oil leakage 


Crankcase pressure too 

high 




Closed crankcase ventilation: -50 - +20 mm wc 

Cont. 

i - 24

External oil leakage, cont. 


Leakage in manifold 

joint 

Leaky crankshaft seal 

Leakage at liner seal via 

overflow hole in cylinder 

block 


gasket 

Low load 

External fuel leakage 


Damaged injector and 

injection pump connections/gaskets 

Defective pulsation 

damper 

Blocked overflow valve 

Leakage at high engine 

speed and low power 

output 

- Change to Bosch overflow 

valve (with ball) 

External coolant leakage 


Leakage in cylinder liner 

seal 

Cold leakage 


gasket 

Water pump leakage 

Leakage at charge air 

cooler connection 

Check at the water pump 

housing’s telltale hole 

- Change to hoses of better 

quality (preferably 

silicone hoses) 

Cont. 

i - 25

External coolant leakage, cont. 


Loss of coolant in 

stationary installations 

with self-venting 

valves 

Coolant pressed out of 

expansion tank 

Check that the self-venting 

valve is not situated 

higher than the highest 

coolant level and that air 

is not drawn in through 

the valve 

- Change the valve or fit 

a manual air screw 

Oil pressed out via crankcase ventilation 


Hole in piston crown 

Bearing seizure in turbocharger 

Oil seepage via pistons - 

liner 

Oil seepage in air compressor 

Increases when white 

smoke limiting device is 

engaged or exhaust 

brake applied 

Turbocharger breakdown 


Loss of power 

Excessive bearing play 

in turbocharger 

Lubrication piping 

between turbocharger 

and filter incorrectly 

connected 

- Check the connections 

i - 26

Compressed air system 


Compressor does 

not maintain sufficient 

pressure in the 

system 

Noise 

Compressor allows 

passage of oil, see 

also “High oil consumption”, 

page 20 

Compressor does 

not discharge 

Moisture/oil in compressed 

air system 

Too much carbon in 

compressor cylinder 

head or discharge 

piping 

Exhaust valves leak 

Worn pistons and cylinders 

Leaking/jammed intake 

valves 

Defective pressure regulator 

Leakage in compressed 

air piping 

Too much carbon in 

compressor cylinder 

head or discharge piping 

Worn big end/main 

bearings 


Compressor gear loose 

on shaft, see also 

“Knocking/noise”, 

page 18 


Piston rings fitted 

wrongly 

Overpressure in engine 

crankcase. 

Defective seals on discharge 

pistons 

Discharge mechanism 

binding 

Defective pressure regulator 

Air dryer not working 

properly 

Empty the compressed 

air tank, retain the air in 

connected compressed 

air components. 

Run the engine at 

1200 r/min and note the 

time it takes for the compressor 

to discharge: 

3 - 3.5 min. for 9/11- 

series engines with 

90-110 dm 3 tank capacity 

2.5 - 3 min. for 14-series 

engine with 90-110 dm 3 

tank capacity 

Check/rectify compressor 

as described in the 

Workshop Manual 

Check operation of air 

dryer, change desiccant. 

If desiccant is oily, see 

“Compressor allows 

passage of oil” above 

- If charging time 

exceeds specified values: 

- Rectify leakage, if any 

- Check/rectify pressure 

regulator 

- Check/rectify compressor 

i - 27

NOTE

NOTE

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