Services

SELECTION OF SITE

Proper space should be there for placement and opening of doors of the Silent DG set.
There should be atleast 1.5 meter free space around the DG set for proper operation and maintenance.
There should be cross ventilation of air to ensure proper cooling of DG set. Exhaust gases and hot air discharge should not re-circulate inside the acoustic enclosure (canopy).
If Genset is to be installed in the room, please ensure proper cross ventilation and surrounding space.
There should be no restriction for fresh air suction and hot air discharge. If 2 nos. DG sets are installed at the site, ensure that hot air outlet of the one DG set does not become the fresh air intake of the 2nd DG set.
If Genset is to be installed in the basement, please ensure ventilation with respect to Air requirement and clear space for every maintenance.
Distance between two SDG set should be minimum 3 meters.
Distance between two SDG set should be minimum 3 meters.
It is preferable to install the DG set in an open area. No shade (roof) is required over it. However, if the AMF Panel is outside the Acoustic Enclosure, then a shelter is recommended for the AMF Panel.
For Roof Top Installation, ensure that the civil structure is capable to bear the static and dynamic load of DG set. The load of the Silent DG set should be borne by Columns and Beams of the building.
Proper space should be there for Earthing.
If there are no space constraints, the DG set should be placed near the distribution panel.
The DG set should be located away from polluted surroundings such as corrosive fumes, cement dust, fibres, cotton and toxic chemicals to avoid overheating of the D.G. Set.
There should be sufficient space around the Genset to avoid resonance and echo effect which contributes to abnormal sound from Genset
The space should be open without any obstacles.

FOUNDATION DETAILS AND GUIDELINES

A. Ground base Foundation (RCC/PCC)

The foundation should be water leveled and at least 3"/4" above the ground level to maintain cleanliness and avoid flooding.
The length and width of the foundation should be at least 600mm to 800 mm more than that of the DG set size i.e. 300mm on each side. Check the foundation level diagonally as well as across the length and width.
Please refer to the foundation drawing attached herewith (page-3).
A rigid foundation ensures the least vibration. Sand Filling should be there around the foundation. 18mm rubber matting must be used over the foundation to minimize the vibration effect and noise leakage.
Ensure that the foundation to support 1.5times of the total wet weight of the single generator and 2 times of the total weight for the multiple generators.
Please refer to the dimension of DG set for deciding the foundation length, width and depth.

Note: Please ensure that the foundation should not be made over any basement, water tank or Sewer Line.

B. Roof top Installation

A rooftop installation requires proper planning and the structural design considerations for dynamic loading.
The weight of Silent DG set should be on Column and Beam through proper foundation.
The RCC foundation should be on the Beam or supported on two Beams.
ISMC Channel or MS “I” Section may also be used to cater the load of the DG set with the canopy. Load of ISMC Channel or MS “I” Section should be on the column of the building.
M.S. Sheet is to be provided at the bottom of the base frame of the Silent DG set for roof top installation.

EARTHING SYSTEM

An Earthing system is required for the protection of equipment and human being, as per Indian electricity Rules 1956.
Separate earth should be used for Genset body and neutral earthing.
4 Nos. earthing pits are required for 3 phase DG set, 2 each for neutral & body.
Ø4 Nos. earthing pits are required for single phase DG set, 2 each for neutral & body.
The min. distance between 2 earthing pits should be 2.0 meters.
An earth pit cover should be provided.
A watering pipe of 25mm with a funnel should be provided for each pit, wherever depth of the earthing pit is not at water level.
Earthing system should be checked with meagre and resistance between 2 earth pits should be less then 1?
The earthing plate/pipe and strip size should be selected as per the rating of the DG set.

SDG Set rating	Recommended Earth Strip/Cable
5-82.5 KVA	8SWG-Copper
100-250KVA	25X3mm Copper/25x6mm GI
320-750KVA	50X6mm Copper/50x6mm GI 2 runs

TYPICAL EARTH PIT / STATION ARRANGEMENT

Exhaust Piping

The exhaust system must be designed to keep the resistance to hot gases (back pressure) as low as possible and load of the extended exhaust pipe / silencer should not be on the engine manifold

The following may please be noted.

There should not be any load or stress on the expansion bellow.
There should be proper support for the exhaust pipe.
Exhaust Pipes should be extended through proper flanges only.
Short bend should be avoided.
Always use proper size MS pipe ( G.I. Pipe and bend should not be used in exhaust piping)
At the time of Genset Installation , Please ensure proper alignment of exhaust silencer with respect to expansion bellow

Exhaust pipe load should not come on Expansion bellow and it should not touch the roof body. As per statutory regulations, exhaust pipe has to be extended above the surrounding stack as below.
H= h + 0.2 x kva Where H = Minimum height of exhaust stack, h= height of building

Exhaust Pipe Details

Engine Model (Air Cooled)	Minimum exhaust pipe OD (mm)
EA10 G1 /EA16 G1	50
HA294 G1/HA394TCI G1/HA494TCI G1	63
HA694TCI G1	76

Engine Model (Water Cooled)	Minimum exhaust pipe OD (mm)
2R1040 G1	63
3R1040T G1/3R1040TA G1	76
4R810TA G1/4R1040TA G1	75
4K1080TA G2 /6K1080TA G2	101
6SL-Series	138
DV-Series	150

Note-

If the extension of exhaust pipe is more than 5 meters above Genset, increase pipe diameter by 13mm for every 3 meters.
If no.of bends are more than 4, increase the diameter of exhaust pipe and bend by 13mm for addition of each bend.
Joining of Exhaust pipe for the both bank is not recommended. In case of necessity common pipe diameter should be at least 10% higher and refer proper procedure (Use of NRV valve and angle between chimni and pipe should be maintained) before joining two exhaust pipe.
Both the Exhaust pipe should not be connected opposite to each other. Angle 0 0 between pipe should be 30 to 45

FUEL PIPING

A supply and return fuel pipe is required in each DG set .
SDGs upto 625 KVA are provided with fuel tanks inside the acoustic enclosure.
Outside fuel tank will be provided as per requirement.
For fuel tank inside the acoustic enclosure, fuel piping is done by the manufacturer/supplier.
However, for Fuel Tank outside the enclosure, fuel piping is to be done by the customer.
Size of the fuel piping should be 12mm upto 250 KVA DG set.
B/C Class M.S. pipe (19 mm - 25mm I.D.) is recommended For fuel piping above 250 KVA DG sets.
MS pipe should be used with proper welded joints.
Stop valve and flange should be used in supply line to engine near fuel tank (for Fuel Tank mounted outside).

PRECAUTIONS TO BE TAKEN FOR FUEL PIPING AND FUEL SYSTEM.

Never use GI pipes in fuel piping of DG set.
Joints should be welded and never threaded.
Pipe should be above ground level with proper MS support.
All joints should be tested for any seepage or leakage.
For 320 KVA and above DG sets, Fuel Tank height should be such that lowest level of Fuel Tank is above Diesel pre-filter height.

CABLING

It has been our experience that most electrical failures are caused by overheating due to loose thimbling or undersize cables.
Please use cable of correct size to carry full load current and thimble of correct size for cable termination.
At no time, loose wires should be tightened on to terminal/busbar with bolts.
Crimping should be done with proper crimping tool.
Ensure tight crimping/terminations to avoid overheating and burning of the cable and terminals.
Ensure proper bending radius is given to the cable to avoid excessive tension on cable termination.
Ensure that the weight of cables does not rest on alternator terminations. Proper support to be provided from the ground separately through cable tray.

For 3 Phase

KVA	15	20/30	35	45/50	62.5/70	82.5	100	125
Al. Cable Size 3.5 core sq.mm	16	25	25	35	70	95	95	150
Copper cable size 3.5 core sq.mm.	6.0 mm2	10 mm2	16 mm2	25 mm2	35 mm2	50 mm2	50 mm2	70 mm2
KVA	140	160	180 /200	250	320	400	500	600/625
Al. Cable Size 3.5 core sq.mm	185	240	240	2X185	2x300	2X300 3x240	4x240	4X300 5x240
Copper cable Size 3.5 core/ sq.mm	70 mm2	95 mm2	120 mm2	150 mm2	240 mm2	300 mm2	2X185 mm2	400 mm2

For 1 Phase

KVA	15	20	30-35	40	50	62	70
Al. Cable Size 2 core/sq.mm	35	50	70	120	120 2x70	150 2x70	150

KVA	15	20	30-35	40	50	62	70
Copper Cable Size 2 core/sq.mm	25	35	50	95	95	120 70x2	120 70x2

Note:-

Correct size cable glands should always be used for holding the cable.
Control wiring should always be done with 2.5 sq.mm copper cable.
From 320 KVA to 625 KVA bus bar terminal box will be provided by customer

BATTERY CHARGING PROCEDURE

A. Battery charging procedure

Specific gravity of acid inside the battery should be 1.23 to 1.28 kg/ltr.

NOTE :-

If dry battery is supplied along with the DG set then initial charging of the battery is required.
If battery is kept ideal for 3 month, then battery should be charged.

B. Method to use battery

If DG set is not in use for a long time then ensure that at positive terminal battery lead is not connected. It should be connected at the time of the commissioning of the DG set.
Charged battery may be used for commissioning of DG set within 15-20 days, else re-charging of charged battery is required.
Always connect the battery with the proper battery charger. The battery should be connected to the battery charger, which is connected with 230V AC supply.
The Battery charger is provided with an AMF Panel (Auto Mains Failure Panel) under the standard scope of supply. 230V AC supply is essential for battery charger operation.

NOTE :- Battery charger is not supplied with a std. manual Panel. So, it is suggested that the DG set must run once a day for 15-20 minutes so that battery is charged by engine dynamo/charging alternator. Battery should not be kept ideal for 6 months.

C. Precaution to be taken during handling of battery

Do not charge the battery at a wet a place.
Flame, Candle and matchbox should not be used near charged battery.
Use hand gloves while handling the charged battery.
Electrolyte level should be medium.
Always switch off the charger first before disconnecting the battery from the DG set.
Never put tools etc. on the battery.
Remove battery terminal ( Positive and Negative ) during any welding work on genset.

SUMP CAPACITY (LITRES)

AIR COOLED

Engine Model	EA10 G1	EA16 G1	HA294 G1	HA394TCI G1	H A494 TCI G1	H A694TCI G1
Lts.	3.5	6.5	5	8	8.3	11

WATER COOLED

Engine Model	2R1040 G1	3R1040T G1	3R1040TA G1	4R810TA G1	4K1080TA G2
Lts.	5.5	8	8	10	14

Engine Model	6K1080TA G2	6SL1500TA G2	6SL1500TA G3
Lts.	18	27	27

Engine Model	DV8TA G1	DV8TA G2	DV10TA G1	DV12TA G1	DV12TA G2
Lts.	41	41	45	50	50

Note:- Recommended K-Oil Premium / Filters Change Interval

First Service and Oil change within 50 hours or 30days from date of commissioning whichever is earlier( G1 Check).
G2 Check within 500 hours or 7 months from date of commissioning whichever is earlier
G3 Check within 1000 hours or 13 months from date of commissioning whichever is earlier
G4 Check within 1500 hours or 19 months from date of commissioning whichever is earlier
After first service Oil change period is 500 hours or 6 months whichever is earlier.
If SDG Set kept ideal ( not in operation) for 6 months or more without preservation than revalidation must be carried out and customer has to bear revalidation cost.

CHECK UP BEFORE STARTING THE DG SET

S. No.	Description	Status
1.	Air cleaner mounting	Fitted/Not fitted
2.	Air cleaner cleanliness	Clean/dirty/replaced Dry or oil type)
3.	Air cleaner clamps Hoses	Cracked/normal/not clamped / tightened
4.	Grade & specs of oil used	15W40 as per koel manufacture's recommendation
5.	Lub oil level & positioning of oil filter	OK/Not OK
6.	Check lub oil safety	OK/Not OK
7.	All Nuts & Bolts	Proper Tightened
8.	Battery condition	Charged/Discharged
9.	Battery Terminal/Leans	Proper/damaged/replaced
10.	Electrolyte level	High/Medium/Low
11.	Fuel Filter	Proper/to be replaced
12.	V Belt for charging alternator	Proper Tightened/not Proper
13.	V Belt tension	Proper/adjusted
14.	Coolant level in the Radiator	High\|Medium\|Low\|filled
15.	Check coolant temp. safety	OK/not OK
16.	Wiring (Engine/Panel)	OK/not OK
17.	Check all wires tightening	OK/not OK
18.	Alternator back cover	Fitted/removed
19.	Cable termination	Proper/loose/Tightened
20.	Canopy door alignment	proper/adjusted/not proper
21.	Canopy door hinge operation	OK/not OK/Adjusted

PRE-COMMISSIONING CHECK

Whenever you want to call a Service Engineer for commissioning, kindly ensure that --

Installation work has been completed (i.e. foundation, earthing, exhaust pipe job has been completed with proper supports, if extended beyond the canopy)
Fuel pipe line job is completed, if Fuel Tank is outside the canopy.
If DG set installed inside a room, a duct to be provide for fresh air & hot air exit should be 1.5 times higher then the canopy inlet & outlet.
Power cable laying, fitting and connection jobs are completed with proper glanding.
If panel is out side canopy, Power Cable Control cable laying, fitting & connection jobs have been completed.
Most important - Battery is charged.
If the DG set is with AMF Panel, then 230 V AC mains or 415 V AC mains (R,Y,B,N) supply is provided at the AMF Panel to check its operation and for Battery Charger.
Diesel is available in the Diesel Tank.
Engine is duly filled with Lube Oil upto "H" mark
Coolant level is up to ‘H’ mark
Load is available.1

Note:- It is mandatory to get your Diesel Generating Sets commissioned on load and kindly do sign the commissioning report made by our Service Engineer.

ROUTINE CHECK POINTS

Check Fuel Level
Drain water from fuel Tank (Especially during winter Season.)
Check Coolant level in the Radiator
Check for any leakage
Check for any loose connections
Check Battery condition
Check Lube oil level and quality (lube oil should not be very thick with visible carbon and metal particles).

DO`s

Check fuel /coolant/lube oil level
Check for any leakage
Check electrolyte level in Battery, It should be between 1.23-1.28 kg/ltr
Check Fan belt tension
Check battery charger
Drain the water from fuel tank,weekly during winters
Check all nuts, Bolts, Engine/Alternator foundation bolts tightness at the time of commissioning then monthly
Check for any loose connections at the time of commissioning then monthly
Use K-cool super plus, Lube K-oil Premium and spares as per KOEL specification and purchase from authorized KOEL service dealer
Refer Engine maintenance manual for routine and daily maintenance check.
Study 'user manual' in detail before usage.
Keep good ventilation which is essential to keep the air,cool and clean.
Use appropriate tools and equipments which are required to carry ot any service.
Ensure all nuts, screw, pipe, connections and covers are properly tightened
Ensure that sufficient diesel fuel ,oil in the tank & lube oil in the engine( for specification, grade of oil & coolant refer to O & M)
Check the battery codition and connections
Check earthing of the generator set
Apply load on the genset gradually
Carry out maintenance repairs & overhauling of the genset as per recommended schedules in the user manual
Call on the authorised service dealer for servicing & maintenance work.
Please refer maintenace maual before doing any maintenance work.
Cable entry hole, if not in use, should be properly closed.

DON`Ts

Do not Repair /Service any part when set is running.
Never operate the genset with any parts or ducting removed.
If any fault is traced, Do not attempt to start the genset unless fault is rectified.
Do not use start push button continously for more than 5 seconds.
Do not check lub oil, coolant level while DG set is running.
Do not change or modify any wiring, it may cause void of warranty.
Do not turn off the fuel supply for stopping the genset unless any emergency.
Do not start genset on load.
Do not allow the genset to run idle for Long periods on no load.
Do not leave behind tools,waste cloth,loose wires etc, after repair or maintenance work is completed near the genset.
If the DG set is with AMF panel do not tuch live wire as Main supply is available in circuit from AMF panel even if DG set is OFF.
Do not get the DG set repaired and serviced by any unauthorized person. It may cause void of warranty.
Do not add acid of any strength to the Battery, for topping up use distilled water only.
Do not attempt to open the locked doors it can cause failure of door lock.

TROUBLE SHOOTING - ENGINE

Important Note - Trouble shooting points are given just for reference. Please do contact KOEL service dealer for any check or repair.

Description	Causes	Remedies
Engine does not start	No fuel in Tank	Fill Fuel in tank
	Air in Fuel line	Vent air from fuel line
	Choked fuel line	Clean and clear fuel line
	Dirty /clogged air cleaner	Check Vaccum indicator, if red ribbon is visible then Clean air cleaner( refer manual for cleaning)
	Dirty or choked fuel filter	Contact to KOEL Service Dealer
	Faulty fuel Pump	Contact to KOEL Service Dealer
	Faulty starter	Faulty starter
	Engine used after a long time	Check and Charge battery or Contact to KOEL Service dealer
	Battery discharged	Charge the Battery
	Loose or dislodged wiring	Check wiring,it should be as per drawing andTightened
	Engine needs overhauling	Contact to KOEL Service Dealer
Engine fails to start	Engine used after a long time	Contact to KOEL Service Dealer
	Engine seized	Contact to KOEL Service Dealer
	Engine needs overhauling	Contact to KOEL Service Dealer
	Faulty starter	Contact to KOEL Service Dealer
	Battery run down/under rating	Contact to manufacturer or Service dealer
	Loose or dislodged wiring	Check wiring,it should be as per drawing andTightened
Engine start but stops after some time	Dirty /clogged air cleaner	Check Vaccum indicator, if red ribbon is visible then Clean air cleaner( refer manual for cleaning)
	No fuel or Low fuel in tank	Fill Fuel in tank
	Poor quality of fuel	Change the fuel and use good quality fuel
	Air in Fuel line	Vent air from fuel line
	Choked fuel injector holes	Contact to KOEL Service Dealer
	Dirty or choked fuel filter	Contact to KOEL Service Dealer
	Faulty fuel Pump	Contact to KOEL Service Dealer
	Water mixed with fuel	Check the reason and sort out or Contact to manufacturer/ KOEL service dealer
	Engine seized	Contact to KOEL Service Dealer
	Engine needs overhauling	Contact to KOEL Service Dealer
Engine not taking load	Dust entry in air inlet system	Make necessary arrangement to stop dust entry without any modification in air inlet arrangement
	Dirty /clogged air cleaner	Check Vaccum indicator, if red ribbon is visible then Clean air cleaner( refer manual for cleaning)
	High exhaust back pressure	Check Exhaust pipe arrangement, it should be as per manufacturer recommendation,Contact to manufacturer
	Derating due to temp,altitide,humidity	Contact to manufacturer
	Poor quality of fuel	Change the fuel and use good quality fuel
	Choked fuel line	Clean and clear fuel line
	Choked fuel injector holes	Contact to KOEL Service Dealer
	Dirty/Choked fuel filter	Contact to KOEL Service Dealer
	Fuel level setting wrong	Contact to KOEL Service Dealer
	Faulty fuel Pump	Contact to KOEL Service Dealer
	Water mixed with fuel	Check the reason and sort out or Contact to manufacturer/ KOEL service dealer
	Radiator fins choked	Clean the radiator fins
	Loose V-Belt	Contact to KOEL Service Dealer
	No coolant or level low in radiator	Top up with K Cool super plus
	Wrongly adjusted valve clearances	Contact to KOEL Service Dealer
	Blown cylinder head gasket	Contact to KOEL Service Dealer
	Valve leakage	Contact to KOEL Service Dealer
	Broken/worn out piston rings	Contact to KOEL Service Dealer
	Worn out cylinder liner & piston	Contact to KOEL Service Dealer
	In correct valve & fuel timing	Contact to KOEL Service Dealer
	Injector needs adjustment	Contact to KOEL Service Dealer
	Faulty governor setting	Contact to manufacturer or KOEL Service Dealer
	Engine needs overhauling	Contact to KOEL Service Dealer
Engine speed does not remain constant	Choked fuel line	Clean and clear fuel line
	Poor quality of fuel	Change the fuel and use good quality fuel
	Choked fuel injector holes	Contact to KOEL Service Dealer
	Damage or dribbling nozzle	Contact to KOEL Service Dealer
	Dirt / choked fuel filter	Contact to KOEL Service Dealer
	Faulty fuel Pump	Contact to KOEL Service Dealer
	Injector needs adjustment	Contact to KOEL Service Dealer
	Faulty governor setting	Contact to manufacturer or KOEL Service Dealer
	Load at the time of starting	Start generator at no load
Engin dos not reach governed speed	Choked fuel line	Clean and clear fuel line
	Dirt / choked fuel filter	Contact to KOEL Service Dealer
	Control lever setting wrong	Contact to KOEL Service Dealer
	Engine overloading	Ensure Load as per rating or manufacturer recommendation
Excessive smoke at no load or low load	Dirt/clogged air cleaner	Clean air cleaner
	Damage or dribbling nozzle	Contact to KOEL Service Dealer
	Faulty fuel Pump	Contact to KOEL Service Dealer
	Engine used after a long time	Contact to KOEL Service Dealer
	Wrongly adjusted valve clearance	Contact to KOEL Service Dealer
	Blown cylinder head gasket	Contact to KOEL Service Dealer
	Valve leakages	Contact to KOEL Service Dealer
	Broken/worn out piston rings	Contact to KOEL Service Dealer
	Worn out cylinder liner & piston	Contact to KOEL Service Dealer
	Incorrect bearing clearances	Contact to KOEL Service Dealer
	Damaged main & connecting rod bearings	Contact to KOEL Service Dealer
	Incorrect valve & fuel timing	Contact to KOEL Service Dealer
	Injector needs adjustment	Contact to KOEL Service Dealer
	Faulty governor setting	Contact to manufacturer or KOEL Service Dealer
	One or more cylinder not working	KOEL Service Dealer One or more cylinder not working
	Engine needs overhauling	Contact to KOEL Service Dealer
Excessive smoke at full load	Dust entry in air inlet system	Make necessary arrangement to stop dust entry without any modification in air inlet arrangement
	Dirt/ clogged air cleaner	Clean air cleaner
	Derating due to temp,altitide,humidity	Contact to manufacturer
	Poor quality of fuel	Change the fuel and use good quality fuel
	Choked fuel injector holes	Contact to KOEL Service Dealer
	Damage or dribbling nozzle	Contact to KOEL Service Dealer
	Control lever setting wrong	Contact to KOEL Service Dealer
	Faulty fuel Pump	Contact to KOEL Service Dealer
	Engine overloading	Ensure Load as per rating or manufacturer recommendation
	Worngly adjusted valve clearances	Contact to KOEL Service Dealer
	Broken/worn out piston rings	Contact to KOEL Service Dealer
	Excessive end play in crankshaft	Contact to manufacturer or KOEL Service Dealer
	Worn out cylinder liner & piston	Contact to KOEL Service Dealer
	Worn out valves and valves guides	Contact to KOEL Service Dealer
	Incorrect valves & fuel timing	Contact to KOEL Service Dealer
	Injector needs adjustment	Contact to KOEL Service Dealer
	Faulty governor setting	Contact to manufacturer or KOEL Service Dealer
	Engine needs overhauling	Contact to KOEL Service Dealer
Engine overheat	Dust entry in air inlet system	Make necessary arrangement to stop dust entry without any modification in air inlet arrangement
	Fresh Air intek and Hot air discharge not proper
	Gap in radiator and Partition. Hot air recirculation inside canopy	Ensure proper sealing of radiator and Partition
	Dirt/ clogged air cleaner	Clean air cleaner
	High exhaust back pressure	manufacturer recommendation,Contact to manufacturer
	Faulty fuel Pump	Contact to KOEL Service Dealer
	Wrong grade of lube oil used	Change the lube oil as per KOEL specification
	Dirt/choked suction tube strainer	Clean the tube strainer
	Clogged oil passage	Check and clear oil passage, Contact to KEOL service dealer
	Radiator fins choked	Clean the radiator fins
	Loose V-Belt	Contact to KOEL Service Dealer
	Contact to KOEL Service Dealer	Block air passage and ensure no air recirculation
	No coolant or level low in radiator	Top up with K Cool super plus
	Engine overloading	Ensure Load as per rating or manufacturer recommendation
	Wrongly adjusted valve clearance	Contact to KOEL Service Dealer
	Prolonged oil change period	Contact to KOEL Service Dealer
	Broken/worn out piston rings	Contact to KOEL Service Dealer
	Excessive end play in crankshaft	Contact to manufacturer or KOEL Service Dealer
	Engine seized	Contact to KOEL Service Dealer
Engine gives out blue smoke	Wrong grade of lube oil used	Change the lube oil as per KOEL specification
	Excessive oil in the sump	Check and rectify lube oil level upto High mark only
	Engine used after a long time	Contact to KOEL Service Dealer
	Broken/worn out piston rings	Contact to KOEL Service Dealer
	Worn out cylinder liner & piston	Contact to KOEL Service Dealer
	Worn out valves and valves guides	Contact to KOEL Service Dealer
Water mixed with fuel	Check the reason and sort out or Contact to manufacturer/ KOEL service dealer
Excessive fuel consumption	Dust entry in air inlet system	Make necessary arrangement to stop dust entry without any modification in air inlet arrangement
	Dirt/ clogged air cleaner	Clean air cleaner
	High exhaust back pressure	manufacturer recommendation,Contact to manufacturer
	Poor quality of fuel	Change the fuel and use good quality fuel
	External/internal fuel leakage	Check for any leakage and rectify
	Faulty fuel Pump	Contact to KOEL Service Dealer
	Engine overloading	Ensure Load as per rating or manufacturer recommendation
	Blown cylinder head gasket	Contact to KOEL Service Dealer
	Valve leakages	Contact to KOEL Service Dealer
	Incorrect valve & fuel timing	Contact to KOEL Service Dealer
	Injector needs adjustment	Contact to KOEL Service Dealer
	Engine needs overhauling	Contact to KOEL Service Dealer
Mixing of Diesel with lube oil	External/internal fuel leakage	Check for any leakage and rectify
	Damage or dribbling nozzle	Contact to KOEL Service Dealer
	Faulty fuel Pump	Contact to KOEL Service Dealer
	Broken/worn out piston rings	Contact to KOEL Service Dealer
	Worn out cylinder liner & piston	Contact to KOEL Service Dealer
	Incorrect valve & fuel timing	Contact to KOEL Service Dealer
	Injector needs adjustment	Contact to KOEL Service Dealer
	One or more cylinder not working	Contact to KOEL Service Dealer
Excessive oil consumption	Dust entry in air inlet system	Make necessary arrangement to stop dust entry without any modification in air inlet arrangement
	Dirt/clogged air cleaner	Clean air cleaner
	Wrong grade of lube oil used	Change the lube oil as per KOEL specification
	Excessive oil in the sump	Check and rectify lube oil level upto High mark only
	External/internal fuel leakage	Check for any leakage and rectify
	No coolant or level low in radiator	Top up with K Cool super plus
	Broken/worn out piston rings	Contact to KOEL Service Dealer
	Worn out cylinder liner & piston	Contact to KOEL Service Dealer
Low Lube oil pressure	Dust entry in air inlet system	Make necessary arrangement to stop dust entry without any modification in air inlet arrangement
	Loose wiring of sensor controller/connection not proper	Tighten connect as per drawing
	Faulty Sensor	Replace sensor
	Dirt/clogged air cleaner	Clean air cleaner
	Wrong grade of lube oil used	Change the lube oil as per KOEL specification
	Dirt/choked suction tube strainer	Clean the tube strainer
	Lube oil dilution	Check and Change the lube oil as per KOEL specification
	Dirt/clogged lube oil filter	Contact to KOEL Service Dealer
	Clogged oil passage	Contact to KOEL Service Dealer
	Faulty oil pump	Contact to KOEL Service Dealer
	Engine overloading	Ensure Load as per rating or manufacturer recommendation
	Prolonged oil change period	Contact to KOEL Service Dealer
	Engine needs overhauling	Contact to KOEL Service Dealer
Diesel knocking	Poor quality of fuel	Change the fuel and use good quality fuel
	Faulty fuel Pump	Contact to KOEL Service Dealer
	Incorret valve & fuel timing	Contact to KOEL Service Dealer
Mechanical Knock	Loose component	Check and ensure all component should be tighten.
	Component fouling with any other component	Check and ensure all component should fitted properly
	Worngly adjusted valve clearances	Contact to KOEL Service Dealer
	Broken/worn out piston rings	Contact to KOEL Service Dealer
	Excessive end play in crankshaft	Contact to manufacturer or KOEL Service Dealer
	Incorrect bearing clearances	Contact to KOEL Service Dealer
	Worn out cylinder liner & piston	Contact to KOEL Service Dealer
	Damaged main & connecting rod bearings	Contact to KOEL Service Dealer
	Loose mounting bolts	Contact to manufacturer or KOEL Service Dealer
	Loose flywheel/wrong adjustment	Contact to manufacturer or KOEL Service Dealer
Excessive Vibration	AVM pad broken or wrong fitment	Replace if AVM Pad broken
	Gap between foundation and base frame i.e. foundation level is not proper	Ensure proper foundation. Level should be proper
	Fluctuation in load	Uniform load should be on Genset
	Faulty governor setting	Contact to manufacturer or KOEL Service Dealer
	Loose mounting bolts	Contact to manufacturer or KOEL Service Dealer
	Loose flywheel/wrong adjustment	Contact to manufacturer or KOEL Service Dealer
Engine rotates very slowly during starting	Engine seized	Contact to KOEL Service Dealer
Battery runs down frequently	Under rated battery	Contact to manufacturer or KOEL Service Dealer
	Canopy lampt remain in ON positionq	Check and ensure proper use of Canopy Lamp
	Faulty starter	Contact to KOEL Service Dealer
	Battery of wrong capacity	Contact to manufacturer or KOEL Service Dealer
	Loose or dislodged wiring	Check wiring,it should be as per drawing and Tightened

Description	Causes	Remedies
No voltage from Alternator	Decfective voltmeter	Check voltmeter and replace
	Short circuit between phases	Check and ensure no short circuit between phases
	Neutral earthing short with body earthing	Check and rectify
	Power cable faulty	Cehck and replace
	Excitation circuit open	Check for loose connection
	Incorrect excitation circuit connection	Check for proper connection
	Low residual voltage	Check for residual voltage. If residual voltage is less than 2.5V(L-N) field flashing required for few seconds
	Grounded excitor field	Check and correct
	Rotating rectifier faulty	Check rotating diodes
	Fuse in AVR failed	Replace fuses
	AVR Defective	Replace AVR
Voltage developed but excitation current is high	Rotating diode faulty	Check rotating diodes and replace faulty diodes
	Prime mover	Adjust prime mover
	Prime mover speed is low	Adjust prime mover speed to rated speed
Low voltage build up	V-Trim pot incorrectly set	Adjust voltage by V-Trim pot in AVR
Low voltage build up	Low prime mover speed	Adjust prime mover speed
Voltage-High	Loose or no connection to 'U' terminals of the AVR	Check and correct
	Incorrect voltage setting	Adjust voltage by V-Trim pot in AVR
	AVR Defective	Replace AVR
Voltage fluctutation	Speed fluctuation of the prime mover	Set the speed of the prime mover
	Incorrect setting of stability pot	Adjust stability pot in AVR
	Leading load power factor	Correct the power factor
	Load hunting,fluctuates rapidly	Check and reduce the nonlinear load
	High percentage of non-linear load	Rectification, Correct percentage of non linear load
Over loading of Generator	Over loading of generator	Check the load and correct. To be in line with name plate rating
	Blocking of ventilation passage	Check ventilation and clean passage if necessary
	Low speed on load	Adjust prime mover speed
	Low load power factor	Reduce the load
	Generator operating at very high voltage	Check voltage and adjust
	High percentage of non-linear load	Check and reduce the nonlinear load
Excessive vibration and noise	Poor alignment	Re-align properly
	Coupling and foundation bolts loose	Tighten the bolts
	Bearing defective	Replace bearing
Over heating of bearing	Incorrect assembly of bearing	Re-assemble correct
Over heating of bearing	Bearing damaged	Replace bearing
Generator does not share KW load proportionately	Prime mover speed droop improperly set	Set prime mover speed properly,Droop ( Governor) characteristic of engines.
Generator does not share KVAR load proportionately	Quadrature droop incorrect	Set quadrature droop correctly by QDC Pot in AVR
	QDC-CT Polarity reversed	Interchange CT secondary
	Interchange CT secondary	Check and rectify

TROUBLE SHOOTING GUIDE FOR MANUAL PANEL

Engine does not start by turning the starting key/push botton provided on panel.

Check connection of battery.
Check Control MCB. It should be in ON position.
Check the battery voltage at terminal 1 and 2 inside panel. It should be 12/24 V. If not, check circuit or get the battery charged before making further attempts as battery may be weak
The Engine cranks but fails to run.

Check the fuel supply line.
Check connection of fuel pipe at fuel tank, it may open.
Air in fuel line
Faulty fuel pump .
Water mixed with fuel.
Load is disconnected.

TROUBLE SHOOTING GUIDE FOR AMF PANEL

Engine does not start from the AMF panel in any mode.

Check the DC supply control MCBs and 3 Phase mains supply. These should be in ON Position.
Check the battery voltage at terminal 1 and 2 in the AMF Panel. It should be equal to 12V/24V. If not, get the battery charged before making further attempts as the battery is weak.
Check all control wires at control terminals in AMF panel.
Check battery terminals. They should be properly tightened and should not be corroded.
Check LLOP connection , it should be properly connected on engine terminal.
Check all wiring connection should be properly tighten and all should be in order as per drawing.

The battery connection may be loose or corroded. Check and correct the problem.
If the MAINS supply is available, set the battery charger to boost and wait till the battery voltage is 12/24V.
Refer KG controller manual for further trouble shooting related to KG controller

Engine starts but there is no Voltage from the control Panel

Check HRC fuses/MCB below the DG/MAINS contactor. MCB should be in ON position and fuse should be OK.
Check the setting of AVM ( Alternator Voltage Monitor).
Check the overload relay , if it is tripped than press the reset lever.
Check power cable connection from Alternator to control panel.

The Main supply is restored, but the load does not transfer.

Check the control MCBs these should be in 'ON' position.
Check if all three phases (RY, YB and BR) of Mains supply are available. All three phases should be available and voltage should be more that the setting of mains voltage monitor or AMF Relay/KG Controller.
If required, lower the voltage setting of mains voltage monitor and differential setting or setting in AMF relays/KG Controller Increase the voltage setting gradually if Mains Voltage is not acceptable on load equipment.
Distance of panel from DG set should not be more than 5 meters.
Check wiring connection of MAINS contactor. Supply to contactor coil should be available. 24 JAKSON &