SPIC Volume 3 Part-2

केवऱ कायााऱयीन उपयोग हे तु
(For Official Use Only)
भारत सरकार GOVERNMENT OF INDIA

रे ऱ मंत्राऱय MINISTRY OF RAILWAYS
SELF PROPELLED
INSPECTION CAR (SPIC)
MAINTENANCE MANUAL
VOLUME – 3[PART – II]

OEM Documentation
IRCAMTECH/GWL/MECH/2020-21/SPIC/MM/1.0
December, 2020
Self Propelled Inspection Car - Maintenance Manual (Version1.0) OEM Documentation
THIS PAGE IS INTENTIONALLY LEFT BLANK
IRCAMTECH/GWL/MECH/2020-21/SPIC/MM/1.0 Page 2
Volume 2
OEM Documentation [PART – II] – Electrical Equipment
All rights reserved. This book or any portion thereof may not be
reproduced or used in any manner whatsoever without authorization
from Indian Railways.
Content in this document is compiled with the inputs provided by ICF

and OEMs
Amendments and Revisions
The correction slips to be issued in future for this report will be numbered as follows:
IRCAMTECH/GWL/MECH/2020-21/SPIC/MM/1.0# XX date .......
Where “XX” is the serial number of the concerned correction slip (starting from 01 onwards).
Version Date Corrections Remarks

1.00 31/12/2020 First Release --
Table of Content
1. Amendments and Revisions ........................................................................................... 4

2. Table of Content ............................................................................................................. 5
Propulsion and Control Equipment
3. OPERATION AND MAINTENANCE MANUAL /8 WHEELER SELF‐PROPELLED INSPECTION

CAR WITH UNDERSLUNG TRANSMISSION/CGPISL
(Document No CGPISL/SPICAC/MM/01 Date: 14th Feb 2019- Revision: 00)
DA Set (40 kVA)
4. USER MANUAL /DA SET/ KOEL

Air Conditioning Unit
5. TECHNICAL MANUAL/ LHB DESIGN COACH WITH R407C REFRIGERANT/ INTEC

(ISSUE – 00 / 20-11-2013)
PUMPS
6. USER AND MAINTENANCE MANUAL / MONOBLOCK PUMPS/ KALSI

VRLA Batteries
7. INSTALLATION AND OPERATING MANUAL / VRLA BATTERIES/ AMARA RAJA

Pantry Equipment
8. INSTRUCTION MANUAL / INDUCTION OVEN (IC3616)/ USHA

9. USER MANUAL / HOT BEVERAGE DISPENSER/ ATLANTIS
10. USER MANUAL/MICROWAVE OVEN (MC28H5025VS)/SAMSUNG
11. USER MANUAL/REFRIGRATOR(RT30N3753SL)/SAMSUNG
DOCUMENT TITLE OPERATION & MAINTENANCE MANUAL
8 WHEELER SELF‐PROPELLED INSPECTION CAR

PROJECT
WITH UNDERSLUNG TRANSMISSION
CUSTOMER INTEGRAL COACH FACTORY, CHENNAI
CG Power & Industrial Solutions Ltd.
Issued By TRACTION MACHINES DESIGN DEPARTMENT, CG

Doc. Ref. No. CGPISL/SPICAC/MM/01 Prepared B. S. Rana
Revision No. 00 Checked L.K. Tiwari
Date 14th Feb 2019 Approved D. M. Nimje
INTRODUCTION
PREFACE
This instruction book covers the operation & maintenance instructions for electric traction
equipment supplied by CG Power & Industrial Solutions Ltd. to Integral Coach Factory, Chennai
for SELF-PROPELLED INSPECTION CAR WITH UNDER SLUNG SINGLE POWERPACK
& AC/DC TRANSMISSION SYSTEM for Indian Railways.
The purpose of this instruction manual is to familiarise maintenance personnel with the
procedures for operating and maintaining the electrical equipment.
This manual covers description of electrical circuits, general maintenance and data on control
gear, electrical machines besides other general information.
The instructions contain adequate details/information required for maintenance of equipment.

Nevertheless, it is not practicable to cover all details and every contingency, which is likely to
arise in service. Should any further information be desired or should particular problem arise, the
matter should be referred to: CG POWER AND INDUSTRIAL SOLUTIONS LTD. Industrial
Systems; D-5 Industrial Area, Mandideep, Bhopal - 462 046.
Continuous efforts on improvement in product design may result changes in details, which may
not be covered in this manual. Although efforts are made to furnish all such changes to the user,
it is advisable to consult CG for obtaining necessary assistance.
CG POWER AND INDUSTRIAL SOLUTIONS LTD.

LAREG AND TRACTION MACHINES DIVISION,
D-5, INDUSTRIAL AREA, MANDIDEEP
BHOPAL - 462 046
MAINTENANCE MANUAL FOR SPIC‐AC/US

INTRODUCTION
CONTENT
S.NO TITLE
1. INTRODUCTION
2. POWER PACK ARRANGEMENT
3. CIRCUIT DESCRIPTION
4. TRACTION ALTERNATOR
5. POWER RECTIFIER
6. TRACTION MOTOR
7. CONTROL GEAR EQUIPMENT
8. MAINTENANCE INSTRUCTIONS FOR CONTROL GEAR EQP
9. DRIVING INSTRUCTIONS
10. SPIC DRAWINGS
11. RECOMMENDED SPARES
12. ANNEXURE: 1
13. ANNEXURE: 2

CHAPTER I
INTRODUCTION
1.0 PERFORMANCE AND GENERAL DATA
2.0 LIST OF ABBREVIATIONS
Maintenance Manual
SELF‐PROPELLED INSPECTION CAR | UNDER SLUNG TRANSMISSION
INTRODUCTION
CHAPTER I
INTRODUCTION
This manual covers operation & maintenance instructions of major power & control equipment used in
Broad Gauge Self Propelled Inspection Car Air conditioned with Under slung transmission system (SPIC-
AC/US). The equipment meets the requirements of ICF’s spec. No. ICF/M/D/SPEC-349 R0, for supply
of complete electrics of SPIC-AC/US. The equipment includes Diesel Engine, Traction Alternator, power
rectifier, traction motors, motor switch group cubicle, all protective devices, and instruments for
measurement & indication and auxiliary equipment.
SPIC-AC/US is a self-propelled motorised 2-axle vehicle, Air conditioned used for periodic inspection,
patrolling. The 8- Wheeler Inspection Car (SPIC) uses the power generated by the diesel alternator set
provided in the SPIC car for propulsion and not the power from live OHE.
Salient features of SELF-PROPELLED INSPECTION CAR:
i. Fully air conditioned self-propelled coach.

ii. Profiled nose cone with driver’s desk on both ends.
iii. 1800 revolving chairs (2+2) with leather- E- leather.
iv. Halogen free rubber flooring.
v. Interior panelling of ACP/FRP.
vi. GPS based PIS/PAS with digital speed indication.
vii. Hot Spot for Infotainment.
viii. Bio toilet with touch free fitting.
ix. Mobile dish antenna for live TV.
x. CCTV Cameras on front and Rear.
xi. Water purifier with water cooler.
xii. Mini Pantry and Lounge.
xiii. Shoe shining machine.
xiv. LED Lighting.
xv. Transition coupling with side buffers
Other Features:
i. Underslung 340 H.P. Power Pack for Propulsion.
ii. Underslung 40 KVA DG set for Air conditioning and hotel load.

INTRODUCTION
These power packs provide traction power to run the car unit at high speeds up to 110 km/h. The under
slung power pack free up the over board floor space for seating the officials & to carry the other useful
equipment’s.
Each power pack consists of following major components:
1. Under floor mounted:
 Diesel engine
 40 KVA DG Set
 Exhaust Silencer for diesel engine
 Water Rising Apparatus for radiator etc.
 Hydraulic Oil Tank.
2. Equipment’s installed over board;
 Control cubicle.
 Driver's desk.
 Air filters for diesel engine air intake.
 110V Battery BOX (Not in CG Scope)
 24V Starter Battery (Not in CG Scope)
 Battery Charger
3. Over the roof
 Engine Radiator Unit.

 AC unit system (Not in CG Scope)
Above equipment with associated accessories are engineered to provide trouble free traction power within
built safety & protection equipment. The controls are developed to provide regulated traction power to
match the demand from driver's console command while maintaining the safety checks all the time during
traction.
All the healthy, operation & faults are brought to driver's console as indicating lamps for easy recognition
of sequences happening in the traction system.

INTRODUCTION
Certain serious system faults not only indicate & warn the driver and also disable the traction power or
shut down the diesel engine depending on the severity of the fault. Under such circumstances, there are
certain "bypass safety" switches provided in the control cubicle. The use of these will enables the driver
to run the traction system for short durations to clear the track for regular traffic.
The bypass safety function is not permitted to use on a regular basis or

for longer periods. Use of bypass safety function for longer periods
could lead to severe damage to the equipment or total failure of the
affected unit connected equipment and severe injury or loss of life,
because the bypass safety function disables systems automatic check
function
User is strictly advised to familiarize about the complete equipment by use of this document provided for
the purpose and follow the driving, operation & maintenance instructions.
The manual contains following information:
- System Description
- Equipment Description
- Circuit Description
- Fault Diagnostics
- Maintenance Instructions

INTRODUCTION
1.0 PERFORMANCE AND GENERAL DATA
GENERAL DESIGN FEATURES
1. Track Gauge : 1676 mm

2. Minimum Radius of Curvature : 175 m
3. Maximum Super Elevation : 185-mm
4. Maximum Super Elevation Deficiency : 100-mm
5. Wheel Arrangement of Power Car : BO-BO (With motorised 2-Axle)
6. Wheel Diameter : 952 mm (New), 914.5 mm (Half Worn)
877 mm (Fully Worn)
7. AXLE Load : 20.32 T (Approx.)
8. Gear Ratio : 20/91
9. No. of power packs : One
10. Input To Traction : 293 HP AT 55C
11. Diesel Engine type : NTA-855R3 of Cummins
12. Power Transmission : AC / DC Electric
13. Traction Alternator : C1009A1 of CGPISL
14. Traction Motor : TM2141C of CGPISL
15. Maximum Operating Speed : 110 km/h
16. Clearance Above Rail Level : Minimum of 102 mm with coaches fully
loaded & wheels in fully worn
condition.
18. Reference Site : Ambient = 0 – 55 C
Max. Temperature in sun 70 C
Humidity = 40 to 100 %
Altitude up to 1000 metres above MSL

INTRODUCTION
2.0 LIST OF ABBREVIATIONS

 ASS - LOAD AMMETER SELECTION SWITCH
 COR - CUTOUT RELAY
 DCS - DRIVER’S CONTROL SWITCH BOX
 ECS - ENGINE CONTROL SWITCH
 ECR 1 - ENGINE CONTROL RELAYS
 ER 1 - GOVERNOR CONTROL RELAYS
 FC21 - ENGINE TRIP RELAYS
 FOLS - FOG LIGHT SWITCH
 HL - HEADLIGHT SWITCH
 HLEM - HEADLIGHT EMERGENCY SWITCH
 HLS - HAND LAMP SOCKET
 IL1 - INSTRUMENT LAMPS
 LCC - LOAD & SPEED CONTROL SYSTEM
 LED - LED INDICATION PANEL
 LRR1 - LOCAL RESET RELAYS
 MC - MASTER CONTROLLER
 MLS - MARKER LIGHT SWITCH
 R11 - HIGH COOLING WATER TEMP MONITORING RELAYS
 R21 - LOW HYDRAULIC OIL LEVEL MONITORING RELAYS
 R41 - LOW LUBRICATING OIL PRESSURE MONITORING RELAYS
 R51 - ENGINE OVERSPEED MONITORING RELAYS
 R61 - LOW COOLING WATER LEVEL MONITORING RELAYS
 R81 - LOCAL ENGINE ON/OFF RELAYS
 R91 - REMOTE ENGINE ON/OFF RELAYS
 RR1 - READY TO START RELAYS
 S11 - ENGINE ON RELAYS
 SLS - SEARCH LIGHT SWITCH
 SR1 - SAFETY RELAYS
 TLS - TAIL LIGHT SWITCH
 GFR - GROUND FAULT RELAY
 GRCO - GROUND RELAY CUT-OUT SWITCH
 MCS1 - MOTOR CUT-OUT SWITCHES
 BIS 110V - BATTERY ISOLATING FUSE TYPE SWITCH 110VDC
 BCS 24V - BATTERY CHARGING SWITCH 24VDC

INTRODUCTION
 RCD1 - REVERSE CURRENT DIODES

 EG - EQUIPMENT GOVERNOR BYPASS SWITCH
 BPCG - BRAKE PRESSURE CONTROL GOVERNOR BYPASS SWITCH
 PBG - PARKING BRAKE GOVERNOR BYPASS SWITCH
 FLS1-CAB - FLUORESCENT LAMP SWITCH-1 CAB
 FLS2-CAB - FLUORESCENT LAMP SWITCH-2 CAB
 CLS - CENTRE LIGHT SWITCH
 VS1 - VOLTMETER (0-150VDC) SWITCH
 VS2 - VOLTMETER (0-50VDC) SWITCH
 S2-3 - BATTERY CHARGING LAMP SWITCH
 LRS1 - ENGINE LOCAL/REMOTE OPERATION SELECTION SWITCHES
 LOP1 - ENGINE LUBRICATING OIL PRESSURE GAUGES
 LOT1 - ENGINE LUBRICATING TEMPERATURE GAUGES
 WT1 - ENGINE WATER TEMPERATURE GAUGES
 BCA1 - BATTERY CHARGING INDICATION AMMETERS
 HM1 - HOUR METERS FOR ENGINES
 BIL1 - BATTERY CHARGING INDICATION LAMP
 TR11,21 - DIESEL ENGINE CRANKING SAFETY TIMERS
 TR12,22 - LUBRICATING OIL PRESSURE SWITCH BYPASS TIMERS
 BD1-2 - BLOCKING DIODES
 WLI1 - WATER LEVEL INDICATION GAUGES
 HOLI1 - HYDRAULIC OIL LEVEL INDICATION GAUGES
MCBs
110 VDC
 GOV-1 SPLY - GOVERNOR – 1 SUPPLY MCB 15A
 GOV-1 CTRL - GOVERNOR – 1 CONTROL MCB 5A
 HL - HEADLIGHT MCB 10A
 L+ - LIGHTS MCB 10A
 EM+ - EMERGENCY LIGHTS MCB 10A
 VM1 - VOLTMETER (0-150VDC) 5A
 ML - MARKER LIGHT MCB 5A
 TL&FL - TAIL LIGHT & FLASHER LIGHT MCB 5A
 FL CAB - FLUORESCENT LAMP CABIN MCB 5A
 FL&CL CAB - FLUORESCENT LAMP & CENTRE LIGHT CAB MCB 5A
INTRODUCTION
 SYS CTRL - SYSTEM CONTROL MCB 30A

 CTRL - CONTROL MCB 15A
 EXC CTRL - EXCITATION CONTROL MCB 10A
 ENG CTRL - ENGINE CNTROL MCB 5A
 COMP UL - COMPRESSOR UNLOADER MCB 5A
 LAMP TEST - LED INDICATIONS LAMP TEST MCB 5A
 ALT. EXC - ALTERNATOR EXCITATION MCB 5A
 RTS - READY TO START MCB 5A
 FAULT IND - FAULT INDICATION MCB 5A
 PB - PARKING BRAKE MCB 5A
24 VDC
 ENG-1 PROT - ENGINE –1 PROTECTION MCB 15A

 ENG-1 SAF-1 - ENGINE-1 SAFETY-1 MCB 5A
 ENG-1 SAF-2 - ENGINE-1 SAFETY-2 MCB 5A
 GOV-1 SPLY - GOVERNOR-1 SUPPLY MCB 5A
 ENG-1 GAUGE- ENGINE-1 GAUGE MCB 5A
 SL - SEARCH LIGHT MCB 5A
 FOL - FOG LIGHT MCB 5A
 VM2 - VOLTMETER (0-50VDC) MCB 5A

CHAPTER II
POWER PACK ARRANGEMENT
Maintenance Manual
CHAPTER II
1. Introduction
The Self Propelled Inspection Car (SPIC) is equipped with a under slung mounted Power packs. The
Power pack consists of one under slung Engine (NTA-855 R), and one Traction Alternator – 230 kW
(C1009A1). The car consists of two bogies with motorised 2 axle by the traction motor. The engine
flywheel is directly coupled with Traction alternator with the help of flex plates. These flex plate
couplings are used to compensate Axial, Angular and radial displacement of connected machines. Flex
plates are provided to absorb shocks on torque, by which it will minimize vibration, and transmits the
power. The output power of alternator is rectified to DC & fed to the traction motors.
These Power pack units are synchronized & regulated to provide total traction power as a single system
when controlled from either cabin. Two cabins one on each end is provided for the purpose. Provision
also exists to isolate any of the power packs and run the vehicle. Driver’s desk mainly consists of
controls for Engine, Alternator and Pneumatic Brakes, Indication lamps, Gauges, switches, speed-time-
distance recorder etc., which will be functioning in conjunction with control cubicles. The complete
power pack is attached beneath the under frame.

2. Major components of power pack
2.1 Engine
The model of the engine used in the equipment is NTA - 855R manufactured by M/s CIL, Pune. It is a
horizontal version engine suitable for under slung mounting. The specification of the engine is provided
in the specification section. This engine is supported at three points, viz, one support at front end
(vibration damper side) and two supports at rear end (Flywheel side). All the three supports are bracket
mounted with Anti vibration units.
(For details of operation and maintenance of the diesel engine refer separate manual of diesel
engine)
2.2 Traction Alternator

The alternator used in the car is C1009A1, manufactured by M/s CG, Bhopal. This alternator caters to
supply electrical power for main Traction. It is under slung mounted with suitable brackets and is driven
from engine directly through the flex plates. The specification of the alternator is provided in the
specification section. This alternator is supported on four points. All the four supports are bracket
mounted, consisting of two Main Brackets which positively holds both the coupled engine and alternator
together. These brackets rest on four Anti vibration units. The AVM’s are pre-compressed in the
assembly position. The mounting fasteners for these AVM are torque tightened and locked with split pin.
3. Power Pack Mounting
The Engine and Alternator (with the flex plates) are coupled together and positively held by two main
brackets at three points on either side of engine & alternator. This whole power pack assembly has five
suspending points, which rests over anti vibration mountings, held rigidly by vertical brackets welded to
under frame structural members. This arrangement has low vibration transmissibility to the under frame.
For details of mounting, refer power pack drawing.

4. MAINTENANCE SCHEDULE FOR SPIC POWERPACK
Diesel
Sl. Engine
Parts Period Maintenance Step Remarks
No. running /
stopped
1. General Daily Stopped  Check visually all equipment for Correct if any
Examination visible defects, loose bolt & nuts, defects
leakages, missing parts etc.
Waste jute should
 Check lube oils, fuel, cooling never be used.
water and air system for leakage
and rectify if necessary.
 Clean all equipment with lintel

cloth.
 Clean the vehicle thoroughly with

a jet of water and scrub down all
dirt and wash again.
2. Diesel Daily Stopped Refer Diesel engine part.

Engine
4. Alternators Daily Running Check for any abnormal noise or over

heating.
5. Diesel Daily Running Refer Diesel engine part.

Engine
6. Gauges & Daily Running Check the Gauge & instrument

instrument operations

NOTES
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CHAPTER III
CIRCUIT DESCRIPTION
1. POWER CIRCUITRY
2. AUXILIARY CIRCUITRY
3. CONTROL CIRCUITRY
Maintenance Manual
CIRCUIT DESCRIPTION
CHAPTER III
CIRCUIT DESCRIPTION
1. POWER CIRCUITRY
1.1 SYSTEM DESCRIPTION
A Self Propelled Inspection Car (SPIC) is used for periodical inspection, patrolling of the track line.
The power equipment of Self Propelled Inspection Car (SPIC) comprises of a power packs, one power
rectifiers & two traction motors to meet all operating conditions of Self Propelled Inspection Car (SPIC).
The power pack consists of a Diesel Engine of Cummins India make type NTA-855R developing a power of
340 HP @ 1800 RPM continuously and a Brushless CGPISL make traction alternator type C1009A1,
matching rectifier, exciter and rotating diode set capable of developing around 293 HP input to traction by
power pack.
The Traction Alternator is a single bearing type and compatible for coupling with Cummins Diesel Engine
mentioned above. The exciter field current is limited to 6 amps during entire working range of SPIC.
The main rectifiers are suitable for over board mounting and are used for rectifying the output of traction
alternators. The power rectifier assembly is suitable for operation under one bridge failure condition
The traction motors (Type TM2141C) are suitable for mounting on SPIC bogie of Indian Railways. The
Traction Motor is self-cooled type and complies with requirements of IEC – 60349-1. The traction motor has
moulded inter-pole & main-pole coils bonded with poles. The two traction motors in 2P combination will
operate in full field only, utilising full capability of traction alternator. Avoidance of going into a weak field
is beneficial from operation point of view, especially utilisation of available adhesion. In addition, such a
combination provides following advantages:
- Reduction in control equipment

- Reduction in maintenance cost
- Avoiding transition jerks and loss of power normally encountered in transition

CIRCUIT DESCRIPTION
An electronic diesel engine speed governing, alternator exciter excitation and load control module, type
LCC107B of GAC make, control the diesel engine speed & excitation of the Traction Alternator. The
experience shows that adoption of such a system enables utilisation of maximum diesel engine power on rail,
thus optimally utilising the installed power.
The diesel engine speed will be regulated through the 8 pre-selected steps (notches). Driver can operate the
SPIC at any notch depending upon speed restrictions / desired.
PERFORMANCE OF THE SYSTEM
Performance obtainable using 340 HP diesel engine at 8th notch & 914 mm half worn wheels and 20/91 gear
ratio, two traction motors fed from a power pack in Permanent Parallel combination (operating in full field
only).
A maximum speed of 110 Km/h is obtainable with the power equipment proposed by us and meets the
following performance requirements as specified in ICF specification no. ICF/MD/SPEC/349_R0. In
addition, use of our equipment gives following performance capability.
1. SPIC can carry 12 tons of payload without any additional equipment.
2. Period of continuous running for 4 hours at 100 kph on general tangent track followed by frequent to
& fro movement at walking speed for 1.5 hours.
3. Period of continuous running at 40 kph on up or down gradient of 1 in 60 for 4 hours to be followed
by frequent to and fro movement at 5 kph for 1.5 hours on the same gradient.
4. When running as a light vehicle, the SPIC shall be capable of running at a speed of
a. 110 kmph on level track.
b. 25 kmph on a 1 in 33 up gradient

CIRCUIT DESCRIPTION
2. CONTROL CIRCUITRY
3.1 110 V DC SUPPLY
110 VDC supply is available in the coach from 110 VDC, 120 A-H battery. This supply is available to
control circuit in all positions of Battery Isolating Switch fuse unit (BIS-110V). During OFF position, we can
charge the battery from external source through Battery charging socket. Regulated battery charger (415V
AC, 3 phase/ 110V, 4.5 KW) supply 110V DC Voltage to the system through Battery isolating switch fuse
unit for control system operation, supply to electromagnetic equipment, electro-pneumatic equipment, train
lighting, Headlight, battery charging, Excitation Control, Governor Supply etc.
3.2 24 V DC SUPPLY
24 VDC Supply is available in the coach from 24 VDC battery. 20 A Diesel Engine mounted Battery
Charging Alternator (BCA) is used for charging the battery, supply to control circuit, electromagnetic
equipment, auxiliary equipment etc. This battery is isolated from the circuit when the battery is in OFF
position. When Diesel Engines are running, supply shall be available from BCA and corresponding charging
current shall be known from Battery Charging Ammeters provided on the Control Cubicle (Cab-1). 24 VDC
Battery supply is used for cranking the Diesel Engines.
3.3 CIRCUIT DESCRIPTION
Preparing Self-Propelled Inspection Car/US for operation: -
a. All the MCBs (110 VDC & 24 VDC) are in ON position.

b. Engine Control Switch Mounted on Driver’s Desk is in IDLE position while Diesel Engine(s)
starting.
c. Motor Cutout switches mounted on control cubicle cabin-1 is in “NORMAL” Position. Depending
on the faulty motor, position of the switch is changed to appropriate condition to isolate the faulty
Traction Motor.
d. Local/Remote switches mounted on the Control Cubicle-1 are in “Remote” Position when the Diesel
Engine is started from driver’s desk. It is in “Local” position when the Diesel Engine is started
locally from the push button station mounted under the frame.
e. All the by-pass switches are in OFF position.
CIRCUIT DESCRIPTION
f. Battery Isolating Switch fuse unit– BIS (110 Volts DC) is in ON position and BIS (24 Volts DC) is
in ON position.
g. Driver’s control switch mounted on Driver’s Desk is in “ON” position.
h. Hydraulic oil level switch (HOLS1) is in close condition, if the oil level is above the specified limit.
i. Diesel Engine mounted water temperature switch (TS11) is in close condition, if the water
temperature is below set position.
j. Diesel Engine mounted lubricating oil pressure switch (PS11) is in open condition before cranking
of Diesel Engine.
k. Diesel Engine mounted over speed switch (SS11) is in close condition, if the speed of the Diesel
Engine is below over speed set speed.
l. Cooling water level switch (CWLS1) is in close condition, if the water level is above set level.
m. Ensure the Master Controller Reverse handle in “OFF” position and Main Handle position is in ‘0’
position.
3.4 CRANKING OF DIESEL ENGINE
Before starting the Diesel Engine, circuit needs to be reset, which bypass the safety system during starting.
The same is accomplished using “Ready to Start” spring loaded switch mounted on the Driver's Desk.
During starting Engine Trip Relay FC21 is energised and “Engine-1 Trip” & “Engine-1 OFF” indications
glow. As soon as the switch is operated, Relays R11, R21, R41, R51 and R61 are energised and cut-off
supply to Engine Trip Relay FC21 & both the indications go off. Now the circuit is set for Diesel Engine
cranking. Press “ON” the Diesel Engine-1 ON” spring loaded switch mounted on the Driver's Desk. As soon
as the contacts of the “Diesel Engine ON” switch is closed, Engine-1 ON relay S11 get energised though
wire no 1654. Contact of S11 inturn operates Remote ON/OFF Relay R91 through wire 225. As soon as the
R91 is energised, 24 VDC supply is available to timers TR11 & TR21, Idling solenoid valve & hour meter
from 209 through Local / Remote Switch & Diesel Engine ON relay NO Contact. At the same time wire no
213 is energised from 209 through Engine ON relay contact and supply is available to magnetic switch
provided on the Diesel Engine (wire no 215). As soon as the magnetic switch is energised, supply is fed to
starting motor and allows Diesel Engine to start. If the Diesel Engine is not started for set time – say 6 sec
(set value of timer TR1), the circuit will break and disconnect supply to magnetic switch. During the Diesel
Engine cranking period, lubricating oil pressure switch is bypassed by Timer 21 contact. The timer is set at
approximately 8 sec. (slightly more than the engine cranking time).

CIRCUIT DESCRIPTION
3.5 SPEED CONTROL OF DIESEL ENGINE(s)

As Diesel Engine starts running from 0 RPM, speed sensors provided on the Diesel Engine develops
frequency signal and give feedback to Speed & Load Control System (LCC-107B) through wire nos. 21A &
22A. Depending up on the speed setting (Notch), LCC-107B controls the speed of the Diesel Engine. LCC-
107B starts pumping current through wire nos. 31A & 32A to Actuator provided on the Diesel Engine till its
speed reaches its set value. Once its speed is reached to set value, LCC-107B maintains the same actuator
current.
Switch ON the “CONTROL” provided on the Driver's Desk. This allows wire no. 1602 to get supply &
“CONTROL ON” indication appears. Move the Master Controller Reverse Handle to either forward or
reverse direction & Main Handle to Notch 1 in depressed deadman condition. There is no change in Diesel
Engine(s) speed. Move the Master Controller Main Handle to notch 2. Diesel Engine(s) speed changes to
approximately 1000 RPM. Move the Master Controller Main Handle to higher notches. Corresponding
speeds are 1200 RPM at 3rd Notch, 1300 RPM at 4th Notch, 1400 RPM at 5th Notch, 1500 RPM at 6th Notch,
1650 RPM at 7th Notch & 1800 RPM at 8th Notch. Depending upon the speed setting / Notch of the Master
Controller, LCC-107B(s) changes the actuator current of Diesel Engine(s).
3.6 TRACTION ALTERNATOR EXCITATION CONTROL
Change the Engine Control Switch to “RUN” position. Ensure that Master Controller Reverse Handle is in
either Forward or Reverse direction & Main Handle is in ‘0’ position with pressed deadman condition.
Switch ON the “EXC ON” switch provided in the Driver's Control Switch Box. This operation set the
control circuit for excitation. Move the Master Controller Main Handle to Notch ‘1’ position with pressed
deadman condition. As soon as the Main Handle moves to Notch 1, LCC-107B (s) get 1st notch speed
through coded signals. Meanwhile, wire no. 3 get supply through Master Controller, Excitation Control
Relay ECR1 get energised and “Excitation-1 - ON” indication appears in LED indication panel. This relay
opens the reset voltage 24 VDC between LCC-107B terminals 13 through wires 203E & 299A. As soon as
the reset voltage is released, the excitation current starts build up from terminals 23 of LCC-107B. Within
few seconds it reaches to its maximum to match the Diesel Engine output power (Gross power – Power
Consumed by Auxiliaries). Move the Master Controller Main Handle to Notch 2. As soon as the Master
Controller Main Handle is moved to 2nd notch, logic signals through wire nos. 4,5,6 & 7 changes the Diesel
Engine speed using LCC-107B to 2nd notch speed i.e. 1000 RPM and excitation changes to get the maximum
output power to match with Diesel Engine output. Depending upon the V-I characteristics (Load Conditions)

CIRCUIT DESCRIPTION
of the Traction Alternator, excitation current varies through wire nos. 1901A & 2101A at fixed notch.
External Resistance 12  keeps the Excitation current always below 10 Amps. However, the maximum
Excitation current required for Traction Alternator is less than 6 Amps. Same procedure is applicable for
higher notches also.
3.7 HEALTHY & FAULT INDICATIONS:
1. TRACTION CONTROL SUPPLY ON (GREEN): This is a healthy indication of system. When the
“Control” Switch provided on the Driver’s Control Switch Box of Driver's Desk is in ON position, wire no
1602 gets supply and the indication glows. If this switch is in OFF condition, Diesel Engine speed control &
Traction Alternator excitation control are not possible.
2. ALTERNATOR EXCITATION ON (GREEN): This is a healthy indication of system, which shows

Traction Alternator excitation is ON. As soon as the Master Controller Main Handle is moved from IDLE to
Notch 1, depending upon the Reverse Handle position, either wire no.1 (Forward) or wire no. 2 (Reverse) is
energised. These wires inturn feed wire nos. 102A & 109A through reverser interlock, Equipment Governor,
Brake Pressure Control Governor and Parking Brake Governors and energise E.P.Contactors LC1 & LC3
mounted inside the Motor Switch Group Cubicle. As soon as these contactors energised, supply is fed to wire
no 1821 and energise Excitation ON Relay ECR. The moment the Relay ECR is energised, indication glows
and excitation starts building up from LCC-107B1.
3. ENGINE ON (GREEN): This is a healthy indication of Diesel Engine. When the “Diesel Engine ON”
spring loaded switch is operated i.e. Diesel Engine cranking operation is performed, Relay S11 energised
through wire no.1654 & 1664 and will remain in energised condition. When the relay S11 is in energised
position, wire no. 1808 gets supply through its NO contact and hence the indication glows. In case of any
protection circuit operates, this relay de-energises and this indication goes off.
4. HIGH COOLING WATER TEMPERATURE (HCWT) – DIESEL ENGINE: This is a fault

indication of Diesel Engine-1. When the Diesel Engine-1 cooling water temperature goes high (more than
the specified limit), the temperature switch provided on the Diesel Engine opens and de-energise the Cooling
Water Temperature monitoring Relay R11 through wire no 243. As a result of this, wire no. 1804 gets supply
through one of the relay contacts, leaving indication “HCWT ENG” on the Indication Panel.
5. AUX EARTH FAULT: In case auxiliary circuit is grounded due to any reason, during operation it causes
Aux Earth Fault to energise through wire no E2. When the AEFR is energised, wire no. 1834 gets supply
through one of its contacts, leaving an indication “AUX EARTH FAULT”. Once the AEFR is energised, it is
mechanically latched. Pressing reset button provided with the AEFR resets mechanical latching.

CIRCUIT DESCRIPTION
6. TRACTION MOTOR OVERLOAD (AMBER): Due to any reason any of the Traction Motor overloads
i.e. Traction Motor current is more than 600 Amps, corresponding Traction Motor overload relay energised,
leaving an indication “TR. MOTOR OVERLOAD” on the indication panel. In case of Traction Motor
overload, supply to traction is cut-off by isolating motor contactors on the Motor Switch Group Cubicle. At
the same time, excitation of respective Traction Alternator (In case of Traction Motor 1 or 2 overload,
Traction Alternator excitation cut-off. To reset the overloaded traction motor circuit, press the “Traction
Motor overload reset” spring loaded switch provided on the Driver’s Control Switch Box. This operation is
possible only when the Master Controller’s Main Handle is in ‘0’ position.
7. RECTIFIER FUSE FAILURE (AMBER): In case of any one-fuse failure in Power Rectifier, Relay
RL1 energises through wire no. 1609. Through one of its contacts, wire no.1814 energised leaving indication
“RECT. FUSE FAILURE”. In case, failure of three different phase-fuses in three different bridges in the
same rectifier panel, the same is considered as Single Bridge failure. In this case also “RECT. FUSE
FAILURE” indication glows.
8. PARKING BRAKE APPLIED (RED): When the parking brake is applied, wire no 1823 energised
through parking brake governor and “PARKING BRAKE APPLIED” Indication glows.
9. MOTOR EARTH FAULT (AMBER): In case power circuit is grounded due to any reason, during
operation it causes Ground Fault Relay (GFR) to energise through wire no E. When the GFR is energised,
wire no. 1824 gets supply through one of its contacts, leaving an indication “TRACTION MOTOR EARTH
FAULT”. Once the GFR is energised, it is mechanically latched. Pressing reset button provided with the
GFR resets mechanical latching.
10. GOVERNOR SUPPLY FAILURE (RED): This is a fault indication of the system. During normal
working conditions, relay ER is energised through wire no 1616 & 1617 and there is no indication “GOV
SPLY FAIL” on the indication panel. Either excitation ON/OFF switch is in OFF condition or Engine
Control Switch is in IDLE position, the Relay ER is De-energised. Once the relay ER1 is de-energised, the
indication glows on the panel. If GOV SPLY FAIL occurs, excitation of Traction Alternator is not possible.
11. ENGINE TRIP (RED): This is a fault indication of Diesel Engine. This indication glows in any of the
following conditions.
a. Hydraulic Oil Level - LOW
(Normal Hydraulic oil Level is lower than the specified limit)
b. Cooling Water Level - LOW
(Normal Water Level is lower than the specified limit)

CIRCUIT DESCRIPTION
c. Lubricating Oil Pressure - LOW
(Normal Lubricating Oil pressure is lower then 10 PSI.
d. Cooling Water Temperature - HIGH
(Normal Cooling Water temperature is more than 91C)
Hydraulic Oil Level & Water Level of Diesel Engine is monitored by R21 & R61 Relays respectively.
Similarly, Cooling Water Temperature & Lubricating Oil Pressure is monitored by R11 & R41 Relays
respectively. Any of these operations goes wrong respective relay de-energises and which inturn energises
Engine Trip Relay FC21. When FC21 is energised, wire no. 1806 gets supply through one of its contacts and
“Engine Trip” indication glows.
12. EMY. TRACTION CUTOFF: When the Emergency off switches are operated during any emergency
conditions, wire no. 1736 is energise and the EMY. OFF Relay is activated, due the activation of the relay
EOR, the wire no. 1841 is also energies and indication appears in the LED indication panel.
13. DEAD MAN BRAKE APPLIED: Whenever the dead man brake function is applied either from Cab I
or Cab II, the Dead Man Relay is activated and due to the activation of DMR, the wire no 1831 is energised
and LED indication appears in the LED indication panel.
14. LOW LUBE OIL PRESSURE: This is a fault indication of Diesel Engine. When the Diesel Engine
lube oil pressure goes low (less than the specified limit), the pressure switch provided on the Diesel Engine
open and de-energise the Low lube oil pressure Relay R41 through wire no 245. As a result of this, wire no.
1835 gets supply through one of the relay contacts, coming the indication “LOW LUBE OIL PRESSURE
ENG” on the LED Indication Panel.
15. HYD OIL FLOW FAILURE: This is a fault indication of Diesel Engine. When the Diesel Engine hyd.
oil flow goes low (less than the specified limit), the oil switch provided on the Diesel Engine open and
energise the Low hyd. oil flow Relay R71 through wire no 219. As a result of this, wire no. 1845 gets supply
through one of the relay contacts, coming the indication “LOW LUBE OIL PRESSURE ENG” on the LED
Indication Panel.
16. SPARE: SPARE LED is available on the LED indication panel of driver desk which is for in case of
failure of one the LED.

CIRCUIT DESCRIPTION
NOTES
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CHAPTER IV
TRACTION ALTERNATOR
1. INTRODUCTION
2. SALIENT FEATURES
3. ALTERNATOR CONSTRUCTION
4. MAINTENANCE SCHEDULE
5. ALIGNMENT PROCEDURE WITH DIESEL ENGINE
6. PROTECTION OF BALL BEARING
7. LONGITUDINAL SECTION
Maintenance Manual
SELF‐ PROPELLED INSPECTION CAR | UNDER SLUNG TRANSMISSION
TRACTION ALTERNATOR
CHAPETR IV
TRACTION ALTERNATOR
1. INTRODUCTION
This Manual comprises chapters, covering `Description', Ìnsulation', òperation' and ‘maintenance’ of
alternator. Alternator has been designed and built in accordance with the generally accepted engineering
practices of Indian Railways Loco/DEMU Sheds. In case of improper installation or improper operation or
improper maintenance, machine gives rise to potential dangers which may cause serious personal injuries or
damage.
While designing this Traction alternator, aspects of user-friendly maintenance and easy manufacture were
kept in mind. Technical data have been laid down for the machines in accordance with the specifications.
It is assumed that the planning and execution of mechanical/ electrical installation, transportation, erection
/commissioning and maintenance will be carried out under the supervision of qualified personnel.
In the case of product maintenance / installation / erection / commissioning, it is advisable to take assistance
or services of the competent CG service centres or inform CG works for the assistance.
The direction of rotation is determined from the bearing end of the machine, it is a single bearing machine,
directly coupled with Diesel engine on one side and supported on ball bearing on the other side.
1.1 TECHNICAL DATA
C1009A1 AC Alternators is a Salient pole, revolving field, brush-less, self ventilated & single bearing
Traction machine. This AC generator is available with SEPARATELY EXCITED SYSTEM (with unique
LCC 107B governor of Governors America Corporation).
Description Make & type CG, C1009A1
Drive-Details of arrangement Direct coupled through flex plates

of bearing and coupling
No. of poles, phases & connections 8 poles, 3 phase, Star

TRACTION ALTERNATOR
Maximum permissible design speed 2250 rpm
One hour rating 544 A, 450 V, 245 kW at 1800 RPM
Continuous rating
High voltage 345 A, 666 V, 230 kW at 1800 RPM

Low voltage 718 A, 320 V, 230 kW at 1800 RPM
Class and type of insulation
Stator Class H
Rotor Class H
Resistance at 20 °C
Rotor winding 0.74 Ohms

Stator winding 0.0089 Ohms
(Per phase)
Resistance per phase exciter rotor 44 mill ohms at 20 °C
Resistance for exciter stator 7.2 ohms at 20 °C.
Details of bearings
Single Ball bearing SKF - 6317 C/3

Grease-type, HP LITHON-3
Capacity 250 GMs
Interval for regreasing 6 months
Repack the grease 2 years
grease requirement in new 210 Gm
Shaft bearing seating diameter 85 mm
Min. permissible radial clearance 0.03 to 0.13 mm

TRACTION ALTERNATOR
Mountings-Details Directly coupled to engine
Weight
Traction Alternator 1385 kgs

Fan 17 kgs
Rotor 605 kgs
Air Filter Assembly 40 kgs
1.2 IMPORTANT HARDWARES
Bolting place Size Quantity Type
Alternator mounting with main

M24 x 70 lg. P12.9 16 nos. Socket head
bracket
Flexible coupling with rotor

M20 x 50 lg. P10.9 08 nos Hex. Hd bolt
shaft
Alternator mounting with

M16 x 70 lg. P12.9 16nos. Socket head
engine adopter

TRACTION ALTERNATOR
1.3 MAINTENANCE SHEET
Week- 6
Sr. No. Nature of job Monthly Yearly
ly Month
01. Physical inspection X
02. Air outlet cover X
03. Air inlet duct X
04. Terminal box. X
05. Terminal connections X
06. Coupling bolts to engine adoper. X

& alt. Stator
07. Alternator fixing bolts to base rail X
08. Topping up of grease in bearing assy. X
Insulation resistance of exciter stator,

09. rotor, main stator , ex. St. X
Pressure Cleaning
10. X
Dismantling
11. Once In
Fan, flex plate fixing bolts with engine 2- year
12. flywheel X

TRACTION ALTERNATOR
2. SALIENT FEATURES OF ALTERNATOR
C1009A1 AC generator is a Salient pole type, revolving field Brush-less type alternator. These AC
generators are available in a SEPARATELY EXCITED SYSTEM (with unique LCC107B of GAC,
Governors America Corporation).
The insulation system of the stator coils has been improved for higher voltage operation of the high-powered
D.E.M.U., D.E.T.C. & shunter. The traction alternator C1009A1 is capable of operation at a top unloading
voltage of 750V DC continuously.
This alternator is especially design for Indian Railways by CG. The class 200 Insulation System with
Polyesterimide Resin provides best protection against moisture, sand, salt, humidity and corrosive
atmosphere ensuring trouble free operations under the most demanding conditions.
Transient voltage dips are lower.
Liberally rated diodes have been used in rotating rectifier assembly to ensure high product reliability
specifically for rotating application.
The rotating diodes are protected by a surge suppresser, which has the ability to chop the transients from
1600 volts to less than 450 volts.
For D.E.T.C. /U.S. power requirement is maintained constant at different notches.
Voltage X current = constant
Depending upon the load requirement, Constant & rated powers have been achieved through excitation,
which have been controlled with the help governor LCC 107B, which is a special feature of D.E.T.C. /U.S.
Depending upon the load requirements of the multiple unit, Governor provides current input to exciter stator,
which induces power in exciter armature, which then rectified by diode wheel (rotating rectifier) and is fed
into main rotating field, ultimately responsible for the power output of alternator.
The diesel engine in the present case has a gross HP of 340 and input to traction is 310 HP at 38 °C of
ambient and at a speed of 1800 RPM. The higher voltage capability of traction alternator enables the
locomotive to be operated at full field of traction motors. AC Generator armature winding is housed in Stator

TRACTION ALTERNATOR
and field Winding is placed on Rotor. Brush-less construction of rotating rectifier gives the required amount
of excitation to the rotating field.
The excitation circuit is designed to ensure that the excitation current does not exceed by 6 Amps at any
operating point.
3. ALTERNATOR CONSTRUCTION
3.1 STATOR
Stator consists of stator frame, stator core, armature windings & terminal box.
3.1.1 STATOR FRAME
Stator frame along with terminal box is a fabricated structure using mild steel plate. It is designed to ensure
correct distribution of airflow over the Stator core and windings.
Stator Frame
3.1.2 STATOR CORE
In stator core, Stampings stack is supported with mild steel end plates at both ends & reinforced with landing
bars, which are welded with complete stack & both end plates. Stampings are made of silicon steel with C6
coating for proper welding of stack. These punching are oriented to 90° length one fourth resulting in better
magnetic properties.
Stator core with winding

TRACTION ALTERNATOR
3.1.3 ARAMTURE WINDINGS
Winding is designed for 8 pole, 3 phase, double layer diamond winding star connected, housed in a open
slots, single turn ( made up of single conductor having no laminations.)
The Connections are made to the phase rings by gas brazing and phase connectors are taken to the terminal
box by means of BUS BAR. The phase rings are properly insulated between line to line and live to earth
parts.
Armature coils are made from polyesterimde enamelled glass lapped Conductor for class 200 suitable for
VPI formed on special formers.
Overhang is properly tied up with the help of resiglass tape to the epoxy bracing ring so that the electrical
and severe mechanical stress in case of any abnormal event can be resisted by the windings. 5th and 7th
harmonics are mitigated by a 60° winding distribution and should not normally be the major target for
reduction by pitching.
Stator Coil
3.2 WOUND ROTOR ASSEMBLY
Rotor consists of shaft, 8 rotor field coils (4 north polarity + 4 south polarity), diode assy, exciter armature.
The rotor is wet wound for eight poles using epoxy compound and properly interlined to have better
resistance to centrifugal force, then locked with support block to have proper locking. The rotor field coils
are vacuum pressure impregnated with solventless resin of class 200.

TRACTION ALTERNATOR
Wound Rotor Assembly
3.2.1 ROTOR HUB:
The shaft is made of forged medium-grade carbon steel IS: 2004 CLASS IV. The shaft is liberally designed
for overload conditions. The rotor shaft is forged and ultrasonically tested to give greater reliability in
performance.
Rotor Hub
3.2.2 ROTOR FIELD COILS
Main field pole is built up of high quality, low silicon, steel sheets, oriented to 180° after every one-fourth
length for better grain orientation and better magnetic properties.

TRACTION ALTERNATOR
Rotor Pole Brick
For forming the rotor field coil, main field pole is directly wound with rectangular copper conductor by wet
winding process using epoxy compound, which gives better insulation properties and mechanical strength.
The coils are formed by winding directly over the pole body to give better rigidity in service and this also
minimises the loosening of poles in service. While assembling the wound poles utmost care is taken during
the production stage. Field coils are fastened to shaft with high tensile steel bolts with specified torque and
locked through tack weld in position.
The coil to coil strap connectors are individually insulated and brazed to the coil leads. The connectors are
held and braced to support plate of diode wheel several layers of Resi-glass tape is applied on the connectors
(live surface) and cured fully to form a rigid connection.
The fully assembled rotor with field coils and connections is subjected to painting with anti-tracking
insulating paint to avoid trapping of moisture and improved electrical properties.
3.3 END FRAME:
End frame is fabricated from thick steel plate construction, Spigot to the stator frame and is fixed by easily
assessable high tensile screws. The end frame supports the exciter winding and bearing assembly. It is so
designed to facilitate the easy accessibility of diode wheel for Maintenance.

TRACTION ALTERNATOR
End Frame
3.4 ROTOR FAN
The rotor fan is manufactured with special Aluminium alloy. Special care is taken to ensure that the fan is
free from any sort of casting defects. All the fans undergo thorough dye penetration and radiographic testing
for highlighting any surface or sub surface defects.
Rotor Fan
3.5 TERMINAL BOX
This alternator stator is having internally 3 phase star connection, brought to the terminal box bus bars.
Phase bus bars are brazed with phase rings, which are supported on the main frame & properly insulated
from earth. The phase bus bars coming out of the frame are properly supported on steel cleats with Resi-
glass tape to minimise the cable tension. Other end of phase cables is fixed on insulating rod through plated
TRACTION ALTERNATOR
hardware to maintain minimum air gap (creepage) between live to live & live to earth parts. Single holed
Lugs are provided for output power cable connection. RTD terminals have been terminated at elex elements
supported inside the same terminal box.
3.6 DIODE WHEEL ASSEMBLY
Diode wheel assembly is made up of solid iron plate in which insulation discs are bonded together with resin.
Heat sink are specially designed for speed up to 2500rpm. The rotating diodes are protected by a metal
oxide varistor against voltage surges arising due to fault conditions on load side. Diodes are suitable upto
PIV of 1600 volts, and specially designed for high `g’ application, 3 positive and 3 negative diodes of
Ruttonsha no. 150LMR is used. Each heat sink is specially designed to accommodate one bridge arm and
output is fed into a common copper connector for all the arms to the rotating field.
Details of rotating rectifier

 Mounted on the same rotor shaft of alternator.
 Support plate is made up of mild steel. Its function is clear form the name given to it
 Heat sink is for carrying out the heat generated in the diodes during their operation
3.7 BEARING ARRANGEMENT
The bearing arrangement consists of inner bearing cap, shrink ring, ball bearing, distance collar, outer bearing
cap. Assembly stages of these parts are as shown in fig. All these bearing components are made of forged
carbon steel as per IS: 2004 class 3 & 4. Self-locating, sealed bearing arrangement has been designed to have
better circulation of grease during service. Grease inlet pipe along with grease nipple (1/4 inch BSP) have
been provide in outer bearing cover for topping up grease during routine maintenance
Bearing Assembly

TRACTION ALTERNATOR
At the outset, it may be emphasised that the routine maintenance of Traction Alternator is much simpler due
to the absence of Commutator and its brush-less arrangement.
Routine maintenance of Traction Alternator therefore, mainly includes periodic cleaning and inspection of
the machine.
It is recommended that the period of inspection should be more frequent in the initial period of service, and
schedule can be subsequently relaxed based on experience. The periodic maintenance schedule chart
accompanied with this manual should be filled and should be periodically sent back to the manufacturer.
4.1 CLEANING
Clean all the dust and dirt from the exterior of the Alternator, taking special care at the areas around air
opening and inspection covers. Air Inlet cover is removed from the alternator by taking out the M12 hex
head screw. Then only the air inlet cover can be removed and it is advisable to take care for withdrawal of
small M6 screw while opening the assembly. Air inlet net to be cleaned only with kerosene or and other
solvent. Dirt & dust of the alternator is to be cleaned by vaccum cleaner. In absence of vacuum cleaner, dry
compressed air is to be used for cleaning. During cleaning it is to be ensured that dust is blown out of
alternator or air inlet duct whenever compressed air has been applied for cleaning.
Wipe the dust over the diode and insulation disc and approachable parts of the rotor field coils and
connections. Best way of cleaning is to moist a clean lint free cloth with solvent for wiping. Recommended
cleaning solvents are given in Table.
While cleaning, look for any defects, hot spots or abnormalities, for taking corrective action consult with
manufacturer.
4.2 PERIODIC INSPECTION
Periodic inspection should be carried out after thorough cleaning and following points should be given
special attention.
Inspect the diode wheel for any damage of knots of resi-glass and cable holdings. Use glass chord of dia. 1.0
to do the needful as per the perception of operating personal. This is only a temporary solution.

TRACTION ALTERNATOR
Check machine exciter for any collection of grease leakage from the bearing assy. If the leakage appears to
be significant then end frame covers as shown in a figure are to be removed and the leakage should be
cleaned.
Check the Main Terminal box and Exciter Terminal Box for dust and use blower.
Check bus bars and connections for cracks or frayed insulation, ensuring complete security, of operating
personnel.
Ensure that there are no loose nuts or bolts in the machine and securely close the inspection cover. One
should be Very careful while doing the job on the an side (coupling side)
4.2.1 PERIODIC TIGHTENING OF BOLTS
To be done every month for the following assemblies in addition to routine inspection check, carry out with
specified torque value. Refer maintenance data for values.
Components Torque (kgm)
Coupling bolts to engine and fan 8-10
End frame to alternator stator frame 8-10
14- 16
Cable connections to Alternator
Main bracket fixing bolts to AVM 69-83
Air inlet covers. 2-3
Replace any cracked spring/lock washer or any damaged bolt and also check locking of the remaining bolts
in rotor if it is taken out for overhauling or for bearing change.

TRACTION ALTERNATOR
4.2.2 INSULATION CHECK
In every 3 months, check the insulation resistance of the rotor and stator with a 500 Volts Megger and record
the IR value. The Alternator can be safely operated with a minimum hot insulation resistance of 1 to 2 Mega
ohms. Further fall in IR calls for additional cleaning and re-painting with insulating varnish of stator and
rotor. Sometimes the accumulation of moisture in the machine leads to low Insulation Resistance, then the
machine needs prolonged drying at low temperature of 100-110 °C till the insulation improves. Specially
take care of the deposition of dirt and during the first heavy rains of the season.
WHILE CHECKING WITH 500 VOLTS MEGGER SHORTENS ALL, AC

& DC BUSBARS TO AVOID DAMAGE TO THE DIODES. REMOVE
THE SHORT AFTER MEGGER CHECK.
4.2.3 RELUBRICATION
50 grams grease (see data for grade) is to be topped up in the end frame bearing assembly only after a year of
service or 150000 Kms of run whichever comes first. . This is to be done in addition to all the above checks.
4.2.4 DIODE REPLACEMENT
In the case of damage/failure in diode, diode of same polarity shall be used for replacement. It is
recommended that the make of diode be only of Ruttonsha for product reliability. After assembly, the
continuity of replaced diode to be checked with multimeter. Diode to be assembled at specified torque value.
For assembly please see the sketches for the detailed assembly.
4.2.5 PERIODIC OVERHAUL
The Alternator is required to be overhauled, even if the same is working satisfactorily. The period of
overhaul can be varied between 4 to 5 years depending on the conditions of operation and maintenance.
However the first overhaul is recommended before completion of 2 years as it is the first of its type in India
and to have the feed back to the manufacturer.
The routine overhaul mainly consists of
 Dismantling & cleaning
 Inspection & reconditioning
 Replacement & reassembly.

TRACTION ALTERNATOR
4.3 DISMANTLING & CLEANING OF ALTERNATOR:
Before undertaking dismantling Alternator, examine its OGA & PART drawings submitted to the customer
during the approval stage and follow it in presence of experienced personnel or someone from manufacturer
side.
It is recommended that, as far as possible, reassemble after overhaul, the same components, which have been
dismantled from the machine.
For dismantling refer the figure attached and proceed as follows.
Clean the Traction Alternator externally.
After removing the alternator from the Engine, Put the slot wedges provides in the air gap of pole tips in
armature portion so that sudden load is not transmitted to the bearings.
Remove bolts of end frame while alternator is kept vertical bearing side up
Use eyebolt of M20 in the taps provided and lift it with the help of wire sling slowly. As soon as the centre is
achieved the slot wedges will fall automatically to ground. It is to be replaced while making the alternator
horizontal. Use the torque level as specified in the table of technical data.
End frame is a push fit on the frame. There are three tapped holes provided on the 725PCD. Jack with M12
bolts to remove the end frame from main stator frame.
Removing the Outer Bearing cap:
Unlock and remove the bolts for the outer bearing cap and clean with a cotton waste thoroughly.
End frame can be removed from the bearing by keeping the rotor coupling face on the stand and pulling the
end frame with the help of sling. First remove from the frame as mentioned above.
Remove end covers and inserts the puller bolts of M20, tapped at both the ends in the inner bearing cap. On
the other end put the plate with a hydraulic jack to pull the distance collar, bearing, shrink ring together.
4.3.1 CLEANING
All parts of the disassembled Alternator, including bearing, bearing housing is to be thoroughly cleaned
before examination.
Cleaning should be attempted by blowing dry compressed, low-pressure air followed by wiping with clean
lintless cloth. Even a stiff Nylon brush or fibre scrapper may be used. In severe cases cloth dampened with
solvent can also be used.
CHLORINATED HYDROCARBON TYPE CLEANING SOLVENTS ARE

NOT RECOMMENDED FOR USE ON EQUIPMENT BECAUSE OF
POSSIBILITY OF INSULATION DAMAGE

TRACTION ALTERNATOR
CLEANING SOLVENTS MAY BE TOXIC AND/OR INFLAMMABLE.

TAKE ADEQUATE PRECAUTIONS AS SPECIFIED BY SOLVENT
MANUFACTURES.
Use following cleaners:
a) For insulation: use non-oil quick drying cleaners.
b) For end bearing fits, shafts, metal surfaces use a cleaner which will not leave an oily deposit on
the finished surface.
c) For bearings use cleaner which will not completely remove the oil film from finished surfaces.
Kerosene, petroleum spirit or petroleum solvents are satisfactory.
Cleaning with steam (alternative method).
d) Heat a washing compound in a steam tank (water and cleaning compound) until the temperature
reaches 100 °C.
e) Place the parts to be cleaned in such a position that the steam can be directed from a hose in all
directions for cleaning.
f) Allow clean parts to cool and blow compressed air for removing moisture.
g) For electrical components heat them in oven till the moisture is removed.
4.3.2 INSPECTION AND RECONDITIONING:
After the thorough cleaning of all parts, inspect and recondition as follows:
4.3.2.1 STATOR
After thorough cleaning of stator examine for any loose wedge or damaged insulation or hot spots. If loose
wedge is found replace them with new ones giving proper packing beneath them.
If any damaged insulation is noticed on end winding portions, the same can be locally repaired with glass
mica tapes and glass tapes.
If a hot spot is noticed on the lead joints, remove insulation and examine the brazed joint. If in doubt re-braze
taking adequate protections for surrounding coils by packing wet asbestos putty all around and carry out
torch brazing with silphos brazing alloy strip and rod. Re-insulate after re-brazing. Check insulation
resistance with a 1000 Volts Megger. IR should be greater than 20 M Ohms. H-V test is to be performed at
1kv for one minute.
If IR is found to be less than the specified limit, when alternator was not in use for a long period of time, for
developing the IR, heat the stator in an oven operating at 100 to 110 °C for 6 hours, and check insulation
resistance and continue heating till IR is satisfactory.
TRACTION ALTERNATOR
4.3.2.2 ROTOR
Check the rotor for any damaged or loose coils by tapping the coils using a wooden mallet. Check rotor field
coil to coil connections for looseness by tapping.
Rotor insulation resistance to be checked with a 500 Volts Megger. If IR value is more than 20M Ohms no
repair is needed to the rotor otherwise it is to be subjected to the following varnish treatment Once again
clean the rotor and the rotor coil surface and blow over the shaft barrel.
Heat the rotor in an oven operating at 100 to 110°C for 6 hours.
Check insulation resistance and continue heating till IR is satisfactory. Rotor - 150M ohms, Exciter rotor
50M ohms.
When the rotor is above the room temperature, apply two bricks coats of solvent less resin, all over the rotor
pole coils, pole body face and connections ring.
Rotor to be cured at 160 c for 10 hours.
Once again check IR value it should be greater than 40M Ohms.
Apply anti tracking insulating varnish and then rotor is to be cured at 160 C for 6 hours
FIELD CONNECTOR REPLACEMENT:
If any field connector or stator overhang is to be replaced or repaired due to damage or failure, follow the
procedure as below:
Cut the Resi-glass binding Tape on the field connector ring at the affected pole coil and remove Resi-glass
tape to the extent required. Un braze the coil to coil connector and if the coil to coil connector is damaged,
replace it with a fresh one, while replacing ensure the connections are made according to the diagram. See
Fig. Stator connection diagram. The bare connector is to be insulated as below:
- One layer half lapped with 0.13mm x 19mm wide kapton mica tape.
- Followed by one layer half lapped 0.038mm x wide P.T.F.E tape.
- Followed by one layer half lapped 0.10mm x 25mm wide Glass tape.
- On the lead to lead insulation between poles use one layer of kapton mica, one layer half lap of
glass mica, one layer half lap of glass tape used above.
- Double the above quantity for stator overhang and 3cms on either side of damaged area.
The Resi-glass taping requires curing at 135 °C for 6 to 8 hours and the entire connector ring portion is to be
resin treated as mentioned in` rotor reconditioning. During this process remove the diode heat sink as it is not
designed for such a high temperature.

TRACTION ALTERNATOR
RECONDITIONING OF ROTOR FIELD COIL
REPLACEMENT:
If a particular rotor coil is to be dismounted, adopt the following procedure:
a) Mounting of field coil on rotor.
1.0 Place rotor vertically (Bearing end up)
2.0 Open coil to diode wheel connections.
3.0 Unlock and open mounting bolts.
4.0 Remove the coil support by hammering the wedge.
5.0 Isolate the faulty coil leads by removing the insulation and de brazing the joints.
6.0 Remove the tack weld of the mounting bolts.
7.0 Hold pole and coil assembly with a Nylon sling and open pole bolts. Torque required will be
around 80 kg-m.
8.0 As pole is directly wound on pole the whole new assembly. Pole is to be replaced in case of
faulty pole. Pole is subjected to VPI after forming and consolidation with epoxy resin.
9.0 Check the IR value of the coil it should be more than 150 mega ohms.
MOUNTING OF FIELD COIL
Clean pole body and paint with anti-tracking insulating varnish.
Hold pole assembly vertically up and bring near to shaft barrel. Assemble with pole bolts. Conduct HV test
on changed coil at 1.0kV for one minute and then tighten pole bolts with specified torque and tack weld to
lock it.
TORQUE IT WITH 80 KG-M

BOLTS M24, CLASS 12.9
LENGTH 140 mm
DO NOT INTER CHANGE ROTOR STRIPS PLACED BELOW THE

EACH POLE WITH ONE ANOTHER. AS THIS GOVERNS THE ROTOR
DIA VARIATION.
After the field coils are installed, the coils connections are to be completed and the rotor needs to be resin
treated in line with the instruction under reconditioning.
TRACTION ALTERNATOR
Dynamically balance rotor, after the final assembly of diode wheel components. Balance weight can be
added on support plate and on coupling face where provision is specially made for this. Balancing should be
done at 1100 rpm within 5 GMS of residual unbalance.
4.3.2.3 BEARING COMPONENTS
Examine outer bearing cap, shrink ring, bearing cap for any dents, score marks. If they are of minor nature
attend with a oil stone and rinse. If the damage is considerable same are to be replaced with new
components.
Examine the followings:
1. Flaking or cracks in the ball path. If found, reject the Bearing.
2. Heavy electrical pitting. If found, reject the bearing.
3. Raised craters around the edges. Stone off (do not file).
4. Mottled distributed pattern of dirt denting. Scrap the Bearing.
5. Evidence of rubbing or turning on the shaft. Look for loose Spacers or interference of the
housing parts. If rubbing is heavy or if there is wear on the shaft, reject the bearing.
Examine the outer race as follows:
Slide the outer ring by hand and if the ball drags, scrap the bearing.
Scrap the bearing if any of the following conditions are discovered on any of the bearing parts.
1. Severe scoring caused by inadequate lubrication.
2. Corrosive pitting caused by moisture or electrolytic action.
3. Break or crack (possibly caused by striking the shafts with a hammer during removal).
4.4 REASSEMBLY OF TRACTION ALTERNATOR
1. Fit the distance collar onto the shaft, if removed, ensuring that it is solidly up to the shaft abutment
face.
2. Fit the bearing by heating it to 100 to 110 °C and shrinking onto the shaft (if already removed),
when cold. Tap the race to ensure that it is solidly up to shaft abutment face. Put identification marks
on both the distance collar and shrink ring.

TRACTION ALTERNATOR
Rest of the procedure to be followed in reverse as described in clause no

9.1, and of course any other best practices can also be adopted depending
on the requirements.
STANDARD REFERENCE CONDITIONS
TEMPERATURE
These alternators are designed for an ambient temperature of 55°C. For marine and other applications where
the ambient temperature is greater than 55 °C, the alternators must be derated to ensure that the actual
temperature does not exceed the specified maximum, Outputs are normally quoted at 55 ° C. These outputs
must be multiplied by the following factors for higher ambient temperatures.
TEMPERATURE MULTIPLIER
(°C)
60 0.95
ALTITUDE
Above 1000m the effectiveness of the air is reduced sufficiently to make derating necessary. For altitudes
above 1000m outputs must be multiplied by the following factors.
ALTITUDES MULTIPLIER
1,500 0.97
2,000 0.94
2,500 0.91
3,000 0.88
3,500 0.85
4,000 0.82

TRACTION ALTERNATOR
HUMIDITY
Machines are tropicalised and can successfully operate in high humidity levels. Correct choice of the
insulating materials and careful assessment of the impregnation varnish system and methods achieve this.
5. ALIGN MENT PROCEDURE OF ALTERNATOR WITH DIESEL ENGINE
1. Rotate the engine freely one or more round complete before alignment.
2. Check the engine crankshaft endplay and note down the end play (x). This should be measured with help
of dial bore gauge. Once the measurement is done keep the crankshaft towards vibration damper end.
3. Check the TIR (Total Indicative Reading) of flywheel housing. The check is mandatory if the engine was
taken for rebuild and housing was removed.
4. Record dimension “a” by using vernier calliper.
5. Apply little grease on flywheel pilot bore, as the rotor slides in the pilot bore during assembly as a guide.
Preparing the alternator for alignment: -
1. This alternator being a single bearing alternator Never ever attempt to rotate the alternator rotor when it is
in uncoupled condition as this may damage the windings of rotor/ stator. Alternator is shipped with rotor
locked by shipping bracket.
2. Remove the shipping bracket and mount the flex plates comprising of 8 nos. (1.2 thk) on the rotor by 8 nos
hex head bolts M20X55 long and torque them to 100 lb-ft torque. Engage alternator fan with outer diameter
of coupling.
3. Place the hand-operated jack properly to lift up the rotor and measure the distance between the rotor and
stator frame. This should be considered to be accurate when measurement in all the directions is equal. This
exercise should be made with a view to make the rotor shaft horizontal to axis of the alternator/rear bearing.
4. Now measure the endplay of rotor by playing the rotor shaft from rear end, note this play as “y” and
finally keep the rotor pushed to the rear end.
5. Measure the dimension “b” with the vernier calliper and note.
Dim “a” stand for distance between alternator stator spigot face &
flex plate face, which is fixed on rotor shaft.
Dim “b” stands for distance between engine adopter spigot face &
flywheel face.

TRACTION ALTERNATOR
Shim selection:
1. if a> b then add up the shims between flex plate & Rotor shaft. These shims must have
thickness as, 0.1 mm, 0.25 mm, 0.5mm, 1.0mm, and 1.6mm.
2. Thickness of shims to be added :- (a-b) + (x+y)/2
3. Choose the thickness of shims nearest in multiples of 0.1mm so that both rotor and crankshaft
are at the centre of the travel in their bearing.
4. Two studs 5/8” unc x 100 mm long are to be fixed diagonally opposite in flex plate mounting
hole of engine flywheel.
5. Move/Tilt the alternator to locate studs that are fixed in flywheel, visibly with the holes in flex
plate.
6. 16 nos socket head cap screws M16X70mm to be used for holding stator frame of alternator
with adopter plate of engine with standard bolt tightening practice (diagonally opposite bolts).
7. Cummins supplied 2 nos out of 8no’s hex head bolt 1/2” unc x 3.5 inch to be inserted through
alternator fan, flex plate to flywheel. These bolts are to be partly tightened.
8. Both the studs are taken out safely through alternator fan.
9. Remaining all the 10 bolts are to be placed at vacated fixing locations. All the 12 bolts are to
be tightened at specified torque value followed by the standard tightening practice.
After assembly of alternator match the load characteristics.

If there is an abnormal change in the characteristics, then
attention is to be paid on the root cause.
6. PROTECTION OF BALL ROLLER BEARINGS
6.1 GENERAL
The ball bearing incorporated into CG Traction machines is of high quality and adequate capacity as
supplied by the leading bearing manufacturers. Every care is taken during assembly to ensure that
the correct fitting-tools are employed, and strict cleanliness observed, to achieve long and trouble-
free operation of bearings in service.
It is essential that equal care is taken of bearings, which may be subject to removal and replacement
during normal overhaul procedures, and of new bearings to be fitted when renewal is necessary.

TRACTION ALTERNATOR
Bearings seldom break down as a result of normal usage; the most common causes of bearing failure
can be traced to mishandling, damage or stress set up during fitting or removal, dirt, corrosion, and
over or under lubrication.
ALWAYS CLEAN BEARING COVERS, CAPS AND HOUSINGS BEFORE

REMOVING BEARINGS, AND USE CORRECT WITHDRAWAL AND
REFITTING TOOLS.
The following information is a general guide to the care and use of roller bearings. More detailed
literature is obtainable from the appropriate bearing manufacturers.
6.2 FITTING AND REMOVING BEARINGS
1) The use of a press or extractor is preferable than to a hammer and drift whenever possible. It is
also preferable to immerse bearing in oil at a temperature of 100 °C for 25-30 minutes, or place in an
oven under the same conditions.
2) If it is necessary to hammer the tool when removing a shaft nut or bearing retaining nut, always
firmly support the shaft, to avoid shock-loading the rolling elements or races.
3) Never strike a bearing directly with a hammer; a mild steel or brass drift or tube should be
interposed between hammer and bearing. The end of the drift or tube in contact with the bearing
should be squared off and free from burrs.
4) Check bearing housings for signs of race creepage.
5) When using presses, extractors or drifts for the fitting/removal of bearings it is essential that no
load be transmitted through the rolling elements of the bearing.
6.3 INTERCHANGEABILITY OF BEARING COMPONENTS
Roller bearing components must not be inter changed.
NOTE: Bearing failure can occur as a result of accidental or indiscriminate interchanging of bearing
components. The component parts of individual bearings must be kept together at all times and not
mixed with other, similar, bearings and bearing components.
6.4 CLEANING AND ANTI-CORROSION TREATMENT
A. General Treatment
Avoid the temptation to spin a bearing after it has been removed from an assembly, and before
cleaning; this is to avoid compressing hard particles, which may be present in the lubricant, thereby
initiating track defects.
B. Bearings which should not be cleaned

TRACTION ALTERNATOR
Do not clean bearings, which are to be returned to the manufacturer for defect examination; such
bearings should immediately be wrapped in grease-resisting paper and boxed.
C. Cleaning the bearings
The importance of cleanliness when dealing with bearings cannot be too highly emphasised. The
parts must be scrupulously clean to enable accurate assessment of serviceability to be made and, if
found to be serviceable, it is of equal importance that they be maintained in a clean condition for
subsequent build into the assembly.
To minimise the risk or corrosion by handling, it is recommended that, so far as is possible,

operators should wear protective gloves during and after the cleaning process.
Bearings or components incorporating bearing surfaces, must in no circumstances be left in a dry

condition, or unprotected against corrosion.
Tri-chloro-ethylene, carbon tetrachloride, or paraffin should not to be

used for cleaning bearings, as any of these agents can promote corrosion.
D. Cleaning Equipment
Where large numbers of bearings are to be processed it may be advisable to provide separate
cleaning, rinsing and inhibiting tanks of a size appropriate to the volume of work. Each tank may be
constructed of mild steel and should be equipped with a drain plug. Wire mesh baskets or platforms
should be provided to hold the bearings clear of sediment in the bottom of the tank. The inhibiting
oil tank should be heated to 90 ° to 100 °C (194 ° to 212 ° F).
1) Initial cleaning tank
The tank should contain an adequate quantity of white spirit / gasoline and should be drained,
cleaned out, and refilled with fresh liquid whenever approximately 100 bearings per gallon of liquid
have been processed, or when excessive contamination is suspected.
2) Second-wash tank
Also to contain white spirit / gasoline and to be topped up with fresh, clean liquid to replace drag-out
losses.
3) Inhibiting oil tank
The tank to contain inhibiting oil such as shell Ensis 100.
4) Mineral jelly tank

TRACTION ALTERNATOR
The mineral jelly must be maintained at 80 ° to 90 °C (176 ° to 194°F) and be periodically topped
up to replace drag-out losses.
The tank should be cleaned out and refilled with fresh mineral jelly whenever contamination is
suspected.
E. Cleaning and temporary inhibiting
To minimise the possibilities of corrosion on the bearing surfaces during cleaning and subsequent
inspection, it is recommended that bearings should not remain unwrapped for more than 4 to 5 hours
while temporarily inhibited. Bearings should always be immersed in a horizontal position in the
cleaning and inhibiting fluids to avoid the retention of air pockets. Rotate the bearings during the
cleaning operation.
The following sequence of operations is recommended and should be carried through with the least
possible delay between each operation.
1) Wash the bearings in the initial wash tank using a bristle brush to remove all dirt or old lubricant.
2) Remove the bearings from the wash tank and allow draining for 5 minutes.
After the initial wash, carbonised bearings may be soaked in hot mineral
oil (90 ° to 100 °C, 194 ° to 212 °F); agitating the bearings slowly, from
time to time. Badly carbonised bearings may be cleaned in a strong
alkaline solution; see the appropriate manufacturer's instructions.
3) Completely immerse and wash the bearings in the second wash tank.
4) Remove the bearings from the tank and allow draining for 5 minutes.
5) Immerse the bearings in the inhibiting oil tank for temporary protection against corrosion.
6) Remove the bearings from the oil and allow thoroughly draining and cooling in still, dry, dust free
air.
At this stage, the bearings should be examined for Defects; however, if

some delay between cleaning and examination is unavoidable, the
components should be wrapped in grease resisting paper.

TRACTION ALTERNATOR
F. Treatment of new bearings
New bearings should not be removed from the package until immediately before fitting. It is
preferable to remove the preservative from the rolling members and race surfaces by immersion in
the inhibiting oil tank as in E5 and 6.
G. Treatment after inspection
After inspection, again wash and inhibit the bearings as described.
If the bearings are not immediately required for fitting they must be wrapped in grease-resisting
paper or unsealed polythene envelopes. Bearing may be stored in this condition for up to 14 days.
Bearings to be stored for longer periods should be treated as follows: -
1) Totally immerse the bearings in the mineral jelly tank for approximately 10 minutes.
2) After cooling, dip the bearing a second time into the mineral jelly, remove immediately and wrap
the bearing In grease-resisting paper. Store in a dust tight box.
6.5 INSPECTION
After cleaning, bearings should be thoroughly inspected together with associated components, such
as seals. The housings and shafts from which the bearings have been removed should also be
examined. Thoroughly examine each bearing for visual defects such as rust and discoloration,
cracks, wear, indentations and bruising, and track defects. Bearings associated with electrical
machines may sometimes be found to contain craters or pits caused by electrical arcing. The craters
will have a centre of black, fused, metal. Unless the damage to the rolling element or track is
slight, bearings should be rejected.
A. Rust and corrosion
Rust on the rolling elements is not acceptable and the bearing should be rejected. Very light
corrosion pitting on the races may be accepted, depending upon the speed and loading of bearings.
B. Discoloration
Slight discoloration of the rolling elements or tracks is acceptable, but if the components turn blue or
brown, indicating excessive heat, the bearing must be rejected.
C. Cracks and fractures
In all cases, the bearing must be rejected
D. Flaking
Flaking appears when fragments of material have broken away from the bearing track. Subsequent
wear in the bearing due to increasing stresses is accelerated. Then bearing must be rejected.
E. Smearing

TRACTION ALTERNATOR
Smearing is the result of the balls or rollers sliding rather than rolling in relation to the tracks ocage,
causing incipient seizure. The bearing should be rejected.
F. Wear
Excessive wear does not occur during normal operation of the bearing. It is generally the result of
misuse in fitting, external vibration when the machine is stationary - causing local shock-loading via
the rolling elements of the bearing, or the ingress of dirt, inadequate or incorrect lubrication is also a
contributory factor.
Non-operating surfaces
(a) Light rust may be removed with fine abrasive cloth, and the bearing thoroughly re-washed as
described Shafts and housings The shafts and housing associated with bearings undergoing
inspection should be examined for defects. Pick-up or scoring on surfaces, which make contact to the
bearing must be rectified by stoning or dressing.
Surfaces, which are worn below the drawing limits, should be built up if possible or the shaft or
housing renewed.
7. LONGITUDINAL SECTIONAL VIEW
Longitudinal section of Traction Alternator

TRACTION ALTERNATOR
NOTES
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CHAPTER V
POWER RECTIFIER
1. BRIEF SPECIFICATIONS
2. FUNCTION OF THE RECTIFIER UNIT
3. DESCRIPTION OF THE RECTIFIER UNIT
4. PRE INSTALLTION CHECKS AND COMMISSIONING
5. MAINTENANCE
6. LIST OF COMPONENTS
Maintenance Manual
POWER RECTIFIER
CHAPTER V
POWER RECTIFIER
1. BRIEF SPECIFICATIONS
The Rectifier Unit Conforms to ICF spec. No. ICF/M/D/SPEC-349 R0 as per following brief specifications.
1. Rectifier Type : 3 Phase Natural Air Cooled Bridge type

2. No. of Bridge in Parallel : Three Nos.
3. Max. Continuous current : 750 Amps. D.C.
4. Max. One hour rating : 1000 Amps. DC
5. Starting Max. Current for 5 Min : 1200 Amps. D.C.
6. Max. Output voltage : 900 V.D.C.
7. Max. Ambient Temp. : 47C
8. Cooling : Natural Air Cooling
9. Mounting of Rectifier : On Board
10. Dimensions mm. (H x L x W) : 1350 x 800 x 450 without side panels
11. Weight : 270 Kgs. Approx
The On-Board mounted Rectifier Unit has been designed to feed the Traction Motor load of the SPICAC. It has
been designed to work on 660 Volts max, 3 Phase, 3 Wires AC Input supply derived from underslung alternator.
The Rectifier Unit has been designed to withstand shocks and vibrations encountered in service of a rolling
stock. It rectifies the three-phase AC voltage into a DC voltage. The equipment meets the requirement of IS:
7788.
2. FUNCTION OF THE RECTIFIER UNIT
The function of the Rectifier is to convert a three-phase supply into DC Voltage, for driving Traction Motors
connected in parallel across the Rectifier. Each of the three bridges are protected by Semiconductor grade Fuses
at the input. In case of a diode failure, the particular bridge is isolated by its fuses. The other two bridges
continue to supply the full load current to the Traction Motors. Hence, n-1 redundancy is built-in. Each of the
Main fuses have a smaller fuse called trip-fuse connected across it. When the Main fuse blows the fault current
is diverted to these trip fuses. These in turn clear the fault current and in the process operate a plunger, which
hits a Micro-switch. This condition stays latched and can be reset only by replacing the Main Fuse and the Trip
Fuse. The potential free N/O & N/C contacts of the Micro switches in turn operate a Contactor to give an
indication in driver’s cabin that a Fuse has blown. In a similar manner failure of a second bridge is indicated by
the operation of a second Contactor. In this condition the Control Circuit of the SPIC must reduce the maximum
load current. A single bridge will no longer be able to carry the full load current of the Traction Motors.
Suitable corrective action must be taken. The Rectifier is protected at the input and the output by suitable
Damping Circuits.
The Rectifier is cooled by natural air through the fins of the Heat Sink.
POWER RECTIFIER
3. DESCRIPTION OF THE RECTIFIER UNIT
The Rectifier has an AC Input and the DC Output terminals are on front bottom side. The draws natural air from
the engine compartment from top and pushes down through the fins of the Heat Sink and is discharged to the
atmosphere through bottom floor.
The side panels of the rectifier unit are made of MS with backup of FRP sheet on inner side for creating higher
creepage path with live terminals of the unit. These are bolted to main frame.
AC & DC Power Terminals (busbars) are accessible by opening front lower panel and CT & PT Terminals are
accessible by opening rear lower panel.
The Diodes and Fuses are accessible by removing front upper panel. The arrangement is as shown below.
D10 D11 D12

FR1 FY1 FB1 BRIDGE ‐ 1
D1 D2 D3
D4 D5 D6
D13 D14 D15
D16 D17 D18

D7 D8 D9
Diodes D1 to D9 – Type OSD 595 N36SQ (With Red cover sleeve)

Diode D10 to D18 – Type OSD 595 P36SQ (With Blue cover sleeve)
FR – Fuses 725 A, 1000 V

POWER RECTIFIER
4. PRE INSTALLTION CHECKS AND COMMISSIONING
4.1 RECEIPT INSPECTION
To facilitate transportation, the rectifier unit should be packed thoroughly in wooden crate. On receipt the crate
shall be checked for any damage. Any visible sign of damage should be reported to us. After unpacking check
the unit internally & externally for any visual damage. Any damage if found, should be reported to us.
.
During the period of unpacking and inspection it must be seen that the unit is not damaged. After unpacking
Insulation Resistance and HV Breakdown tests may be performed if necessary.
4.2 INSTALLATION
The Rectifier Unit should be lifted and placed in position using the 4 lifting eyebolts that fitted on top side of the
unit. Rectifier Unit should be fixed by the 4 mounting bolts and nuts.
Then connect
a. Input and output cables to the respective terminals

b. Control cables to the control terminal board
4.3 COMMISSIONING
The unit must be subjected to routine checkup including checking of the relevant connections. One has to go
through the technical particulars and general feature sections. After checking all the details the Rectifier Unit is
ready for use.
Before applying Main AC Power to rectifier, following procedure to be followed.
Now unit can be energized with 3 Phase AC Supply.
Initially the load may be at half the value for few hours. Check all the components and joints for any abnormal
heating or temperature rise or failure. The Load may be gradually increased, in steps till full load is reached. It
is suggested to report any abnormal behavior to the manufacturer.

POWER RECTIFIER
5. MAINTENANCE
Although due to sufficiently rated quality components and material very low maintenance is required for the
unit, but following steps will help in giving trouble free service.
Atleast once a month open the side panels and clean the dust & soots collected on panels and within the unit with
dry compressed air or any other suitable means
Check all electrical connections and mechanical assemblies. If found loose, refit it.
Check healthiness of rectifier fuses. Failure of fuse will be indicated by ejected plunger of corresponding Trip
Indicator Fuse. If found blown, replace both main and trip indicator fuse after rectifying cause of fuse failure.
Clean the Insulators with cloth / brush.
Check conditions of resistors and capacitors. Replace if found damaged.
In case of failure of diode, please follow following removal & refitting procedure.
Removal of Diode
Unscrew the lead of diode from busbar.
Remove the diode by removing the Allan bolts using suitable key.
Clean the diode with clean cloth. Check its healthiness. If found defective, use new one to replace it
Mounting of Diode
Clean the base of diode with clean cloth.
Apply a thin layer of silicon oil or good quality contact grease
Clean the surface area of heatsink on which diode is to be placed.
Using same/ same size Allan bolts refit the diode. Initially tighten bolts alternately half to one turn at a time so
that diode is clamped with equal force all over. Finally using torque wrench complete tightening of the bolts. The
specified torque limit is 1.7 to 2 KN.
Connect the end of lead on busbar.

POWER RECTIFIER
6. LIST OF COMPONENTS
Qty./Unit
S.No. Item & Type Manufacturer
(Nos.)
1 Rectifier Diode Type OSD 595 P 36SQ RUTTONSHA 09
2 Rectifier Diode Type OSD 595 N 36SQ RUTTONSHA 09
3 Heatsink Type HT350, 200 mm. long RUTTONSHA 09
4 Hole Storage Capacitor 0.47 MFD / 2000 V GE/ ICAR 18
5 Semiconductor Fuse 725A, 1000 V Type 170L 9598 BUSSMANN 09
6 Trip Indicator Fuse Type TI-1200 GE/BUSSMANN 09
7 Microswitch Type : 2K3B033018, 2 C/O KAYCEE 18
8 Diode Type A3FMR160 for fuse blow supervisory circuit RUTTONSHA 12
9 D.C. Contactor Type: MN022E - 110V.D.C Coil L&T/ SIEMENS 02

Potentiometer 10K, 1W, 10T (Type 3590) for fan speed
10 BOURNS 01
Control
GILBERT
11 Resin Cast Current Transformer 1000 / 5A Type RCT01 01
MAXWELL
12 Resin Cast Potential Transformer 1000 / 125V Type RCT01 01
13 Fuse Link 2A , 415VAC Type NSD 2 BUSSMANN 01
14 AC Damping Capacitor 25 MFD / 660 V ICAR / GE/ YASH 12
15 DC Damping Capacitor 10 MFD / 500 V ICAR / GE 04
16 Earthing Capacitor 0.1MFD 1200VAC Type FMD 52 El-Ci_Ar 24
17 AC Damping Resistors 5 Ohm / 300 Watts W/W 03

IRESCO/PEC/
18 DC Damping Resistor 2 Ohm / 200 Watts W/W SURE/ KIYOSH 01
19 DC Damping Resistor 50 KOhm / 50 Watts W/W 01

POWER RECTIFIER
NOTES
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CHAPTER VI
TRACTION MOTOR
1. GENERAL INFORMATION
2. TECHNICAL DATA
3. CONSTRUCTION
4. ERECTION AND COMMISSIONING
5. MAINTENANCE AND INSPECTION
6. RECONDITIONING AND REPAIRS
8. TROUBLE PHENOMENON AND REMEDIES
9. INSPECTION SCHEDULE
Maintenance Manual
TRACTION MOTOR
CHAPTER VI
TRACTION MOTOR
1. GENERAL INFORMATION
The traction motor type TM2141C is a four pole self ventilated machine with a built in fan for DEMU / DETC
(Diesel Electric Multiple Unit / Diesel Electric Tower Car) Application. The machine is mounted on the Axle
with the help of taper roller suspension bearings. The general information about the traction motor is as
illustrated below.
Model : TM2141C
Type : Self-Ventilated
Field : Series Field with Commutating Poles
Field Strength : 100%
Continuous Rating : 187 kW (input), 600Volts, 340 Amps,
1520Rpm, (100% Field Strength)
Application Rating : 111 kW (Input), 327 Volts, 340 Amps,
(Continuous) 840 Rpm, 100% Field Strength
Reduction Gear : Single Reduction (91/20)
Clearance between Gear : 140 mm
case & top of rail with new
wheel diameter.
1.1 FEATURES
– The tractive effort is transmitted from the traction motor to the axle through a single reduction gearing.
– The traction motor is of the Self-ventilation system with the built in Fan sucking air through the Filter
Ducting Arrangement.
– The traction motor is of four poles, series wound with commutating poles.
– The Armature and Field windings are of class 200 insulation.
– The tungsten inert gas (TIG) welding is used for connecting Commutator riser to Armature Coil Leads
for better reliability.

TRACTION MOTOR
2. TECHNICAL DATA
The maintenance of the traction motor should be conducted with respect to the following technical data:
2.1 SPECIFICATIONS
a. Model number : TM2141C

b. Type-form : Enclosed, Self-ventilated type
Series excitation with commutating poles
c. Poles : 4
d. Insulation Class : Class-H
e. Continuous Rating : 187 kW, 600 V , 340 A, 1520 rpm
2.2. RESISTANCE VALUES : At 20°C At 115°C
Armature winding : 0.0114 Ω ± 5% 0.0156 Ω ± 5%

Series field winding : 0.0128 Ω ± 5% 0.0176 Ω ± 5%
Commutating pole winding : 0.0084 Ω ± 5% 0.0115 Ω ± 5%
2.3 ARMATURE DETAILS
Core diameter : 406.4 mm

Core length : 330 mm
Brg. to Brg. distance : 795.00 ± 0.20
(Outer face of Distance Collars)
2.4. ARMATURE BANDING
Material : 0.33TK x 25 wide (Glass Banding Tape)

Turns on PE winding : 100 Nos. Approx.
Turns on CE winding : 100 Nos. Approx

TRACTION MOTOR
2.5 ARMATURE BEARINGS

Pinion side Commutator side
Type of bearings : NU324EMC4 NH314EMC4
Manufacturer : SKF/FAG SKF/FAG
or Equivalent or Equivalent
Radial clearance of free : 0.125/0.165mm 0.090/0.125mm

bearing when new (internal)
2.6. COMMUTATOR
Diameter when New : 280 mm

Minimum usable Diameter : 260 mm
Mica thickness : 1.0-mm nominal
No. of Commutator Bars : 200 Nos.
Avg. Voltage between bars : 12 V.
Reactance Voltage : 2.3 V at Cont. Rating
3.8 V at Max Speed, Max Voltage Point
2.7. CARBON BRUSHES
Numbers per brush holder : 2.

Brush grade : EG14D
Brush type : Split
Brush size : 20 mm x 40 mm Split x 57 Lg.
Brush spring : Max.3.2kg/brush
Pressure Min.2.8kg/brush
Brush wear limit : Brush rejection length is 32 mm
2.8. BRUSH HOLDERS
Number per motor : 4

Clearance bottom of brush : 3 mm Nominal
holder to commutator
Sparking tip gap : Adjustable, Nominal 12mm

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2.9. POLE BORES (AVERAGE)
Main pole (at center) : 420.12 mm (Nominal air gap = 6.86mm)

Commutating pole (at center) : 412.20 mm (Nominal air gap = 2.90mm)
Tolerance allowed on the Pole Bore Dim is ± 0.2 mm.
2.10. LINER AT BACK OF POLE
Main pole : 1.0-mm nominal (Magnetic steel)

Commutating pole : 4.6 mm brass + 2.1 Mag. Steel
2.11. GEAR CASE
Initial charge of Lubrication : 6.5 Kg Max.

3.5 Kg Min
Type of Gear-case compound : HP Gear tak 2. or

Bharat Camex Compound .F
2.12. WEIGHT
Motor with pinion : 1800 kgs.

Armature : 600 kgs.
Gera Wheel : 150 kgs.
Gear case : 90 kgs.

TRACTION MOTOR
TRACTION MOTOR TYPE TM2141C

LONGITUDINAL SECTION DRAWING

TRACTION MOTOR
3. CONSTRUCTION
The basic construction of the traction machine is illustrated in the Longitudinal section drawing indicating the
components used. The motor construction can be divided under the following heads.
1) Armature
2) Stator with coils & End-frames
3) Suspension Bearing
4) Gear-case, Gear, Pinion etc
3.1 ARMATURE
ARMATURE SHAFT
The shaft is manufactured & ground from Ni. Cr. Mo. Steel to BS 970 EN-25 "V" Bars forged material, which is
ultrasonically tested to avoid any flaws in the raw material for better reliability.
ARMATURE CORE
The Armature core is built up of coated electrical sheet laminations to reduce the eddy current losses.
ARMATURE END-RINGS
The Cast Steel Armature End-ring supporting the Core at pinion end has a mounted lightweight Fan for
ventilation. The material of the armature end-ring is forging for withstanding the load. The End-ring on the
commutator end is also manufactured from the Forged Material. The fan sucks the air from the commutator end,
which travels from the armature core through the End-rings & escapes from the openings provided on the pinion
end.
COMMUTATOR
The Commutator is built up with silver bearing copper Commutator bars with the alkyd vinyl bonded mica.
Commutator Hub & Commutator End-ring are of forged type. The anti-creepage PTFE Sleeves is fitted on the
exposed portion of the Steel Vee-Ring.
ARMATURE WINDING
The armature winding is lap wound type providing four parallel paths. The armature power coil conductors are
kapton-covered conductors for better performance. The armature is insulated & wound with class "H" insulation
TRACTION MOTOR
material. The resi-glass banding at both the overhang portions is done with the banding machine under tension.
Complete wound Armature is subjected to Vacuum Pressure Impregnation (VPI) in solvent less polyester resin.
The Armature Coils are held in the slot portion with the help of slot wedges.
EQUALIZER WINDING
The equalizer winding provides for 50 % Equalization.
ARMATURE BEARINGS
For the armature bearings installed at both commutator and pinion sides, a sealed type cylindrical roller bearing
with an additional advantage of intermediate grease refilling systen is employed. At the commutator side, Type
NHJ314EMC4 roller bearing is used and at the pinion side, type NU324MC4 is used. These armature bearings
can be operated for 3 years duration without dismounting.
ARMATURE BEARING COMPONENTS
The armature bearing-greasing labyrinth consists of forged bearing components accurately machined. The extra
firm variety felts are provided in the grooves of the end frames to prevent the lubrication leakage. The distance
collars at both the ends are shrink fitted, for the adequate location of the armature roller bearings. The grease
thrower at the Pinion end is shrink fitted outside the Bearing Cover P.E for protection against the ingress of
dust/Gear Case Compound.
3.2 STATOR
MAGNET FRAME
The magnet Frame is of casted type, with the terminal box provision for the main lead terminations. The frame
pole pads are machined accurately to avoid any variations in the pole bores thereby affecting the air gap. The
magnet frame is provided with a bracket for vertical mounting of Gear-case which also provides support to the
top half of Gear-case.
MAIN POLES
The main pole cores and coils are potted to the core with solvent-less polyester resin for better performance &
mechanical endurance. The Main Pole coil is of flat wound type with the frame side coil with 10 turns &
armature side coil with 9 turns. The coils are connected by brazing. The two open coils (N-pole) have the
terminals integral with them whereas the two crossed coils (S-poles) have terminals brazed with them. The main
pole field coils are of construction as illustrated in the fig.

TRACTION MOTOR
COMMUTATING POLES
The Commutating pole core and coils are also potted with solventless polyester resin. The Compole coil is of 16
turns wound edge-wise. The terminals & connectors are of robust design to avoid the failures under
vibrations/impact. The Compole connections are made from the flexible cables.
BRUSH HOLDER AND CARBON BRUSHES
This motor is 4-pole type motor and the brush holders are mounted on the frame pads by bolting arrangements.
The brush holders and carbon brushes can be inspected by inspection windows provided. The brush holders are
mounted on the frame pads by two insulating rods. The Brush Holders are manufactured from High tensile Brass
castings. The Carbon brushes of EG14D are of split type for smooth commutation.
END-FRAMES
The end-frames at both the ends are of Cast steel with the P.E. end-frame having the provision of integral arm
with the body for supporting the gear-case.
TERMINAL BOX
The terminal box has been provided in the centre location. The crossover line is fixed to the insulating rod and
lead supporter is used at the outlet of lead wires on the fitting-out side. On the reverse of the terminal cover, the
packing is stuck to prevent dust from coming into the terminal box. Four Main cables come out in the terminal
box which are connected in the sequence of A, AA, FF, F, E when viewed from the front with the Pinion side on
the right side & commutator side on the left.
3.3 MOTOR SUSPENSION ARRANGEMENT
The Motor Suspension on axle consists of taper roller bearings and suspension tube. The suspension tube
arrangement replaces the traditional use of axle caps & also avoids frequent maintenance. The use of taper-roller
bearings in the suspension arrangement allows the motor to run at high speeds.
3.4 GEAR CASE, GEAR WHEEL & PINION
GEAR CASE
The gear compound is filled from the inspection cover installed on the gear case. The Gear case is fabricated
type with the assembly in two halves i.e top & bottom half for ease in assembling & dis-assembling. The Top
half of gear-case is vertically supported and mounted on frame and end-frame arm PE. The bottom half is
horizontally bolted with frame and mounted on end-frame arm on PE side.
TRACTION MOTOR
EARTHING LEAD ASSEMBLY
The earthing lead assembly is installed on the M8 tapped hole provided on the Magnet Frame.
GEARS & PINIONS
The gear & pinions are manufactured by BS 970 En 354 Case carborised steel conforming to RDSO Spec.
MP280009. The gears & pinions are machined in accuracy grade of 6 of BS 235:1987. The gear ratio of 20:91
has been adopted to suit the requirements of the Diesel Electric Multiple Unit application. The Bellow
arrangement provides the inlet for the air through the Commutator end, which escapes through the Pinion end.
3.5 EARTH BRUSH AND EARTH BRUSH HOLDER
The earth brush holder is installed in the terminal box of the magnet frame. The earth brush is made of metallic
carbon and pressed to the axle by the coil spring.
4. ERECTION AND COMMISSIONING
4.1 COMMISSIONING PRE-CHECKS
Before the motor is mounted on the bogie there are certain checks which need to be performed to assure a
reliable service in future. They are mentioned as underneath:-
4.1.1 LIGHT RUN OF MOTOR AT 1000 RPM
Subject the motor to a light run for 30 minutes to check that it runs freely and with quiet bearings. Also record
the Bearing temperature at both the ends. The vibration level of the motor should also be within the permissible
values of 30 microns.
IT IS NOT ADVISABLE TO RUN BEARINGS AT HIGH SPEED UNDER

LIGHT LOAD CONDITIONS FOR LONG PERIODS BECAUSE OF THE
POSSIBILITY OF ROLLER SKID, WHICH MAY CAUSE SCUFFING OF
THE TRACK AND ROLLER SURFACES.
The motor shall be subjected to a run at no load as per the test schedule & corresponding voltage & current shall
be recorded, the readings must be comparable to the values declared in the test results.

TRACTION MOTOR
4.1.2 MEASUREMENT OF INSULATION RESISTANCE
The Insulation Resistance of the windings of the motor (complete) shall be recorded with 1 kV Megger. In no
case the IR Value should be less than 50 Mega-Ohms. In case the value is below the recommended value, the
individual windings should be separated & IR value of individual windings should be checked.
4.1.3 MEASUREMENT OF COLD RESISTANCE
The cold resistances of the different windings i.e. Armature, Main Pole and compole windings should be
measured with the help of the VI method and the variations in the values shall not be more than 5% of the
nominal prescribed values. The Armature winding resistance is measured across the 30 Commutator bars through
the inspection window and then the resistance so obtained is to be multiplied by (50/30) = 1.667 to get the
complete Armature winding resistance.
4.2 ASSEMBLY AND ERRECTION
As regards the assembly of the various other components on the traction motor i.e. Gear case, Pinion and locking
plate, Earthing Brush assembly etc., refer to Reconditioning and Repairs. The Earth lead assembly is to be
fixed along with the copper washer & M8 bolt on the M8 tapped hole provided on Top of the Magnet frame.
5. MAINTENANCE AND INSPECTION
These checks are to be performed in the condition where the main motor has been installed on the truck.
5.1 BRUSH HOLDERS AND CARBON BRUSHES
The brush holder and carbon brush are important components in particular and have a great effect on
commutation. It is therefore necessary to always perform correct maintenance for obtaining normal operation.
If dust worn powders of carbon brush etc. enter between the holder case pocket and carbon brush and the motor
is operated in the sticking state of carbon brush poor contact with the commutator surface is caused and results in
poor commutation and/or flash-over from time to time. Therefore, in the check of brush holder, blow out the
holder case pocket with air and wipe with a dry cloth carefully.
Contamination of surface of insulating rod may cause a creeping short-circuit. So it should be cleaned by white
gasoline-infiltrated rag as frequently as needed.
In case that the surface of insulating rod has been roughened by flashover etc. correct with emery paper and
clean. If the surface is heavily damaged and cannot be corrected by emery paper and also, crack or seizure is
found in the insulating rod, replace with new one.

TRACTION MOTOR
The carbon brush in the traction motor is tilted, clearance between holder case pocket and carbon brush increases
in the revolution. So, check to see as required that the pocket dimension of brush holder case and carbon brush
dimension are as specified. If the pocket is found worn beyond the maximum wear limit, replace it with new one.
The quality (material) and shape of carbon brush have a great effect on commutation therefore the specified one
must be used without fail. If any carbon brush of different material is used then, it may cause poor commutation,
unusual wear, damage of commutator surface etc. So never use any carbon brush made of different material from
that in use.
Brush Holder: Side view

TRACTION MOTOR
Brush Holder: Top view
Check if the carbon brush has such length that it can be used sufficiently till the next check.
Check for Crack in the Carbon brush.
There shouldn’t be break of the pigtail (lead wire of carbon brush).
There shouldn’t be any looseness, drop-off etc. in the tamped part of pigtail.
The-carbon brush shouldn't be left seized in the holder case pocket.
Contacts of the carbon brush and commutator should be proper in condition.
If the carbon brush can no longer be used till the next check because of wear, replace it with new one. If the
dimension is found equal to 37 mm during the check of carbon brush, it may wear down to 32 mm-wear limit,
before the next check comes round. All such carbon brush should be replaced.

TRACTION MOTOR
Carbon Brush
After inserting the carbon brush into the pocket of brush holder try to move the carbon brush up and down and
make sure that it moves smoothly.
When setting the brush spring after inserting the carbon brush into the brush holder be careful so that the lead
wire (pig tail) of carbon brush is not caught by the spring.
When the worn out carbon brush has been replaced with new one, make slide fitting so that the carbon brush
contacts the commutator surface correctly. For making slide fitting of the carbon brush, move emery paper along
the commutator surface with the sand side of the emery paper applied to the brush and repeats this procedure a
few times.
HANDLE GENTLY IN MAKING SLIDE-FITTING TO AVOID DAMAGE

TO THE COMMUTATOR SURFACE.
After completion of the slide-fitting blow away brush powder with compressed air.

TRACTION MOTOR
Tighten the terminal bolts of carbon brush lead wires securely.
The brush holders are fitted on the Magnet frame Brush gear mounting pads. Carbon brushes can be inspected
through the Inspection Cover openings provided on the frame. The latch type inspection covers provides access
to the brush holders.
DO NOT RELEASE THE BRUSH SPRING FROM HAND SUDDENLY

OR DO NOT DROP THE SPRING OFF THE SPRING SUPPORT. THIS
MAY BREAK THE CARBON BRUSH.
5.2 COMMUTATOR
As long as commutator is operated in good condition a film with a certain luster is formed on the
commutator surface. However, if a brush made of different material is used or dust gets on the surface,
ideal film won’t possibly be obtained. Unless otherwise wear of the brush, rough surface of the
commutator, stepped wear of the commutator, etc. are caused, there is no need to be concerned about the
film on the commutator.
Moreover, if such abnormalities occur, perform the maintenance of commutator. Moreover, after turning
the commutator the gap between the commutator and brush holder shall be ensured by shifting the
support block for the brush gear assembly towards the commutator side along the oblong hole provided
in the support block and then ensuring the torquing of around 12kg-m.
The securing block is welded on the brush gear mounting pads on the traction motor magnet frame
which become integral with the magnet frame. Also the securing block and the support block have
serrated faces (16 T.P.I) for ensuring proper grip.
The anti-creepage PTFE coated support spindles support the brush holders on the support block. Also the
sparking tip arrangement is provided on the brush holders and end frames with a nominal gap of 12 mm.
The dimension of the center line of the carbon brush from the top of the serrations of the securing block
is critical and should be maintained as shown in the fig.

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5.3 GEARCASE AND LUBRICATION
The maintenance checks of gear case and gear lubrication oil should be made placing importance on the
following aspects:
Open the Oil filler cap & check the Gear compound level.
Gear Case – Bottom half
When checking the Gear Compound level, if it is checked immediately after stop of the train, it will be
felt as if the gear compound is short. So, check the level after 20 to 30 minutes have elapsed, so that the
complete compound collects in the Gear case.
When supplying the compound, heat it to 60 – 80 °C (so that it can flow smoothly)
After the gear oil has been supplied, keep it for 20 to 30 minutes with the motor left in its stationary
state, and then check the compound level.
Check to see that there is no leakage of the gear compound. If any leakage of the gear compound is
discovered or consumption of the compound is considerably heavy, the felt sealing of gear case might
have worn off. So, check for drop - off of the sealing by removing gear case.
Check for obstructions of the breather. If it is discovered clogged with something, blow it out with air.

TRACTION MOTOR
Gear Case – Top half
Check for looseness of the gear case mounting bolts and for cracks in the gear case.
5.4 GEARCASE CHECKING
During the first few weeks in service, check the level of lubricant every week on several vehicles
and look generally for any sign of leakage. All checks should be carried out with the Gear case
warm after a run, but after allowing a short period to settle the lubricant. Continue these weekly
checks until the lubricant level has fallen to the minimum permissible as indicated by the dipstick,
note the time lapse. The shortest time interval on the representative batch of vehicles may be used
as a basis for the lubrication schedule, after allowing a safety examination. Thus, if the shortest time
interval is two months, specify topping up at monthly intervals.
5.5 ARMATURE BEARINGS
Since the armature bearing is an important mechanical part, it must always be kept in good
lubricated state. For this, a regular maintenance is essential. In the routine check, check for unusual
sound, oil leak etc. during rotation of the bearing and re-supply grease every year. At the time of
overhaul, exchange the whole grease.
SOUND OF BEARINGS
a. In the operation, always pay attention to the working sound of the traction motor and if any
unusual sound and/or vibration are observed, stop the operation immediately, dismount the motor
and look for the real cause carefully.

TRACTION MOTOR
b. When the traction motor is removed from the truck be sure to perform the running light test of the
motor and check for unusual noise. Check for the noise applying a noise detector bar to the outside
of side cover nearest the bearing at both pinion and commutator sides. In this case even for other
few motors check for noise. When comparing the working sound of these motors with each other, it
can be judged easily whether the sound is different from the usual one.
5.6 REFILLING OF GREASE
a. The grease to be refilled intermediately should be of the same kind as that used
in assembly.
b. The intermediate refilling intervals and the amount of grease refilled should be
as described in the Chapter Reconditioning and repairs.
5.7 EXAMINATION OF GEARS
Whenever a gear case is removed from a motor, examine the gears carefully. They should be coated
uniformly with lubricant, which should show no sign of being contaminated with dirt or water.
If the gears are to re-enter service immediately clean thoroughly using xylol or a similar solvent
applied with a brush. Wipe with a cloth afterwards. If the gearwheel is likely to stand for a time,
clean only ten to twelve teeth spaced equally round the periphery, leaving lubricant on the reminder
of the gearwheel as protection. After examination, if the condition of these cleaned teeth is
satisfactory, recoat them with gear compound.
The teeth should be free from cracks and the flanks should have a uniform, unscored polished
appearance. The tooth profile should be substantially the same as that of a new gear. If a gearwheel
has chipped, broken or badly worn teeth discard it and fit a new gearwheel.
Ensure that, as far as possible, gearwheels are returned to service with the pinions with which they
were meshed originally. Do not over fill the gear case, which may flood the PE armature bearing
and cause premature bearing failure. Use the opening provided on oil filler unit for measuring the
maximum lubricant level.
ENSURE ALSO ON NO ACCOUNT, LUBRICANT LEVEL GOES BELOW

THE MINIMUM LEVEL. USE DIPSTICK FOR MAINTAINING
MINIMUM LEVEL.

TRACTION MOTOR
Gear and pinion is to be critically examined before allowing them further for service.
PRECAUTIONS
Whenever a gear or pinion wears significantly there is step created near the root of the tooth where the
tip of the mating tooth runs out of engagement. If the gear center distance is exactly correct, this step
will occur at the lowest point of contact between the mating teeth. However the gear center distance
cannot be controlled exactly in service due to axle bearing wear. As the gear center distance spreads, the
teeth become further out of alignment, this forms step at varying depths.
If the same gearings are used there will be very severe tip loading of the tooth and very poor profile at
the root end of the tooth. This can cause severe noise, vibration and premature failure. The step is to be
dressed up with the help of small hand grinder. Care should be taken during the grinding operation not
to under cut the tooth. Step should be removed before checking the profile of the tooth by profile gauge
otherwise faulty readings will occur.
GEAR TOOTH WEAR
Gear tooth wear is measured by scaling the width of the land or tip of the tooth. The gear wheel and
pinion should be removed from service when width at tooth tip or maximum wear per flank measures
less or more respectively than the following limits:
Gear Wheel Pinion

Min Tip Width Max. wear per Min.Tip Width Max. wear per
flank flank
1.8 mm 1.8 mm 0.8 mm 1.8 mm
PROFILE DEVIATION LIMIT
The maximum profile error on any worn gear wheel when checked by a profile checking gauge should
be within 0.2 mm to 0.4 mm Gears/Pinions having more deviation in profile than above should not be
used.
Feeler gauges of .05, .1, .15, .2, .25, .3, .4 mm thickness may be required for this purpose. Profile
checking gauges can be made as per the instructions given below:
Instructions for Making Gear Tooth profile gauge (using a new gear as a pattern)
1. Be sure that the gear used as a pattern is new. The gauge can only be as accurate as the gear from which
it is made. The gear should be thoroughly cleaned before using as a pattern.
TRACTION MOTOR
2. Make a "partial" mould. The gear itself will complete the mould.
3. Wax all surfaces, which will receive the moulding compound with silicone wax CP mould release. This
material is made by the Chemical Development Corporation 53 endicott St. Danvers, Mass U.S.A.
4. Lay the pinion or gear on a flat smooth waxed surface with the bore vertical. If a table is not available
make a flat plate and clamp it to the side of the gear or pinion.
5. The pinions are made with tapered teeth that are the tooth is thicker at the outboard (small-bore) end
than at the inboard (large bore) end. The pinion should be laid on the flat surface, with the outboard
(small-bore) and face down. Thus the gauge will be moulded to fit the thicker end of the tooth.
6. Place the partial mould in position against the tips of the teeth. Make sure that all the surfaces that will
contact the moulding compound have been coated with wax as described. The partial mould and the
pinion should be clamped in position with "C" clamps to prevent anything from disturbing their position
during the hardening process.
7. Mix eleven (11) parts of Ren Die Surface Coat RP-3260-B with one (1) part of Ren die Surface Coat
Hardner RP-3260-B by weight. These materials can be obtained from Ren Plastic Inc. P.O. Box. 1256,
Lansing 4, Michigan, U.S.A.
8. This is a modified epoxy resin which has a pot life of about 30 minutes at room temperature after the
hardener is added.
OBSERVE THE PRECAUTIONS STATED ON THE CAN, ESPECIALLY

AVOIDING ANY CONTACT WITH THE SKIN.
9. Pour the thoroughly mixed resin into the mould until full. Allow the mould to set for several hours,
preferably 12 hours or more.
10. Remove the parts of the mould the pattern pinion or gear the partial mould and the plate, if one was
used. Care should be taken to slide the plastic off the end of the gear teeth so as not to disturb the
profile surface of the newly moulded gauge.
6. RECONDITIONING AND REPAIRS
6.1 REMOVAL OF PINION FROM SHAFT
Two methods of pinion removal have been arranged
(1) Injection method

TRACTION MOTOR
(2) Mechanical
The second method is intended to be used when the injection equipment is not available. When using the
injection equipment, it is not necessary to remove the armature from the magnet.
a. REMOVAL OF PINION USING INJECTION EQUIPMENT
This method is recommended for the withdrawal of the Pinion from the shaft, as it is superior to the mechanical
method of withdrawal.
Special Tools Required: Injection Equipment.
TO PREVENT PERSONAL INJURY, SOME LOCKING DEVICE/PLATES

SHOULD BE USED, TO RETAIN THE PINION AS IT RECOILS DURING
THE RELEASE PROCESS.
Couple up the injection equipment. Prime the pump with glycerine and continue pumping until the pinion
releases.
Disconnect the injection equipment from the shaft and remove the pinion. Blow out the holes in the shaft and
fit the plug for protection.
Glycerine is used by `Brush', but the standard recommended use is oil.
b. REMOVAL OF PINIONS MECHANICAL METHOD
This method is not recommended for the Pinion withdrawal.
Special Tools Required: Withdrawal Tackle, Packing Peg, Hammer etc.
Attach the withdrawal tackle to the pinion, tighten the nuts on the studs and strike the release pawl with a heavy
lead hammer, tightening the nuts until the pinion releases.
IT IS NOT ADVISABLE TO STAND IN LINE WITH THE SHAFT

DURING WITHDRAWAL OPERATION SINCE THE RECOIL, WHEN
THE PINION IS RELEASED MAY CAUSE PERSONAL INJURY.

TRACTION MOTOR
6.2 MOUNTING PINION ON SHAFT
When mounting the traction pinion on the shaft, great care must be taken and the following procedure should be
adhered to: -
Ensure that the shaft and bore of the pinion are free from burrs and irregularities; these should be polished out
with grinding paste. Remove any sharp edges from the oil distribution channel on the shaft.
Thoroughly clean the injection holes and fitting surfaces with white spirit.
Check the bed of the fitting surfaces using a light smear of Prussian blue paste. A minimum of 85% bed
uniformly distributed is required and should be obtained without lapping. Remove the pinion and thoroughly
clean the bore and shaft.
Gently "feel on" the pinion ensuring that it is home on the taper.
Using suitable gauges, measure the dimension between the end of the shaft and the face of the pinion. Record
this figure for comparison purposes after final pinion fitting. Suspend the pinion in a thermostatically controlled,
free circulating oven or use Induction Heater to attain the above temperature on Pinion Bore. Heat the pinion to a
temperature of 140 °C to 160 °C above ambient, for at least 6 hours in the Oven.
Remove the pinion from the oven, quickly wipe the bore clean and slam the pinion on the shaft. Allow the shaft
and pinion to cool to room temperature. Measure the distance from the end of the shaft to the face of the pinion
and subtract this dimension from the one previously recorded. The figure obtained is the advance of the pinion
along the taper and must fall between the limits 2.6 mm to 2.9 mm. If the correct advancement is not obtained,
remove the pinion and reheat, making the necessary temperature adjustment. Fit the nylon plug in the injection
hole.

TRACTION MOTOR
6.3 WITHDRAWAL OF ARMATURE FROM MOTOR FRAME
Special Tools Required:

 Outer Race Retaining Ring,
 Guide Plug
 End frames Support Tackle
Clean all external parts of the motor before proceeding to dismantle. Lift all the brushes and wrap suitable
protection around the commutator face.
At the commutator end remove the bearing cap, using three M12 forcing off screws, the clamping plate, locating
ring and grease deflector.
Fit the outer race retaining ring and armature guide plug.
Fit the lifting eye adapter, End frame support tackle and the lifting eye. Turn the motor on end, commutator end
downwards, and rest it on suitable packing blocks. Using a spirit level accurately set the motor axis vertically.
Attach crane hook to the lifting eye and raise crane sufficiently to take up the strain.
Unlock and remove the six M20 screws and lock washers securing the pinion end to the motor frame.
Use three M20 screws to jack the endframe spigot clear at the same time raise the crane to take the weight of the
armature.
When the end frame is clear of the motor frame, carefully lift the armature clear and place it horizontally on
timber blocks, approx. 350 mm high.

TRACTION MOTOR
Motor raised in vertical condition Armature being lifted from Stator
6.4 EXTRACTION OF PINION END ARMATURE BEARING

 Outer Race Bearing Withdrawal Tackle
 Race Bearing Withdrawal Tackle.
Withdraw the armature from the motor frame, using the procedure described in the previous section.
Dismantle the armature lifting tackle, and remove the pinion from the armature shaft, as described in the relevant
section.
Remove the bearing cover using two M12 forcing-off screws.
Release the grease thrower from the armature shaft using injection equipment.
Remove the grease deflector.
Slide the end frame off the armature shaft. The bearings outer race and roller cage will come away with the
housing, leaving the inner race on the shaft.

TRACTION MOTOR
Fit the outer race withdrawal tackle. Ensure that the claws remain correctly located, while extracting the bearing
from the endframe, otherwise the rollers will be damaged.
To remove the bearing inner face from the shaft, the withdrawal tackle should be assembled as shown. Ensure
that the billets remain securely clamped in their correct positions while the withdrawal nuts are progressively
tightened.
Inner race removal (Commutator End)
Inner race removal (Pinion End)
Outer race removal (Pinion and Commutator End)

TRACTION MOTOR
6.5 ASSEMBLY OF ARMATURE BEARINGS
Ensure that the bearing housing of End frames is perfectly clean and free from caked grease etc. Check the felt
grease seals in the outer race pressing ring (PE), and replace if necessary. The felts must be cut accurately and
square (6mm x 6mm). When fitting, secure them in the grooves with Anabond binder or some adhesive. Allow
some time for the adhesive to set, then lightly oil the felt seals with lubricant.
NOTE: It is essential that the procedures referring to roller bearings be observed.
1. Fill the bearing housing cavity with grease.

2. Thump grease between the rollers and onto the cage at the back of the bearing.
3. Fit the bearing in to the housing with the identification marks facing outwards.
4. Ensure that the outer race is pressed right home to the locating shoulder.
5. To fit the inner race, heat it to 90 - 100 °C by immersion in an oil bath.
6. Ensure that the shaft seating is clean and unblemished and slip the race into position while hot.
7. The race to be fitted with identification marks outwards.
8. Hold the race in position against its distance collar until it has contracted sufficiently to grip the shaft.
9. Using a tabular drift, tap the inner race when at ambient temperature to ensure that it is hard up against
the distance collar.
10. The PE and CE distance collar may be machined in the assembled condition on the shaft to maintain the
perpendicularity and the bearing to bearing distance (see TECHNICAL DATA) for achieving limited
value of bearing run-outs.
RECOMMENDED BEARING GREASE FOR THE ARMATURE BEARINGS
1. TYPE:-SERVOGEM RR3 OF IOC OR HP LITHION 3
QTY. OF GREASE (FOR INITIAL FILLING)
PINION END : 0.400 kgs approx.

COMMUTATOR END : 0.165 kgs approx.
2. REPLENISHING QUANTITY & PERIOD
PINION END : 0.06 kg approx. (every 4 months)

COMMUTATOR END : 0.03 kg approx. (every 4 months)

TRACTION MOTOR
6.6 BEARING ASSEMBLY WITH END FRAME
Special Tool Required: Endframe Support Tackle.
If it was necessary to dismantle the pinion end bearing, fit the Pinion end frame, with outer race and roller cage
assembled, on to the armature shaft, and carefully slide the rollers on the inner race. Thump grease between the
rollers and onto the cages at the front of the bearing.
Fit the grease deflector and pack the space between bearing and deflector with grease.
Heat the grease thrower to 125 °C above ambient and fit it on the shaft to abut against the bearing inner race.
Retain the grease thrower in this position until it has cooled. Ensure that the bearing cover is clean and the grease
drains clear. Apply ‘jointex’ sealing compound & packing (Nitrile Rubber) to the joint faces of the endframe and
bearing cover and secure the cover with M12 screws and spring washers. Fit the endframe support tackle and
lifting eye.
6.7 ARMATURE ASEMBLY INTO MOTOR FRAME.

 Outer Race Retaining Ring
 Guide Plug.
1. Fit the CE endframe spigot, with outer race and roller cage assembled, in to the motor frame.
2. When the end frame is fully – home, secure with M20 screws and bend the locking washers.
3. Fit the outer race-retaining ring to the End frame.
4. Turn the motor frame on end, commutator end downwards, and rest it on suitable packing blocks using a
spirit level, accurately set the motor axis vertically. Fit the armature guide plug to the shaft. Attach a
crane hook to the lifting eye on the armature and lift the armature to a vertical position.
5. Carefully lower the armature into the motor frame, ensuring that the rollers do not damage the inner race
at the commutator end.
6. When the pinion end frame spigot enters the motor frame, pull it fully home by means of the five M20
fixing screws secure the screws by use of locking washers as shown.
7. Carefully turn the motor to the horizontal position, and remove all tools and lifting tackle.
8. At the commutator end, thumb grease between the rollers and into the cage at the front of the bearing.
Fit the grease deflector and locating ring, and fil the cavity between this and the grease deflector with
grease.
TRACTION MOTOR
9. Secure the clamp plate to the shaft with the M12 screws and locking plate and turn up the corners of the
plate.
10. Fill the outer bearing cap with grease, and apply `Jointex' sealing compound to the joint Surfaces of the
bearing cap and End frame.
11. Secure the cap with M12 screws and spring washers.
12. Remove protection from around commutator face lower the brushes and check bedding. Mount the
pinion on the shaft, using procedure described.
6.8 REMOVAL OF BRUSH GEAR ASSEMBLY
1. Lift the springs and support them on the cylindrical pins on the Brush Holder body. Now remove the
pigtails of the brushes from the Brush holder by loosening the screws then carefully remove the carbon
brushes.
2. Remove Screws and washers from the brush holder mountings and detach the cable terminals from the
brush gear.
3. Remove Screw and washer and detach the brush gear assembly (excluding the Securing block, which is
welded on the frame pads) from the magnet. When the new Brush Gear Assy is mounted on the frame it
should be borne in mind that the brush holder pocket centre line exactly coincides with the main pole
centre lines.
4. Unlock and remove the Screws and spring washer securing the insulating support spindles with sleeves,
to the support block.
5. Remove the insulating support spindles from the brush holder. The support spindles (insulating rods) are
fixed in the support block counter bore dia for better grip.
6.9 ASSEMBLY OF BRUSH GEAR
To assemble the brush gear to the magnet frame as per procedure explained above but in reverse order. Ensure
that the insulating rods are clean and dry and the set screws are secured.
Remove protection from around commutator face.
Fit and lower the carbon brushes and retains them with the pressure springs. Also screw the pigtails of the
Carbon brushes on the provision made on the Brush holder body. Carry out the bedding of the brushes, as per the
standard practice followed in the Conventional Motors of Railways.

TRACTION MOTOR
6.10 REMOVAL OF FIELD POLES FROM MAGNET FRAME
The main pole coils and interpole coils are resin bonded (Potted) onto their respective pole bricks, & if required
to be replaced, must be essentially replaced by a wound brick assembly.
DO NOT DISTURB THE POLES AND CABLES UNLESS

ABSOLUTELY NECESSARY. BEFORE DISTURBING THE POLES,
MEASURE AND RECORD THE MAIN POLE AND INTERPOLE AIR
GAPS TO ENSURE THAT THE MOTOR IS REBUILT WITH THE
ORIGINAL GAPS.
The air gap is half the difference between the armature and pole face diameters. The tolerance allowed on the air
gaps (armature side) is ± 5 % approx. from the nominal value Remove the insulation tape from the coil
terminals. Remove the set screws and washers and detach the cable terminals. Remove the set screws and
washers and detach the poles.
6.11 ASSSEMBLY OF FIELD POLES FROM MAGNET FRAME
ENSURE THAT THE MAIN POLE ON THE SUSPENSION TUBE

SIDE IS MOUNTED WITH SPECIAL REDUCED HEAD BOLT. ONLY.
Also proper recommended torque level should be applied on the Main pole & Compole mounting bolts. Also,
proper recommended torque level should be applied on the M.P. and C.P. Mounting bolts. After assembly,
mounting bolts shall be locked with the help of the rectangular locking pieces in the counter bore dia. & then the
RTV compound should be filled to avoid any dust ingress through the counter bore area.
Secure the main poles and interpoles in their correct positions in the magnet frame, with Mounting Bolts and
washers. Measure the armature air gaps and ensures that the dimensions previously recorded are maintained and
the pole spacing equalized. When the poles are correctly positioned and secured, tack weld the locking bar in the
counter bore to lock the Main Pole & interpole Mounting Bolts.
Secure the cable terminals with Screws and washers (Plated only), and tape the terminals with Silicon rubber
Tape - two layer half lap to overlap the cable insulation by 50 mm followed by one layer half lap glass tape. Now
TRACTION MOTOR
shrink the Silicon Rubber tubes on the exposed portions. Apply insulating varnish over the connections and
cable. Check the cable insulation with a 1000-volt Megger. This should not be less than 2 Megaohms when cold.
Check field system polarities with a compass.
CABLES AND CONNECTIONS MUST BE INSULATED FROM EACH

OTHER AND HELD CLEAR OF THE ARMATURE.
6.12 REMOVAL OF GEAR CASE
1. Remove all the old lubricant and dirt from used gear case with a steam lance or a caustic solution.
2. Do not burn gear compound from the Gear case as warping will result.
3. Rinse the Gear case thoroughly in boiling water to remove all traces of caustic solution.
4. Dry and repaint the Gear case.
5. Renew all felt seals.
6. Check that the two halves of the Gear case fit together, that is the groove in the top half fits over the
groove of the bottom half and that the semi-circles of each opening are in reasonable alignment.
7. If the two halves do not fit together properly it may be because they were not originally assembled and
machined together.
8. Each half of Gearcase is stamped with the same number.
9. Check these numbers (the number will be found at the pinion end of the Gear case on the road wheels
side, near the horizontal joint).
6.13 ASSEMBLY OF GEAR CASE
1. Lift the bottom half gear case up around the gearwheel until the felt seals around the motor shaft opening
and the axle openings rest on the bearing cap and gearwheel hub respectively.
2. Insert one M36 mounting bolt, fitted with new lock washers, and screw down to support the gear case,
but do not tighten.
3. Heat about 3.5 kg of gear lubricant to about 85 °C and pour it over the pinion and gearwheel or
alternatively paint this lubricant onto the teeth.
4. Lower the top half Gear case over the gears until the felt seal rests on the bearing cap and insert and
screw down the M30, M36 mounting bolt. Do not tighten bolt.

TRACTION MOTOR
5. Fit two M30 joint bolts and nuts, using new lock-washers and tighten with torque value at 35 kg-m.
6. Tighten the two M36 mounting bolts at specified torque of 65 kgm.
7. Top up Gear case with lubricant-use dipstick.
Maintenance scheduling is very important and critical for the efficient performance of the electrical machines.
During periodical inspections, incipient faults or defects can be located and rectified. Such attention definitely
reduces the cost of repair and lengthens the life of the equipment. The most suitable intervals between service
maintenance occasions can only be determined by actual service experience. Initially, the intervals should be as
specified until it becomes possible to change them as experience is gained. In the case of lubricants, the
quantities and frequency of lubrications specified should similarly be treated as guide only. The actual interval
between lubrication and quantity of lubricant should be determined from experience and individual duties of
each machine.
A complete history of each machine, detailing the maintenance effected, lubricant consumption, list of renewals,
replacement etc. is therefore of the utmost importance and is thus advised to maintain such records.
7.1 PUTTING INTO SERVICE
After putting new or reconditioned machines into service for the first time, the following checks should be
carried out, during or at the end of first week of operation:
Check that after the motor has been mounted backlash exists between pinion and gearwheel. New gears are
manufactured to have a nominal backlash of 0.2 to 0.7mm, as measured on the outer i.e. non-relieved end of the
gears.
Check tightness of all bolts, particularly axle caps, gear case and brush gear bolts. Examine commutator and
brush gear and check that skin on the commutator is being formed and carbon brushes are bedded correctly.
Check that after a load run, temperatures of axle Suspension Taper Roller Bearings are not excessive.
Check for leaks of gear lubricant. Measure and record gearcase compound.

TRACTION MOTOR
7.2 ROUTINE MAINTENANCE
a. Monthly
1. Before removing the commutator covers, brush off loose dust or dirt.
2. Examine the commutator and clean the outer, have a well-polished surface and free from bar marking or
bar edge burning.
3. Remove any copper beads from the commutator surface with fine carborundum cloth. Deposits from
dirty or greasy hands should be removed by a solvent.
4. Examine the brush gear and clean the insulating rods.
5. Checks that the brush springs sit correctly on the brushes and that the springs are in good condition.
6. Check carbon brushes for wear.
7. Fit new brushes in place if any brush is unlikely to last until the next inspection.
8. See the Technical Data for minimum length and brush grade.
9. Bed all new brushes to the curvature of the commutator.
10. Check the brushes for mechanical damage, breakage of flexible, etc. Fit new brushes if necessary.
11. Check that the flexibles are firmly secured to the brush holder.
12. Check brushes for freedom in the brush-holder and if stick ring cleans both the brush and brush-way in
the holder.
13. Do not soak the brush, as the solvent will eventually ooze out, affecting the commutator and causing the
brush to jam in the holder.
14. If the brush appears to be excessively slack in the brush-holder, check the brush size and discard
the brush or the holder as the case may be.
15. If brush holders have to be removed from the machine, slip thin; clean press board between each brush-
holder and the commutator to avoid damaging the commutator surface.
16. On replacing brush-holders check the clearance between the underside of the brush-holder and the
commutator. See Technical Data.
17. Look carefully for any signs of flash over, overheating, loose connections or damaged insulation.
18. Top up Gear case to the level of gear oil filler unit. See Technical Data for Grade of lubricant.
19. Top up axle Suspension bearing Grease - See Technical Data & Suspension unit arrangement
Assembly & Disassembly for grade of grease.
b. Three monthly
1. Monthly service plus blow out machines using clean dry compressed air.
2. Take particular care to direct air under the commutator in order to remove dirt lodged in the armature
core ducts.
3. Check tightness of all brush gear bolts.
4. Check tightness of bolts securing Suspension Tube and gear case.
5. Check air inlet bellows for cracking tearing or collapsing. Renew if necessary.
6. Check for leakage from the Gear case and Axle caps. Top up the bearings with the recommended
quantity of bearing grease. Top the roller suspension bearing with grease.
7. Top the armature bearing with grease. Refer to the recommended quantity of the bearing grease.

TRACTION MOTOR
c. Six Monthly
Three monthly services plus: -
Clean outlet provided on PE End Shield in bottoms.
d. Annually
Six monthly services plus:-
1. When motors are removed from bogies for wheel turning etc. clean pinion and gearwheel and check for
tooth wear.
2. Before fitting the gear cases, clean out old lubricant to avoid the possibility of gears running
subsequently in contaminated lubricant.
e. Overhaul-Three yearly
1. Remove traction motors from the bogies for overhaul and run on no load at about 1000 rpm and check
for noisy bearing rough commutator, vibration and brush chatter.
2. Dismantle the motor and clean the armature and field system. Dry out to remove any detrimental
moisture.
3. After drying out, check the hot insulation resistance of the traction motor & if found more than 1 Mega
ohm applies a high voltage test at 1.5 kV.
4. Check the armature for open and short circuits by a commutator bar-to-bar test at 600 V.
5. Remove the brush holder from the machine. Clean and inspect for brush clearance in the holder-spring
pressure and damage Recondition as necessary.
6. If the field coils and connections are in good condition then dry paint the interior of machine with
insulating varnish such as E-233 red of Dr. Beck or equivalent. If the field coils require repair, remove
and recondition individually. Check the armature bearing details for damage & renew as necessary.
7. Inspect the shaft for damages to pinion and bearing seating and ensure that it is straight.
8. Inspect the armature for loose bands, solder throwing etc. Recondition as required. If the commutator is
worn or damaged, skim the commutator and undercut the mica. It should be ensured that the
Commutator is turned only upto the safe wearing depth diameter i.e. 260 mm
9. Varnish impregnates the repaired or reconditioned armature with the polyester VPI Resin FT2005 of Dr.
Beck.
10. Inspect the axle bearings for wear, distortion and cracks. Also ensure the intactness of the suspension
tube bolts.
11. At the end, dynamically balance the armature ensuring that the maximum unbalance does not exceed
3gm-mm, reassemble the machine and paint the exterior of the machine.
12. Run the machine on no load at about 1000-RPM for 120 minutes to ensure correct operation of the
bearings. When installing the motor in the bogie ensure that all bolts are tightened to the specified torque
values. Fill the Gear case with the correct lubricant to the maximum specified level.
13. After assembly with the bogie, run the motorized bogies for 240 minutes to ensure proper alignment of
the gears and proper seating of gear case felts over axle.
Initially, it is expected that the temperature of the areas near to the felts will go upto 100°C but, after
excess felt has been worn off, the temperatures of these areas will return back to normal temperature
zone of 50-60° C.

TRACTION MOTOR
8. TROUBLE PHENOMENON AND REMEDIES

TROUBLE
TROUBLE POSSIBLE
PHENOME INSPECTION AND REMEDY
PART CAUSE
NA
Commutati 1. Carbon a. Grade or Form Examine if different grade is used and inspect the actual
on brushes brush spring pressure, if some abnormality is found
Trouble adjust as designated.
b.Excessive wear Check for spring pressure, should be within specified
limits
c. Chattering Remove oxygenated film of commutator surface or
vibration change grade of brush
d.Brush Sticking Clean the brush holder pocket, check for any
deformation in the pocket, use a new carbon brush
e. Copper picking/ Machine is running over loaded for periods more than
spotting the specified limits
f. Sticking of oil Unequal oxygenated film causes excessive wear, replace
film with a new one.
g. Unbalance of Looseness of pig tail, insufficient contact of brushes
brush current with commutator. Replace carbon brushes.
h. Brush wear Lift up of carbon brushes causes spark and damage.
Replace with a new one.
2. a. High-bar, low-bar, Color change, unequal oxygenated film, abnormal wear
Commutator deformation, ovality of brush may cause the flashover. Polish commutator
surface with lathe.
b. Joggle wear and Wear of brush. Polish commutator surface with lathe
roughening of surface
c. Bad chamfering or Reform
bad undercutting
d. Shorting of bar by Inspect and clean
dust and foreign
material between
grooves
e. Abnormal temp. rise Color would change at abnormally high temperatures.
Examine ventilation and load.
f. Black bar Adjust commutation
g. Vibration Examine radial and lateral clearance of bearings.

Vibration of truck and unbalance of armature.

TRACTION MOTOR
Abnormality shall be adjusted according to the

maintenance data
3. Brush a. Wear of inside Big gap to brush worsens sliding performance. Measure
Holder of carbon way dimension, replace with new one.
b. Improper Crookedness pitch, gap should be examined and
attaching adjusted.
c. Improper spring Check pressure and adjust pressure as designated.

pressure
4. Other a. Inadequate condition Color of commutator surface may be changed (ex.
parts of riser, shorting of Black)
armature coil
b. Invasion of dust, Roughening of commutator surface. Machine

rain commutator.
Prevent invasion of water.
c. Wheel slip, skid Change current limit
d. Over current, Examine safety relay

Over voltage
Over 1. Bearing a. Bruise, scratch, rust Replace with new one
Heating
b. Improper quantity of Replenish with new grease.
grease Apply proper grease
c. Improper attaching, Check attaching and adjust it.
fitting or clearance of Check clearance and replace it with good one.
bearings
2. Coils a. Layer short, Find trouble part and replace it.
insulation breakdown
Other 1. Insulation a.Insulation breakdown Abnormality in megger
Trouble of coil, commutator. DC component shall be systematically examined so as
breakdown Lead wire.Inner to find troubled part
connection, brush Repair the damaged parts according to insulation.
holder
Oil Leakage 1. Armature a. Improper grease Check the quantity of grease. Refer recommended
bearing quantity quantity of grease
grease
2. Gear case a. Excess charge of gear Check the compound
compound
b. Bad packing and Replace with new packing and oil sealing.
compound sealing

TRACTION MOTOR
9. INSPECTION SCHEDULE
INSPECTION INTERVAL
REPAIR
INSPECTION ITEMS AND LIMIT OR TRIP MONTH THREE SIX YEARL TWO
STANDARD OPERATIO LY MONTH MONT Y YEAR
N RANGE LY HLY LY
1. TRACTION MOTOR IN GENERAL
a. Appearance in general 0 0 0 0 0 0
b. Attaching of Inspection cover 0 0 0 0 0 0
c. Loosening of bolts, damage of 0 0 0
lockwashers 0 0 0 0
d. Invasion of dust and water 0 0 0
e. Condition of lead wire, and cleat,
contact of 0 0 0 0
terminals. 0 0 0 0
f. Oil leakage of bearing 0 0 0
g. Grease adding to armature bearing
h. Grease adding to motor suspension
bearing
2. ARMATURE
2.1 Commutator
0
a. Diameter : 280 mm a. 260 mm 0
b. Eccentricity b. 0.03 mm 0
c. Inequality in diameter c. 0.05 mm 0
d. High or low bar d. 0.03 mm 0
e. Under cutting depth : 0.9 to 1.5 0

TRACTION MOTOR
INSPECTION INTERVAL
REPAIR
INSPECTION ITEMS AND LIMIT OR TRIP MONT THRE SIX YEARL TWO
STANDARD OPERATIO HLY E MONT Y YEARL
N RANGE MONT HLY Y
HLY
f. Chamfering sharp edge cutting : 0 0

0.3 mm 0
g. Width of riser : 20 mm
(excluding TIG welding) 0
h. Difference of voltage drop
between bars within 5% 0
i. Dielectric test newly
manufactured : 2,500 V/ 1 min
Repaired : 1,500 V/1 min
2.2 Armature Coil

0
a. Cleaning 0
b. Interturn insulation test
2.3 Shaft, bearing and Pinion

a. Diameter of shaft bearing on a. 120 + 0.05 0
pinion side : 120 mm + 0.03
b. Diameter of shaft bearing on b. 70 + 0.04 0

commutator side : 70 mm + 0.02
c. Wrap of shaft (deflection of shaft
end) c. less than 0
d. Taking off, cleaning, inspection 0.03 mm
and oiling of bearing 0
e. Interference fit shall be applied
to inlay of inner ring of roller
bearing and shaft of pinion side. 0
Temperature of heating : 110 –
120º C
f. Interference fit shall be applied
to inlay of inner ring of roller
bearing and shaft of commutator
side 0
Temperature of heating : 110 –
120º C
g. Radial clearance of the roller
bearing on pinion side 0

TRACTION MOTOR
INSPECTION INTERVAL
REPAIR
N RANGE MONT HLY Y
HLY
h. Interference fit shall be applied 0

to inlay of pinion.
Interference Heating temperature :
140 – 160º C above ambient
i. Contact degree of armature shaft 80 % 0

and taper of pinion shall be more minimum for
than 90 % used
0
j. Ultra sonic and magnetic particle
testing shall be carried out about
shaft.
3. STATOR
3.1 Magnet frame 0
a. Dimensions of mounting parts

(as shown in drawing)
b. Lead wire with damaged
covering or damaged terminal shall
be replaced. Less than 10
c. Damage of core of lead wire and %
connector may be used
3.3 Brush holder and Carbon Brush 0 0 0 0

a. Cleaning and check
b. Spring pressure (at assembly) at 2.50 to 3.30 0 0 0
At Brush height 57 mm : 3.20 kgf kgf/brush
/brush
At Brush height 32 mm : 2.80 kgf/
brush
c. Dimensions of brush holder 0
0
pocket 20.3 mm
Thickness : 20.00 mm
Width : 40.00 mm 40.3 mm

TRACTION MOTOR
INSPECTION INTERVAL
REPAIR
N RANGE MONT HLY Y
HLY
d. Clearance between Brush holder 0 0
Face and commutator surface
Gap : 2 – 3 mm nominal
Distance between brush end face 0

and commutator end face : more 0 0 0 0
than 4 mm
Service length
e. Length of carbon brush : 25 mm
Exchange
f. Chipping of carbon brush limit : 32 mm 0 0 0 0 0
g. Pigtail breaking of brush less than 10 % 0 0 0 0 0
3.4 Gear Case

0
a. Check the gear compound level 0 0 0 0
b. Check the packing of gear case. 0
Worn packing should be replaced.
c. Gear compound leakage 0 0 0 0 0
4. ASSEMBLY TEST AND

OTHERS
a. Bedding of carbon brush 0 0 0 0
b. Dielectric test
New : 2.5 kV, 50 hz for 1 min 1.5 KV/1min
Repaired : 1.5 kV, 50 hz for 1 min (Repaired) 0
c. Insulation Resistance test
d. No – load test
Examine abnormal vibration or More than 1.0 0 0
abnormal noise MΩ
i. 1000 rpm for 1 hour in both 0
directions.
ii. 2000 rpm for 15 min in both
directions.

TRACTION MOTOR
NOTES
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CHAPTER VII
CONTROL GEAR EQUIPMENT
Maintenance Manual
CONTROL GEAR ITEMS
CHAPTER VII
CONTROL GEAR ITEMS
Master Controller
Master Controller is used to select various speed of Diesel Engine as well as to change the direction of
vehicle. It has two handles, which function is explained below:
i) Accelerating Handle:
This handle has nine notch positions i.e. 0-1-2-3-4-5-6-7 & 8. The vehicle will accelerate as the driver moves
the handle from a lower notch to a higher notch.
ii) Reversing Handle:
It has three positions i.e. REVERSE - OFF - FORWARD. The position of this handle decides the direction of
movement of train.
A locking key is also provided. Reverse Handle cannot be operated unless the locking key is inserted in the
keyhole & rotated by 90o clockwise.
Mechanical interlocking is provided to prevent unauthorised operation of either accelerating or reversing

handle. It has following features:
I) Reverse handle can be moved to either “Forward” or “Reverse” position only when the key is inserted
inside the keyhole & rotated by 90o clockwise.
ii) Accelerating handle can be moved only when reverse handle is either at “Forward” or “Reverse" position
i.e accelerating handle cannot move when reverse handle is at “0” position.
iii) Reverse handle can be moved only when the accelerating handle is at “0” position.
iv) A deadman’s mechanism is provided with the accelerating handle. When the accelerating handle is
depressed deadman contact closes & when the handle is released, it opens to cut off the traction control
supply & thus the power to Traction Motors. The mechanism is so designed such that it trips only when the
“Reverse Handle” is either at forward or reverse position.
v) Key can be removed only after the accelerating handle is brought to “off” position and reverse handle is
brought to “0” position.

CONTROL GEAR ITEMS
Make & Type No : Inder Engg., 9MC-MU-018

Operating Voltage : 110V DC
Current Rating : 10 Amps (Thermal)
Motor Overload Relays
It is used for protection of Traction Motor from current overloading.
The relay has two coils -
a) Operating Coil: It is single turn coil, which passes through the yoke of relay.
b) Resetting Coil: This coil is provided for resetting the overloaded relay to resume normal operation. This
coil is suitable for remote resetting operation.
The relay has six auxiliary contacts (3NO+3NC) for use in control & indication circuits. When the motor
current exceeds the value at which the relay is set to trip, the yoke gets magnetised, which pulls down the
armature of main coil. At the same time armature of reset coil is released and position of auxiliary contacts is
changed.
Thus the supply to E .P .Contactor coil, through auxiliary contacts of overload relay is cut off, which in turn
breaks the power circuit thus preventing the motor from overloading.
Make & Type No : Inder Engg

Current Rating : 900 Amps
Reset Coil : DC 110V, 1 Minute
Reset Coil Resistance : 160 
Calibration range : 600A, 700A, 800A and 900A
Trip Coil Setting : 650A.
Capacity of contact (Auxiliary)
i) Thermal : 3A
ii) Rupturing : 0.5A, 110 V.
Min. operating voltage (Hot) : < 66V

CONTROL GEAR ITEMS
E.P. Reverser
E. P. Reverser is used to change the direction of field current of Traction Motor, thus changing the direction
of the coach. It is a 2-Pole off load switch, which carries rated current during its operation. It has two sets of
Magnet valves, one each for forward and reverse operation. It has 2 power contacts and 2 auxiliary contacts
(change over type). When forward coil is energised, all 2 power contacts and 2 auxiliary contacts operate &
make connection in forward direction. Similarly reverse connection is made when reverse coil is energised.
Make & Type : Inder Engg. (P-RP52)

Rating of main contacts : 1000 Amps (Thermal)
No. of main poles : 2 Nos. (Change over type)
Rated Operating Air Pressure : 5 Kg/cm2
Rated coil Voltage : 110 V DC
Rating of Auxiliary Contacts : 10 Amps (Thermal)
Min. operating voltage : 68 Volts
Min. Operating Pressure : 4 Kg/cm2
Electro-pneumatic Contactor
EP Contactors are required to connect / isolate the Traction Motors to / from the power circuit. These
contactors are On-Load Switches and are required to isolate the motors on load from the power circuit.
These EP Contactors are fitted with a cylinder and piston, which operate main contacts of copper with silver
/ silver cadmium oxide tips. These silver tips are protected from damage due to arcing. A blow-out coil is
fitted to extinguish the Arc when the main contacts are open (on-load) and this is assisted by an arc chute.
When the magnet valve is energised, air is admitted to the cylinder. This causes the piston to rise and main
contacts close.
One set of auxiliary contacts are provided, when the magnet valve is energised the auxiliary contact arm
shall move upwards and shall cause the auxiliary contacts to close.
When the magnet valve is de-energised, air exhausts from the cylinder and the piston moves downwards to
open the main contacts and at the same time the auxiliary contact arm also moves downwards and open the
auxiliary contacts.
CONTROL GEAR ITEMS
Make & type : Inder Engg., (9-24PC2)

Operating Voltage : 110 VDC
Operating pneumatic pressure : 4.5 Kg/Cm2
Main Contacts Rating : 750Volts, 1000 Amps
Auxiliary Contacts Rating : 3Amps @ 110 VDC
Load Ammeter Shunt
Two separate load ammeter shunts are provided one for motor no. 1 and other for motor no. 2 to measure the
motor current.
Rating : 1000A / 75mV

Make : AE, Mumbai
Ground Fault Relay

Ground fault relay operates in the event of ground fault in power circuit. It is a current operated relay. Once
the ground fault has occurred, the relay gets latched & it can be reset manually with the help of reset knob
provided on the relay. A cutout switch is provided in series with the relay coil to isolate the relay from power
circuit.
Trip Coil Setting : 180-280 mA

Rating of Auxiliary Contacts : 5 Amps (Thermal)
Resistance of Coil : 630 at 20 C.
General Purpose Relay - 1
It consists of General Purpose Relays for sequencing, interlocking & protection.

Make & Type No : Schneider
Coil Voltage : 120V DC
Contact Arrangement : 4 NO
Add on Block : 4 Amps; 2NO+2NC or 4NC

CONTROL GEAR ITEMS
General Purpose Relay - 2
Make & Type No : Schneider

Coil Voltage : 24V DC
Contact Arrangement : 4 NO
Add on Block : 4 Amps; 2NO+2NC or 4NC
Resistor Panel
Resistor panel provides external resistance to the exciter stator coils of Traction Alternator for limiting the
excitation current to a safe value in the event of failure of excitation control function.
Make & Type No : PEC; PPR 300

Rating : 12  , 300 watts
Bypass switches:
Bypass switches are used to bypass a protection circuit when the corresponding protection circuit is not
working properly or intended to bypass under strict vigilance. The circuits/relays, which can be bypassed,
are listed below with their operating pressure range:
Make & Type No : RGK; 1510.4430

SPST : 15 Amps, 250V AC/DC
Driver’s Control Switch Box:
Driver’s control switch box contain switches for various control operations. It has spring-loaded switches as
well as change over type switches.
All the switches in the top row are mechanically interlocked with Driver’s Control Switch removable handle.
The switches can be unlocked by pressing the handle down by 10mm and turning it clockwise by 45 degrees.
The handle can be inserted/removed in OFF position only. Moreover, the top row switches are automatically
reset to normal position when the handle is removed.
10 Auxiliary switches are also provided, which operate when the Key is inserted and kept in ON position.

CONTROL GEAR ITEMS
Make : Inder Engg.

Thermal Current rating of contacts : 10 Amps
Breaking Capacity of Contacts : 2Amps inductive Load at 110V DC
Main Switches : 2NO + 1NC
Driver’s Control Switch : 8NO + 2NC
Lamp rating : 125V, 10W
Wire wound Resistor : 250   3%, 3W
Engine Control Switch
Engine control switch has two positions namely ‘IDLE’ & ‘RUN’. The switch put-off the excitation of
Traction Alternator there by preventing Power to Traction Motors unless it is switched to ‘RUN’ position &
Master Controller is taken to notch 1 or higher notches.
Make : JSL
Brand Name : JMP
Rating (Thermal) : 25 Amps, 500V AC
Contact Arrangement : 3NO + 3NC
Load Ammeter and Ammeter selection switch
Ammeter and Selector Switch is provided for indication/measurement of load current. Using selector switch
load current of Traction Motors 1 & 2 can be selected. Motor current of rest of the motor currents cannot be
measured with the selector switch & Load ammeter. Load Ammeter has a basic rating of 75 mV and is
shown in 1000 Amps DC range.
Load Ammeter
Make & Type No : AE; SM144
Rating : 0-75mV/0-1000 A
Dimension : 144 x 144 mm
Ammeter Selection Switch
Make & Type No : KAYCEE; RP125B
Rating : 16 Amps AC/DC, 2 way with off

CONTROL GEAR ITEMS
Motor cutout switch
2 Nos. switches are provided in Control Cubicle to isolate either a single motor or a pair of motors in the
event of fault on Traction Motors. The operational sequence of switches is listed below.
1) MCS-1: ALL in /Motor 1 out / Motor 3 Out / Motor 1 & 3 Out
2) MCS-2: All in /Motor 2 Out / Motor 4 Out / Motor 2 & 4 out
“Off” position indicates normal/healthy operation.
Make : KAYCEE (programme Switch)

Rating : 16 Amps, 250V AC/DC
No of Poles & Positions : 4 Pole & 4 Way
Voltmeter and voltmeter switch
One no. Voltmeter and one no. Voltmeter switch is provided in Control Cubicle, for measurement of system
control voltages 110 V DC & 24 VDC. Voltmeter switch is connected in series with the voltmeters. The
indication on voltmeter is available only when the switch is turned on.
Voltmeter
Make & Type No : AE; SQ96
Rating : 0-150V DC
Dimension : 96 x 96 mm
Voltmeter switch
Make & Type No : RGK; 1510.4430
Rating : 15 Amps, 250V AC/DC
Battery (110V) Isolation switch fuse unit:
This switch is provided to isolate entire control and auxiliary circuit from 110 V battery. 63 Amps in-built
fuses are also provided in the switch.
Make : Scheider
Contact Rating : 63 Amps

CONTROL GEAR ITEMS
Reverse Current Diode
Reverse current Diode is provided for protection of batteries against discharging, when the supply is not
available.
Make : Ruttonsha
Average Forward Current : 150 Amps
PIV at rated junction temperature : 1000 V
Battery (24V) Isolating Switch
Make & type : Inder Engg.

Rating : 250 Amps, 415V, 50 Hz
Timers
Make & type : ETR650, Siemens

No. of Changeover Contacts : 4 Nos.
Local/Remote Switch
Type & Make : Kaycee (Program Switch)

Rating : 16 Amp, 2-pole, 3-way
Light Selection Switch
Type & Make : Kaycee (Program Switch)

Rating : 16 Amp, 2-pole, 3-way
Instrument Lamp
Type & Make : Siemens, 3SB0420-2A

Rating : 110 VDC
Lamp : 110 VDC, 2W
CONTROL GEAR ITEMS
Auxiliary Fuse Panel
Type & Make : Siemens, 3NH3 030

Rating : 125 Amps
Fuse Rating : 32Amps, 3NA1001
Fuse Rating : 63 Amps, 3NA1015
Hand Lamp socket
Ratings : 10 Amps, 3-pin
Miniature Circuit Breaker (MCB)
MCB’s are used to protect electric circuits against overloading caused by excessive currents due to sustained
overloads or short circuits. MCBs are used in CAB-1 and CAB-2.
Make : Schneider
Specification : SPEC/E-12/1/04 & SKEL-3700
Ratings : 5A, 10A, 15A & 30 Amps
LED Indication Panel
16 LED Module indication panel is mounted on the Driver’s Desk-DPC. The LED indications are provided
to identify various fault & healthy features of the vehicle.
Make & Type : Inder Engg & 16 LED

Voltage of operation : 110 VDC

CONTROL GEAR ITEMS
NOTES
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2 POLE E.P. REVERSER
Maintenance Manual
INDEX:
* DESCRIPTION
* CONSTRUCTION
* RATING
* LUBRICATION
* OVERHAUL
* REPAIRS & REPLACEMENT
* TEST & ADJUSTMENT
* CONTACT GAP
* TERMINAL DETAILS
DESCRIPTION:
The E.P. Reverser is remotely controlled off-load operated switch used for reversing the direction of
rotation of traction motors.
CONSTRUCTION:
The E.P. Reverser assembly consists of the following main parts, power contact blocks interlocks
and cylinder assembly. These main parts along with other components are mounted on an end
frame, cylinder and end frame have special mounting feet to bolt the reverser in position. When a
command from master controller is given either to the forward or reverse direction, the
corresponding interlock on the reverser closes to activate either the forward or reverse magnet valve
which in turn operate the main reverser contacts to switch traction motor fields to correspond to the
position of the master controller command.
MOUNTING:
The E.P. Reverser is mounted with the help of four holes provided in the mounting feet in the
cylinder and end frame at centre distance of 504.8mm.
RATING:
The reverser is rated for carrying 1000Amp. D.C. continuous, the insulation level is 750 volts D.C.
and the nominal operating air pressure 4.0 Kg/cm2.
LUBRICATION
Cylinder Assembly
Once in a year, remove the cylinder caps at the ends of the cylinder and apply several drops of
delvac 930 or equivalent oil to the cylinder walls.
OVERHAUL:
1. Immerse the piston washer along with the rack in delvac 930 or equivalent oil.
2. Remove the piston washer and rack from the oil and insert them in the cylinder.
3. Operate the reverser manually to distribute the oil over the cylinder walls.
INSPECTION & MAINTENANCE:
Inspect the contact main blocks. If the contacts are excessively worn, burnt, or pitted, they must be
replaced. Contacts that are pitted less than 0.8mm may be dressed with a fine file. It should be
ensured that, on the stationary contact, the curvature is not destroyed by filling.
Inspect the operation of the reverser by pressing the armature of the magnet valve. Sluggish
operation indicates either of the following:
a. Dry cylinder walls or leaking piston washer. If the piston washer shows signs of wear or
deterioration or if air leakage persists replace the piston washer.
Sticky or leaking magnet valves
b. See instructions for attending to the MAGNET VALVES
Maintain gap, over-travel and contact pressure of contacts and fingers as given under
DATA. Check for air leak by applying soap water to the cylinder caps.
TESTING BEFORE DISASSEMBLY:
Measure the contact pressure, contact gap and over-travel on both the main and auxiliary interlock
fingers. For values see DATA.
2. High Voltage tests:
a. Apply 1500 volts a.c. for one minute between interlock contacts and ground.
b. Apply 4000 volts a.c. for one minute between adjacent main contacts and main
contacts to frame with interlocks and magnet valves earthed.
3. Check for air leaks at piping joints and magnet valves with soap solution.
4. Check air pressure required for operation in either direction. Minimum air pressure is 3.85
Kg/cm 2.
5. Check condition of the contacts. Identify contacts those are pitted or burnt for repair or
replacement.
6. Check the condition of the terminal bars and spacers. Identify terminal bars or spacers that
are cracked, burnt or broken for replacements.

REPAIR & REPLACEMENT:
Power fingers can be replaced or repaired without disassembly of the reverser. Proceed as follows:
1. Remove the screws holding the terminal block and shunt of power finger to the terminal bar.
2. Remove the nut holding the spring location plate on the pillar.
3. Remove the finger and repair or replace it.
4. Reassemble the Reverser in the reverse order.
5. Check the finger operation as mentioned under FINAL TEST AND ADJUSTMENTS
ADJEUSTMENT:
Stationary contacts can be replaced or repaired without disassembly of the reverser in the following
manner:
1. For outside contacts, remove the bolts holding the terminal bars to the end frame remove the
two terminal bars and stationary contacts from the cylinder. Slide the spacers and contacts
from the terminal bars and inside surface of spacers to remove dirt accumulation, if any.
Reassemble the Reverser in the reverse order.
Check the operation of the reverser as mentioned under FINAL TEST AND
ADJUSTMENTS.
2. For inside contacts, remove the two bolts holding the terminals bar end frame and cylinder.
Lift the terminal bar with the contacts and slide them from the terminal bar. Repair or
replace the contacts and assemble the Reverser in reverse order.
1. Remove the bolts holding the end frame to the terminal bars
2. Slide the end frame off the shaft. Care should be taken so as not to damage the insulated
spacers between the end frame and the finger blocks.
3. Remove the power fingers from the block.
4. Replace the block and reassemble the Reverser in reverse order.

MANUAL OPERATING LEVER:
Remove the springs from the lever and remove the four bolts holding ratchet, pinion and bracket
subassembly to the cylinder.
2. Remove the pinion from the Reverser. Care should be taken not to damage the pinion teeth.
3. Disassemble the pinion as follows. Remove the circlip cotter pinion from the pinion and
press the shaft out of the castings.
4. Reassemble the Reverser in reverse order
CYLINDER:
1. Remove the cylinder caps and then remove the complete rack assembly from the cylinder.
2. Check the appearance of the cylinder. Remove small ridges or scoring with a suitable cloth.
3. Check the piston washer and replace, if necessary,
TEST & ADJUSTMENT:
Contacts Alignments
1. Edges of the mating contacts should not be more than 2.0 mm out of alignment when the
contacts are closed.
2. All main contacts should close in such a manner that no contact closes in advance of any
other by more than 1.2 mm.
3. Test the self-alignment of the fingers as follows:
a. Force the fingers out of alignment as far as they will normally go.
b. Operate the reverser at least 10 complete cycles with nominal air pressure (4.0
Kg/cm 2).

c. Align fingers so that a 0.05 mm feeler gauge cannot be inserted more than 25% of
the contact width Maximum gap between the silver contacts should not exceed
0.254mm at the open side.
d. Force the fingers out of alignment in the opposite direction to step "a" and repeat
steps "b" & "c", above.
Contact Gap
Contact Gap is the distance between the contact finger and the inside stationary contact when the
contact finger is fully wiped with the outside stationary contact.
Contact Pressure
Contact pressure is the amount of kg force the contact finger spring applies to the contact finger as
it rests against the stationary contacts.
Measure the contact pressure follows:
1. Use a spring balance and a measuring arm.
2. With air on the reverser and contact fingers fully wiped, place the measuring arm on the
contact fingers. Pull the spring balance until the contact finger just breaks away from the
stationary contact.
3. Read spring balance when the contact finger just breaks away.
a. On the outside contacts the reading should be between 4.0 and 4.5 Kg
b. On the inside contacts the reading should be between 5.8 & 6.5 Kg.
INTERLOCK ADJUSTMENT:
Main contacts should make contact before and open after the interlock fingers. This is
accomplished by setting the interlock contacts in the following manner.
1. Loosen the lock nuts on the stationary contact screws.
2. With air on the reverser and the main contacts fully wiped, hold the lock nut and turn the
contact screw towards the contact finger until it just touches the finger.
3. Turn the contact screw four more turns towards the contact finger to obtain the proper over-
travel.
4. Hold the contact screw and tighten the locking nut.
5. Repeat steps 1 to 4 on all fingers
OPERATION TEST:
1. Minimum air pressure to operate the reverser is 3.80 Kg/cm sq. To perform the air pressure
test, use a tank, which is having the minimum air pressure. Then check the operation of the
reverser in either direction. If a regulator is available, air pressure may be set with the
regulator.
2. Check the piping and magnet valves for leaks with soap water.
3. Check visually to see that no fingers are bent.
TERMINAL DETAILS
The holes provided for power cables are suitable for 12.7 mm diameter bolts.
The control cables should have M5 terminals.
MAGNET VALUE FOR E.P. REVERSER:
* DESCRIPTION
* MOUNTING
* RATING
* INSPECTION & MAINTENANCE
* DISASSEMBLY

* RE-ASSEMBLY
* TESTING
* TERMINAL DETAILS
DESCRIPTION:
Reverser magnet valve is an Electro-pneumatically operated valve, which controls the flow of
compressed air to and from Electro-pneumatic apparatus.
This is a metal to metal seat valve and it consists of the following parts: Valve body, coil, armature,
armature support, valve stem, valve seat, spring and plug.
When the coil is energised, the armature is pulled down towards the core causing the valve stem to
close the exhaust port and the valve to open the inlet port thus admitting compressed air to the
apparatus.
When the coil is de-energised, the valve stem is pushed up by the spring, thereby closing the inner
port and opening the exhaust port enabling the compressed air from apparatus to escape.
MOUNTING:
The magnet valve is mounted on the apparatus with the help of two holes provided on the valve
body at a distance of 27mm. The overall dimensions of the magnet valve are approx. 80 x 80 x 128
mm. This magnet valve is supplied mounted on the Electro-pneumatic apparatus.
RATING:
Operating voltage for coil (Nominal) : 110 VDC
Minimum : 66 VDC
Normal operating air pressure : 4.0 Kg/Cm sq.
Resistance of operating coil : 939  at 20 C.

INSPECTION & MAINTENANCE:

The following procedure will assist in the inspection and maintenance
1. Check magnet valve operation by depressing the armature. If the valve sticks, it must be
cleaned.
2. Check for leaks by applying soap water to the pipe connections and exhaust port. Tighten
all leaky connections. Small amount of leakage through the exhaust port is acceptable, if the
locomotive leakage test can still remain within limits. If excessive leakage is found,
disassemble the valve for cleaning as indicated below.
DISASSEMBLY:
a. Remove the valve bolt to release the valve and spring.
b. Remove the armature stop and armature to release the valve stem.
c. Remove the coil from the valve body using a suitable spanner.
d. Thoroughly clean the upper and lower interior. Clean the valve stem seat etc. by dry
compressed air.
e. Clean the body of valve.
RE-ASSEMBLY:
a. Install the valve stem, spring and valve bolt at the bottom.
b. Install the washer, the coil and lock the coil with a circlip.
c. Install the exhaust valve stem, armature and armature stop.
TESTING:
1. Apply soap water & check that there are no air leaks.
2. Check the operation of the magnet valve at minimum operating voltage with nominal
operating air pressure.
TERMINAL DETAILS:
The control cables should have M5 terminals.

NOTES
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GROUND FAULT RELAY
Maintenance Manual
GROUND FAULT RELAY
GROUND FAULT RELAY
INDEX:
* INTRODUCTION
* MOUNTING
* DATA
* RATING
* MAINTENANCE & REPAIR
* ARMATURE AND CONTACT ADJUSTMENT
* TERMINAL DETAILS
INTRODUCTION:
The ground fault relay is a remotely controlled Electro-magnetic device used for opening power
circuits in the event of electrical grounds. It incorporates a latching mechanism and adjustable
springs for setting the pick-up current.
Any ground in the system completes the circuit and energises the operating coil of the relay, the
relay picks up and its auxiliary contacts open the main power contactors. An indicator provided on
the relay base points to a red dot when the relay is in the tripped condition and it must be mutually
reset after the ground fault has been cleared.

GROUND FAULT RELAY
DATA:
Contact Pressure - 105 to 180gm
Over-travel - 2.7 mm minimum
Armature Gap - 4.5 to 6.5mm
Operating Coil
- Resistance - 63.0 ohms at 20 C
- Pickup current - 180 to 280 mA.
The primary parts of the relay are an operating coil mounted on a pole piece, an armature that is
spring loaded and supports the movable contacts, and both normally closed and open contacts.
MOUNTING:
The relay is mounted on two holes at a centre distance of 138 mm with interlock fingers vertical and
contacts pointing downwards. The overall size of the relay is 152.4 (W) x 182.6 (D) x 157.2 (H)
mm.
RATING:
The relay contacts are rated for carrying 5A DC continuously, the insulation level being 120 V DC.
MAINTENANCE & REPAIR:

General repairs and replacement of contacts can be done without removal of the relay. However, if
the core or the coil is to be replaced, the relay must be removed from the base. For doing it, remove
the four screws holding on the reset button and give access to the two screws holding relay to the
base. Remove the screws and washers and remove relay from the base.

GROUND FAULT RELAY
DISASSEMBLY:
i. Remove screws and washers to release coil leads. Remove screws and washers to separate
the interlock assembly portion of the relay from the pole piece and core.
ii. Remove screws and washers which attach the armature and finger support assembly to the
spring bracket. This will also free springs. Remove screws and washers to release finger
support from the spring bracket.
iii. To release NC & NO contacts, remove nuts and washers. With the NC & NO contacts
removed the armature can be separated from the finger block after ends of the movable
contact finger shunts have been taken off the screws. Finger can now be slid out of the
spring bracket along with the spring.
RE-ASSEMBLY:
Re-assemble the relay in the reverse manner of disassembly.
CONTACT MAINTENANCE:
As the contact tip wear out or burns away, the contact gap become progressively greater and the
contact over-travel decreases. Therefore, periodic inspection and adjustment of the fixed contacts is
necessary to restore normal contact gap and over-travel. If the contact tips have worn or burnt
through or if experience shows tips will be worn through prior to the next inspection period, replace
the contacts
ARMATURE & CONTACT ADJUSTMENT:
The following special tools are required in adjusting the contact and armature gaps.
1. Contact adjuster.
2. Contact over-travel gauge.
3. Armature gap gauge.

GROUND FAULT RELAY
Checking the armature gap
Remove No.3 normally open contact and insert the armature gap gauge. The proper gap gauge to
be used can be determined from the minimum and maximum gap limits. If the gap is excessive,
check for a cracked or broken finger block or bent pole piece. Correct by replacing the damaged
parts. If the gap is less than allowable tolerance, check for any obstructions at the armature pivot
knife edge or where the armature extends through the finger block.
Normally closed contact adjustment
Install over-travel gauge. Use the contact adjuster gauge the N.C contacts at right angle util a 0.0 to
0.1mm gap is obtained between all. Use a feeler gauge for checking gap. Remove the gauges and
operate the armature by hand. See that all contacts make at the same time.
Normally Open Contact Adjustment
Install the overtravel gauge as shown in fig.8. Block the relay armature in the closed condition to
hold the gauge in position. Use the contact adjuster gauge and bend the N.O. contacts at right angle
as shown in fig.9 until 0.0 to 0.1mm gap is obtained between all contacts. Use feeler gauge to
check the contact gap. Remove the gauges and the block from the relay and operate the armature
by hand. See that all contacts make at the same time.
TERMINAL DETAILS:
The control cables should have M5 terminals

GROUND FAULT RELAY
NOTES
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CHAPETR VIII
MAINTENANCE INSTRUCTIONS
Maintenance Manual
CHAPTER VIII
MAINTENANCE INSTRUCTIONS
1. INTRODUCTION
ELECTRIC TRACTION EQUIPMENT must be reliable in order to avoid failures, traffic delays and loss
of revenue due to lack of public confidence. The equipment must also operate cheaply for economical
operation in service.
These requirements can only be fulfilled if preventive measures are taken, in the form of periodical
Service Maintenance and Overhaul, which must be thoroughly organised and meticulously and
conscientiously carried out at the times recommended in this Maintenance manual.
The intervals, at which Service Maintenance and Overhaul are carried out, are calculated on the basis of
either time or distance travelled and will depend upon the type of equipment, the nature of service, and
climatic conditions. In the case of diesel-electric equipment, the intervals may depend upon the number of
hours the engine runs.
If the weekly mileage is regular and approximately constant, a time-period basis of maintenance is
probably more satisfactory; but if the weekly, monthly or seasonal mileage is subject to wide variations,
the use of the time period basis would introduce differences in the distance travelled, in which case the
distance basis of maintenance would be preferable.
1.1 Service Maintenance
This is carried out on a regular basis in order to maintain the equipment in sound condition and to prevent
service failures. If maintenance is carried out efficiently at the established periods, the equipment will
operate reliably between overhauls.

Maintenance is usually carried out in the running shed and comprises examination, cleaning, lubrication,
any necessary adjustments for wear, and changing worn consumable parts such as carbon brushes,
contacts, arc chutes etc. fitting new or re-conditioned parts.
Consumable part must not be allowed to wear beyond the specified minimum dimensions. If it is
estimated that a part will become fully worn before the next maintenance occasion, it must be replaced by
a new or reconditioned part. In addition, a sufficient margin for wear should be allowed in case a normal
maintenance occasion is missed, due to the hazards of severe weather or other unusual traffic conditions.
The intervals at which the various maintenance operations are carried out can only be determined by
observation and experience. At first, the intervals should be about one week or 3200 km, and they should
be lengthened gradually as experience is gained without, of course, endangering the reliability of the
equipment. Eventually, when the maximum intervals have been established, they should, if possible, be
arranged to fit the occasions when the vehicle visits the running shed for maintenance of the mechanical
parts of the vehicle.
1.2 Overhaul
This is carried out in the workshop, and comprises repairing and reconditioning the equipment; that is,
dismantling, replacing worn or defective parts by new or reconditioned components, re-assembling the
equipment and testing it for correct operation.
The periods between overhauls are best determined by withdrawing the equipment for service after a
period of two years or 160,000 km, and subjecting it to a detailed examination, which will also necessitate
a certain amount of dismantling. If it is found that the equipment has not reached the Overhaul state, it
should then be returned to service.
In general, periods between overhaul should not be less than three years. These periods are, however,
capable of being extended to five years or more provided.
a) Modern high-grade lubricants are used.

b) Maintenance is efficiently carried out.
c) Thorough attention is given to cleanliness.

Experience on many railways, in different parts of the world, has shown that more frequent maintenance
and overhaul are necessary for the mechanical parts of the vehicle than for the electrical equipment. As
the program for the electrical work must be built up gradually, and the periods extended as experience is
gained, every endeavour should be made to fit the electrical program into the mechanical program, in
order to minimise the time that the vehicle is out of service.
1.3 Records
Accurate records should be kept of the maintenance and overhaul work carried out in order to determine
the amount by which the Maintenance and Overhaul periods may be extended. "Cardex" is a suitable
system for this purpose, and it would contain card for each of the items on which records are to be kept,
for example, armatures, machine stators, gears, pinions pantograph wearing-strips (if fitted), cleaning
filters and radiators, etc.
2. CLEANLINESS
Cleanliness is essential to good maintenance and trouble-free service, and the work of cleaning must be
thoroughly carried out at the established intervals.
Metallic dust from the wheels and brake shoes is detrimental to equipment and, if the dust is allowed to lie
on insulation surfaces or to penetrate coils, it can cause electrical failure.
This dust, when dry, is usually easy to remove, but if it becomes bound with water or oil, its removal is
more difficult. Operators must, therefore, avoid leaving deposits, which have this binding action.
The degree of cleanliness, which can be maintained, depends to a large extent on the location of the
equipment and whether it is totally enclosed, ventilated, or outside-mounted.
When no ventilation is required because the production of heat is low, apparatus is enclosed in dust-proof
cases, compartments or cupboards; ensure that the rubber or felt jointing of the covers or doors is
maintained in good condition.
Ensure that the devices for keeping covers and doors closed are also well maintained and lubricated when
necessary.
Compartments, which cannot be seated easily, for example when they are provided with sliding doors, are
sometimes pressurised with filtered air. When this is the case, it is important to ensure that any failure of
air supply is restored without delay, and the filter is cleaned regularly, or changed when necessary.
Although the frequency of cleaning totally enclosed apparatus is much less than that required for
ventilated or roof-mounted apparatus, it must not be neglected if failure is to be avoided.

Apparatus such as resistors and rectifiers, etc., which have to dissipate heat to avoid excessive
temperature, are either free-ventilated or force-ventilated with unfiltered air and require frequent cleaning,
as they readily become contaminated with dirt and brake shoe dust.
On electric vehicles on which roof-mounted apparatus is fitted, there are large porcelain insulators, which
may collect much falling dirt and therefore must be kept clean. Rubber hose for the pantograph air supply
must also be cleaned and kept free of oil and grease. Examine all roof equipment and check for
mechanical damage; remove any debris that may have lodged on the roof.
3. LUBRICATION
In general, lubricants should be used sparingly to avoid contaminating insulation and other parts of
apparatus. Clean the electrical sliding contacts of knife switches, drum switches and reversing switches
etc., periodically, then lightly smear them with 4 x grease (supplied by Dow Corning, USA)
Pivots for contactors and hinged contact fingers, etc., are lubricated during assembly, chiefly as rust
inhibitor prior to being placed in service. Do not add lubricant at periodical maintenance because the
pivots have an extremely long life, even when operating dry, and if lubricants were added it would tend to
contaminate other parts of the apparatus, thus forming a dirt-collecting surface. Lubricate pivots only at
overhaul with grade SAE 30 oil.
Lubricate cylinders, piston, rods, sliding parts and solid (no oil-impregnated) rollers, etc., periodically
with grade SAE 30 oil.
Do not add grease to ball bearing between overhauls, unless otherwise specified in this manual; clean and
re-pack them at overhaul with Shell Alvania 3 or other approved grease. Also use this grease for smearing
the teeth of racks and pinions, and for lubricating sleeve-bearings.
Lubricate oil-impregnated rollers and bearing bushes with grade SAE 30 oil only an overhaul.
Lubricate the hinges on pantograph current-collectors with no-water-soluble grease or oil.
The foregoing information is given as a guide, and it is recommended that operators discuss with an oil
company's local representative, the lubricants best suited to the particular climatic conditions under which
the equipment will operate.

4. TIGHTNESS OF BOLTS SCREWS AND NUTS
It is essential that all bolts, screws and nuts are kept tight, because any loosening can cause failure of the
vehicle as well as damage to adjacent or associated apparatus. There is also the possibility of fire being
caused by arcing at loose terminals.
Suitable locking devices are provided in the form of high grade spring locking-washers, locking plates,
grub screws or prick-punching etc., and when dismantling take place these locking devices must be
replaced by devices of the same grade of material and in the same form as originally supplied.
Contactor contacts, which are subjected to repeated impacts, connections, which are subjected to severe
heating cycles such as those, associated with resistors, and the smaller sizes of cable terminals, are items
which are most liable to loosen.
Before the equipment enters service, carefully check every electrical connection and contact. Repeat this
check after a week and then every three months for the first twelve month's operation. If at the end of
twelve months, no further loosening is detected, it can be assumed that all connections will maintain their
tightness for an indefinite period and the checking may be discontinued.
The reason why certain contacts and connections become loose is due to the copper deforming slightly
when under pressure, and the repeated tightening causes it to become compacted and work hardened.
5. ELECTRICAL INSULATION
Insulation can fail either by puncture through the body to the material, or by surface breakdown.
Puncture depends upon the quality and thickness of the material and the voltage across it. It follows,
therefore, that if insulating material has suffered damage, it must only be replaced by material of the
original thickness and quality.
Surface breakdown depends upon the quality of the surface of the material, its cleanliness and freedom
from moisture, the surface length, and the voltage across it.
If the surface is contaminated by dirt and/or moisture it becomes slightly conducting and a minute current
will flow along a very narrow track. This current will produce heat along the track, which may cause the
dirt and/or the surface of the insulation to carbonise and the "tracking" current to increase. The action

then becomes cumulative and if the surface is not cleaned, a flashover of power current will occur sooner
or later.
The insulation surface between two points at different voltage level is known as the "creepage distance"
while "tracking" is the term applied to the visible evidence of the passage of minute currents along
irregular tracks on the insulation surface.
The top surface of horizontal insulation is, of course, mere prone to contamination by dirt and moisture
and requires more frequent cleaning than vertical surfaces.
When an insulation surface becomes damaged by tracking or has deteriorated with age, it can be
reconditioned by painting it with good anti-tracking enamel. Such as grey insulating enamel which can be
supplied by brush and which is air-drying.
When apparatus is being overhauled, take the opportunity to recondition the insulation surface, if this
appears to be necessary. If porcelain insulation suffers surface damage, fit new porcelain; however, the
surface of Mycalex insulation or resin-bonded asbestos can be reconditioned by cleaning it with fine glass
paper.
Porcelain insulators which are exposed to the weather may become encrusted with a hard surface of
carbon, copper and brake-shoe dust, etc., which is difficult to remove. By coating the surface with
Metroarc-17 or Silicone-110 grease, the contaminants may be removed easily at suitable grease intervals;
re-grease the porcelain insulators after cleaning. First, apply the grease thinly on the hands, then run the
hands lightly over the porcelain surface.
6. ARC CHUTES
The arc-chute walls, especially the area adjacent to the contact tips, will exhibit charring and soot from the
arc, and splatter from the contacts dependent on the severity and duration of the arc. Maintenance work is
rarely necessary but it is important to examine the arc chute interior for unusual charring or an unusual
extent or copper splatter on the arc horns or splatters which would indicate a fault on the Contactor or its
associated equipment.
If an arc chute is removed for inspection, always refit it in its original position so that the pattern of its
characteristic wear can continue. To achieve this, mark each arc chute to correspond with its Contactor.
When an arc chute has reached its safe limit to working life on a heavy-duty Contactor it may be
economic to extend its life by interchanging it with the chute from a lightly loaded Contactor.

Record any such interchanges so that the equipment inspectors understand the reason for wear on the
lightly loaded Contactor, the arc chute of which may normally remain almost as new.
After fitting an arc chute and during any inspection of arc chutes, ensure that the chute is securely in
position and, PROVIDED THAT THE CONTACTOR IS NOT LIVE, manually operate the Contactor and
observe that the moving contact does not foul the chute.
Ensure that spare arc chutes are always available in the running sheds, safely stacked and kept clean and
dry, to enable any damaged or badly-eroded chute to be changed quickly.
Overhaul
Asbestos develops a skin, which would not be disturbed by rough filing. Use a fine file or glass paper to
remove loose dirt and any copper globules, which may foul the moving contact.
Since un-weathered asbestos is hygroscopic, new or freshly repaired arc chutes should be kept warm and
dry. Wet arc chutes can cause low readings of insulation resistance on the power circuits.
Mycalex is not hygroscopic and the surface can be reconditioned by rough filing, if necessary.
Examine the arc chute mounting arrangement. Recondition Starting threads on mounting blocks and
screws.
Examine the arc-chute interior for signs of rubbing or transferred paint due to fouling by the piston
insulator or the blow cut coil.
Erosion in the form of creators in the side plates, and gutters in the top and bottom spreaders can often be
repaired with an arc-resisting cement provided that the erosion has not penetrated too deeply. Clean
thoroughly with glass paper the part to be cemented. The cement can then be applied with a knife and the
repair dried in an oven or air dried before the chute is used again.
Scrape any soot from the joints between side plates, splitters and spreaders and look for penetration by the
arc in to the joint. Fill any such penetration with arc-resisting cement. Use this cement to coat the joints
during re-assembly of any arc chute components, which are prone to severe penetration.
Ensure that any copper inserts in the arc-chute body are securely fixed.
Ensure that incorrect re-assembly does not allow the arc to strike any fixings, especially which pass
through the arc chute.
7. ARCING HORNS
Contactors with un-swept top arcing horns depend upon a good fit between the horn and the chute to
produce a gas proof joint for the protection of the blow-out coil; this close fit must be preserved when a
new arc chute or horn is fitted. This fit should be equivalent to a clearance not greater than 0.25 mm
between horn and chute.
When arcing horns become badly eroded at their tips and become appreciably shortened, fit new horns.
When unswept top arcing-horns become eroded to half their original thickness, fit new horns.
8. CONTACTS
Copper and silver are in general use as contact materials. Although the resistance values are similar, silver
is an inferior arcing material due to its rapid erosion and is used only for low-voltage control-circuits with
light arcing duty and for heavy-current contacts with no arcing duty.
Silver forms on its surface a low-resistance sulphide, which is brown to black in colour, and need not be
disturbed.
Copper forms an oxide, dark in colour, which has a high resistance. This would cause overheating if it
were left on a contact face.
For Contactors (which interrupt current frequently as distinct from a switch or an isolator) copper is used.
Each contact is formed in the shape of a foot with a distinct heel and toe and the moving contact is spring-
mounted on a pivot. As the Contactor closes, initial contact is made at the toes of the contacts and, as
closure proceeds, the moving contact rolls and slides over the fixed contact until final contact is made at
the heels. The action is reversed when the Contactor opens; the area of contact travels to the toes where
the contacts separate, so that the arcing when current is broken has its roots at the toes of the contacts. By
this means, the transfer of current can take place across well-mated surfaces free from arcing. The action
of the moving contact is termed KNUCKLING and is a combined rolling-and-sliding motion.
Copper contacts for light-duty contactors and for switches do not always have a distinct toe and heel with
a knuckling action, but they are always given a sliding action or WIPE, which promotes a self-cleaning
action of any copper oxide that may have formed.
In general, silver contacts close with a simple butting action and such contacts are termed BUTT contacts.
The term OVER-TRAVEL is used for both wiped and butt contacts with reference to some particular
point on the moving contact or its carrier and denotes the distance that this point would travel after making
initial contact if the fixed contact were then removed. It is therefore an indication of the amount the
contacts can wear before effective contact fails.
In some applications, a Contactor may combine the properties of copper and silver by having a pair of
copper contacts with silver inserts at the current-carrying areas. On other contactors, separate pairs of
contacts in parallel are used, one pair of copper and one pair of silver, with the silver, contacts closed only
in the fully-closed position of the contractor and the copper contacts making and breaking the current.
DO NOT USE EMERY OR GLASS PAPER to clean contacts, as particles of these materials, which
might adhere to the surfaces, would cause faulty contacts.
DO NOT USE WIRE WOOL to clean contacts or any other electrical apparatus.
When contact tips are being fitted, tighten them lightly, and then finally tighten them with the Contactor
energised or firmly held in its closed position. This will give the best possible bedding of the contacts.
Some contact carriers have a ledge on which the contact locates, so that no movement can take place
during the repeated closing of the Contactor and such contacts must be seated fully with the fixing screw
and tightened before finally tightening with the Contactor fully closed.
On a rebuilt Contactor, the fixed-contact holder may be askew, thus preventing good bedding of the
contacts. Correct the contact holder by slackening its fixings, then tightening with the Contactor closed.
If the contact tips are discoloured by overheating, examine them for dirt or a coating of copper oxide on
both the front and rear conducting surfaces; check also the tightness and bedding of the contacts with each
other and with their holders. Overheating may also be caused by low contact-pressure due to worn
contacts, lack of over travel, or a weak knuckling-spring.
Examine knuckling or contact springs periodically to ensure that no stiffness has developed in the hinge,
and that the spring has not weakened. An experienced inspector will quickly discover any abnormality of
the hinge or the spring pressure by manipulating the device.
Fit new contacts in place, if any, which have worn to half their original thickness of copper or silver.
Always fit new contacts in pairs since it is not practical to bed a new contact with a worn one. Except on
small contactors and auxiliary contacts hand filing of badly worn contacts to produce a true surface
capable of being correctly mated, is a highly-skilled operation and is rarely successful. If it is attempted,
the filing should be carried out with the contacts in a vice so that pivots or pistons are not stressed, and no
metal particles fall on the apparatus.
Transference of metal from one contact to the other occasionally occurs in inductive circuits. When this
occurs, file the contacts to their normal contour in a vice, or if the transference is appreciable, fit new
contacts.

Restrict filing in position to a fine file to remove copper oxide and small high spots on current-carrying
surfaces, also to remove copper beads from contact edges and arc-rupturing areas, since these may foul the
arc chute or may eventually drop into the moving parts of the contactor.
Copper contacts
After a few weeks in service, the appearance of the contacts will indicate where the interruption is taking
place by a rough copper surface and where current carrying takes place by bright copper areas. A dull
surface indicates where the contacts are not mating; such a surface on the heel of a contact would indicate
that the knuckling action is incomplete or that the contacts are misaligned.
A regular inspector will appreciate the condition to be expected from the contacts. Since each pair will
develop contact wear and copper splatter on the arc horns and arc chutes characteristic of its position in
the circuit. As a guide to the amount of wear to expect, the inspector should at first learn whether each
pair of contacts breaks or makes current or both or is simply used for isolation. Note that the contact wear
on some contactors with light duty or infrequent heavy duty under fault conditions, may be largely due to
mechanical hammering and knuckling. The inspector should be able to recognise unusual wear, which
may indicate a fault on the contactor or on its associated equipment.
Current-carrying areas which have a bright appearance, but which have become rough and pitted, indicate
good contact and need not be disturbed.
Silver Contacts
In normal operation only a visual inspection is necessary between overhauls.

On control circuits with inductance, arcing will cause a transfer of metal, but the resulting pip and trough
will not normally warrant attention until the overhaul stage. When appreciable erosion has occurred,
smooth the surfaces with a fine file and readjust the contact gap and overtravel.
The contact pressure of control and auxiliary contacts are not critical, but it is necessary to ensure that they
have adequate overtravel, so that they will be effective even after some wear has taken place.
On power circuits, there will be no arcing unless there is fault condition.

9. PNEUMATIC PISTONS AND CYLINDERS
9.1 Lubrication
Lubricate the cylinders and piston rods of E.P. Contactors periodically with grade SAE 30 oil, otherwise
their operation will become sluggish, and this will be detrimental to the general operation of the
equipment, particularly to rupture the arc. Lack of lubricant will also cause rapid wear of the cylinder
wall, piston rod and guide.
In order to lubricate the piston rod of an E.P. Contactor, raise the piston in its cylinder (by pressing the
magnet valve button) and add a small quantity of oil to the countersink which surrounds the rod at the top
of the cylinder to lubricate the cylinder, inject a small quantity of oil through the special oil-hole in the
cylinder wall.
E. P. Contactors with horizontally disposed cylinders do not require the piston rod to be lubricated,
because the rod passes through a clearance hole in the end of the cylinder.
Lubricate the cylinders of reversing switches and change over switches with grade SAE 30 oil, through
nipples provided in the cylinder walls. Before adding the lubricant, ensure that the piston is coincident
with its nipple. When one piston has been lubricated, move the piston assembly to the other end of its
stroke (by pressing the relevant magnet-valve button).
Before refitting a piston in to its cylinder, smear the cylinder wall thoroughly with oil.
Lubricate the rack, pinions and levers of reversing switches and changeover switches with Shell Alvania 3
or 4x grease.
9.2 Dismantling and assembling
Cylinder walls have a very fine and smooth finish to avoid wearing out the rubber piston seal. Great care
must be taken, therefore, to ensure that the surface is not damaged.
When dismantling the pistons of pneumatic contactors, it should be borne in mind that the return spring is
under compression. When the nut holding the piston to the rod is released, it will tend to fly out of the
cylinder and might be damaged or cause damage to neighbouring apparatus or injury to personnel.

Carefully examine rubber seals at over haul; fit new seals if appreciable wear is evident. Seals are slightly
elastic and must be stretched and forced over the lip on the piston in to the groove.
When fitting a piston rod, anneal the copper washer seal in order to ensure an airtight joint, when refitting
a cylinder cover, use a new jointing gasket because the existing gasket is invariably damaged during the
removal of the cover, and pieces of the old gasket adhere to the cylinder and cover. Ensure that all traces
of the old gasket are removed before fitting the new gasket.
Pneumatic cylinders for contactors are sometimes provided with a loose tube on the piston rod which acts
as a piston stop to protect the return spring against over-compression. During re-assembly work, this tube
must not be omitted.
10. RESISTORS
 The following types of resistor are most commonly used on traction equipment
 Expanded metal or metal strip wound on edge
 Wire wound, mica insulated metal tubes
 Vitreous enamelled, wire wound, porcelain tubes
 Flat, wire or metal tape wound mica elements
Maintenance
 Check that all nuts, bolts and screws are tight.

 Ensure that all connections, tapping and terminals are secure and in good condition.
 Inspect resistors for damage and overheating; if necessary fit new units.
 Examine insulators and supports, remove cracked or chipped insulators and fit new ones.
 Wipe insulators with clean, dry cloth-Blow-out resistor banks with dry compressed air.
Overhaul
 Repeat maintenance.
 Re-varnish insulation surfaces, other than porcelain.
 Clean metal support frames and covers, repaint if necessary
 Check resistance values to figures given "Data for Control Apparatus".

NOTES
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CHAPTER IX
DRIVING INSTRUCTIONS
Maintenance Manual
CHAPTER IX
1. OPERATING INSTRUCTIONS FOR DRIVER
1) Preparation of Vehicle for Service

The driver should be provided with a master controller key and driver's control key. Before taking
a train into service, the driver must check the following points.
1.1 Check that all sealed switches are in OFF position.
1.2 Insert driver's control switch (DCS) key in Driver's Control Switch box (BL box) and turn in ON
& OFF.
1.3 Insert the master controller key and operate FORWARD & REVERSE and keep it in the OFF
position.
1.4 Switch on 24-Volt DC Battery isolating switch in the engine room.
1.5 Switch on 110 Volt DC battery isolating fuse switch behind driver's seat.
1.6 Switch on both battery voltmeter switches and check for

i) Starting battery voltage reads 24V
ii) Control battery voltage reads above 88V
1.7 Switch on all MCBs (control and auxiliary) except rectifier blower motor MCB
i) Switch on 110 V MCB and 24 V MCB in the engine control panel
ii) Throw the local/remote selector switch in the engine control panel to remote side.
1.8 Insert DCS key in the BL box & turn it ON.

1.9 Switch ON control switch in the BL box. Control ON indication will come on LED indication
panel.
1.10 Press lamp test switch and see that all LED indications are glowing.
1.11 Keep Engine Control Switch (ECS) in "IDLE" position.
1.12 Press "Engine ON" switch.

“Engine ON” indication will come and “Engine TRIP” indication will go OFF.
1.13 Switch ON rectifier blower motor MCB. Rectifier blower motor will start functioning now.
Rectifier cooling fan failure indication will go off.
1.14 Keep the test sequence switch in OFF condition and ECS continue to be in "IDLE" position.
1.15 Allow the engine to run in IDLE position till feed pipe pressure reaches 7 Kg/cm sq. For fast
build-up of the pressure engine can be notched up accordingly.
Note: Alternator Excitation ON switch on BL box should necessarily be in OFF condition.
2. Instructions for driving
2.1 Ensure that parking brake is released. If not, release the parking brake switch.
2.2 If feed pipe pressure is built up to 7 Kg/cm sq. and guard's key is inserted, driver's interlock relay
(DIR) will operate thereby drive function released indication will come. It is now possible to take
traction.
2.3 Put ECS switch in "RUN" position
2.4 Switch on Excitation ON switch in BL box. Alternator Excitation ON indication will come.

2.5 Ensure that brake pipe pressure is 5 Kg/cm sq.
2.6 Move the master controller key in clockwise direction by 90 & set the reverse handle of master
controller to the FORWARD position.
2.7 Depress deadman's handle and move it in the Notch-1 position.
2.8 Now, the master controller can be moved to next notch.
3. Instructions for shutting off the vehicle
3.1 Bring the master controller handle to OFF position & release the deadman's knob.
3.2 Switch OFF the excitation.
3.3 Apply parking brake
3.4 Put ECS switch in "IDLE" position. Switch off engine by pressing Engine OFF switches.
3.5 Switch off the Control Switch in BL box.
3.6 Bring DCS key in off position and remove it from DCS box.
3.7 Switch off control battery and starting battery-isolating switches.
3.8 Close all the doors and windows of the driving cab.

NOTES
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CHAPTER X
SPICAC_US DRAWINGS
1. Wiring Schematics
2. General Arrangement Drawings
Maintenance Manual
SPICAC DRAWINGS
CHAPTER X
SPICAC_US DRAWINGS
A. Wiring Schematics
S. No. Description Drawing No.

1 Power Schematic CG/SPIC/180805 R1
2 Control Schematic Cab - 1 CG/SPIC/180807 R1_S1
3 Control Schematic Cab - 2 CG/SPIC/180807 R1_S2
4 Auxiliary Schematic CG/SPIC/180808 R1
5 Power pack schematic CG/SPIC/180806 R1
B. General Arrangement Drawings
S. No. Description Drawing No.

1 Traction Alternator CGA/101004_R6
2 Terminal box assembly CGA/201101_R4
3 Traction Motor 11290003_R5
4 Power Rectifier CGPR/SPIC/180801 R3_S1 & S2
5 Power Rectifier – Circuit diagram CGPR/SPIC/180802_R1
6 Driver’s Desk CG/SPIC/180803_R2
7 Control Cubicle CG/SPIC/180801_R2
8 Motor Switch Group Cubicle CG/SPIC/180802_R1
9 Resistance Panel CG/SPIC/180804_R0
CG/SPIC/180805
IF IN DOUBT -ASK SHEET 1 OF 1
MATERIAL :- NA
SPECN :- NA
FINISH :- NA POWER SCHEMATICS
SIGN NAME FOR SPICAC
DRN. BSR
CHD. AU
REVISED AS PER ICF
BSR
APPD. LKT
COMMENTS VIDE ICF Lr. No. DATE :- 20-02-2018
MD/D/SPIC/109 Dt. 12/09/18
14.09.18
SCALE :- NTS
DRG No. - REV.
No. REVISION DATE GEN. TOL. ALL DIMENSIONS IN mm CG/SPIC/180805 01
CG/SPIC/180807
MATERIAL :- NA
SPECN :- NA
CONTROL SCHEMATICS
FINISH :- NA
SIGN NAME
CAB I
DRN. BSR FOR SPICAC
CHD. AU
REVISED AS PER ICF APPD. LKT
COMMENTS VIDE ICF Lr. No.
BSR
DATE :- 20-02-2018
MD/D/SPIC/109 Dt. 12/09/18
14.09.18
SCALE :- NTS
DRG No. - REV.
CG/SPIC/180807
SHEET 2 OF 2
IF IN DOUBT -ASK
MATERIAL :- NA
SPECN :- NA
CONTROL SCHEMATICS
FINISH :- NA
SIGN NAME
CAB II
DRN. BSR FOR SPICAC
CHD. AU
REVISED AS PER ICF
BSR
APPD. LKT
MD/D/SPIC/109 Dt. 12/09/18
14.09.18
SCALE :- NTS
DRG No. - REV.
CG/SPIC/180808
MATERIAL :- NA
SPECN :- NA
FINISH :- NA AUXILIARY SCHEMATICS
DRN. BSR
CHD. AU
REVISED AS PER ICF
BSR
APPD. LKT
MD/D/SPIC/109 Dt. 12/09/18
14.09.18
SCALE :- NTS
DRG No. - REV.
CG/SPIC/180806
MATERIAL :- NA
SPECN :- NA
FINISH :- NA POWER PACK SCHEMATICS
DRN. BSR
CHD. AU
REVISED AS PER ICF
BSR
APPD. LKT
MD/D/SPIC/109 Dt. 12/09/18
14.09.18
SCALE :- NTS
DRG No. - REV.
1 2 3 4 5 6
CG/SPIC/180803
SHEET : 1 OF 3
*
6"-DUPLEX PRESSURE GAUGE CAB FAN (G)
ISSUE :- 3
*
6"-DUPLEX PRESSURE GAUGE
LED PANEL
BC / PB SPEEDOMETER
AMMETER
CAB FAN (D)
SPARE
CAB LIGHT (D)
MOBILE CHARGING UNIT
262 *
CAMERA UNIT
601
521
FP / BP DCS
SPARE
A A
*
230
WIPER CONTROL
SPARE
*
CAB LIGHT (G)
* WIPER CONTROLLER
IF IN DOUBT -ASK
PRESSURE SWITCH
1110
*
MAGNET VALVE ( HORN)
832
EARTHING POINT
200
MAGNET VALVE (DEAD MAN)
B EARTHING POINT B
EMERGENCY CUT OFF
*
PEDAL OPERATED HORN SWITCH - ELEC.
FOR TB ARRANGEMENT
SEE DETAIL - ''X''
2850
CONNECTORS
25x25 C-CHANNEL ARE LOOSE SUPPLY
(SEE NOTE-1)
438
TB-15
ENGINE OFF HEAD LIGHT 400 536 536 400 'D' BOARD
PAR. BRK RELEASE 65 NOS. TB 53 NOS. TB 64 NOS. TB
80
HEAD LIGHT (D/B)

TB-12 TB-16
315
'A' BOARD CONT TB DESK-I
511
TB-13
'B' BOARD
TB-17
AUX. TB DESK-I
STMC
532
HORN AUX. EARTH TB-14
403
*
250
FAULT RESET 'C' BOARD

BRAKE VALVE SPARE ENGINE CONTROL
C CONTROL ASSY SWITCH C
530
DETAIL - "X"
TB ARRANGEMENT DETAIL
CHAIR MATERIAL :- - .
SPECN :- -
All information contained in this document
FINISH :- -
OGA OF
is confidential and should not be used
NOTE :- DRIVER DESK FOR

SIGN NAME
1. DETAIL OF LOOSE SUPPLY 25x25 C-CHANNEL TO WELD BETWEEN FLOOR & REVISED AS PER ICF COMMENTS 17/10/18
SPIC
2 DRN.
D BOTTOM 50 SQ. STRUCTURE OF SPIC. BSR
D
2. * MARKED ITEMS ARE IN ICF SCOPE OF SUPPLY. CHD. AU
without piror consent of
CG POWER AND
3. * MARKED ITEMS IS COMPLIED. REVISED AS PER ICF COMMENTS VIDE 18/09/18 APPD. LKT
INDUSTRIAL
1 ICF LR. NO. MD/D/SPIC/109 DATE :- 18-09-2018
4. TO ICF SPEC. - ICF/MD/SPEC-349R0. DT. 07/09/18 SOLUTIONS LTD.
SCALE :- NTS
NOTE : FOR LED PANEL DETAIL REFER SHEET NO. 3. No REVISION DATE GEN. TOL. ALL DIMENSIONS IN mm DRG No. - CG/SPIC/180803 REV.
2
1 2 3 .
4 5 6
1 2 3 4 5 6
CG/SPIC/180803
SHEET : 2 OF 3
ISSUE :- 3
A A
IF IN DOUBT -ASK
BOTTOM ELEVATION
C
B B
A B
BACK ELEVATION C
VIEW B VIEW A
TEST SEQUENCE
INST. LIGHT
EXCITATION ON/OFF FOG LIGHT
MARKER LIGHT
C TAIL LIGHT CL C
NOTE :-
PAINTING :
1. ALL FABRICATED PARTS AND FRP TOP COVER SHALL BE OF RAL-9018 PAPYRUS WHITE.
2. ALL DETACHABLE INTERFACING PLATES SHALL BE OF RAL-5003 OXFORD BLUE.
SPOT LIGHT (D)
FLASHER LIGHT
SPOT LIGHT (G)
MATERIAL :- - .
SPECN :- -
IGA OF
FINISH :- -
SIGN NAME
DRIVER DESK FOR
REVISED AS PER ICF COMMENTS 17/10/18
2 DRN. BSR SPIC
D ISOMETRIC VIEWS CHD. AU D
APPD. LKT
CG POWER AND
REVISED AS PER ICF COMMENTS VIDE 18/09/18
ICF LR. NO. MD/D/SPIC/109 DATE :- 18-09-2018
INDUSTRIAL
1
DT. 07/09/18 SOLUTIONS LTD.
SECTION C-C No REVISION
SCALE :- NTS
DATE GEN. TOL. ALL DIMENSIONS IN mm DRG No. - CG/SPIC/180803 REV.
2
1 2 3 .
4 5 6
CG/SPIC/180801 1 2 3 4 5 6
1804 SHEET 1 OF 4
1574 ISSUE :-1
36
A A
IF IN DOUBT -ASK
E
PROVISION FOR SPARE
TYCO CONNECTOR(2
Nos.)
MCB SPARE TYCO

G CONNECTOR 1 NO.
MCB
1768.01
B B
1704
1641
CUT OUTS OF
BATTERY 100X170 FOR
CHARGING CABLE ENTRY
SWITCH
BATTERY CUTOUT
SWITCH
C C
300
M10 TAPPED HOLE Right view
FOR EARTHING PAD
7 Nos.HOLES 2 Nos.HOLES WITH NOTE-
14 Nos. TYCO CONNECTORS
WITH M32 CABLE M50 CABLE GLAND 3 Nos.HOLES WITH M50 1. PAINTING WILL BE DONE AS
GLAND CABLE GLAND A. PRIMER SYNTHETIC ENAMEL GRAY COLOUR.
B. OUT- SYNTHETIC ENAMEL SIEMENS GREY RAL- 7032

C. INSIDE PU WHITE THICKNESS 60
DD1 DD2
MATERIAL :- -
322
SPECN :- -
FINISH :- - OGA & IGA of
CONTROL CUBICAL
A BOARD B BOARD C BOARD D BOARD CONTROL AUX. MSG. RECTIFIER A BOARD B BOARD C BOARD D BOARD CONTROL AUX.
SIGN NAME
REVISED AS PER 17/10/18

2 ICF COMMENTS BSR
DRN.
D 825 825 CHD. AU
D
REVISED AS PER ICF LKT
CG POWER AND
APPD.
3 HOLES. 15
1
COMMENTS VIDE ICF LR 18/09/18
DATE :- 18-09-2018
INDUSTRIAL
NO. MD/D/SPIC/109 Dt.
07/09/18 SCALE :- NTS SOLUTIONS LTD.
NOTE- FOR DETAIL OF LABELS OF EQUIPMENTS REF. SHEET NO. 3 & 4 REV.
No. REVISION DATE GEN. TOL.ALL DIMENSIONS IN mm DRG No. - CG/SPIC/180801 02
1 2 3 4 5 6
CG/SPIC/180802 1 2 3 4 5 6
520
SHEET 1 OF 2
RP MOUNTING ARRANGEMENT
10 ISSUE :-1
170
3
13 Nos. CABLE GLAND
13 HOLES OF 41
FOR GLANDS 4X 18
MOUNTING
A A
HOLES
IF IN DOUBT -ASK
540
400
BOLTED SIDE
BOTTOM COVER
1500
B 650 B
1663
1625
1600
Bottom view
WITH COVER PLATE
2 Nos. PMA
200
75 GLAND
144
550
5
25
SHUNT CONNECTOR
25
CABLE ENTRY HOLE
600
450
75 4 Nos. M16 TAPPED
C 25 HOLES FOR EYE C
RP CABLE BOLT
ENTRY
HOLE
144
100
50
600
M10 TAPPED HOLE TOP VIEW

700 FOR EARTHING PAD

MATERIAL :- -
LOOSE BOTTOM CHANNEL SPECN :- -
FINISH :- - OGA of MSGC
SIGN NAME
NOTE- 2 BSR (SPIC)

DRN.
D 1. PAINTING WILL BE DONE AS CHD. AU D
A. PRIMER SYNTHETIC ENAMEL GRAY COLOUR. CG POWER AND
DRAWING UPDATED AS PER 13/09/18 APPD. LKT
B. OUT- SYNTHETIC ENAMEL SIEMENS GREY RAL- 7032 1 ICF REQUIREMENT.
DATE :- 27-08-2018
INDUSTRIAL
C. INSIDE PU WHITE THICKNESS 60 SOLUTIONS LTD.
SCALE :- NTS
REV.
1 2 3 4 5 6
CG/SPIC/180804 1 2 3 4 5 6
170 SHEET 1 OF 1
4X 12 ISSUE :-1
MOUNTING HOLES
TERMINAL BLOCKS
A A
IF IN DOUBT -ASK
3 Nos. RESISTORS
1 NO. POWER DIODE
36 ,300W
B B
540
560
C C
50 50
25 HOLE FOR
81.5
CABLE ENTRY 100

WITH CABLE
37
GLAND MATERIAL :- -
SPECN :- -
FINISH :- - OGA & IGA of RP
SIGN NAME
2
(SPIC)
D DRN. BSR D
CHD. AU
CG POWER AND
APPD. LKT
1 DATE :- 27-08-2018
INDUSTRIAL
206 SOLUTIONS LTD.
SCALE :- NTS
REV.
1 2 3 4 5 6
CHAPTER XI
RECOMMENDED SPARES & TOOLS
Maintenance Manual
CHAPTER XI
LIST OF RECOMMENDED CONSUMABLE MAINTENANCE SPARES FOR

SELF-PROPELLED INSPECTION CAR - US
1. Carbon Brushes for Traction Motor - 4 Sets

2. HRC fuse for Control gear - 1 Set
3. Trip Fuse for power rectifier - 3 Nos.
********

RECOMMENDED LIST OF SPARES FOR 2 YEARS FOR 2 SETS OF

SELF-PROPELLED INSPECTION CAR - US
1) TRACTION ALTERNATOR
1.1 Ball Bearing : 1set

1.2 Diodes : 2sets
2) TRACTION MOTOR
2.1 Armature : 1 No
2.2 Stator Assembly : 1 No
2.3 Carbon Brushes : 4 Motor sets
2.4 Brush Holders : 1 Motor sets
2.5 Armature Bearings : 2 Nos. each
(CE & PE)
2.6 Axle Bearings (CE & PE) : 1 Motor sets
2.7 Lubricators (2Nos/set) : 1 Motor sets
2.8 Gear Case felt seals : 1 Motor sets
2.9 Gear Case : 1set
2.10 Bellows : 1 Nos.

LIST OF SPECIAL TOOLS
EQUIPMENT QTY
1. TRACTION ALTERNATOR
1.1 Lifting Shackle 1 No
2 TRACTION MOTOR
2.1 Lifting Shackle 1 No
2.2 Extractor for PE Bearing 1 No

inner race
2.3 Extractor for CE bearing 1 No
2.4 CE protecting sleeve and lifting cap 1 No
2.5 Retaining plate for PE Bearing 1 No
2.6 Lifting Cap P.E. 1 No
2.7 Protecting Sleeve PE Bearings 1 No
3. Control Gear No Special Tools required

RECOMMENDED LIST OF PRINCIPLE SUB-ASSEMBLIES REQUIRED AS

EMERGENCY STANDBY FOR 2 SETS OF SPICAC
SL. NO EQUIPMENT QTY
1. Traction Alternator 1 No
2. Traction Motors without pinion 2 Nos.

Gear case, GC etc
3. E.P. Line Contactors 2 Nos.
4. Motor Reverser 1 Nos.
5. Master controller 1 Nos.
6. 24-Pin Connector 2 Nos.
7. Overload Relay 1 No.
8. Diesel Engine 1 No
********

NOTES
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CHAPTER XII
ANNEXURE: 1
TROUBLE SHOOTING-POWER PACK
Maintenance Manual
ANNEXURE: 1
Annexure 1
Trouble shooting – Power pack
Sl. No. IN CASE OF CAUSE REMEDY
Drained battery Check & charge battery

Engine does
1
not crank
Incorrect /loosen battery Check the battery connections
connections and rectify
No fuel in tank Add sufficient fuel

Fuel filter clogged Clean the fuel filter
Engine cranks
2 but doesn’t Identify any loose
Improper Fuel connections at pump
starts connections and rectify
Restriction in air inlet / exhaust Check piping and rectify if
any restriction exists
Air entering in the fuel system Check all the fuel
connections, tighten if found
loose
Starts but does Inspect fuel line for any

3 Fuel suction line restricted
not throttle blockage
Inspect fuel sample / verify

Fuel contaminated by connecting a temporary
fuel tank
Remove and clean the filter
Air inlet filter clogged
Excessive element
4
exhaust smoke
Contaminated fuel Check the fuel sample &
replenish with new fuel
Restriction in air inlet / exhaust
Check piping and rectify if
any restriction exists
Low engine
5
output power Check the lube oil level in
Excessive lubricating oil sump with dipstick provided
and reduce if it is high
ANNEXURE: 1
Check any leakage /

Improper / leakage in fuel flow to
restriction at connections,
fuel pump
rectify if any
Malfunction of throttle solenoid

Check and rectify if any
valves
Malfunction of tachometer Test and rectify

Low engine
Fuel line restricted Check and rectify
6 speed at full
throttle Excessive traction load on the
Reduce the vehicle load
power pack
Release the brake on desk and

Vehicle brakes applied bring brake handle to
‘Release & running’
Vehicle does Check & select master

not moves Controls not engaged in Forward / controller direction selector to
7 Reverse required position, if not
when engine
throttled selected
Release the parking brake

Parking brakes applied with operating switch
provided on desk
Check and open the isolating

cock at air inlet side and
System Pressure not developed Check for proper functioning
of Limiting valve and non-
return valve
No water Check water availability at

Insufficient suction head / inlet
outlet from pipe outlet / inspect for any
8 restricted
water rising block in the pipe
apparatus
Isolating valve at outlet is closed Check and open the valve
Check for proper connections

Hose / pipe joints leaking or
/ routing with respect to
disconnected
drawing
TIGHTENING TORQUE
Annexure 2
TIGHTENING TORQUE IN N-m FOR THREADED COMPONENTS.
MATERIAL PROPERTY CLASS AS PER IS:1367

8.8 10.9
MIN.YIELDSTRESS N/mm2 640 900
SIZE SCREW BOLT SCREW BOLT
M4 2.5 1.5 3 2
M5 6 3 8 4
M6 10 7 15 11
M8 24 18 34 26
M8x1.0 29 23 41 32
M10 46 38 64 53
M10X1.0 53 41 75 57
M12 76 63 107 89
M12X1.5 93 70 130 99
M14 117 90 165 126
M14X1.5 137 121 193 170
M16 176 139 248 195
M16X1.5 196 156 275 220
M18 245 186 344 261
M18X1.5 264 220 372 310
M20 328 264 461 372
M20X1.5 343 294 482 413
M20X2.0 333 284 468 399
M22 421 343 592 482
M22X1.5 441 392 620 551
M22X2.0 431 362 606 510
M24 549 411 772 579

TIGHTENING TORQUE
M24X1.5 578 441 813 620

M24X2.0 568 431 799 606
M27 921 539 1296 758
M27X1.5 1078 637 1516 896
M27X2.0 1029 607 1447 854
M30 1264 725 1778 1020
M30X1.5 1539 921 2164 1296
M30X2.0 1470 882 2068 1241
M33 1735 2440
M33X1.5 2059 2895
M33X2.0 1980 2785
M36 2216 3116
M36X1.5 2706 3805
M36X2.0 2608 3668
M36X3.0 2402 3378
The above values apply to bolts of lengths in excess of 5 times the thread diameter. For
smaller lengths the valves are to be reduced by 10%.
To get lb-ft multiply the above values by 0.737
To get lb-inch multiply the above values by 8.85
To get kg-m multiply the above values by 0.102

SELF PROPELLED INSPECTION CAR
(40kVA, 415V, 50Hz DA Set)

DA SET USER MANUAL
POWER WHENEVER YOU NEED IT
TYPE: LIQUID COOLED (DV SERIES ENGINES)

Enriching Lives
Dear Customer,
Ideas diesel generating sets.
Each Kirloskar Green genset is a result of painstaking research by us over decades. The research takes
into consideration the arduous operating conditions and user practices to create a world class reliable
product.
We have not only designed the genset, but also its major aggregates – Kirloskar Green AC Generator,
Sound Proof Outdoor Enclosure and Control Panel.
This Users Manual of Kirloskar Green Power Ideas genset has been prepared by keeping in mind needs
of most of the users. Thus, the manual only illustrates user serviceable maintenance practices and
parts. In case you desire more detailed information about the genset, its engine, AC generator, or control
panel, please let us know.
We are sure, Kirloskar Green Power ideas genset will serve you well for years as you continue to
maintain it as presented in this manual.
Yours faithfully,
For Kirloskar Oil Engines Ltd.,
Pune, INDIA
Head, Power Generation Business
Enriching Lives
While asking for assistance to our Authorised Service Dealer,
please provide the following information.
Your Name & Phone or Mobile Number.
Engine Serial Number.
Name of the Company.
Engine Location.
General Description of assistance required.
And the service will be on its way.
FOR EMERGENCY CONTACT

In the very unlikely event of you are not receiving the prompt attention
from our eld force, following are the contact details of our Help Desk
and area e for your assistance.
HELP DESK CONTACT NUMBER - +91 880 63 344 33

HELP DESK TOLL FREE NUMBER - 1800 233 3344
KIRLOSKAR OIL ENGINES LTD.

LAXMANRAO KIRLOSKAR ROAD, KHADKI, PUNE - 411 003.
email ID - koel.helpdesk@kirloskar.com
www.koel.co.in
PREFACE
This manual deals with the Kirloskar Green Power Ideas (KGPI) genset operation. The manual also explains
components and parts which a user can service on their own. The maximum performance of the genset
largely depends on its proper maintenance and upkeep. So, please ensure proper Genset maintenance as
per the instructions and schedule given in this manual. This user manual is divided into 6 Sections. These
relate to Genset, Diesel Engine, Alternator, Warranty, Customer Service, Area Office Contacts and Check
Call Cards. Please go through a synopsis of each section.
Section A – Genset Warranty
The Warranty Section is most important for you to understand completely. It gives you description
of all the “ifs and buts” of the warranty clauses and the means to get benefit from KGPI extended
warranty. It also contains a log sheet that you need to fill religiously. Please record the daily running of
the DG set and various parameters.
Section B – Customer Service Package
To ensure maximum life and best performance of your genset, we provide free commissioning
checks and maintenance checks. KOEL Service Dealer will carry out free service checks as mentioned in the
package. Please keep in mind that you would be required to pay for the consumables like lube oil filters,
fuel filters, lube oil, etc.
Section C – Genset User Manual
This Section takes you through to understand each aspect of the genset, its major components and
their operation. Chapter 3 tells you about the installation procedures and subsequent chapter take care of
the electrical control systems and optional equipment that can be used. You must read Chapter 6 and 7
thoroughly to understand the maintenance procedures for genset and batteries.
Section D – Engine User Manual
This part of the manual gives you a complete understanding of the engine operation and
maintenance from a user perspective. All the fluid systems, namely, lube-oil, fuel oil, cooling liquid flows
have been described because the upkeep of these three systems is significant to obtain optimum
performance from the engine. Later in this section, you must go through to comprehend the trouble-
shooting, remedial and engine preservation measures. This section takes care of all the models of engines
used in a KGPI genset. Efforts have been made to highlight those specific areas which are unique to a
particular engine model.
Section E – Alternator
Here we have given you a brief knowledge about the Kirloskar Green (KG) Alternator coupled to the
diesel engine. User needs to read the safety requirements and all the “do’s & don’ts”. In the end, you are
provided with the fault, cause and repair tables so that every time you don’t need to rush to a mechanic.
Section F – Service Network
KGPI takes care of you anywhere everywhere. And this last section contains the information (contact
details) of our zonal offices, area offices and service dealer locations. Each time you run into a problem
with your genset, just look for your nearest office/service dealer location in this section and KGPI will take
care of the rest.
Intimation Card
Please ensure that your manual has the intimation card. We request you to fill the required details
completely in the intimation card and post it to us immediately.
CONVENTIONS
Each warning/most important instruction in the manual succeeds the sign.
All the significant procedures are highlighted in bold letters in the manual.
All the illustrative diagrams in the manual show only the user-serviceable parts. The
numbers in the round boxes for every part are described below the illustration.
The logo displayed at the top corner of each page is the Kirloskar Green Power Ideas
brand logo.
••••••••••••••Enriching Lives ••••••••••••••
SERVICE NETWORK
Authorized GOEM
Service Dealerships
Enriching Lives
KOEL Area Offices
Service
State Address Telephones Mobiles
Manager
Kirloskar Oil Engines Limited Anil Pandey 011-28715826 +91-
4-C/6, New Rohtak Road, 919910116895
New Delhi Opp. Liberty Cinema,
Karol Bagh,
New Delhi-110005
Kirloskar Oil Engines Limited Ravindra Kain 0161- +91-
Plot No. 12, Sherpur Chowk, 2546667/668/669 9810937556
Punjab N.P.C. Tempo, Union Street,
Near Arun Gas Godown,
Ludhiana – 141 003
Kirloskar Oil Engines Limited Varun Bali Tel :0141- 2370007 / +91-
Rajasthan Plot No. 3, Purohit Ji Ka 2370014 9829205552
Bagh, Off M. I. Road, Jaipur
– 302 001
Kirloskar Oil Engines Limited Kapil Shah/ 0522-2741440 / +91-
498/143 KA, New Faizabad Sudhir 2741441 9918000838
U.P. Road, /7678893875
Near IT College Crossing,
Lucknow – 226007
Kirloskar Oil Engines Limited Manna Arindam 033-22170858 +91-
Poonam Building, /60/61 9674003617
Flat No. 8A and 8B, 8th
West Bengal
Floor,
5/2, Russel Street,
Kolkata – 700071
Kirloskar Oil Engines Limited Mohit 0361-
29, 1st Floor,G.N.B.Road, Choudhary 2131334/2457616
Assam Pan Bazar,
Above Avery India Ltd.,
Guwahati – 781 001
Kirloskar Oil Engines Limited Santanu Das 0674- +91-
No. 178/A, Zone-B, 2588021/2588047 9778477870
Odisha Mancheswar Industrial
Estate,
Bhubaneshwar – 751010
Kirloskar Oil Engines Limited Narendra :+91-
Meena Plaza, South Kumar Roy 9031061077
Museum Road,
Bihar
Budh Marg,
Patna – 800001
Service
State Address Telephones Mobiles
Manager
Kirloskar Oil Engines Limited Kumar 0651- +91-
C/O Shri Ram Logistics Prabhakar 2301197/2211255 9771417061
Services,
Jharkhand 4P, 4th Floor, Shri Gopal
Complex,
Kutchery Road,
Ranchi – 834 001
Kirloskar Oil Engines Limited Kadhirvel 044 - 3744624/625 +91-
Nelson Towers, 1st Floor, /Bharanikumar 7299995717
2nd Wing No. 51, /9444990295
Tamil Nadu
Nelson Manickam Road,
Aminjikarai,
Chennai – 600029
Kirloskar Oil Engines Limited Vardhaman 040- +91-
D No. 5-2-220 To 222 Deepakkumar 27534197/27534176 9550500066
2nd Floor, Sri Padmavathi
Andhra Towers,
Pradesh Hyderbasti, Opp Andhra
Bank, Ranigunj,
Secunderabad – 500003
Kirloskar Oil Engines Limited Vijay T B 080-25587562/ +91-

15, Shri Laxmi Complex, 3rd 30578174 9900021100
Floor, St. Marks Road,
Karnataka
Opposite Bowring Institute,
Adjacent to India Garage,
Bangalore – 560001
Kirloskar Oil Engines Limited Shaji Mathew 0484- +91-
No. 39/2694-A1, Anugraha, 2385756/2385757 9744716767
Kerala
Panthiyil Lane, Warriam
Road, Cochin – 16
Kirloskar Oil Engines Limited Prashant Falke : 0731-3913101/11 :+91-
B-1, Radhakrishna Complex, 9826026463
10/1, Manorama Ganj,
M.P. Geeta Bhawan Square,
AB Road (Agra-Mumbai
Road),
Indore – 452 001
Kirloskar Oil Engines Limited 079-
Ground Floor, ‘D’ Block, 26929687/26929689
Gujarat Pruthvi Complex, Near
Jodhpur Char Rasta,
Ahmedabad – 380015
Kirloskar Oil Engines Limited Malay Amin/ 020- +91-
Maharashtra Laxmanrao Kirloskar Road, Rohit Patil 25810341/25815341 9922431561/
Khadki , Pune – 411003 9881495639
INDEX
Section A - Warranty
Section B - Customer Service
Section C - Genset
Section D - Diesel Engine
Section E - Alternator
Enriching Lives
· Best Quality Products Delivered
------------·Enriching Lives ------- --·

Operational and Maintenance Manual:
Diesel Genset
Warranty
Important
1. This warranty is applicable for Kirloskar Green Power Ideas (KPIG) gensets
manufactured by/under license from Kirloskar Oil Engines Limited (KOEL). Before
commissioning of the genset, please go through the contents of this Warranty
Section carefully.
2. For details of KOEL Authorised Service Dealer for your genset, please contact KOEL
Helpdesk.
3. For availing the warranty services please ensure following:
a) Produce this warranty booklet to KOEL authorised Service Dealer, when

requested.
b) Carry out first service check (G1) at 50 hours or 30 days from date of
commissioning, whichever is earlier. Carry out second service check (G2) at
250 hours or 6 months from date of commissioning, whichever is earlier.
Thereafter carry out subsequent service checks at every 500 hours or 6
months, whichever is earlier provided KOEL Premium Oil is used in the
engine.
c) Use recommended grade of lube oil and ensure periodic change of lube oil, as
recommended.
d) Use genuine air filter elements, lube oil filter elements, fuel filter elements,
coolant and additives, sourced from KOEL Authorised Service Dealer.
e) Please maintain the log-book for the genset at your end. The suggested
format for log-book is provided on page A-9.
f) Carry out all preventive maintenance and repair work of genset, through KOEL
authorised service dealers only.
g) The performance of genset depends on the quality and grade of lube oil and
periodic preventive maintenance. To ensure the genuinity of oil, KOEL has
launched the lube oil branded as K-Oil Premium. Please use K-Oil Premium
and genuine filters sourced through KOEL authorised parts and service dealer
and avail extended warranty.
A--1
Diesel Genset
Please provide following details to our Authorized

Service Dealer for quick restoration of your genset.
- Genset Model and Serial Number.
- Engine serial Number.
- Detailed site address
- Contact Person and Telephone/Mobile Number.
- Number of hours run till date
- Nature of failure
A-2
Diesel Genset
GENSET MODEL AND SERIAL NUMBER
ENGINE MODEL AND SERIAL NUMBER
KG ALTERNATOR SERIAL NUMBER, MAKE AND TYPE
PANEL SERIAL NUMBER
G1 (1ST SERVICE) CHECK CARRIED OUT ON
G2 (2ND SERVICE) CHECK CARRIED OUT ON
SERVICE DEALER'S STAMP AND SIGNATURE
A-3
Diesel Genset
Use K- Oil Premium Kirloska Genuine filters K Coo Supe Plus and avai two years warranty
KIRLOSKAR GREEN D.G. SET WARRANTY
For Power Generation Non-Cellular Application Engines -
This warranty is applicable to Kirloskar Green (KG) diesel genset. The warranty is for 2 years from
the date of installation or 5000 operating hours or 30 calendar months from date of dispatch
whichever is earlier as detailed below, subject to use of Kirloskar K-Oil Premium. Kirloskar
genuine filters. K-Cool Super Plus and services sourced through KOEL authorised Service
Dealer.
For Power Generation Non Cellular Application Engines and KG
Alternator -
The warranty is for 2 years from the date of installation or 5000 operating hours or 30 calendar
months from date of dispatch whichever is earlier, subject to use of Kirloskar K-Oil Premium.
Kirloskar genuine filters. K-Cool Super Plus and services sourced through KOEL authorised
Service Dealer.Refer details in pages ahead.
Kirloskar Oil Engines Ltd. hereby warrants that this Kirloskar Green Genset is free from defects in
material, design and workmanship. This warranty shall be limited for repairs and replacement under
normal use, regular check up and maintenance of the Kirloskar Green Genset as per our
maintenance schedule and purchase and servicing of the Kirloskar Green Genset through our
authorised dealer.
This warranty is the only document given by us warranting the Kirloskar Green Genset. No other
document giving any warranty terms conflicting these contents shall be considered and entertained.
Kirloskar Oil Engines Ltd. is not liable to service, or repair of Kirloskar Green Genset free of costs
during the warranty period, for the Kirloskar Green Genset purchased from person other than an
authorised person or DG set Dealer or AGOEM of Kirloskar Oil Engines Ltd.
Kirloskar Oil Engines Ltd. is not liable for any loss or damage, direct or consequential, labour
charges or the effect of any accident resulting from defective material, faulty workmanship or
otherwise. In any case the liability of Kirloskar Oil Engines Ltd. will not exceed the Kirloskar Green
Genset price or the market value of the Kirloskar Green Genset whichever is lower and shall be
without interest.
Use K-Oil Premium for your Gensets.

For details of K-Oil Premium, please contact our Authorised Service Dealer.
A-4
Diesel Genset
This warranty does not apply for the following:

1. The Kirloskar Green Genset or engine failure due to any misuse including improper
shutdown, improper handling and adjustments, negligence, over speeding, alteration
of specification and due to accident or Act. of God.
2. Kirloskar Green Genset or engine if not maintained as per the maintenance schedule
given by Kirloskar Oil Engines Ltd.
3. If K-Cool Super Plus engine coolant is not used for liquid-cooled Genset.
4. Damage due to improper installation of the parts, components and accessories.
5. For the parts supplied under warranty or voluntarily or at special rates or free of charge,
the warranty will be applicable only to the unexpired portion of D G Set warranty.
6. Damage due to use of improper lubricant or the lubricant used other than suggested by
Kirloskar Oil Engines Ltd.
7. Normal wear and tear of the components of Kirloskar Green Genset / Engine.
8. For resale of Kirloskar Green Genset or if the Kirloskar Green Genset purchased is
second hand.
Warranty period for DG set components is as below.
For Power Generation Non Cellular Application
•Proprietary parts not manufactured by Kirloskar Oil Engines Limited like:
• Starter
• Alternator
•Fuel injection pumps
Service Dealer.
•Kirloskar Green Alternators
30 Calendar Months from Date of Despatch or 5000 operating hours or 24 calendar months from
date of installation, whichever occurs first.
• All other Electrical Components supplied along with Genset like:
•Sensors
•Switches
•Engine Safety Units
•Actuator
•Controller card A-
Diesel Genset
Service Dealer.
**Warranty is not applicable for fuse & charging bulb.
•Kirloskar Green canopy Components supplied along with Genset like:
•Locks •Hinges •Fuel level gauges •Exhaust fan
Service Dealer.
**Warranty is not applicable for foam,canopy door & panels, bulb, and tubes
• Kirloskar Green Control Panel Components supplied along with Genset like:
•AMF module
•Relay card / board
• LVM / GVM
•Current transformer
•Battery chargers
•Switches
•MCB
•Contactors
Service Dealer.
**Warranty is not applicable for fuse, charging bulb and contactor coil
For Power Generation Cellular Application -

•Proprietary parts not manufactured by Kirloskar Oil engines like:
• Starter
•Alternator
•Fuel injection pumps
•Battery
•Exhaust Fan
A-6
Diesel Genset
For Power Generation Cellular Application - 15 Calendar Months from Date of Dispatch or 2500
operating hours, whichever occurs first. The warranty is subject to analysis of defect by the
respective authorised dealer of manufacturer.
• All other Electrical Components supplied along with engine like:
•Sensors
•Switches
•Engine Safety Units
•Fuel level gauge
15 Calendar Months from Date of Dispatch or 2500 operating hours, whichever occurs
first.The warranty is subject to analysis of defect by the respective authorised dealer of
manufacturer.
**Warranty is not applicable for fuse and charging bulb.
•Kirloskar Green canopy Components supplied along with Genset like:
•Locks
•Hinges
• AVM
manufacturer.
**Warranty is not applicable for foam, bulb, and tubes.
• Kirloskar Green Control Panel Components supplied along with Genset like:
•AMF module
•Relay card / board
• LVM / GVM
•Current transformer
•Battery chargers
•Switches
•MCB
•Contactors
manufacturer.
**Warranty is not applicable for fuse & charging bulb & contactor coil.
Any claim or obligation in connection with the sale or performance of Kirloskar Green Genset shall
be subject to Pune Jurisdiction.
A-7
Diesel Genset
Conditions precedent to Kirloskar Green Genset warranty.

The Kirloskar Green Genset warranty given by the company is subject to the below condition which
are to be observed by every purchaser/user of Kirloskar Green Genset, without which the warranty
claims if any will be rejected.
A. Proper installation of the Kirloskar Green Genset is the sole responsibility of

the owner of the Kirloskar Green Genset.
B. Operation & Maintenance as recommended by the company within the limits
mandated by the specifications.
C. Any defective part claimed, to be returned to Kirloskar Oil Engines Ltd., if such
part is replaced by the company under warranty, the returned part becomes
the property of the company, this transportation charges to be paid by the
customer.
D. In case of interchange of part between Kirloskar Green Gensets / Engine shall
void the warranty. Unauthorised repair work will make the warranty null and
void.
E. For the proprietary parts not manufactured by Kirloskar Oil Engines Ltd., such
as Fuel Injection Equipment, Electrical Equipment and Instruments etc. the
warranty terms of respective supplier will be applicable.
The warranty detailed above is offered for the Kirloskar green power
ideas Diesel Genset consisting of Kirloskar Engine, Kirloskar Green AC
Generator & sound proof enclosure branded Kirloskar Green and
control panel.
To meet specific customer needs, your Genset may not contain

Kirloskar green power ideas AC Generator, soundproof enclosure, or
control panel. If so warranty for such aggregates may please be availed
from the manufacturers of these aggregates. The seller of the Genset
will be happy to provide you the details.
Log Sheet
Please find a sample of Log Sheet on following sheets for your reference. You are requested to
maintain a separate log book registering the following mentioned parameters in the table.
A-8
Diesel Genset
Engine_ RPM HP
Date
Daily use in
hours
Hour meter
reading
Coolant
Temp (°C)
Pressure
(Kg/cm2) or
Lube Oil (bar)
Temp
(°C)
Fuel added
(Liters)
Lube oil
added (liters)
Engine
(RPM)
Current
(Amp) 3-
phase or 1-
phase
Voltage (V)
Frequency
(Hz)
PF & kW in
Controller
kWH meter in
Controller
Remarks -
Record
events of
maintenance
/ repairs
A-9
Diesel Genset
Engine_ RPM HP
Date
Daily use in
hours
Hour meter
reading
Coolant
Temp (°C)
Pressure
(Kg/cm2) or
Lube Oil (bar)
Temp
(°C)
Fuel added
(Liters)
Lube oil
added (liters)
Engine
(RPM)
Current
(Amp) 3-
phase or 1-
phase
Voltage (V)
Frequency
(Hz)
PF & kW in
Controller
kWH meter in
Controller
Remarks -
Record
events of
maintenance
/ repairs
Diesel Genset
Engine_ RPM HP
Date
Daily use in
hours
Hour meter
reading
Coolant
Temp (°C)
Pressure
(Kg/cm2) or
Lube Oil (bar)
Temp
(°C)
Fuel added
(Liters)
Lube oil
added (liters)
Engine
(RPM)
Current
(Amp) 3-
phase or 1-
phase
Voltage (V)
Frequency
(Hz)
PF & kW in
Controller
kWH meter in
Controller
Remarks -
Record
events of
maintenance
/ repairs
Diesel Genset
Engine_ RPM HP
Date
Daily use in
hours
Hour meter
reading
Coolant
Temp (°C)
Pressure
(Kg/cm2) or
Lube Oil (bar)
Temp
(°C)
Fuel added
(Liters)
Lube oil
added (liters)
Engine
(RPM)
Current
(Amp) 3-
phase or 1-
phase
Voltage (V)
Frequency
(Hz)
PF & kW in
Controller
kWH meter in
Controller
Remarks -
Record
events of
maintenance
/ repairs
Diesel Genset
SECTION - B PROMPT CUSTOMER SERVICE PACKAGE

(Single windows service for entire KGPI D.G. Set)
All you've to do is whistle. And we'll be there.
........................Enriching Lives . .. .. .
_
A-12
Time FIRST SERVICE CHECK (G1) - ENGINE SIDE Date
D G Set Parameters (Within 30 days from date of commissioning or first 50 hours of Genset run, whichever is earlier.) S. R. Number :
Engine Type : Application Code / Sr. No. :
Radiator Sr. No. : Turbocharger Sr.
No. : FIP Sr. No. :
Electronic Governor Sr. No. : Installation Dt

: Commissioning Date:
Hours run and the date of visit :
Make of Alternator : Rating : Sr. No. :
Phase : Single / Three Type : B rus hless / B rush Type Frame :
Alternator Control Panel : AMF / Non AMF Make : Sr. No. :
Type of Load : Resistive / Inductive / Capactive /
Canopy : Sr. No. :
DG Set Tested on full load for hours.
Current
Lube Oil Pressure : Lube Oil Temp. : Voltage : R: Amp.
Y: Amp.
Water Temp. : Abnormal Noise : Frequency : B: Amp.
Ambient temp. (air temp. near air-cleaner element) :
S afeties : Low Lube Oil P ress ure – Working / Not Working

High Lube Oil / Water Temp – Working / Not Working
V Belt Failure – Working / Not Working
Leakages, if any and the corrective action
Overall Performance of DG Set OK / Not OK.
Remarks of the service dealer representative :
Educated Customer on routine maintenance to be carried out :

t Cleaning of Air Cleaner (Dry / Oil Bath), Restriction Indicator operation. Yes/ No
t Lube Oil & Oil Filter Change Yes/ No
t Fuel / Filter Element Change Yes/No
t Cleaning of Radiator Cooling ns Yes/ No
t Cleaning of Liner & Cylinder Head Fins in case of Air Cooled Engine. Yes / No
Customer Remarks : Customer Name :
Site Address :
Tel. No.
Name, Signature & Designation of AGOEM Name & Address Name, Signature & Designation of
Customer Representative. Service Dealer Representative.
N.B. - Please fill the information, as applicable. Page No. 1 of 3

1) KOEL HEAD OFFICE COPY
ALTERNATOR CHECK POINTS - DURING G1 CHECKS
S l No. S ervice P oint R emark
1 Alternator Checks to be carried out during stop condition for
Main S tator Winding leads tightnes s at Main Terminal. OK / NOT OK
All AVR connections tightnes s . OK / NOT OK
Outgoing cable connections tightnes s . OK / NOT OK
2 Check for Seperate Earthing connections for neutral & Genset body,
both should be connected to earth pit. OK / NOT OK
Pour sufficient water in to E arth pit. DONE / NOT DONE
C heck outgoing main cable connection at terminal. OK / NOT OK

Observe proper lugs, crimping & glands.
3 Start the Set and observe the following parameter-
C heck for stable out put voltage from Alternator. OK / NOT OK
Check for Balance load. ( unbalance should not be more than 10 % of total load ) Balance / Unbalance
Current ( Amp ) - R- Y- B- N- phase respectively
Voltage (Volts ) - RY - YB- BR-
Power factor ( if available )-
4 Connected Load details - Unit - KW/ KVA

Total Motor load connected -
AC / DC Drive ( 3 ,6,12 pulse ) load connected.
UPS connected -
Other load details like fan / lights. -
Total Load connected -
Site Address :
Tel. No.

CHECK FOR CONTROL PANEL - DURING G1 AND G2 CHECKS
Sl No. Service Point Status
1. Check the tightness of crimping of cables -
Mains cable tightness & lugs crimping & gland in control panel . OK / not OK
Generator cable at control panel and alternator terminal. OK / not OK
C orrect cable s ize with correct lugs . OK / not OK
C onnection are tight. (All power & control cable) OK / not OK
2. C heck the E arth connection of control panel. OK / not OK
C heck control panel is mounted on AV mounting or check vibration. OK / not OK
3. Accessories -
AMF module type
MCCB ( make & rating )
Mains contactor ( make & rating )
Generator contactor ( make & rating )
4. Check for tightness of following connections -
Connection at main terminal board are tight with proper lugs or solder end Ok / not OK
Power connection at both C ontactors are tight. OK / not OK
Connection at all fus es or MC B are tight. OK / not OK
Check the proper tightness of all relays at relay base with proper relay locking clips. Ok / not OK
5. Check the Battery voltage and ensure that battery is fully charged OK / not OK
Battery voltage
S pecific G ravity of battery s olution ( required 1.270 ) OK / not OK
Ensure all cells of battery are with electrolyte battery solution to max. level OK / not OK
Ensure charging of battery by charging alternator (if provided) or by Battery charger OK/ not OK
C heck B attery terminal for cleanlines s and tightnes s . OK / not OK
6. Checking of electrical accessories -
Check all the gauges are working. OK / not OK
Check the exhaust fan working and direction of fan. OK / not OK
C heck s olenoid s upply is not more than 15-20 s ec. OK / not OK
7. C heck all the meters for working on control panel working. OK / not OK
8. Mains voltage ( EB Power ) -
Mains current ( EB Power ) -
9. Generator voltage -
Generator current-
10. Ensure AUTO / MANUL mode operation of AMF pannel. OK / not OK
Site Address :
Tel. No.

Time SECOND SERVICE CHECK (G2) - ENGINE SIDE Date
( Within 6 months from commissioning or second oil change) S. R. Number :
1 Application Code & Engine serial no & Type :
2 Customer Name :
3 Date of service check : G1 G1 S. R. Number
4 Installation date : Commissioning date :
5 No. of Hours run :
Service points: Action taken
1 t Change engine lube oil. t Done

(Drain the Engine Oil when the Engine is warm. Top up 0.5 liters more for
2,3,4 cylinder engines or as applicable to cotmpensate Lube Oil Filter Capacity.
t Always replace Lube Oil filter element with every oil change. t Done / OK
2 t Incase of oil bath type air cleaner, clean air cleaner & re it with fresh lube oil. t Done / OK
Clean the precleaner bowl if applicable.
t In case of dry type air cleaner element follow the practice mentioned in O & M manual. t Done / OK
3 For Air Cooled Engines :

t Check for proper cowling ment for e ective cooling of the engine. t Done / OK
t Clean the cylinder liner & cylinder heads Clean by removing main cowling & t Done / OK
direct compressed air ow on the s, or clean with brush.
For Liquid Cooled Engines :
t Check up coolant level in radiator, compensatory tank or heat exchanger t Done / OK
& top up if required.
(For initial add Radiator coolant as recommended. Keep the cap
open after topping up & run the engine on low idle speed to remove air pocket.)
(Do not top up cooling system with plain water, use only recommonded coolant.)
t Check whether radiator are choked. Educate customer on how to clean the t Done/ OK
radiator externally.
4 t Check button of feed pump. If choked, clean it. (educate customer) Cleaned.
t Drain the water from Water Separator. Cleaned.
t Change primary and main fuel filters as per O & M schedule. t Done / OK
hence not
necessary.
5 Check for all External Fasteners as per Spe ed torques. Tightened

(Tighten all foundation bolts)
6 Check battery lead connections, check spe gravity of electrolyte. OK/ corrected
7 Check Belt tension and condition, & adjust /replace if required. Replaced/
Corrected/OK
8 If the engine is turbocharged, check for

t Leakages in air intake/exhaust piping t Done / OK
t Hose connections tightness t Done / OK
N. B. - Please fill the information, as applicable. Page No. 1 of 4
SECOND SERVICE CHECK (G2) - ENGINE SIDE
( Within 6 months from installation date or second oil change )
DG Set Tested during inspection for hours . C urrent
Lube Oil Pressure : Lube Oil Temp. : Voltage : R: Amp.

Y: Amp.
Coolant Temp. : Abnormal Noise : Frequency : B: Amp.
Ambient temp. (air temp. near air-cleaner element) :

S afeties : Low Lube Oil P res s ure – Working / Not Working
High Lube Oil / C oolant Temp – Working / Not Working
V Belt Failure – Working / Not Working
Leakages, if any and the corrective action
Overall Performance of DG Set OK / Not OK.
Remarks of the service dealer representative :
Educated Customer on routine maintenance to be carried out :

t Cleaning of Air Cleaner and checking of restriction Indicator operation. Yes/ No
t Lube Oil & Oil Filter Change Yes/ No
t Fuel / Filter Element Change Yes/No
t Cleaning of Radiator Cooling ns Yes/ No
t Cleaning of Liner & Cylinder Head Fins in case of Air Cooled Engine. Yes/ No

ALTERNATOR CHECK POINTS - DURING G2 CHECKS
1. C heck for Abnormal noise during running. OK / Not OK
2. Check the ventilation grill is clean and free from dust for proper cooling . OK/NotOK
3. Check power cables connected at terminal are tight and proper lugs condition. OK/NotOK
4. Check for tightness of External Fastener of Coupling and Adaptor. OK/NotOK
5. P ut water in the E arth P it. OK / Not OK
6. C heck for P roper E arthing connections . OK / Not OK
C heck the tightnes s of AVR connections . OK / Not OK
7. Start the Set and observe the following parameter-
C heck for stable out put voltage from Alternator. OK / Not OK
Check for Balance load. Load difference should be less than 10% of load Balance / Unbalance
in phases for 3 phase DG.
Current ( Amp ) - R- Y- B- N- phase respectively
Voltage (Volts ) - RY - YB- BR-
Power factor
8 Canopy Checks
C heck C anopy doors for proper fitment and alignment OK / Not OK
Check Canopy for external & internal rusting. OK / Not OK
Check Canopy locks for proper operation. OK / Not OK
Check temperature d erence between canopy inside & outside by closing the Di rence -
doors and running the Genset on full load for atleast 30 minutes.

CHECK FOR CONTROL PANEL - DURING G1 AND G2 CHECKS
Sl No. Service Point Status
1. Check the tightness of crimping of cables -
Mains cable tightness & lugs crimping & gland in control panel . OK / not OK
Generator cable at control panel and alternator terminal. OK / not OK
C orrect cable s ize with correct lugs as per KOEL specifications. OK / not OK
C onnection are tight. (All power & control cable) OK / not OK
2. C heck the E arth connection of control panel. OK / not OK
C heck control panel is mounted on AV mounting or check vibration. OK / not OK
3. Accessories -
AMF module type
MCCB ( make & rating )
Mains contactor ( make & rating )
Generator contactor ( make & rating )
4. Check for tightness of following connections -
Connection at main terminal board are tight with proper lugs or solder end. OK/ not OK
Power connection at both C ontactors are tight. OK / not OK
Connection at all fus es or MC B are tight. OK / not OK
Check the proper tightness of all relays at relay base with proper relay locking clips
5. Check the Battery voltage and ens ure that battery is fully charged OK / not OK
Battery voltage
S pecific G ravity of battery s olution ( required 1.270 ) OK / not OK
Ensure all cells of battery are with electrolyte battery solution to max. level OK/ not OK
Ensure charging of battery by charging alternator (if provided) or by Battery charger OK/not OK
C heck B attery terminal for cleanlines s and tightnes s . Apply petroleum jelly to battery terminals. OK / not OK
6. Checking of electrical accessories -
Check all the gauges are working. OK / not OK
Check the exhaust fan working and direction of fan. OK / not OK
C heck s olenoid s upply is not more than 15-20 s ec. OK / not OK
7. Check all indicated parameters on control panel. OK / not OK

8. Mains voltage ( EB Power ) -
Mains current ( EB Power ) -
9. Generator voltage -
Generator current-
10. Ensure AUTO / MANUL mode operation of AMF pannel. OK / not OK
Site Address :
Tel. No.


SECTION – C GENSET
-------Enriching Lives _
Diesel Genset
Genset
C1. About KOEL ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ C‐1 C1.1
State‐of‐the‐art Manufacturing Setup ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ C‐1 C1.2
Design and innovation ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ C‐1 C1.3
Kirloskar Green Power Facts ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ C‐1 C1.4
Awards and Accolades ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ C‐2 C1.5 Note
‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ C‐2
C2. Safety ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ C‐2
C3. Ratings Plate‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ C‐3
C4. Lifting the genset ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ C‐3
C5. Moving the Genset ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ C‐5
C6. Technical Data ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ C‐7
C6.1 Gensets with Acoustic Canopy ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ C‐7
C6.1.1 Air Cooled Gensets ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ C‐7
C7. Genset with Air‐cooled Engine ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ C‐7
C7.1 Introduction ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ C‐7
C7.2 Description Of Genset Package ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ C‐7 C7.3
Canopy ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ C‐7 C8.
Engine ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ C‐8 C8.1
Cooling System ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ C‐8 C8.1.1 Air
Cooled Engine ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ C‐8
C8.2 Engine Governor ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ C‐8
C8.3 Brushless Alternator ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ C‐9 C8.4
Vibration Isolation ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ C‐9 C8.5 Fuel
Tank and Base Frame ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ C‐9 C8.6 Silencer
and Exhaust System ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ C‐10 C8.7 Genset Circuit
Breaker ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ C‐10 C8.8 System Protection
‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ C‐11 C8.9 Control Panel ‐ ‐ ‐ ‐ ‐ ‐ ‐
‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ C‐11 C8.10 Control Panel Power Supply
‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ C‐11 C8.11 Control Panel Mounting ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐
‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ C‐11
C9. Components of a Genset ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ C‐11
C9.1 View from Blower side ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ C‐11 C9.2
View from Starter Motor side ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ C‐14 C10.
Installation ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ C‐15 C10.1
Location ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ C‐15
C10.2 Foundation‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ C‐17
C10.2.1 Features of Foundations ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ C‐18
Diesel Genset
C10.2.2 Soil Load Bearing Capacity ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ C‐19

C10.2.3 Calculation for Foundation Depth ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ C‐19 C10.3
Cooling and Ventilation ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ C‐19 C10.3.1
Genset installed in a room ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ C‐20 C10.3.2
Ventilation check ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ C‐20 C10.4
Air Intake Installation ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ C‐21 C10.4.1 Air
Inlet ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ C‐21 C10.5 Exhaust
Installation ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ C‐21 C10.5.1 Exhaust
piping dimension recommendation ‐ ‐ ‐ ‐ ‐ ‐ ‐ C‐22 C10.5.2 Flexible
Connections ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ C‐26 C10.6 Fire Precautions ‐
‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ C‐26 C10.7 Electrical Connection ‐
‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ C‐26 C10.7.1 Earthing/Grounding ‐ ‐ ‐ ‐ ‐ ‐
‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ C‐27 C10.7.2 Protection ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐
‐ ‐ ‐ ‐ ‐ ‐ ‐ C‐28 C10.7.3 Loading ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐
‐ ‐ C‐28 C10.7.4 Power Factor ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ C‐
28 C10.8 Noise Control ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ C‐29
C10.9 Pre‐commissioning Checks ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ C‐29
C10.10 Prior to Starting ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ C‐30
C10.10.1 Warnings ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ C‐31 C10.10.2
Manual Mode (Non‐AMF) Operation ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ C‐32
C10.10.2.1 Starting the Genset ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ C‐32 C10.10.2.2
Stopping The Genset ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ C‐33 C10.11 AMF
Operation ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ C‐33 C10.11.1
Activating AMF ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ C‐33 C10.12 Daily
Checks ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ C‐34
C11. Battery ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ C‐35
C11.1 Battery Maintenance Schedule ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ C‐35
C11.1.1 Battery Tips ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ C‐37
C12. Optional Equipment ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ C‐38
C12.1 Battery Charger ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ C‐38
C12.2 Heater ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ C‐38
C12.2.1 Engine Heater Plug ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ C‐38
C12.2.2 Anti‐condensation Heater ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ C‐38
C12.3 Electronic Governor ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ C‐38
C13. Maintenance ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ C‐39
C13.1 Daily Maintenance ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ C‐39
C13.1.1 Maintenance every Six Months or 250 Hours ‐ ‐ ‐ ‐ ‐ ‐ ‐ C‐40
C13.1.2 Alternator Unit Cleaning ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ C‐40
C14. Control System‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ C‐40
C14.1 Control Panel ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ C‐41
2
Diesel Genset
C14.1.1 AMF panel ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ C‐41

C14.1.2 Non‐AMF panel ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ C‐42
C15. Kirloskar Green Controller ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐C-42
C15.1.1 KG 745 Controller ‐ ‐ ‐‐ ‐ ‐ ‐ ‐‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ C-42
C15.1.2 Features ‐ ‐ ‐ ‐ ‐ ‐ ‐‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ C-43
C16.1.3 Installation Instructions‐ ‐ ‐ ‐ ‐‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ C-44
C16.1.3.1 Before installation ‐ ‐ ‐ ‐ ‐ ‐‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ C-44
C16.1.3.2 Following conditions may cause damage‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐‐ ‐ ‐ ‐ ‐ ‐ ‐ C-44
C16.1.3.3 Following conditions may cause abnormal operation‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ C-45
C16.1.4 Views‐ ‐‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ C-46
C16.1.4.1 Front View‐ ‐‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ C-46
C16.1.4.2 Rear View‐‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ C-46
C16.1.5 Electrical Installation‐‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐‐ ‐ ‐ ‐ ‐ C-47
C17. Operation‐‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ C-48
C17.1 Quick Start Guide‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ C-48
C17.2 Stop Mode‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ C-48
C17.3 Auto Mode‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ C-48
C17.4 Manual Mode‐ ‐ ‐ ‐‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ C-48
C17.5 Test Mode‐ ‐ ‐ ‐‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ C-49
C17.5 Load Transfer and Contactor Operation‐ ‐‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ C-50
C17.6 Speed Sensing‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ C-50
C17.6.1 MPU‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐‐ ‐ ‐ ‐ ‐ ‐ ‐‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ C-50
C17.6.2 Generator‐ ‐ ‐ ‐ ‐‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐‐ ‐ ‐ ‐ ‐ ‐ ‐‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ C-50
C17.7. Battery Charging Alternator‐ ‐ ‐ ‐ ‐ ‐ ‐‐ ‐ ‐ ‐ ‐ ‐ ‐‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ C-51
C17.8 Battery Charging Alternator Excitation‐ ‐‐ ‐ ‐ ‐ ‐ ‐ ‐‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ C-51 C17.9
Battery Voltage Monitoring and Charging Detection‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ C-52 C17.10
Trouble shooting‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐‐ ‐ ‐ ‐ ‐ ‐ ‐‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ C-53
C17.11 Error Messages‐ ‐ ‐ ‐ ‐‐ ‐ ‐ ‐ ‐ ‐ ‐‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐
4
Diesel Genset
Genset
C1. About KOEL
Incorporated in 1946, Kirloskar Oil Engines Limited (KOEL) is a part of the Kirloskar Group.
KOEL is one of the leading and largest manufacturer of diesel engines ranging from 4 HP to
800 HP and from 2,400 HP to 11,000 HP with the annual manufacturing volumes exceeding
3,20,000 engines.
Branded as 'Kirloskar,' KOEL engines are used as prime movers and are most preferred choice
when powering earthmoving and construction equipment, agro-industrial applications, material
handling equipment, marine applications and equipment used by the defense forces.
Today KOEL is one of the world's leading players in the Diesel Genset market and is committed
to offer best in its class products and services to all customers across the globe.
C1.1 State-of-the-art Manufacturing Setup
The engines are manufactured in a most eco-friendly environment in India at our Pune-Khadki,
Kolhapur- Kagal, Rajkot and Nashik Plants. The Kagal factory has both domestic and export
oriented unit.
The manufacturing plants are well equipped with most advance and high-tech machineries,
having state of the art, cutting edge technology for machining of all the critical components.
C1.2 Design and innovation
KOEL has an ultra modern Research and Engineering facility for Design, Development and up-
gradation of engines, systems, controls and canopy. A team of dedicated and experienced
professionals carry out the proactive cutting edge research to develop innovations that delight
customers in India and abroad to give KOEL the edge over competition.
C1.3 Kirloskar Green Power Facts
•Fully integrated Gensets and Power systems to meet current as well as future needs of
customers.
•Market leader with full range from 5 kVA to 625 kVA.
•Every 2nd Gen-set in the country is a Kirloskar Green Genset.
C--1
Diesel Genset
•Over 75,000 Gensets all over the country help to run the Indian Telecom Network.
• More than 15,000 Gensets deployed along the Indian Borders providing reliable power to the
Defence forces.
•More than 100 special containerized Genset packages, supplied for critical Defence
applications.
• Large number of satisfied customers from Manufacturing, Software, Construction,
Infrastructure sector in 320 kVA to 625 kVA range.
C1.4 Awards and Accolades
•KOEL pursues highest quality adherence for zero defect

•Rated “Most Preferred Brand” and “Customer Service Support Leadership” by Frost &
Sullivan.
• Winner of the Rated Best in Class in service by AC Nielsen.
•ISO 9001 certification for Quality Management System since 1992 by ABS QE Inc.
•ISO/TS 16949:2002 for Quality Management System since 2007 by ABS QE Inc.
•ISO 14001 certification for Environment Management System since 1999 by TUV NORD.
•OHSAS 18000:2007 certificate for Health, Safety 6k Environment since 2009 by TUV NORD.
C1.5 Note
•The information provided for this manual is subject to change without notice as we
continuously endeavor to offer the best products to our customers.
•Ensure that the use lube oil, filter filler, coolant, carbon sludge is not thrown away in open
land, gutters and landfills. This could lead to contamination of soil, rivers, streams and ground
water supplies.
•Ensure complete adherence of the local legislation rules of pollution control, electrical
installation, safety, fire hazard, waste treatment and waste disposal.
C2. Safety
KOEL encourages safety as a corporate philosophy.
•It is important that every individual of the team engaged in installation and subsequent
operation is thoroughly aware of the entire process and appreciates the criticality of each
action.
•Ensure that the tools and tackles used are of adequate capacity and are in proper working
conditions.
• Strictly follow all universal and local safety norms.
•Always remember that there are no short cuts in safety.
C-2
Diesel Genset
C3. Ratings Plate

The genset’s model and serial number are stamped on nameplate along with engine rating,
electrical ratings, and referred standards. The name plate details must be given while ordering
spares and asking for service. KOEL gensets are built by the company themselves as well as
by Genset Original Equipment Manufacturers (GOEMs), who produce under license from the
company. The gensets from KOEL or GOEMs carry different ratings plates to identify the source
of manufacture.
KIRLOSKAR OIL ENGINES LTD.
GENSET MODEL
PRODUCT CODE
MFG. DATE/SR. NO.
NOISE LIMIT
TYPE APPROVAL
CERTIFICATE
NO.
Figure C - 1: Ratings Plate - KOEL manufacture
Manufactured by
XYXYXY Road, Pune 411 003. INDIA.
Figure C - 2: Ratings Plate - GOEM manufacture
C4. Lifting the genset

The genset is a heavy object that demands great care while lifting and transporting.
C-3
Diesel Genset
C-4
Diesel Genset
C-5
Diesel Genset
Lifting the genset
C-6
Diesel Genset
•Only trained and qualified personnel should lift the genset.

•All personnel should wear personal protective gear such as safety shoes, helmets etc.
•All equipment used for lifting should be rated for handling the weight of the genset.
•Attach the sling hooks of lifting crane etc. only in the lifting eyes (holes) provided on the base.
•Attaching hooks anywhere else could permanently damage the genset.
•Use spreaders to move straps away from the body of the genset.
•The width of spreader must be greater than the genset’s width.

•Do note use chains or wire rope.
•Use slings of soft material like Nylon rope / flexible belt to avoid damage to the genset.
Use of flexible belt for lifting
C5. Moving the Genset
C-7
Diesel Genset
Figure C - 7: Use of lifting tackle and crane

Moving the genset to its installation location requires extreme vigilance and care.
•Only trained and qualified personnel should lift the genset.

•All personnel should wear personal protective gear such as gloves, safety shoes, helmets
etc.
•All equipment used for lifting genset should be rated for handling the weight of the genset.
• Attach the sling hooks of lifting crane etc. only in the lifting eyes (holes) provided on the
base.Use correctly rated equipment for lifting the genset.
•Use specially designed tackles with spreaders to lift genset.
•Use flexible belt to prevent damage to genset.
• Travel at a slow speed while transporting the genset,
•Ensure that the genset does not sway while moving, if required, stabilize with extra belts held
by personnel.
•Personnel should stand at the corners of genset to ensure that the moving object does not
foul any structure.
•Ensure that the moving genset does not touch any personnel.
•Ensure no personnel puts their body appendages (hands, feet) below a suspended genset at
low height or walk below a suspended genset at a higher height.
C-8
Diesel Genset
C6. Technical Data
C6.1 Gensets with Acoustic Canopy
C6.1.1 Air Cooled Gensets
Table 1: Air Cooled Gensets*
Rated Maximum Representative

Genset Engine recommended Dimensions Approx.
output at
Model Model Genset rating at [Length x Width x Weight
1500 rpm
0.8 pf Height]
(bhp) Continuous (mm) (kg)
KG1-15AS HA294 20.5 15 1772 X1185 X1818 894
KG1-25AS HA394TCI 32 25 2132 X1185 X1951 960
KG1-40AS HA494TCI 56 40 2400 X1050 X 2150 1290

KG1-62.5AS HA694TCI 83 62.5 3176 X1328 X 2061 1710
* = All ratings at Normal Temperature and Pressure (NTP) conditions.
C7. Genset with Air-cooled Engine
C7.1 Introduction
KOEL genset is carefully designed to provide optimum performance and reliability with great
economy and minimum maintenance. This genset package is a result of over 55 years of
actual site experience to deliver a comprehensive system built with advanced engineering
concepts and backed by an efficient service network.
Please read this manual to understand operation and maintenance of the genset. By following
instructions in the manual and proper care, the genset will be always ready to respond to any
emergency standby or prime power needs.
C7.2 Description Of Genset Package
Gensets consist of an alternator driven by a diesel engine. The engine has systems such as
fuel, exhaust, cooling, electrical and control. These topics are covered in detail elsewhere in this
manual.
The engine has a governor that maintains the engine speed within a set tolerance to deliver
rated power and frequency as per ISO 3046, DIN 6271 AND BS 5514. The alternator produces
output with correct voltage, optimum wave form, fast response and precise voltage regulation.
C-9
Diesel Genset
C8. Engine
The engine of the genset has proven reliability and is specifically designed to operate in
conjunction with an alternator. The heavy duty engine is a 4-stroke, compression ignition prime
mover fitted with all accessories necessary for reliable operation.
C8.1 Cooling System
KOEL offers gensets with air cooled as well as liquid cooled engines. This manual covers only
air cooled engines. Liquid cooled engines are covered under an independent manual.
C8.1.1 Air Cooled Engine
The engine is cooled by a high capacity cooling air blower mounted on engine and driven by v-
belts off the crankshaft. The blower forces air over cylinder liners and cylinder heads to cool
engine temperature for best performance. Hot air leaving engine is routed away using air guide
ducts. For enclosed gensets, ventilation is ensured by using special fans that remove radiated
heat from engine and alternator while avoiding hot air recirculation.
All engines applications require careful attention to air flow for ensuring best performance. The
notes provided in the Installation Section of this manual offer guidelines for selecting a location
for your genset. Consult KOEL Helpdesk for optimum genset site plan and layout for your
application.
C8.2 Engine Governor
The primary function of the governor system is to maintain engine speed in relation to varied
load requirements. This is accomplished by the governor which senses engine speed and
controls the engine fuel rate, in order to maintain practically constant speed. The engine speed
governor maintains engine speed within limits regardless of the steady load. As the alternator
load increases, the engine speed is reduced.
Because the speed must remain relatively constant, the governor, sensing engine speed, will
increase fuel flow to the engine, thus adjusting horsepower to a point sufficient to maintain
engine speed and compensate for the load change. The same principle is applied when the
load decreases. As the load is reduced the speed would increase, the governor will then reduce
fuel delivery thus decreasing the horsepower to maintain the proper speed.
C-
Diesel Genset
C8.3 Brushless Alternator
The alternator is coupled to the engine with a flexible coupling.

Brushless excitation type alternator eliminates the maintenance associated with slip rings and
brushes. The internal components of the alternator are designed so as to assure efficient and
economical operation.
The control system consists of an automatic voltage regulator (within the alternator), protective
circuits and the necessary instruments to allow you to monitor the operation of genset. On most
models current is supplied through twelve leads enabling the operator to reconnect the genset
to obtain a variety of three phase voltages up to 480 volts. Single phase units supply current
through a two or three lead connection offering a variety of voltages from 120-250V. Units can
be supplied in 50 Hz outputs. See Alternator Section for further details of connections available.
A brushless alternator is a synchronous rotating field type unit, which produces alternating
current. This alternator unit is completely self-contained and is designed and constructed to
provided trouble free operation, ease of maintenance and long service life.
C8.4 Vibration Isolation
All gensets are fitted with anti vibration mountings which are designed to reduce vibration being
transmitted from the rotating mass of the genset to the foundation on which the genset is
mounted. Vibration isolators are selected to suit the particular duty and are fitted between the
engine, alternator feet and the base frame. On some of the models the vibration isolators are
fitted between the base frame and the foundation depending on the system requirement.
C8.5 Silencer and Exhaust System
Exhaust silencer is provided to reduce noise emission from the engine and designed to direct
exhaust gases to areas where they will not be objectionable.
On ‘stand alone’ open gensets, the exhaust silencer is generally placed outside the Genset
room, with suitable extension piping from engine. Stainless steel expansion bellow is provided
on the engine, to facilitate the exhaust piping. For generating sets with acoustic canopy,
residential type silencer is fitted inside or outside the canopy with flange fitting at the outlet to
enable discharge of exhaust gases at desired location, through extension piping, as required.
C8.6 Genset Circuit Breaker
To protect the alternator winding, a suitably rated moulded case circuit breaker or miniature
circuit breaker (depending on the genset model) is supplied mounted in a strong fabricated steel
enclosure.
Current transformers are fitted on each of the phases on the cabling to the circuit breaker
Diesel Genset
enclosure for current measurement. In some configurations the main circuit breaker may be
incorporated in the automatic transfer panel.
C8.7 System Protection
Control system provides protection of the engine against faults such as high temperature, low
oil pressure, over speed, low fuel level or other conditions. The system also prevents damage
to the cranking motor by automatically disengaging the motor after engine starts and deep
discharge of the starting battery by avoiding cranks if engine fails to start.
C8.8 Control Panel
All control panels are mounted in welded steel enclosures equipped with a sealed hinged door
for easy access and servicing. The control panel is available in several variations to suit the
requirement of the installation.
C8.9 Control Panel Power Supply
Engine instruments and the control panel are supplied from the battery fitted to the genset. This
battery also provides power for operation of the cranking motor to start the engine and for the
stop solenoid.
C8.10 Control Panel Mounting
The control panel and main circuit breaker are normally located on a separate stand that is
mounted on the base frame or canopy to ensure vibration free running. More complex control
systems have floor standing control panels. For a genset with acoustical canopy, the control
panel is fitted inside the enclosure. Suitable glass cover opening is provided on the enclosure
to view the instruments.
C9. Components of a Genset

The following drawings show the view of genset from blower side and starter motor side. The
engine shown in image of this manual are only for illustration. Your genset may have different
appearance.
C9.1 View from Blower side
Various components are visible in this view. Only components relevant to identification, genset
operation or maintenance are listed here. More details of other details are available in the engine
section.
Diesel Genset
The following drawings show the various system of Genset.
Diesel Genset
Diesel Genset
Diesel Genset
Diesel Genset
Diesel Genset
Diesel Genset
Diesel Genset
Diesel Genset
Diesel Genset
Diesel Genset
Diesel Genset
Diesel Genset
Diesel Genset
Diesel Genset
Diesel Genset
Figure: View from Front side
Base Frame
This is the frame on which the genset is mounted.
Lifting Eye
Use the four lifting eyes spaced around the base frame to lift the genset the holes in the eye
should be used to attach a suitably rated lifting hook of a crane.
Diesel Engine
Prime mover that drives the alternator.
Alternator
Generates AC electrical power when rotated by the engine.
Diesel Genset
Anti-Vibration Mount
Four Anti-Vibration Mounts help isolate the engine and alternator vibrations from reaching the
canopy.
Control Panel
Contains switch gear, gauges, controls and engine termination.
Air Cleaner
Cleans air meant for combustion of dirt and air-borne particles.
Air Intake
Intake for cool air from atmosphere.
Exhaust Silencer
Reduces noise borne in the engine exhaust.
Exhaust Bellows
Flexible portion to match vibrating exhaust pipe with rigidly mounted silencer.
Lube Oil Filler
Used to fill lube oil in the engine sump.
Lube Oil Filter
Cleans lube oil as it circulates through the engine.
Lube Oil Drain
Used for conveniently drain the lube oil from the sump during maintenance.
Fuel Filters
Diesel passes through two fuel filters to trap different sizes of dirt particles.
Blower
Cools the engine by forcing air over fins on cylinder heads.
C-30
Diesel Genset
C-31
Diesel Genset
C10. Installation
C10.1 Location
Selecting a location for the genset is very important part of any installation procedure. Locate
the genset in an area that will provide adequate ventilation and physical protection for the unit.
Place the genset to allow easy movement all around for maintenance and replenishment of fuel
etc. Ensure 1 to 2 meters space all around the genset.
Figure C - 11: Space around a genset
C-32
Diesel Genset
•Adequate fire fighting facilities suitable for diesel, oil and electrical fires should be available at
location.•The location should be clean, dry and have good drainage capabilities.
•The space around the gensets should be adequate to undertake major overhaul or service
operations. In some cases it may be necessary to remove major components.
•The location must allow free ventilation of inlet air and exhaust.
•Ideally the genset should be in open air. In case genset is to be mounted in side the building,
ensure proper ventilation around the genset.
•Choose the direction of placement such that natural wind helps in air flow of the genset.
• Locate the genset as near as possible to the load.
•Place the genset at one end of the site in the direction of wind to avoid dust entry into the
genset.
•In case the site’s atmosphere contains extra suspended particles like at Cement or Textile
factories, stone quarry, the genset may be placed at some distance.
• For highly dusty sites refer to the supplier representative for recommendation.
•The site selection should be complete before the genset reaches to location.
•Ensure sufficient illumination at the installation site. The interiors of acoustic canopy should
be clearly visible without help of any extra lighting.
•Provide suitable, safe access to elevated items.
• Standard tool kit (not supplied with genset) should be available easily and quickly. It should be
protected from corrosion and stored in a dry place.

•If spares are supplied along with the equipment, they should be protected from corrosion and
stored in a dry place.
•While designing the layout, provision should be made for:
-Proper laying of cables.
-Free access to fuel lines and filters.
-Sufficient space in front of the breather vent.
-Space for draining of coolant and lub oil.
-Adequate oil storage space.
-Space for safe storage of spares.
C10.2 Foundation
The foundation provides a leveled platform to seat and seal the Genset.
•Supports 1.5 times of the total dead weight of the single genset and 2 times of the total dead
weight for multiple gensets.
•Support the dynamic load of genset while in running. For dynamic load of the genset, please
refer to manual or contact the supplier.
•Isolate the surrounding structures by absorbing the vibration of genset while running.
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Diesel Genset
C10.2.1 Features of Foundations
•Provide a reinforced concrete foundation for the genset. Do not install acoustic canopy on
loose sand or clay.
•The foundation should have sufficient mass in proportion to the size of the genset to provide
the rigid support necessary for minimizing deflection and vibration.
•Before easing the genset on the foundation, ensure that no hard material such as stones or
steel objects remain on the mounting surface as this may damage fuel tank at the bottom.
•Design the foundation while considering safe load bearing capacity of soil.
•The length and breadth of foundation should be at least 150-300 mm more on each side than
length and breadth of the acoustic canopy.
•Ensure sufficient space for personnel to walk all around the foundation.
•Check the level of foundation diagonally as well as across length for even flatness.
•In case surface is rough, lay nitrile rubber strips, 15mm thick and equal to the width of the
base frame, under the genset, along the periphery of the base frame.
•It is recommended to raise foundation height about 150 to 200 mm above ground level, to
help maintain cleanliness and avoid flooding.
•Ensure that concrete is completely set and cured before positioning the canopy.
•Consult a qualified structural engineer when seismic events are in consideration.
•The foundation may be located on soil, structural steel, building floors etc., provided the total
weight of the foundation and genset package does not exceed the allowable bearing load of
the support.
•Allowable bearing loads of structural steel can be obtained from Engineering Handbooks
while local building codes will provide the allowable bearing loads for different types of soil.
C10.3 Cooling and Ventilation
In case of air-cooled engines, a v-belt driven blower draws in cool and fresh air from
atmosphere.
•The blower’s draft passes over fins on the cylinders and cylinder head to cool the engine.
•If the engine is fitted with an intercooler, part of the cool air from blower passes through the
intercooler to reduce temperature and increase density of turbo-charger’s output.
•The alternator has a shaft-mounted ventilation fan to circulate cool air through its interiors.
•The hot air is channeled out of the canopy through special ducts.to avoid recirculation.
•The exhaust should flow in the direction of cooling airflow.
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Diesel Genset
Figure C - 13: Airflow through genset

• A temperature rise of 5-15 oC (9-27 oF) in the cooling air can be expected at full load.
•The radiated heat given off by the engine, generator and exhaust piping can result in a
temperature high enough to adversely affect operation and performance of the genset.
• Locate the genset in a room or area that will provide or allow sufficient ventilation to remove
this heat as well as radiated heat from the engine. If possible, provide exhaust fans to drive
hot air outside.
•If acoustic canopy is placed in an enclosed place, ensure that it is well ventilated and exhaust
gases are driven out of the enclosure.
•It may be necessary to add a flexible connection between the canopy and building ventilation
to ensure positively discharged of hot air from building. Consult KOEL for dimensions and
design of ventilation system of gensets fitted in buildings.
• For weather protection, louvers should be fitted to the intake and exhaust openings. These
can be either of the fixed or movable type.

• Manually operated movable louvers may be acceptable in some cases, but they are not
acceptable for automatic standby units.

•The cooling airflow should not be depended upon to open/close the louver vanes.
•Ensure that the exhaust releases in the direction of wind flow.
C10.3.1 Genset installed in a room
For basement installations, forced ventilation through air ducts is required. Contact supplier
representative for recommendation of values of air required and fan flows for various gensets
rated at 1500 rpm. Ensure the exhaust piping has lagging inside the room and silencer is fitted
outside the room.
C10.3.2 Ventilation check
Maximum allowed temperature rise above ambient in genset canopy air intake is 7°C.
C-21
Diesel Genset
• Measure the ambient air temperature outside the canopy in shade.

•Measure the temperature inside the canopy near air cleaner inlet of engine.
•Calculate temperature difference between canopy temperature and ambient i.e. delta T.
•It may be necessary to measure actual airflow using an anemometer.
C10.4 Air Intake Installation
C10.4.1 Air Inlet
•Engine inlet air must be clean, dry and as cool as possible. These conditions will drastically
effect both engine life and performance.
•Air temperature near air cleaner should not be more than 5°C above ambient. Sufficient
window openings are required to maintain air inlet temperature within the limit.
•Normally the inlet can be taken from the area surrounding the installation site. However, in
some cases the condition of the air surrounding the machine may warrant ducting the air from
outside or another room.
• When it does become necessary to duct air in, the air cleaner should remain mounted to the
engine as opposed to a remote mounting (such as on a roof or in another room). This will
eliminate the possibility of dirt leaking through the duct work upstream of the air cleaner.
C10.5 Exhaust Installation
The exhaust system is used to direct exhaust gases to non-confined areas and reduce the noise
to tolerable levels. When designing a system the main objective is to minimize back pressure.
Excessive back pressure in an exhaust system will create horsepower loss and increase the
engine operating temperature, and emissions.
•Exhaust pipe outside the canopy should be lagged with aluminum sheet cladding. Typical
thickness of lagging - 50mm.
•If exhaust pipe length is more than 7 meter, add additional flexible bellows.
• Higher back pressure in exhaust system than specified limit will lead to:
-Higher fuel consumption
-Poor performance
-Engine component failure due to higher exhaust temperature
-Reduced engine life
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Diesel Genset
 


Figure C - 14: ERW and GI pipes
•Use of 'B class' MS ERW pipes or prefabricated stainless steel pipe and long bend elbows is
recommended for exhaust piping.
•Never use galvanized water pipes (GI pipes) for exhaust piping as they are heavy and costly.
C10.5.1 Exhaust piping dimension recommendation
•A maximum of 4 bends is acceptable in the exhaust pipe.

•Increase the pipe diameter by approximately 12.2 mm (0.5 inch) after every 5 meters length
above silencer.
•Curve the pipe. Do not use right angle bends.
C-22
Diesel Genset







Figure C - 15: Use Curved Pipe for Exhaust

Figure C - 16: Do not use Angle Pipe for Exhaust
•Provide a rain cap to avoid entry of rain water into the engine. Add a slope to the horizontal
run of the exhaust piping downwards, away from engine to the condensate trap. Silencer
should be installed with drain plug at bottom.
Figure C - 17: Raincap
C-23
Diesel Genset
•If the exhaust pipe cannot be bent at 90 degree, provide a rain cap over the pipe’s mouth, as
shown. In such case, the distance between exhaust pipe end, and the rain cap should be
higher than at least twice the diameter of the pipe.
Figure C - 18: Raincap on straight Exhaust Pipe

•Fit a loose grill over the end of the exhaust to prevent birds or small animals entering the pipe.
•For installations in the basement or inside a room, the exhaust piping should be directed
outside through the wall or the ceiling.
• For installations in populated areas, direct the exhaust above roof height of adjacent
buildings, as per statutory requirements.

• When bends are required in an exhaust system, always make the radius at least 150% of the
inside diameter of the pipe.

•As most exhaust system designs are governed by the physical characteristics of the building
or room in which they are located, it is of the utmost importance that the exhaust pipe be
routed in a path offering the least amount of turns or bends so not to increase back pressure
more than 50 mm of Mercury Column.
•Generating sets with acoustic canopy are provided with exhaust outlets having connecting
flanges. Exhaust gases from the outlet can be routed away to desired location.
•For up to 3 meter distance exhaust pipe size same as provided on the outlet can be used. For
longer lengths total exhaust system assessment should be done by competent person.
•In no case, exhaust back pressure should exceed 50 mm of Mercury Column when measured
at exhaust manifold of engine, at rated load.
•Be sure that all pipes are well supported and that springs or other dampers are used at points
of high vibration.
•Due to the heat radiation of the exhaust pipes it is recommended that all pipes be located at
least 250 mm from any combustible material.
• Wrapping the exhaust pipes with high temperature insulation or installing fitted insulated
sections will aid in preventing excessive heat radiation within the room.
C-24
Diesel Genset
•At points where the piping passes through a wall or roof, a metal thimble guard 300 mm in
diameter slightly larger than the pipe should be installed.
•Bevel the end of the pipe at a 30 - 45 degree angle. Should the pipe end be horizontal, bevel
the pipe from the top back to the bottom. This will not only reduce the noise levels at the outlet
but will also minimize entrance of precipitation on horizontal pipes.
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Figure C - 19: End of Exhaust Pipe

•The level or height at which the outlet is situated should be sufficient to prevent fumes and
odours from becoming an annoyance or potential hazard. Also, an exhaust pressure actuated
raincap is recommended for use on vertical outlet pipes.
•Any long horizontal or vertical piping should include water legs and drain traps at their lowest
points so that water does not reach either the silencer or the engine. It is also recommended
that a slight slope downward from the silencer to the water leg or rain trap be added to assure
the proper removal of water.
•By locating the silencer as close to the engine as possible you will be able to minimize the
noise level in the exhaust piping.
•Each genset installation should have it’s own exhaust system and should not be connected to
a system accommodating more than one genset as the possibility of exhaust gas and
condensation back-flow may cause permanent damage to an idle engine.
Health Warning
•Inhalation of exhaust fumes is potentially lethal.
• The correct installation of exhaust systems to prevent accumulation of exhaust gas cannot be
overemphasized.
•Additionally, prolonged exposure to engine exhaust noise can be damaging to hearing.
•A genset should never be operated without a fully installed exhaust system and all personnel
in close vicinity should wear ear protection.
C-25
Diesel Genset
C10.5.2 Flexible Connections
The exhaust piping should be connected via a flexible joint located on the engine exhaust
outlet.
This connection serves three purposes.
-It relieves some of the weight of the exhaust piping from the engine.
-It isolates the exhaust system from vibration.
-It allows for some movement of either the genset or exhaust system components.
Long piping runs should be divided into sections separated by additional flexible connections.
This will also compensate for the expansion and contraction of the piping itself due to
temperature change. Any insulation material used for a flexible connection should allow for the
expansion and contraction of the connections, due to temperature changes.
C10.6 Fire Precautions
Note the following points when designing a genset installation:

•The room should be designed so that there is an easy escape route for operating personnel in
the event of fire within the room.
•A recommended type of fire extinguisher or fire extinguishing system should be provided to
fight the fire.
•Personnel manning the genset should be trained in identifying and fighting various types of
fires.
•Gravity operated fire valves operated by fusible links, mounted above the engine, can be
installed in the fuel lines.
•The room should be kept clean and free from accumulated rubbish which can be a fire
hazard.
C10.7 Electrical Connection
Only fully qualified and experienced electrical technicians should be allowed to carry out
electrical installation work.
Warning: Never attempt to work on live wiring. Always stop the genset and open
the circuit breaker on the load cables before working on the alternator or it’s
connectors. Disable starting of engine while working on genset.
•All electrical work should be carried out in accordance with any applicable National, Local
Standards, Codes or Regulations.
•The electrical connection to the genset should be made with flexible cable to prevent the
transmission of vibration and possible damage to the alternator or circuit breaker terminals.
C-26
Diesel Genset
•If it is not convenient to use flexible cable throughout then a link box can be installed close to
the set with a flexible connection between it and the set.
•The cable may be laid in a duct or on cable tray. When bending cable reference must be
made to the recommended minimum bending radius. No rigid connection should be made
between the set and the cable support system, eg, cable tray.
•When single core cables are used the gland plates must be of non-ferrous material, eg,
aluminum, brass or a non- metallic material such as teflon.
•The cable must be suitable for the voltage being used and adequately sized to carry the rated
current with allowances made for ambient temperature, method of installation, proximity of
other cables, etc.
•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 auto
transfer switch, or if the machine is to be paralleled.
C10.7.1 Earthing/Grounding
Earthing/Grounding should be done in accordance with applicable National, Local Code or

Regulation. These regulations vary and advice should be sought from the local supply utility to
comply with their requirements. The factory connects the frame of the alternator to the frame of
the genset therefore the complete mass of the genset is at the same potential. The connection
if required of the generator winding star point / neutral to earth is the responsibility of the
installation technicians.
Figure C - 20: Typical Earth Pit

•Any leakages in current will be earthed through the shortest route in the link.
• The size of the link used for the main earth connection should be adequate size as shown in
table.
Table 3: Recommended Size of Earthing Conductor
Genset Rating Recommended Earth Strip /Cable
5-82.5 kVA 8 SWG - Copper
C-27
Diesel Genset
Table 3: Recommended Size of Earthing Conductor (Continued)
Genset Rating Recommended Earth Strip /Cable
100-250 kVA 25x3mm CU / 25x6mm GI

320 - 500 kVA 50x6mm CU / 50x6mm GI 2 runs
625 - 750 kVA 50x6mm CU / 50x6mm GI 2 runs
•The generating set and all associated equipment must be earthed before the set is put into
operation.
•4 earth pits are required as per Indian electricity rule / local electricity regulations.
•2 earthing pits for genset / control panel body.
• 2 earthing pits for neutral,
•Check the Resistance between 2 earth pits.

•Earthing in Rocks and Rocky area to done using grounding Transformers / Zig Zag
Transformers or Use soil conditioning agents - Marconite conductive aggregate and bentonite
moisture retaining clay on Earth electrode back fill.
•Each earth pit to be separated by five times of its depth.
•Earthing resistance must be less than 3 ohms.
C10.7.2 Protection
The cables connecting the genset with the distribution system should be protected by means of
a circuit breaker or fuses to disconnect the output in case of overload or short circuit.
C10.7.3 Loading
When planning the distribution system it is important to ensure that the genset has a balanced
load. Loading one phase excessively as compared to other two phases this will cause
overheating in the alternator windings, imbalance in the phase to phase voltage output and
possible damage to sensitive 3 phase equipment connected to the system. Ensure that no
phase current exceeds that of the current rating of the genset.
Reorganizing an electrical distribution system may be necessary if a genset is to be connected
to an existing installation.
C10.7.4 Power Factor
Determine the power factor (cos phi) of the connected loads while ordering the genset. Power
factors below 0.8 will overload the generator. The genset will provide its kilowatt rating and will
operate satisfactorily from 0.8 to unity power factor. Particular attention must be given to
installation with automatic or manual power factor correction equipment to ensure that a leading
power factor is not present under any conditions. This will lead to voltage instability on the
generator output and may result in damaging overvoltages.
C-28
Diesel Genset
C10.8 Noise Control
The genset is available with accessories and components that reduce noise emissions. These
include residential and super critical silencers, acoustic louvers, splitter vents, fan silencers and
acoustically treated canopies.
The requirements for each site vary enormously and for any critical installation KOEL
recommends a consultation with the dealer at an early stage. The information needed to select
acoustic equipment is:
•The model and capacity of genset

•The designed noise level at a fixed distance, normally 1m or 7m.
• Environmental conditions, ambient temperature etc.
•The location and overall site plan.
Noise emissions from diesel gensets (without acoustic treatment) are at sound pressure levels
of between 100 dB(A) and 110 dB (A) at 1m. Kirloskar Gensets with acoustic canopies have a
typical noise pressure level of 75 dB(A) or less (average) at a distance of 1 meter from the
canopy.
Intermediate levels of treatment will prove more economic and are often satisfactory depending
only on the nature and type of installation. Hospital Care Areas will require more attention than
the normal commercial / industrial installation.
C10.9 Pre-commissioning Checks
Pre - commissioning checks will be conducted by the supplier’s commissioning team.

•Before starting the DG set, ensure that it is positioned on a level surface so that proper liquid
levels can be obtained. This is especially important for mobile or vehicle mounted gensets.
•Ensure that the top of the canopy does not accumulate rain water. If the foundations are
absolutely flat, a 1o slope is built into the design of canopy to ensure drainage of water.
• Hardware:
-Open the doors of the genset on both sides and check the tightness of all the fixing
hardware of the various systems.
-Tighten, if found loose.
-Check all hardware on engine- alternator coupling, mountings, fan and radiator mounting.
•Hose check:
-Check proper fitting of Fuel hose. Air hose and Exhaust hose.
•Bellow alignment:
-Check correct alignment of the expansion joint or bellow on the exhaust line.
• Leakage:
-Check for damage on the canopy and for openings on canopy roof which might lead to
water and sound leakage.
C-29
Diesel Genset
-Repair the damages (if any) and close the openings.

•Power cables:
-Check the proper termination power cables are terminated properly and are without
damage.
•Control cables:
-Check that the control cables are terminated properly and are without damage.
•Lube Oil level:
-Check that the lube oil is filled up to marked level.
•Coolant level check (for liquid-cooled engines):
-For filling coolant do not step on or climb on engine its components.
-A ladder is provided for the easy accessibility of radiator cap for filling the coolant.
-Ensure proper coolant level in the compensation tank.
•Battery:
-Ensure that the battery used is of correct rating and is connected with the right polarity.
•Cable routing:
-Check whether the power and the control cables are properly routed and secured with
cable ties.
•Cleanliness:
-Ensure that the inside and outside of the genset is dry and clean.
-Remove stains with diesel oil and clean up any oil spillage mark on the floor of the
canopy.
-Ensure that no debris is left inside the canopy which could clog moving parts or become a
fire hazard.
C10.10 Prior to Starting
• Study and familiarize the aspects of genset.
•Get trained by the seller or authorized service dealer before starting the generator.
•Maintain a log book to record all electrical and mechanical parameters with starts and stop
timing.
•Carefully follow all the instructions mentioned in the Pre-commissioning checks.
•Check the Lube oil level, Coolant level and Fuel level. Top up if necessary.
•Check that the restriction indicator of the air cleaner is in the healthy zone.
•Ensure that the load change over switch or the breaker is in off position.
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Diesel Genset
C10.10.1 Warnings
•Please read, understand and comply with the following warnings to avoid fire hazard
and damage to the genset.
•Prolonged inhalation of exhaust fumes may result in serious illness or death.
•Prolonged exposure to the noise levels of a diesel engine can impair hearing unless proper
ear protection is worn.Check levels of engine oil, radiator coolant, battery electrolyte and fuel.
Top up as necessary.
•Ensure that the Genset is operated in a well ventilated area with all exhaust fumes piped
away.
•In case the controller fails to start the engine, investigate the reasons before trying to restart.
Checks during commissioning.
•Always shut the genset prior to connecting, or disconnecting, load cables. Only restart after
proper connections has been made.
•If at any time the generator stops because of a fault, the fault should be rectified before trying
to restart the generator.
•Before connecting batteries, ensure control panel is switched off.
•Before starting the genset, ensure that engine and alternator are earthed correctly.
•Adhere to the local and national regulations for the grounding of gensets.
•Confirm following of regulations that describe methods of connection and minimum sizes of
grounding conductors based on the size of the load cables.
•Adequate grounding of the genset is necessary for both stationary and wheel mounted units
to prevent the possibility of injury or death in the event of electrical fault.
•Do not smoke or use naked flame in vicinity when filling the fuel tank.
•Fill the fuel tank only when Genset is switched off and the engine is cold.
• Spilled or vaporized fuel ignites easily.
•Do not connect or disconnect load connection or perform maintenance while the Genset is in
operation.
• To avoid an accidental start of the engine, always disconnect the battery when performing
major operations.
•As the battery system is negative earth, disconnect negative connection first and reconnect
negative connection last.
• The door of the control panel and alternator connections should not be removed while the
genset is in operation. The cover, when removed, exposes live electrical connections.
•Maintenance on the control panel should only be carried out by a trained and qualified
personnel.
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Diesel Genset
•Always shut down the genset and switch off circuit breaker prior to connecting, or
disconnecting load cables. Restart only after making firm connections.
C10.10.2 Manual Mode (Non-AMF) Operation
C10.10.2.1 Starting the Genset
•In this mode, the user starts and stops the engine. The user also transfers the load from
mains to genset and back, as required.
•Before starting, ensure load is disconnected from genset. Ensure people and material/tools
are clear of the engine.
•Check if Manual Mode is selected on the EMS 934 controller by the lit state of lamp on the top
left of the MAN button. If not, operate MAN button once and verify the lighting of the lamp.
MAN
• To start the engine operate the Manual Start button once.

•The controller will initiate cranking to start the engine. If the engine fails to start, the controller
will try again. If the engine does not start despite several attempts, the controller indicates a
Start Failure condition and inhibit further cranking. See Controller section for more details.
•After engine starts:
-Check for any leakages.
-Allow engine to idle for 3 minutes and then start connecting load in steps.
-Check engine parameters like Oil pressure, coolant temperature and battery changing
rate at regular intervals, while the genset is in operation.
-Maintain log book.
-Check for exhaust smoke.
-Check for any abnormal sounds.
-Check for alternator parameters, like voltage, ampere, kW and Power Factor on all
phases.
-During commissioning, cross check the meter readings with a calibrated multimeter or
clamp - on meter.
-Ensure that the load is balanced in all phases and within rated output of the genset.
-Check that all engine and alternator parameters on the controller are working.
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Diesel Genset
C10.10.2.2 Stopping The Genset
•Disconnect the load from the genset.
•Operate the Stop Button once. STOP

•The controller will keep the engine running for several seconds due to a Cool down timer for
ventilating the engine and alternator.
•After engine stops, check for any leakages.
• Top up fuel tank.
•Close the canopy securely.

•Switch off the Control Panel.
C10.11 AMF Operation
•Unlike Manual Mode operation, AMF (Automatic Mains Failure) panel is active all the time.
•If mains supply is in limits, the panel connects that feeder to load through mains contactors.
•If mains supply is out of limits (or failed), the AMF panel deselect the mains supply and starts
the genset.
•Once the genset is running, the AMF panel connects the load to alternator through the genset
contactors.
• While the genset feeds the load, the AMF panel monitors mains supply for a return back to
normalcy.
•Once the mains supply restores, the genset transfers load back to mains feeder and shuts the
genset after elapsing of cool down timing.
•AMF panel also monitors engine safety parameters for genset.
C10.11.1 Activating AMF
•Before activating, ensure people and material/tools are clear of the engine. Ensure that no
mishap could occur once the load is charged from either mains or genset supplies.
•Check if Auto Mode is selected on the EMS 934 controller by the lit state of lamp on the top
left of the AUTO button. If not, operate AUTO button once and verify the lighting of the lamp.
AUTO
AUTO
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Diesel Genset
•Now the controller will automatically decide the operation of engine and selection of supply
(mains or genset).
•Switch on panel and all circuit breakers. Ensure that the load is connected to mains supply.
•Switch off mains supply, the controller will start the engine and transfer load to genset supply.
• While engine is running, check engine parameters like Oil pressure, coolant temperature and
battery changing rate at regular intervals.

• Maintain log book.
•Check for exhaust smoke.
•Check for any abnormal sounds.
•Check for alternator parameters, like voltage, ampere, kW and Power Factor on all phases.
•During commissioning, cross check the meter readings with a calibrated multimeter or clamp
- on meter.
•Ensure that the load is balanced in all phases and within rated output of the genset.
•Check that all engine and alternator parameters indications on the controller are working.
•Reconnect mains supply, the controller will transfer load back to mains supply and stop
engine after a cool time timer delay.
•Ensure battery charger inside panel working when load is on mains by observing rising
battery terminal voltage.
•At any time of genset operation operate STOP button to stop the engine including the delay of
cool down time. STOP

•In case genset is to be stopped immediately, use the Emergency Stop switch on the panel
and canopy. This is not recommended unless there is a situation that demands the engine to
stop immediately.
C10.12 Daily Checks
Perform these checks daily before starting. If the genset runs infrequently except for standby
duties, these checks may be performed at a weekly interval.
• Visually check entire genset. Watch for potential leaks of fuel, coolant and lubrication oil.
seals.
•Check the alternator for obstructions in the cooling air ventilation screens.
•Check the alternator and control box for accumulation of dirt and dust.
•Clean any dirt/dust accumulations to avoid electrical hazard and cooling problems.
•Check the air cleaner. Clean or replace if necessary.
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Diesel Genset
•Check the fuel level.

•Check the engine coolant level.
•Check the engine oil level.
•Ensure no obstruction to the radiator/cooling air flow.
•Check the condition of the fan, alternator belts and their tension.
•Check hose condition and connections.
•Check battery terminals for corrosion.
•Check the battery electrolyte level, top-up with distilled water if necessary.
•Refer to the engine maintenance section for specific engine maintenance requirements.
•Replace and secure all parts removed for inspection and maintenance before starting the
genset.
•Drain condensate traps in the exhaust system, if fitted.
•Check for exhaust leaks.
•Check for any abnormal noise or vibration.
•Check for fluid leakage or high temperature.
•Dispose of any unnecessary items in the vicinity of genset that may inhibit operation or
represent cause of potential injury.
•Check the control panel for readings within set limits.
C11. Battery
Resistance in starting circuit has a significant effect on the cranking of the engine. Locate the
batteries as close as possible to the genset.
The batteries should be accessible for easy servicing. Maintenance procedures should be
carried out rigorously since the batteries have to be in perfect condition to start the diesel engine.
Note: Batteries emit inflammable gas. Do not smoke or create sparks or naked flames adjacent
to batteries.
C11.1 Battery Maintenance Schedule
Table 4: Battery Maintenance Schedule
Checking
No. Description Result
Frequency
1. Check battery electrolyte level after Monthly Electrolyte level to match MAX line on
removing the vent caps battery. Don’t cross over MAX line
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Diesel Genset
Table 4: Battery Maintenance Schedule (Continued)
2. In case of low level, top up the same As & when Top up the level up to MAX by DM
with Battery Grade DM Water only ( found Water only
Don’t use Acid )
3. Keep battery terminals sufficient tight Monthly Clean & Dust / corrosion free terminal
& clean & Dry joints
4. Don’t hammer on terminals while As required Terminals should be gently tighten

fitment with clamps
5 Always ensure the vent plugs are Monthly Vent holes on plugs are clean & vent
Clean & hold tightly on battery top plugs are always in intact position on
cover battery top
6. Clean the battery top cover by wet Monthly Clean & dust free battery top
cloth& Dry it with dry cloth
7. Avoid any physical short circuit As required No short circuit / Accident hazards
between the battery terminals while
checking / Maintaining the batteries
8. Ensure proper fitment of battery in Monthly Battery fit properly in battery box /
cradle cradle
9. Don’t use the battery for other than Every day Good battery life
Engine cranking
11. In case of DG Set remains Idle ( As required Good battery life

without operation ) for more than 3
weeks, please ensure followings :-
• Remove Negative cable of
battery.
• Ensure battery in adequate
charged condition before
removal.
• In case of low charge, remove
battery and use external charger
to raise charge to correct level.
12. In case of any battery problem, report As required Fast decision on battery claim & less
immediately to KOEL Service resolution time
Department
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Diesel Genset
C11.1.1 Battery Tips
Follow the tips to get the maximum life from your battery.
•The top of the battery must be kept clean and dry.

• Vaseline should be applied to cable clamps and terminals, Never apply
grease.
• Terminal corrosion dirt and moisture cause loss of power and make the battery weak.
•Battery open circuit voltage checked regularly and recorded in the service record.
•A faulty electrical system will damage the battery.
•The charging voltage setting measured across the battery terminals shall be maintained at
14.00+ 0.20 volts for 12V System and 28.0 V + 0.4 Volts for 24Vsystem.
•The recommended Specific Gravity of a fully charged battery is 1.270+ 0.005 at 27 oC. Take
immediate corrective action if case of any deviation.
•Electrolyte level must always be maintained in line with the bottom of the vent hole In case of
any drop in the electrolyte level, add pure distilled water. NEVER ADD ACID!
•. Keep battery away from places near fire as hydrogen gas generated from the battery may
cause fire and explosion.
•Shorting the battery terminals with a wire etc. will lead to fire and explosion.
• To prevent potential of harm, keep battery away from the reach of children and personnel who
do not have knowledge of battery.

• Wear the protection goggle and hand gloves while I handling the battery, since battery water
may cause blindness and severe burns.

•Do not add excess distilled water above the barrel level. Excess flow may cause damage and
burns.
•Do not drop and shake the battery, as it may cause injuries/damages.
•Care should be taken while handling the battery, as sulphuric acid may cause blindness and
severe burns.
•If battery water gets in the eyes, flush eyes thoroughly with clean water and seek medical
attention.
• When battery water gets in mouth, rinse immediately with plenty of water and seek medical
attention.
• When battery water gets into contact with skin, wash thoroughly with soap and water and
seek medical attention.

•IT IS STRONGLY RECOMMENDED TO NOT USE BATTERY ADDITIVES OR DOPES.
•Social Responsibility and Govt of India Notification:
-Lead acid batteries contain Lead and Sulphuric Acid, which are highly toxic and extremely
hazardous to health and environment
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Diesel Genset
-Lead poisoning affects the Central Nervous System, causing irreversible retardation and
subsequent death.
-As per the notification of the Govt of India, "It shall be the responsibility of the consumer to
ensure that used batteries are not disposed off in any manner other than depositing with
the dealer, manufacturer or at the designated collection centers”.
-It is mandatory for our authorized dealers to accept a used battery and provide
corresponding rebate on purchase of a new battery
•Please note that violations of these guidelines may lead to legal action and prosecution by
Government Authorities
C12. Optional Equipment
C12.1 Battery Charger
A mains powered battery charger is recommended for gensets meant for Non-AMF standby
duty. This is especially important if the genset does not run often. The battery charger will ensure
that the battery is kept in the peak condition for quickly starting the genset when required. The
battery charger has automatic charge control, thus avoiding overcharging of the battery.
In case of AMF genset, a mains powered battery charger is usually built in the panel.
C12.2 Heater
C12.2.1 Engine Heater Plug
To ease cold weather starting, a 12 VDC heater plug is fitted to the inlet manifold. This heater
plug is energized for a preset interval before cranking the engine. The passage of electrical
current through the heater plug heats the device and the air inside the inlet manifold. The 12
VDC supply to the heater plug should be switched off during cranking to ensure maximum
battery capacity for the starter motor. Ensure that the heater plug is not energized when the
engine is running.
C12.2.2 Anti-condensation Heater
Alternators are offered with heaters to prevent condensation, These heaters are fitted to the
alternator stator winding. These operate at a relatively low temperature and do not require a
thermostat. These heaters should be switched off when the genset is running. An external AC
power supply is required to power these heaters.
C12.3 Electronic Governor
Genset engines are available with Electronic Governors to closely regulate engine speeds and
therefore output frequency. Electronic Governor is recommended for gensets powering critical
loads and also when two or more gensets are required to run in synchronisation.
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Diesel Genset
C13. Maintenance
A good maintenance programme is essential for long genset life. Please find a program that
should keep your machine in top running condition. Also included in this programme are routine
maintenance operations required for the engine and alternator (see Engine Maintenance and
Alternator Maintenance Sections).
It is good practice to have all of the maintenance and service operations performed by trained
personnel familiar with genset maintenance. This, along with a good service records system,
should aid in developing an efficient maintenance program. The service records of each genset
should include information such as complete nameplate data with model and serial numbers,
all drawing and wiring diagrams, spare parts stock lists, as well as a service schedule and a
copy of this manual. These records will allow quick reference and may help to diagnose a
problem in the future.
C13.1 Daily Maintenance
Perform this maintenance before every start up. If the genset is used for standby applications
with little running, these procedures may be required after longer periods like every weekly.
to weekly.
•Make a visual check of the entire genset. Watch for signs of potential leaks from the engine
fuel system, cooling system or lubrication seals.
•Check the alternator for obstructions in the cooling air ventilation screens.
•Check the alternator and control box for heavy accumulation of dust and dirt. Clean any
heavy accumulations as electrical hazards, as well as cooling problems could arise.
•Check the air cleaner. Clean or replace if necessary.
•Check the fuel level.
•Check the engine coolant level (in case of liquid cooled engines).
•Be sure that the radiator air flow or blower air flow is not obstructed.
•Check the condition of the blower, fan and alternator belts and their tension.
•Check all hose connections and hose conditions.
•Check the engine oil level.Maintain the level at ‘H’ mark, top up if level is low.
•Check the battery terminals for corrosion.
•Check the battery electrolyte level and fill with distilled water if necessary.
•Ensure cleanliness around genset. Dispose of any unnecessary items in the vicinity of the
genset that may inhibit operation or represent cause of potential injury.
•Refer to the engine maintenance section for specific engine maintenance requirements.
• Start the genset after all checks have been made.
•Drain condensate traps in the exhaust system, if so equipped, and check for exhaust leaks.
•Check for any abnormal noise or vibration.
•Check for leakage of air, fuel, oil or coolant.
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Diesel Genset
•Check the control panel for indications of abnormal operation.
C13.1.1 Maintenance every Six Months or 250 Hours
•Repeat the daily maintenance checks.

•Check all safety devices by electrically simulating a fault to ensure that all systems will
function properly in the event of a fault.
•Clean all battery cap vents.
• Start the genset and observe the readings for all parameters are within limits.
• Tighten all exhaust connections.

• Tighten all electrical connections.
•Check and adjust belt tension of Blower assembly. Replace belt if not in good condition.
•Do external cleaning of Charge Air Cooler fins and coiling.
•Refer to the engine maintenance section, for further details.
C13.1.2 Alternator Unit Cleaning
The alternator unit should be cleaned inside and out on a regular basis. The frequency of such
cleaning depends on the environmental conditions of the operating site. The following procedure
should be applied when cleaning is necessary:-
•Disconnect all power.
• Wipe dust, oil, water or any other liquids from the external surfaces of the alternator unit. All of
these materials can work their way into the windings and may cause overheating or insulation
breakdown.
•Remove these same materials from the ventilation screens around the circumferences of the
unit. Do not permit such material to accumulate on these screens as this will obstruct air flow.
Such debris is best removed with a vacuum cleaner to avoid redepositing of these materials
on other parts of the equipment.
•DO NOT USE COMPRESSED AIR, STEAM OR A HIGH PRESSURE WATER CLEANER.
•Use a vacuum cleaner to clean the windings of the alternator unit. This will remove dust from
the coils that cannot be reached with a wiping cloth.
C14. Control System

Most diesel gensets work fully or partially without continuous human supervision. This
necessitates an electrical and electronic control system that ensures safe operation for the
genset all the time.
The Control System has several design objectives, some or all of which may be present on a
particular genset:
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Diesel Genset
• Means of starting and stopping the Generator Set on user’s command.

•Detect various conditions like failure of mains or restoration of main for starting or stopping
genset automatically.
•Monitor and display engine and genset parameters.
•Compare engine and genset parameters against set levels to ensure operation within safe
limits.
•If the parameters deviate from the set levels, generate alarms to warn the operator.
•If the parameters exceed another set of levels, automatically trip (shut down) the genset to
protect the installation, load and personnel.
• Typical conditions for alarm and trip condition are low oil pressure, high coolant temperature,
over speed, under speed, low coolant level, low fuel level etc.
C14.1 Control Panel
The genset are provided with a control panel with the following typical components:
•Electronic unit that provide logic to control genset,

•Gauges for displaying engine and genset parameters.
• Termination for sensor wires from engine.
• Termination for solenoid and relay outputs to engine.
• Termination for alternator incoming supply.
• Termination for load.
•Fuses and circuit breakers

•Alternator Circuit Breaker for connecting the generator output to load and automatically
disconnecting the load in case of overload or short circuit.
• Mains and Genset contactors.
•Battery charger.
C14.1.1 AMF panel
Auto Mains Failure (AMF) panel contains electronic logic for automating genset operation
including transferring power from mains to genset and vice-versa without human intervention.
AMF logic performs the following functions:
•Senses mains supply parameters for operation within set parameters.

•If mains supply is acceptable, the AMF logic selects the mains contactor and the load is
charged from mains feeder.
•If the mains supply goes out of set parameter limits, the AMF logic deselects the mains
contactor and starts the genset.
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Diesel Genset
•Once the genset is running and the parameters are within set limits, the AMF logic selects
genset contactor to charge load from genset feeder.
•AMF logic displays the engine and electrical parameters while the genset is running.
•The AMF logic monitors genset safety to ensure operation within limits
• The AMF logic also monitors mains feeder for a return back to normalcy.
•Once mains restores, the AMF logic deselects the genset contactor and selects the mains
contactor to charge load from mains feeder.
•The AMF logic shuts the genset down in the prescribed sequence and restarts the monitoring of
mains feeder for operation within safe limits.
• The AMF logic offer several timers that add delays necessary for correct operation.
C14.1.2 Non-AMF panel
Non-AMF panel provides basic genset safety and display functions. The task of starting, stopping
of genset as well as selecting between mains and genset feeder is done by the operator.
C15. Kirloskar Green Controller
C15.1.1 KG 745 Controller
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Diesel Genset
C15.1.2 Features
Reactive power protection
4-Line back-lit LCD text display
Five key menu navigation
Front panel editing with PIN protection
Customizable status screens
Power save mode
Support for up to three remote display units
9 configurable inputs
8 configurable outputs
Flexible sender inputs
Configurable timers and alarms
3 configurable maintenance alarms
Multiple date and time scheduler
Configurable event log (250)
Tier 4 CAN engine support
Integral PLC editor
Easy access diagnostic page
CAN and Magnetic Pick-up/Alt sensing
Fuel usage monitor and low fuel alarms
Charge alternator failure alarm
Manual speed control (on compatible CAN engines)
Manual fuel pump control
Engine exerciser
“Protections disabled” feature
KW & kVAr overload protection
Reverse power (kW & kV Ar) protection
LED and LCD alarm indication
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Diesel Genset
Power monitoring (kW h, kVAr, kVA h, kVAr h)
Load switching (load shedding and dummy load outputs)
Automatic load transfer (KG7320)
Unbalanced load protection
Independent Earth Fault trip
USB connectivity
Backed up real time clock
Fully configurable via DSE Configuration Suite PC software
Configurable display languages
Remote SCADA monitoring via DSE Configuration Suite PC software
User selectable RS232 and RS485 communications
Configurable Gencomm pages
Advanced SMS messaging (additional external modem required)
Start & stop capability via SMS messaging
Additional display screens to help with modem diagnostics
DSE Net® expansion compatible Before installation
C16.1.3 Installation Instructions
C16.1.3.1 Before installation
 Read the user manual carefully, determine the correct connection diagram.
 Remove all connectors and mounting brackets from the unit, then pass the unit through the mounting
opening.
 Put mounting brackets and tighten. Do not tighten too much, this can break the enclosure.
 Make electrical connections with plugs removed from sockets, then place plugs to their sockets.
 Be sure that adequate cooling is provided.
 Be sure that the temperature of the environment will not exceed the maximum operating temperature
in any case.
C16.1.3.2 Following conditions may cause damage
•Incorrectconnections.
•Incorrect power supply voltage.
• Voltage at measuring terminals beyond specified range.
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Diesel Genset
• Voltage applied to digital inputs over specified range.
•Current at measuring terminals beyond specified range.
•Overload or short circuit at relay outputs
•Connecting or removing data terminals when the unit is powered-up.
•High voltage applied to communication ports.
•Ground potential differences at non-isolated communication ports.
•Excessive vibration, direct installation on vibrating parts.
C16.1.3.3 Following conditions may cause abnormal operation
•Power supply voltage below minimum acceptable level.

•Power supply frequency out of specified limits
•Phase order of voltage inputs not correct.
•Current transformers not matching related phases.
•Current transformer polarity incorrect.
•Missing grounding.
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Diesel Genset
C16.1.4 Views
C16.1.4.1 Front View
C16.1.4.2 Rear View
C-46
Diesel Genset
C16.1.5 Electrical Installation
Do not install the unit close to high electromagnetic noise emitting devices
like
Contactors, high current bus bars, switch mode power supplies and the like.
ALWAYS remove plug connectors when inserting wires with a screwdriver.

Fuses must be connected to the power supply and phase voltage inputs, in close proximity of the
unit.
Fuses must be of fast type (FF) with a maximum rating of 6A.
Use cables of appropriate temperature range.
Use adequate cable section, at least 0.75mm2 (AWG18).
Follow national rules for electrical installation.
Current transformers must have 5A output.
For current transformer inputs, use at least 1.5mm2 section (AWG15) cable.
The current transformer cable length should not exceed 1.5 meters. If longer cable is used,
Increase the cable section proportionally.
Current Transformers must be used for current measurement. Direct connection is not allowed.
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Diesel Genset
C17. Operation
C17.1 Quick Start Guide
STOPPING THE ENGINE: Press STOP button; the engine will enter cooldown
mode. Press again STOP button for immediate stop.
STARTING THE ENGINE: Press MANUAL then press RUN

butt
on MANUAL LOAD TRANSFER: Use MAINS and GENSET
buttons. LOAD TEST: Press TEST button. The genset will run and
take the load. AUTOMATIC OPERATION: Press AUTO button.
Mode can be changed anytime without negative effect. Changing the operation
mode while the genset is running will result into a behavior suitable for the new operating
mode.
C17.2 Stop Mode
The STOP mode is entered by pressing the button. In this mode, the genset will be in a
rest state.
When STOP mode is selected, if the genset is running under load, then it will be
immediately unloaded. The engine will continue to run during Cooldown Timer and will stop
afterwards.
If the STOP button is pressed again, then the engine will immediately stop.
If the engine fails to stop after the expiration of Stop Timer then a Fail to Stop warning will
occur.
In this mode, the mains contactor will be energized only if mains phase voltages and frequency
are within the programmed limits. If enabled, the mains phase order is also checked.
If a Remote Start or Force to Start signal arrives in STOP mode, the genset will not start
until AUTO mode is selected.
C17.3 Auto Mode
The AUTO mode is entered by pressing the button.

The AUTO mode is used for the automatic transfer between genset and mains. The controller
will constantly monitor the mains availability. It will run the engine and transfer the load when a
mains failure occurs.
Diesel Genset
If a panel lock input is defined and signal is applied, then mode change will not occur.
However display navigation buttons are still enabled and parameters may be visualized.
The mains availability evaluation sequence is below:

•If at least one of the mains phase voltages or the mains frequency is outside limits, the mains
will be supposed failing. Otherwise mains is available.
•If a Simulate Mains signal is present, then mains are made available
•If a Remote Start signal is present, then mains are unavailable
When mains are evaluated as “unavailable” then an engine start sequence begins:
•The unit waits during Engine Start Delay for skipping short mains failures. If the mains is
restored before the end of this timer, the genset will not start.
•The unit turns on the fuel and preheat glow plugs (if any) and waits for preheat timer.
•The engine will be cranked for programmed times during crank timer. When the engine fires,
the crank relay will be immediately deactivated. See section Crank Cutting for more details.
•The engine will run at idle speed during Idle Speed Timer.
•The engine will run unloaded during engine heating timer.
•If alternator phase voltages, frequency and phase order are correct, the unit will wait for the
generator contactor period and the generator contactor will be energized.
When mains are evaluated as “available” again then an engine stop sequence begins:
•The engine will continue to run for the mains waiting period to allow mains voltages to
stabilize.
•Then the generator contactor is deactivated and the mains contactor will be energized after
mains contactor timer.
•If a cool down period is given, the generator will continue to run during the cool down period.
•Before the end of cool down, the unit will reduce the engine speed to idle speed.
•At the end of cool down, the fuel solenoid will be de-energized, the stop solenoid will be
energized for Stop Solenoid timer and the diesel will stop.
• The unit will be ready for the next mains failure.
If the operation of the genset is disabled by the weekly schedule, then the AUTO led
will flash, and the operation of the genset will be as in the OFF mode.
Diesel Genset
C17.4 Manual Mode
The MANUAL mode is entered by pressing the button.
When the RUN button is pressed, the engine will be started regardless of the mains
availability.
The starting sequence is as described below:

•The unit turns on the fuel and preheat glow plugs (if any) and waits for preheat timer.
•The engine will be cranked for programmed times during crank timer. When the engine fires,
the crank relay will be immediately deactivated. See section Crank Cutting for more details.
•The engine will run at idle speed during Idle Speed Timer.
•The engine will run unloaded until another mode is selected.
The MANUAL mode allows also manual contactor control through MC and GC
buttons.
When a contactor button is pressed, the related contactor will change position. Thus if it was
on, then it will turn off. If it was off then it will turn on.
If the other contactor was on, then it will turn off, the controller will wait for the related contactor
timer and the contactor will turn on. This will prevent manual closure of both contactors.
If Emergency Backup mode is enabled and if the mains are off, then the mains
contactor will be deactivated and the generator contactor will be activated.
When the mains are on again, a reverse changeover to the mains will be performed, but
the engine will be kept running unless another mode is selected.
In order to stop the engine press button or select another mode of operation.
C17.5 Test Mode
The TEST mode is entered by pressing the button.

The TEST mode is used in order to test the genset under load.
Once this mode is selected, the engine will run as described in the AUTO mode, regardless of
the mains availability and the load will be transferred to the genset.
The genset will feed the load indefinitely unless another mode is selected.
Diesel Genset
C17.5 Load Transfer and Contactor Operation
The unit provides for both Mains and Generator contactor control even though in many
applications this function will not be used, instead an MCB is used to switch the generator to
and from the load. Contactor outputs are controlled in both Manual and Auto operating modes.
The Mains contactor output can be setup to deactivate the Mains contactor in several ways
-"Immediately when the start button is pressed or the autostart input is activated.
-"A short delay after the start request
-"When the genset is running and able to take load.
The Generator contactor output will activate only after the Mains contactor has opened and only
when the genset able to take load. The timing is controlled by the XFR DELAY configuration
setting.
If the genset was started by activating the Autostart input, then deactivating the input will move
the sequence to the "Run On" sequence then to the"Cool Down" sequence. During cool down
the Generator contactor output is deactivated and after a delay the Mains Contactor output is
controlled to re-activate the Mains contactor.
C17.6 Speed Sensing
The unit can obtain speed information from one of four sources.
-Magnetic pickup unit (MPU)
-Generator output 50/60Hz if used for genset control (internally connected from GL1)
-Battery charging alternator
C17.6.1 MPU
The magnetic pickup unit counts teeth on the flywheel and is mounted in the bell housing. It is
important to ensure the gap between the MPU face and the teeth is 1mm to 2mm, as this
distance greatly affects the output of the MPU. The unit requires a minimum of 3VRMS at low
speed to ensure proper crank disconnect. Setup requires calculating the number pulses per 10
revolutions and the calculated number is then entered into the menu system "Cal Value".
Calculate: Number of Teeth x 10 = Speed Pulses Per 10 Revolutions.

Eg: 125 teeth x 10 = 1250.
Enter the number 1250.
C17.6.2 Generator
If the unit is used in a genset application the speed source can be the generator 50/60 Hz
Diesel Genset
output and is connected internally within the unit from the AC input connectors. AC should NOT
be connected directly to the speed MPU / Magneto input. For correct crank disconnect the
generator must be providing a detectable output at low speed and therefore the voltage at 300
RPM must be greater than 40VRMS. This can be affected by the AVR and must be confirmed
to provide suitable signals and timing for proper crank disconnect.
For setup the number of pulses per 10 revolutions must be calculated and entered into the menu
system "Cal Value". The generator output frequency and standard RPM must be known.
Calculate Speed Calibration value as follows:

Cal Value = (Freq x 600) / RPM.
Eg: (50Hz x 600) / 1500 = 20
C17.7. Battery Charging Alternator
A low cost speed source can be derived from the battery-charging alternator if fitted. It
unfortunately is also the most troublesome, and not recommended for reliable and repeatable
long-term service. The difficulties arise from the in-exact relationship of alternator output
frequency and engine RPM. As a result of slippage and variable mechanical coupling both
calibration and long-term stability are compromised.
The ratio of crank pulley to alternator pulley is indeterminate, as it depends very significantly on
where the coupling belt rides in the V grove. Belt tension plays a very significant role, as does
belt wear and instantaneous belt loading. Immediately after starting an engine the alternator is
required to re-charge the partially discharged battery. The loading on the alternator is very high
and belt slippage is common as is belt set low in the V groove. The output frequency may be
lower than expected. If speed calibration is performed at this time, the speed representation will
be too low and subsequently as the load reduces on the alternator, the engine speed will appear
to erroneously increase.
The battery charging alternator output frequency and current RPM must be known. This is
achieved by independently running the engine, and measuring the battery charging alternator
frequency on the W (sometimes D+) terminal. Excitation must also be provided to ensure self-
excitation and an adequate output signal. Some small variation in reported speed may result
but this can be calibrated out later during engine commissioning. For setup the number of pulses
per 10 revolutions must be calculated and entered into the menu system "Cal Value".
Calculate Speed Calibration value as follows:

Cal Value = (Freq x 600) / RPM.
Eg: (257Hz x 600) / 1500 = 102.8.
C17.8 Battery Charging Alternator Excitation
The battery charging alternator excitation system is implemented using a burst mode pulse
Diesel Genset
system. This ensures reliable self-excitation while managing current consumption during
standby, heat dissipation during fault conditions, and pulsing the battery-charging alternator
prior to cranking for improved speed signal output.
During standby and Ready, the alternator excitation is pulsed once per minute to maintain some
level of residual magnetism in the alternator but still maintaining minimum power consumption.
On receiving a start signal, the unit pulses the alternator excitation input with a burst of 200mA
pulses.
The pulse width is dependent on the battery voltage. This pulse burst establishes a definite
magnetic field in the battery-charging alternator prior to cranking. This ensures a significant
speed-sensing signal is generated for crank disconnect sensing.
The alternator excitation is turned off and the engine is cranked without the usual alternator
burden loading the cranking process. This aids easier starting. When the engine has fired and
is running, more 200mA pulse bursts are applied. Given the alternator is rotating at more than
the 3000RPM the alternator will achieve self-excitation.
If self-excitation is not achieved this process will repeat for a few seconds before the excitation
failed warning is given
Alternator excitation may also be used as a secondary crank disconnect signal for the case
where the speed signal has failed immediately the engine starts to run. This feature can be
disabled if not required by setting "Excite Dis" to NO.
For systems where a battery-charging alternator is not fitted, turning off the excitation warning
will disable the excitation system.
C17.9 Battery Voltage Monitoring and Charging Detection
A battery is considered charged if (assuming a 12V system. x2 for 24V) its terminal voltage is
above 13.1Volts. Typically a fully charged battery has a terminal voltage of 13.6V, above this
and the battery is being overcharged. During cranking the large discharge current will reduce
the battery terminal voltage below 12.5V and the battery cannot increase the terminal voltage
again without the assistance of a charger. This sequence provides a useful mechanism to
determine if a battery is being actively charged.
Many applications have a current meter to show charging current. Such meters provide very
limited value as a good battery will recover its terminal voltage very quickly and then be
maintained with a very low level of trickle current. This trickle current is usually too small a
percentage of the current meters range to provide any useful information.
The unit constantly measures the battery terminal voltage and can detect proper charging and
discharging performance. Voltage readings are taken and compared against an inbuilt voltage
profile. If the battery terminal voltage falls outside the critical voltages for each action then a
battery warning is indicated.
Diesel Genset
During standby, and particularly where an on line charger is not available, monitoring the health
of the battery is vital. The unit regularly wakes and measures the battery voltage, if it falls below
the set point a warning is issued to ensure the operator is aware of the need for battery
recharging.
C17.10 Trouble shooting
The unit displays the following messages when an alarm occurs. Alarms shut down the engine,
set the alarm output and flash the alarm indicator. The alarm indications can be cleared after
the genset has stopped, by pressing the stop button. The hooter can be silenced with the
Hooter Button. .
Table 26: Trouble shooting
Message Cause
Low Oil Pressure Oil pressure has not reached the Oil Alarm set point (Oil Alarm) at
the end of the run up time or has dropped below this value when the
engine is running.
Check:
• Engine oil level

• Cleanliness of oil filters
• Wiring between sender/switch and panel
• Function of sender/switch
Low Fuel Level Fuel level is less than the minimum value set point.
Check:
• Fuel level in tank

Diesel Genset
Table 26: Trouble shooting (Continued)
Message Cause
High Engine Temp High Engine or liquid Temperature.

Engine temperature has exceeded the high temperature set point.
The temperature icon turns on. Either message may also be shown
depending on temperature system setup.
Check:
For Air Cooled Engine:
• Blower operation.
• Obstruction to cold air intake and hot air exhaust
• V Belt status and tension.
• Overloading of engine.
• Clogging of cooling surfaces.
• Closing of engine cowls,
For liquid Cooled Engine:
• Coolant level in header and radiator.

Caution: Open radiator cap only when engine has stopped
and is cold. Never open radiator pressure cap when
engine is hot, even if it is not running.
• Obstruction to cooling airflow for liquid as well as air cooled
engines.
• Radiator fan function.
• Clogging of radiator cores.
• Coolant leaks causing reduction in quantity
High Canopy Temp Canopy temperature switch was activated.
Check:
• Is the canopy interior temperature really hot? Investigate and

correct the reasons.
Diesel Genset
Message Cause
Low Water Level For liquid cooled engines only:
liquid Level has gone below the level sensor.
Check:

Under speed Engine speed has dropped below the under speed set point.
Check:
• Overloading of engine
• Wrong setting of fuel pump
• Wrong setting of governor
• Friction in the engine
• Faulty speed sensor or wrong setting of sensor
Over speed Engine speed has exceeded over speed set point.
Check:
• Engine running free of load

High Rev Engine has exceeded safe operating speed.
Check:
• Engine running free of load

C-60
Diesel Genset
Message Cause
No Speed Signal Engine has lost speed signals while running.
Check
• Wiring between sender and panel

• Function of sender
• Wrong setting of sender
Start Failure The engine has failed to start.
Check
• No fuel in tank
• Clogged air cleaner
• No compression
• Wrong setting of pump
• Weak battery
• Faulty starter motor
• Faulty or loose wiring to motor
• Stop solenoid or governor stuck at ‘no fuel’ position
Stop Failure The engine has failed to stop.
Check
• Faulty stop solenoid or governor

• Faulty or unadjusted linkage between stop solenoid or governor
and fuel pump
• Faulty wiring to stop solenoid or governor
• Faulty setting of governor
• Dirt in injectors
E-S Lock out The emergency stop input has stopped the engine.
Check
• Emergency switch active on the canopy or panel? If yes, verify

the reason for operation and reset the panel.
• Wiring between switch and panel
• Function of switch
C-59
Diesel Genset
Message Cause
Oil Pressure Flt The unit has detected that the Oil Pressure sender has become open
circuit. Normally this indicates a faulty sender or broken wiring. This
will only shut down when the Oil System is set to Sender.
Check:
• Oil level in sump

• Clogged oil filter
Engine Temp Flt The unit has detected that the engine temperature has not risen to 50
degrees within the first 5 minutes of running or the temperature
sensor has shorted to common. Normally this indicates a faulty
temperature sender or broken wiring.
Check:

• Obstruction to cooling airflow for liquid as well as air cooled
engines.
• Radiator fan function.
• Clogging of radiator cores.
C17.11 Error Messages
The following warning messages indicate potential problems. When a warning occurs, the
message associated with the warning is displayed. Warnings clear automatically when the
warning condition is cleared.
Table 27: Error Messages
Message Cause
No Excitation Excitation voltage is low when engine is running. This indicates a

probable charging fault or the alternator belt has broken.
C-60
Diesel Genset
Table 27: Error Messages (Continued)
Message Cause
Low Charge Volts Battery Voltage is below the charging voltage setpoint when the
engine is running. Indicates that the alternator is not charging the
battery.
Under Voltage Battery Voltage is below the low battery setpoint.
Over Voltage Battery Voltage is above the high battery volts setpoint. This may be
due to a faulty regulator or battery charger.
Oil Lock Out The unit has detected that the oil pressure is above the oil pressure
alarm set point with the engine not running. This warning prevents
the engine from attempting to crank with the engine potentially
running. This may be due to a faulty oil sender or a very tight engine.
This warning is disabled if Oil Pressure Check before Cranking is set
to Off.
Tacho Lock Out The unit has detected that a speed signal is present with the engine
not running. This warning prevents the engine from attempting to
crank with the engine potentially running. This warning can
sometimes be caused by ripple generated by mains powered battery
chargers.
Excite Lock Out The unit has detected that Excitation is present with the engine not
running. This warning prevents the engine from attempting to crank
with the engine potentially running. This warning can sometimes be
caused by ripple generated by mains powered battery chargers.
AutoStart On The unit has detected an Autostart signal when not in auto mode,
indicating the engine needs to be started in Auto mode.
Low Oil Pressure The Oil Pressure has dropped below the Oil Pressure Warning set
point while the engine is running. The Oil Pressure Icon is lit.
High Engine Temp Engine/liquid temperature has exceeded the high temperature
High Water Temp warning set point after the Temperature monitoring delay has
expired.
High Canopy Temp Canopy Temperature was activated after the Temperature monitoring
delay has expired.
Low Fuel Level Fuel level is less than the warning set point.
Fuel Level Flt The unit has detected that the fuel sender is open circuit. This is only
a warning, and will not shut down the engine
No Speed Signal A speed signal could not be detected after the engine had started
C-59
Diesel Genset
Table 27: Error Messages (Continued)
Message Cause
Maintenance The time since the last maintenance has exceeded the maintenance
time. The alarm output is not activated for this warning. The warning
ALARM
is cleared by pressing and holding the button for 30

seconds. If the engine maintenance is carried out prior to the timer
ALARM
expiring, pressing the button for 60 seconds will reset the

timer.
C-60
•••••••••••••••• Enriching Lives ••••••••••••••••
Diesel Genset
Engine - HA series
D1. Model ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ D‐1
D1.1 Rating plate ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ D‐1 D1.2
Rating Plate Location ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ D‐2 D1.3
Cylinder Numbering ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ D‐2 D1.4 Direct
Injection ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ D‐3 D2. General ‐ ‐ ‐
‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ D‐3
D2.1 Your engine needs ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ D‐3
D2.2 Service and Maintenance ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ D‐3 D2.3
Maintenance and Repairs‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ D‐3 D2.4 Safety
‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ D‐4
D3. Engine Illustrations ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ D‐5
D3.1 HA294 G1, Service Side ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ D‐5
D3.1.1 HA294 G1, Exhaust Side ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ D‐6 D3.1.2
HA394 TCI G1, Service Side ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ D‐7 D3.1.3 HA394
TCI G1, Exhaust Side ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ D‐8 D3.1.4 HA494 TCI G1,
Service Side ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ D‐9 D3.1.5 HA494 TCI G1, Exhaust
Side ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ D‐10 D3.1.6 HA694 TCI G1, Service Side ‐ ‐ ‐
‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ D‐11 D3.1.7 HA694 TCI G1, Exhaust Side ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐
‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ D‐12 D3.2 Lube Oil System ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐
‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ D‐13 D3.2.1 HA294 G1 NA ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐
‐ ‐ ‐ D‐13 D3.2.2 HA694 TC ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐
D‐14 D3.3 Engine Fuel System ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ D‐
15 D3.4 Fuel Pump‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ D‐15
D3.4.1 In‐line Fuel Pump ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ D‐15 D3.4.1.1
Rotary Fuel Pump ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ D‐16 D3.5 Engine
Cooling System ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ D‐17 D3.6 Air
System‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ D‐17 D3.6.1 Dry
type Air Cleaner ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ D‐18
D3.7 Exhaust System ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ D‐19
D4. Engine Operation ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ D‐21
D4.1 Commissioning ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ D‐21
D4.1.1 Filling Engine Oil ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ D‐21
D4.1.2 Adding Fuel ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ D‐21
D4.1.3 Fuel System Ventilation ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ D‐21
D4.1.3.1 For In‐line Fuel Injection Pump ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ D‐21
D4.1.3.2 For Rotary Fuel Pump ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ D‐22 D4.1.4
Other Preparations ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ D‐22 D4.1.5
Additional Maintenance Work ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ D‐23
Diesel Genset
D4.2 Starting ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ D‐23

D4.2.1 Before Starting ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ D‐23
D4.2.2 Starting without Engine Heater ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ D‐24
D4.2.2.1 Starting the Engine ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ D‐24 D4.2.2.2
Stopping The Genset ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ D‐25 D4.2.3 Starting
with Engine Heater ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ D‐25
D4.2.3.1 Starting the Engine ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ D‐25 D4.2.3.2
Stopping the Engine ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ D‐25
D4.3 Electrical System ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ D‐25
D4.3.1 Electrical Equipment ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ D‐26 D4.3.2
Battery Cable ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ D‐26 D4.3.3
Recommended Battery Capacity ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ D‐26 D4.4
Monitoring System ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ D‐26 D4.4.1
Engine Lube Oil Pressure ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ D‐26 D4.4.2 Engine
Oil Temperature ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ D‐26 D4.4.3 V‐
Belt Failure Switch ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ D‐27 D4.4.4 High
Cylinder Head Temperature Switch ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ D‐27 D4.5 Operating
Conditions ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ D‐27 D4.5.1 Winter
Operation ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ D‐27 D4.5.2 High Ambient
Temperatures and High Altitude ‐ ‐ ‐ ‐ ‐ ‐ D‐28
D5. Operating Media ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ D‐28
D5.1 Lube Oil ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ D‐28
D5.1.1 Quality Grade ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ D‐28 D5.1.2
Viscosity ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ D‐28 D5.2 Fuel ‐ ‐ ‐
‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ D‐29 D5.2.1 Quality
Grade ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ D‐29 D5.2.2 Winter Grade
Fuel ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ D‐29
D6. Routine Maintenance‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ D‐31
D6.1 Maintenance Schedule ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ D‐31
D6.1.1 Log of Maintenance Work ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ D‐32
D7. Service & Maintenance ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ D‐33
D7.1 Lubrication system ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ D‐33
D7.1.1 Oil Change Intervals ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ D‐33 D7.1.2
Checking Oil Level ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ D‐34 D7.1.3
Changing Engine Oil ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ D‐35 D7.1.4
Changing Oil Filter Element ‐ Spin On Type ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ D‐36 D7.2 Fuel
system ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ D‐37 D7.2.1
Changing Fuel Filter ‐ Spin On Type ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ D‐37 D7.2.2
Changing Fuel Filter ‐ Element Type ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ D‐38 D7.2.3 Fuel
Strainer ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ D‐39 D7.3 Cooling
System ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ D‐40
ii
Diesel Genset
D7.3.1 Cleaning Intervals ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ D‐40

D7.4 Combustion Air Filter ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ D‐41
D7.4.1 Air Cleaner Service Intervals ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ D‐41 D7.4.2
Dry Type Air Cleaner ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ D‐41 D7.5 Belt
Drives‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ D‐43 D7.5.1
Checking V‐Belts ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ D‐43 D7.5.2
Replacing Fan V‐ Belt ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ D‐44 D7.5.3
Tensioning Alternator Belt ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ D‐44 D7.5.4
Changing Alternator Belt ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ D‐45 D7.5.5 V‐belt
Failure Warning System ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ D‐45 D7.5.6 Visual
Inspection of V‐Belts ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ D‐46 D7.5.7 Re‐tensioning
of Alternator Belt ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ D‐46 D7.6 Adjustments‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐
‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ D‐46 D7.6.1 Checking Valve Clearance ‐
‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ D‐46 D7.6.2 Adjusting Valve Clearance ‐‐‐‐
‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ D‐47 D7.7 Accessories ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐
‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ D‐48 D7.7.1 Checking Battery and Cable Connectors ‐ ‐ ‐ ‐
‐ ‐ ‐ ‐ ‐ ‐ D‐48 D7.7.2 Checking Electrolyte Level ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐
D‐48 D7.7.3 Checking Electrolyte Density ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ D‐49
D7.7.4 Lifting Tackle ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ D‐50 D7.8
Engine Cleaning ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ D‐50
D7.8.1 Cleaning the engine with Compressed Air ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ D‐50 D7.8.2
Cleaning the engine with Cold Cleaning Agent ‐ ‐ ‐ ‐ ‐ ‐ ‐ D‐51 D7.8.3
Cleaning the engine with High Pressure Steam Jet ‐ ‐ ‐ ‐ ‐ D‐52
D8. Faults, Causes & Remedies ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ D‐52
D9. Engine Preservation ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ D‐54
D9.1 About Preservation ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ D‐54
D9.2 Preserving Engine ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ D‐54
D9.3 Commissioning Preserved Engine ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ D‐55 D10.
Technical Specifications ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ D‐55 D10.1
Engine Specifications for CPCB II ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ D‐55 D10.2 Power
Output for CPCB II ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ D‐56 D10.3 Torque
Wrench Setting ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ D‐57
iii
Diesel Genset
HA series Diesel Engine

D1. Model
D1.1 Rating plate
The engine model and engine serial number are stamped on nameplate along with engine
rating, rpm and referred standard. The name plate details must be given while ordering spares
and asking for service.
Figure D - 1: Engine Rating Plate
D--1
Diesel Genset
D1.2 Rating Plate Location
The name plate is fixed on engine crankcase as shown in the figure.
Figure D - 2: Location of ratings plate
D1.3 Cylinder Numbering
The engine in the illustration is from the HA family, The engine in your genset may be different
from the one shown in the image.
Figure D - 3: Cylinder Numbering
D-2
Diesel Genset
D1.4 Direct Injection
Engines are with direct fuel injection to deliver high performance and meet pollution
regulations.
Figure D - 4: Direct Injection
D2. General
D2.1 Your engine needs
•Clean high speed diesel oil.

• Lubricating oil of specified quality and viscosity grade.
•KOEL recommends use of K-Oil Premium.

•Fresh air for combustion of fuel, for cooling of engine and genset.
•Genuine spare parts for its maintenance.
D2.2 Service and Maintenance
•Sound service and maintenance practices will ensure that the engine continues to meet your
requirements.
•Recommended preventive maintenance at regular intervals must be observed. The service
and maintenance work should be carried out conscientiously.
• Special care should be taken under abnormally demanding operating conditions.
D2.3 Maintenance and Repairs
•Shut down the engine before carrying out maintenance or repair work.
D-3
Diesel Genset
• When the work is complete, be sure to install safety devices that may have been removed.
•If you have to work on a running engine, ensure that all clothing is tight fitting and cannot
entrap the moving parts.
•Observe all industrial safety regulations when engine are operating in enclosed spaces or
underground.
•Please contact your KOEL dealer for spare parts enquiry. Use only genuine spare parts.
D2.4 Safety
• All Safety instructions (for both engine and operator) in this manual are designed by the
accompanying symbol. Please follow them carefully.

•The attention of operating personnel should be drawn to these instructions.
•General safety and accident prevention regulations laid down by law must also be observed.
D-4
Diesel Genset
D3. Engine Illustrations
D3.1 HA294 G1, Service Side
Figure D - 5: HA294 G1 NA Service Side

Table 1: HA294 G1, Service Side
Number Item
1 Cooling blower
2 Lifting hook
3 Fuel injection pump
4 Flywheel housing
5 Crank pulley
6 Oil filler neck/ cap
7 Lube oil sump

8 Lube oil filter
9 Fuel filter
10 Air cowling
11 V-belt
12 Feed pump
13 Lube oil drain plug
D-5
Diesel Genset
D3.1.1 HA294 G1, Exhaust Side
Figure D - 6: HA294 G1 NA Exhaust Side
Table 2: HA294 G1, Exhaust Side
Number Item
15 Charging Alternator
16 Starter
17 Crankcase
18 Crankcase breather
19 Flywheel
20 Rocker cover
21 Air intake manifold
22 Exhaust manifold
D-6
Diesel Genset
D3.1.2 HA394 TCI G1, Service Side
Figure D - 7: HA394 TCI G1 Service Side
Table 3: HA394 TCI G1 Service Side
Number Item
1 Cooling blower
2 Lifting hook

4 Flywheel housing
5 Crank pulley
6 Belt tensioning unit
8 Lube oil sump
9 Lube oil filter
10 Fuel filter
11 Air cowling
12 V-belt
13 Feed pump
D-7
Diesel Genset
D3.1.3 HA394 TCI G1, Exhaust Side
Figure D - 8: HA394 TCI G1 Exhaust Side
Table 4: HA394 TCI G1 Exhaust Side
Number Item
16 Starter
17 Crankcase
19 Flywheel
20 Rocker cover

22 Exhaust manifold
23 Turbocharger
24 Intercooler
D-8
Diesel Genset
Number Item
1 Cooling blower
2 Lifting hook
4 Flywheel housing
5 Crank pulley

8 Lube oil sump
9 Lube oil filter
10 Fuel filter
11 Air cowling
12 V-belt
13 Feed pump
D-9
Diesel Genset
Number Item
16 Starter
17 Crankcase
19 Flywheel
20 Rocker cover
22 Exhaust manifold
23 Turbocharger
24 Intercooler
Diesel Genset
Number Item
1 Cooling blower
2 Lifting hook
4 Flywheel housing
5 Crank pulley
8 Lube oil sump
9 Lube oil filter
10 Fuel filter
11 Air cowling
12 V-belt
13 Feed pump

Diesel Genset
Number Item
16 Starter
17 Crankcase
19 Flywheel
20 Rocker cover
22 Exhaust manifold
23 Turbocharger
24 Intercooler
D-12
Diesel Genset
D3.2 Lube Oil System
D3.2.1 HA294 G1 NA
Figure D - 13: Lube Oil System HA294 G1 NA
Table 9: Lube Oil System HA294 G1 NA
Number Item Number Item
1 Lube Oil Sump 12 Camshaft Bearing
2 Suction Pipe 13 Push Rod

3 Lube Oil Pump 14 Rocker Arm Bearing
4 Pressure Relief Valve 15 Metering Plug

5 Delivery Pipe 16 Push Rod Cover Tube
Lube Oil Cooler Tappet with groove for pulse fed

6 17
rocker arm lubrication
Lube Oil Filter Restrictor ( for lubrication of

7 18
gears)
8 Relief Valve (not shown) 19 Spray Nozzle for Piston Cooling
9 Oil Gallery 20 Connection for Pressure Gauge
10 Main Bearing 21 Oil Pressure Gauge

Large End Bearing Fuel Pump Connected to Lube
11 22
Oil Circuit
D-13
Diesel Genset
D3.2.2 HA694 TC
Figure D - 14: Lube Oil System HA694 TC
Table 10: Lube Oil System HA694 TC
1 Oil Sump 13 Camshaft Bearing

Suction Pipe Tappet with groove for pulse
2 14
fed rocker arm lubrication
3 Oil Pump 15 Push Rod
4 Pressure Valve 16 Rocker Arm Bearing
5 Delivery Pipe 17 Metering Plug

6 Pipe to Oil Cooler 18 Push Rod and Cover Tube
7 Oil cooler plate type 19 Restrictor Hole
8 Lube Oil Filter 20 Nozzle for Piston Cooling

9 Safety Valve 21 Oil Pipe to Turbocharger
10 Oil Gallery 22 Oil return Pipe
11 Main Bearing 23 Oil Pressure Gauge
12 Big-End Bearing
D-14
Diesel Genset
D3.3 Engine Fuel System
Figure D - 15: Fuel System for In-line Fuel Pump
Table 11: Fuel System
1 Fuel tank 7 Fuel Injector
Fuel pipe - tank to fuel Leak-off pipe

2 8
pump
3 Fuel feed pump 9 Fuel overflow line
4 Fuel filter 10 Overflow valve
5 Injection pump 11 Fuel return line to tank
Fuel injection pipe A Clearance; keep as far

6 apart as possible.
(Minimum of 200 mm)
D3.4 Fuel Pump
Depending on the type of engine, the fuel pump may be In-line or Rotary type.
D3.4.1 In-line Fuel Pump
Fuel is supplied to In-line Fuel by an in built feed pump. A set of fuel filters ensures the supply
of clean fuel to the In-Line fuel pump. The pump creates a high pressure stream of diesel that
is led to the individual engine cylinders through high pressure pipes. The pump has a Stopping
Lever that helps stop the engine when required. The pump also has an Accelerating Lever that
sets the engine speed.
D-15
Diesel Genset
Figure D - 16: In- line Fuel Pump
D3.4.1.1 Rotary Fuel Pump
Some engines are fitted with Rotary Fuel Pump. Fuel is supplied to the Rotary fuel pump by a
fuel lift pump (feed pump) a spin-on fuel filter ensures the supply of clean fuel to the rotary fuel
pump.
Figure D - 17: Rotary Fuel Pump
The schematic diagram below shows the fuel circuit of the engine.If fuel tank is installed below
fuel pump level, then the bottom level of fuel tank should be less than 1 meter below the feed
pump inlet. Fuel pipe from fuel tank to feed pump should be of 9mm I.D.
D-16
Diesel Genset
Figure D - 18: Parts of Rotary Fuel Pump
D3.5 Engine Cooling System
Air cooling for the engine is achieved by quiet, highly efficient and integral axial blower that has
sufficient reserve capacity to cope up with high ambient temperatures. The blower is driven by
the engine crankshaft pulley through V-belts. The V-belts tension is maintained by belt tensioning
unit.
Air flow from the blower is directed on the liners and cylinder heads by detachable sheet metal
lower & upper cowlings.
Figure D - 19: Cooling Air Flow
D3.6 Air System
Engine requires fresh, clean, cool, and sufficient quantity of air to burn the fuel and deliver
satisfactory performance. Use of clean air avoids unnecessary wear and tear of engine
component. Your engine may look different from the ones illustrated in this manual.
D-17
Diesel Genset
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Figure D - 20: Air Inlet System

Depending on the type of engine, an Air System consist of Air Cleaner or Air Filter, various
Hoses, Turbocharger, Intercooler and Air Inlet Manifold. A simple engine uses basic natural
aspiration while more complex and powerful engines have Turbocharger and/or Intercooler.
• The Air Intake draws in cool air from the atmosphere.
•The air is then cleaned in the Air Filter which separates heavier particles in air by a swirling
action.
•Subsequently, a fine paper element inside the AIr Filter screens the smaller particles from the
air.
•This clean air gets compressed by the Turbocharger. The compression of air also raises its
temperature, which is detrimental to the performance of engine.
•This compressed but hot air is cooled by the Intercooler which is a variety of heat exchanger.
•The Intercooler receives a cooling draft of air from the blower. The cooled and compressed air
from the output of Intercooler enables the engine to deliver maximum output over a variety of
altitudes.
D3.6.1 Dry type Air Cleaner
Figure shows the construction of dry type air cleaner used on HA series engines. Dry type Air
Filters are used in heavy duty engines. The filtration efficiency of Dry type air cleaner is 98.9 -
99.9%. Generally two elements are used in this type of air cleaner - Main element & Safety
element.
Restriction indicator is provided for all dry type air cleaners. Cleaning of filter element is required
when restriction indicator shows red signal even after engine has stopped.
D-18
Diesel Genset
Figure D - 21: Dry Type Air Filter
Figure D - 22: Parts of Air Filter
D3.7 Exhaust System
The Exhaust System is necessary to direct exhaust gases to non confined areas and reduce
the noise level to tolerable level. Exhaust system should exert minimum back pressure on
engine. Exhaust back pressure should be restricted to less than 50 mm of Hg.
Exhaust system consist of exhaust manifold, adaptor & exhaust silencer. Exhaust piping should
be lagged to avoid injury to operating personnel. Total length of exhaust pipe should not
D-19
Diesel Genset
exceed 15 meters and should have maximum of four right angle bends. Avoid using elbows.
Increase pipe I.D. by 1.5” after every 5 meter length of exhaust pipe. Expansion bellows &
flexible pipes should be installed between engine and exhaust piping.
The exhaust pipe outlet should be bent so that outgoing exhaust gases are not recirculated.
The exhaust pipe outlet should be bent in the direction of wind and the end should be cut at an
angle of 45 degrees.There should be rain trap to avoid rain water entry. If rain cap is used the
distance between exhaust pipe and rain cap should be 2.5 times diameter of exhaust pipe.
Figure D - 23: Exhaust System

The figure shows HA694 Engine with exhaust outlet facing downwards. Exhaust silencer is
mounted separately on the equipment and connected to exhaust manifold by flexible piping.
D-20
Diesel Genset
D4. Engine Operation
D4.1 Commissioning
D4.1.1 Filling Engine Oil
Figure D - 24: Engine Oil Filler

Engines are delivered with first fill oil.
D4.1.2 Adding Fuel
Never fill the tank while the engine is running. Observe cleanliness and do not spill any
fuel.
Figure D - 25: Use High Speed Diesel

Use only High speed diesel fuel. For fuel specifications refer D5.2.
D4.1.3 Fuel System Ventilation
D4.1.3.1 For In-line Fuel Injection Pump
• Loosen overflow valve 1 on the fuel pump.
• Loosen hand pump 2 of the fuel feed pump at the knurled grip by unscrewing it.
D-21
Diesel Genset
•Operate the hand pump till fuel flow without air bubble at overflow valve.
• Tighten the overflow valve while fuel is flowing simultaneously operating the hand pump.
• Tighten the hand pump at knurled grip.
•Refer image Figure D - 26:.
Figure D - 26: Fuel System Ventilation for In-line FIP
D4.1.3.2 For Rotary Fuel Pump
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Figure D - 27: Ventilating a Rotary Fuel Pump

The Rotary Fuel pump gets clean fuel through a feed pump and a spin-on fuel filter.
• Loosen Overflow Connection on the fuel pump.
•Operate the hand pump on top of fuel filter till fuel flow without air bubble through the overflow
connection.
• Tighten the overflow connection while operating the hand pump leading to a fuel flow. This will
avoid air entrapment in the fuel system.
D4.1.4 Other Preparations
•Check battery and lead connections.
D-22
Diesel Genset
•Also check cable connection at the starter and alternator end for tightness.
•Remove engine lifting tackle.
• Trial run
-After completing the engine preparations run the engine for about 10-15 min. at no load.
-While engine is running check lube oil pressure (3.5 to 4.5 kg/cm2) and lube oil
temperature is within limits.
•During and after trial run
•After trial run and engine stationary
-Check oil level, refer D7.1.2.
-if required top up oil, refer D4.1.1.
-Re-tension V-belts, refer D7.5.
•Running in
-During running in period- about 50 running hours, check oil level twice a day.
-After running in, checking oil level once a day will be sufficient.
D4.1.5 Additional Maintenance Work
The following maintenance should be carried out after 50 operating hours;

•Change lube oil refer D7.1.3.
•Change oil filter element /cartridge, refer D7.1.4.
•Change fuel filter element / cartridge, refer D7.2.1.
•Check V-belts and re-tension if necessary, refer D7.5.
•Check the engine for any leakages.
D4.2 Starting
D4.2.1 Before Starting
Before starting, make sure that nobody is standing in the immediate vicinity of the
engine or driven machine.
After repair work;

Check that all guards have been replaced and all tools have been removed from
the engine.
When starting with Engine Heater Plug, do not use any other starter substance (e. g. injection
with start pilot).
Caution: If the speed regulator has been removed for any reason, the engine must
not be started under any circumstances. Disconnect the battery.
D-23
Diesel Genset
D4.2.2 Starting without Engine Heater
D4.2.2.1 Starting the Engine
•The user starts and stops the engine through the EMS 934 controller.
•Before starting, ensure completion of genset’s daily maintenance.
•Ensure that load is disconnected from genset. Ensure people and material/tools are clear of
the engine.
•Check if Manual Mode is selected on the EMS 934 controller by the lit state of lamp on the top
left of the MAN button. If not, operate MAN button once and verify the lighting of the lamp.
MAN
• To start the engine operate the Manual Start button once.

•The controller will initiate cranking to start the engine. If the engine fails to start, the controller
will try again. If the engine does not start despite several attempts, the controller indicates a
Start Failure condition and inhibit further cranking. See Controller section for more details.
•After engine starts:
-Allow engine to run for 3 minutes, ensure all parameters within limits and then start
connecting load in steps.
-Check engine parameters like Oil pressure, coolant temperature and battery changing
rate at regular intervals, while the genset is in operation.
-Maintain log book.
-Check for exhaust smoke.
-Check for any abnormal sounds.
-Check for alternator parameters, like voltage, ampere, kW and Power Factor on all
phases.
-During commissioning, cross check the meter readings with a calibrated multimeter or
clamp - on meter.
-Ensure that the load is balanced in all phases and within rated output of the genset.
-Check that all engine and alternator parameters on the controller are working.
D-24
Diesel Genset
D4.2.2.2 Stopping The Genset
•Disconnect the load from the genset.
•Operate the Stop Button once. STOP

•The controller will keep the engine running for several seconds due to a Cool down timer for
ventilating the engine and alternator.
•After engine stops, check for any leakages.
• Top up fuel tank.
•Note fuel consumed for hours operated.

•Check oil level 30 minutes after stopping. If low, top up and note the oil consumption.
•Close the canopy securely.
•Switch off the Control
If the engine does not start in first attempt wait a minute then try again. if the engine does not
start after two attempts, refer to the Diagnosis Chart D8.
Where possible, disengage the engine from any driven equipment. Do not start the engine if it
is separated from load for any reason or if engine speed regulator has been removed for any
reason.
D4.2.3 Starting with Engine Heater
The procedure for stating the engine with Engine Heater is similar to procedure as in Starting
without Engine Heater.
D4.2.3.1 Starting the Engine
After starting is initiated, through Manual Start button

I , the controller first activates the
Engine Heater for a preset time. Then the controller goes to the normal start sequence as
mentioned in D4.2.2.1.
D4.2.3.2 Stopping the Engine
The sequence for stopping the engine is same as mentioned in D4.2.2.2.
D4.3 Electrical System
Standard engines are equipped with 12V, negative earth electrical starting system.
D-25
Diesel Genset
D4.3.1 Electrical Equipment
Table 12: Electrical Equipment for R series
12 V Electrical system
12V DC, 35 Amp

Alternator 12V DC, 55 Amp
12V DC, 65 Amp
12V DC, 2.0 KW

Starter 12V DC, 2.7 KW
12V DC, 3.0 KW
D4.3.2 Battery Cable
Battery Cable (Copper) = 35mm2
D4.3.3 Recommended Battery Capacity
Table 13: Battery Capacity
Genset with
Recommended Battery
Air Cooled Engine Series
HA2, HA3, HA4 12 V, 88 AH
HA6 12 V, 130 AH
D4.4 Monitoring System
D4.4.1 Engine Lube Oil Pressure
The display of EMS 934 controller indicates lube oil pressure of engine. If the pressure drops
below the set value, the controller will stop the engine automatically. During running, the
pressure must be above minimum as indicated in D10.1.
D4.4.2 Engine Oil Temperature
The display of EMS 934 controller indicates the lube oil temperature. If the temperature goes
beyond the set value, the controller will stop the engine automatically. Refer diagnosis chart
(Refer D8.) for the cause of high oil temperature.
D-26
Diesel Genset
D4.4.3 V-Belt Failure Switch
HA294 G1NA, HA394TCI G1, HA 494 TCI and HA /694 TCI are provide with a V-Belt Failure
Switch. If the V - Belt fails, lever of automatic belt tension actuates an electrical switch to trigger
the controller and stop the engine to prevent engine overheating.
Figure D - 28: Belt Failure Switch
D4.4.4 High Cylinder Head Temperature Switch
HA294 G1 engines have a High Cylinder Head Temperature Switch that detects high cylinder
head temperatures (Set point 175 ± 5 oC) and stop the engine via the controller. This protects
the engine in case of belt failure.
D4.5 Operating Conditions
D4.5.1 Winter Operation
•Lube Oil Viscosity

-Select the oil viscosity (SAE grade) according to the ambient temperature when the
engine is started, see D5.2.1.
-Increase oil change frequency when operating below -10°C, see D7.1.1.
•Diesel Fuel
-Use winter- grade diesel fuel operation below 0°C, see D5.2.2.
•Additional Maintenance Work
-Drain the sludge from the fuel tank once a week. (Unscrew the drain plug.)
-If necessary, allow the oil in the oil bath air cleaner and the engine oil to settle at the
ambient temperature while checking oil level.
-Below -20°C after removing the starter if necessary, smear the ring gear on the flywheel
via the pinion bore from time to time with cold resistant grease.
•Cold- Start Aid
-At low temperatures the genset can be offered Engine Heater.
• Battery.
-Efficient cold starting requires a healthy battery, see D7.7.1.
-The starting limit temperatures can be lowered by 4-5°C by heating the battery up to
about +20°C (to do so, remove the battery and store in a warm place.)
D-27
Diesel Genset
Figure D - 29: Focus for Winter Operation
D4.5.2 High Ambient Temperatures and High Altitude
•As the altitude and ambient temperature rise, the density of air tends to decrease, which
affects the maximum power output of the engine, the exhaust gas quality and in extreme
cases the starting behavior.
•The engine can be used for operating conditions other than NTP conditions: (Temp. - 27 oC,
Relative Humidity 60% and 100 meters above sea level ) however power output will have to
be derated accordingly.
•In case of doubts about engine operation under severe conditions, refer to your dealer /
equipment supplier whether engine has been derated for power to enhance service life,
reliability and exhaust gas quality. Consult KOEL Service for more details.
D5. Operating Media
D5.1 Lube Oil
D5.1.1 Quality Grade
K-Oil Premium lube oil is recommended to use in the engine. It has the correct viscosity and
detergency grades for the best all round performance..
Warranty is applicable on use of ‘K-Oil Premium’ engine oil only.
D5.1.2 Viscosity
Multi-grade oil should be used. As the viscosity of lube oil is dependent on temperature. the
choice of SAE grade should be governed by the ambient temperature prevailing at the engine
operating site.
D-28
Diesel Genset
Figure D - 30: Temperature versus Oil Viscosity

Optimum operating behavior will be attained if you take the accompanying oil viscosity diagram
as a guide Should be temperature fall temporarily below the limits of the SAE grade selected,
cold starting may be affected but the engine will not be damaged.
In order to keep wear to a minimum, do not exceed application limits for extended period of
time.
D5.2 Fuel
D5.2.1 Quality Grade
The commercially available diesel fuel with sulphur content less than 0.05% be used. If sulphur
content is higher, then oil change period should be halved. The following specifications /
standards are approved
•IS 1460 : 2005
•ASTM D975 - 88 :1-D & 2-D
D5.2.2 Winter Grade Fuel
Waxing may occur at low temperatures clogging the fuel system and reducing engine
efficiency. If the ambient temperature is less than 0 deg. C. Winter grade fuel ( suitable down to
- 20deg.cel. ) should be used. This fuel is usually available from filling stations well in advance
of the cold months.
•At temperatures below -20deg C. kerosene should be added to the diesel fuel. The relevant
percentages are given in the diagram at the right.
D-29
Diesel Genset
If summer grade diesel fuel must be used at temperatures below 0 deg.C, up to 60% kerosene
can be added (see diagram).
Figure D - 31: Temperature versus Fuel Type
Table 14: Legend for Temperature vs. Fuel Type
Type Explanation
I Summer diesel fuel
II Winter diesel fuel
A Outside temperature
B Percentage of kerosene to be added
Diesel fuels must never be mixed with petrol.
Mix in tank only. Fill with the appropriate amount of kerosene first, then the diesel fuel.
D-30
Diesel Genset
D6. Routine Maintenance
D6.1 Maintenance Schedule
KOEL Underslung 40kVA Genset Maintenance Schedule

Revison 0
Schedule Name
D
A
E
50Hrs
Every
Every
Every
Daily
1000
3000
First
250
Inspection points Remarks
Check for leakage (hoses, clamp) ©

Cooling system
Check & Adjust the V-belt tension © ©
Replace V-Belts
® 3000Hrs
Check for leakage ©

Check the oil level © Top up, when oil level reaches low mark
Lubrication system Change the lubricating oil

®®
Replace the oil filter cartridge
®®
Check the leakage for intercooler © (Hoses,clamp)
Replace the air cleaner Outer

element ®
Replace the air cleaner Inner
element (Safety) ®
if vacuum indicator gets red , replace
Check air cleaner vacuum indicator © outer element
Check the exhaust gas leakages in
Intake and Exhaust System exhaust line © ©
Check the exhaust bellow
condition(visual) © ©
Check Air Cleaner evacutor valve &
remove dust if any ©
Visual Check of Heat Shield ©
Clean the intercooler by air 2 bar
Max ©
Replace the air inlet hoses 5000 hrs
check the air inlet hoses & clamps © ©
Table 15: Maintenance Schedule for HA series engines
D-31
Diesel Genset
Maintenance Schedule
Check and arrest the leakage in fuel lines and connections.

©
Check the flexible fuel pipe/hoses conditions
©
Remove sediment from fuel lank Clean fuel tank every one
© year
Check fuel level of fuel tank
©
Clean fuel tank Clean fuel tank every one
Fuel System year
Drain the water seperator If provided
©
Replace the fuel filter Cartridge
® ®
Replace coarse fuel filter
®
Check the injection nozzle 3000 Hrs
Check the state of exhaust gas

©
Check the battery charging & battery voltage
©
Check genset safety system
© ©
Engine Check the compression pressure
Operation ©
Injector check
©
Check for abnormal noise
©
Adjust Intake / Exhaust valve clearance When Necessary
© ©
Check Specific Gravity and electrolyte level in batteries
©
Check battery terminals and vent plug
© ©
Check and tighten all electrical connections
© ©
Check main Alternator ( terminals, power cable tigtness)
and condition of lugs
Electrical Check Alarms

Systems ©
Check Panel Condition and all connections
©
Check charging alternator belt
©
Replace Charging Alternator belt
®
Check earthing
©
Radial and axial clearances of turbocharger
©
Other
Check trubo supply and drain pipe for tightness and
leakage ©
D-32
Diesel Genset
Top overhaul 4000+ hrs or nearest possible
check point.
Check and tighten all external fasteners
©
Visual Check all AV mountings for Nut bolt tightness and First 250 hrs then every 900
rubber condition © hrs
Mounting
Check for torque of AVM bolts
©
© = Check and Adjust, ®= Replace * first inlet and exhaust valve clearance check is at 600 Hrs.Then
every 900 hrs ie at 1500 hrs , 2400 hrs.
Note - KOEL recommends to use KOEL CARE Genuine Oil and coolant for preventive maintenance
to obtain best perfromance
Table 15: Maintenance Schedule for HA series engines (Continued)
-Change the lube oil every 250 hours, if using lubricant other than K-Oil Premium.
-Above maintenance schedule is applicable for Standard Operating Conditions.
D6.1.1 Log of Maintenance Work
Table 16: Maintenance Log
Hours Date Remark Signature / Stamp
50
250
500
750
1000
1250
1500
1750
2000
2250
2500
2750
3000
3250
D-33
Diesel Genset
3500
3750
4000
4250
4500
Table 16: Maintenance Log (Continued)
Hours Date Remark Signature / Stamp
4750
5000
5250
5500
5750
6000
6250
6500
6750
7000
7250
7500
7750
8000
8250
8500
8750
9000
D7. Service & Maintenance
D7.1 Lubrication system
D7.1.1 Oil Change Intervals
•The oil change intervals are dependent on engine application and operating environment.
Refer subsequent table below.
.
Table 17: Oil Change Interval
D-34
Diesel Genset
Engine Operating Conditions - Normal Duty
Naturally Aspirated, Turbocharged and Every 500 hours or 6 months.

Turbocharged Aftercooled
•If the engine runs fewer hours than stated in the table, oil should be changed at least once in
a year.
D-35
Diesel Genset
•The oil change period in table refer to following operating conditions: Ambient temperature
down to -10deg.C. sulphur content less than 0.05%
•If the sulphur content is above 0.05% to 1% or operating temperature is below -10deg.C. then
oil change intervals should be halved.
•If case fuel containing more than 1% sulphur, contact KOEL Service.
Recommended lube oil change period is applicable in only case when using K-Oil
Premium in the engine, sourced from KOEL Service Dealer.
Change the lube oil every 250 hours, if using lubricant other than K-Oil Premium.
.
D7.1.2 Checking Oil Level
•Ensure engine is horizontal.

• Stop the engine if running, wait for 30 minutes.
•Remove the oil dipstick.

• Wipe the dipstick with clean, non-fibrous cloth.
•Insert the dipstick to the stop and remove again.

•Check oil level, it should be between Max.and Min. mark.
•If required top up to Max. mark.
Figure D - 32: Markings on Oil Dipstick
Oil level should never be below Minimum mark. Oil level should not exceed Maximum
mark.
D-36
Diesel Genset
D7.1.3 Changing Engine Oil
Figure D - 33: Oil Temperature

•Ensure that the engine or vehicle is on a level surface.
• Start the engine at idle.
•Allow the engine warm up.
•Achieve Lube oil temperature of approximately 80 oC.

•Switch off the engine.
Figure D - 34: Oil Draining

•Place oil tray under the engine.
•Unscrew drain plug.
•Drain oil.
•Fit oil drain plug, with the new gasket and tighten firmly.
•Fill with lube oil.
-For grade / viscosity.Refer D5.1.2.
-For quantity, Refer D5.1.1
•Confirm correct oil level. Refer D7.1.2
Take care when draining hot oil. Danger of scalds! Do not let used oil run into the soil
but collect it in a container ready for proper disposal.
D-37
Diesel Genset
D7.1.4 Changing Oil Filter Element - Spin On Type
Figure D - 35: Removing Oil Filter Cartridge

•Remove the filter cartridge by rotating it anti-clockwise with commercial tool.
•Collect dripping oil in a tray.
•Destroy the removed cartridge.
Figure D - 36: Fitting new Oil Filter Cartridge

•Clean sealing surface of filter carrier rim.
•Apply light film of oil to the rubber seal of new cartridge.
•Assemble the new cartridge by rotating it clockwise.
•Sealing gasket of cartridge be hand tight.
D-38
Diesel Genset
Figure D - 37: Tightening new Oil Filter Cartridge

• Tighten the oil filter cartridge with another half - turn using commercial tool.
•Check oil level, see D7.1.2.

•Check oil pressure, see D4.4.1
•Check cartridge seal for leaks, see D7.1.4.
Beware of burns from hot oil.
D7.2 Fuel system
D7.2.1 Changing Fuel Filter - Spin On Type
Figure D - 38: Removing Fuel Filter

•Remove the cartridge by rotating in anti-clockwise using commercial tool.
•Collect dripping fuel in a tray.
•Destroy the removed cartridge.
D-39
Diesel Genset
Figure D - 39: Fitting new Fuel Filter Cartridge

•Clean the sealing surface of filter.
•Apply light film of oil or diesel fuel to the rubber gasket of the new fuel filter cartridge.
•Screw in the new cartridge finger tight against the gasket.
Figure D - 40: Tightening new Fuel Filter Cartridge

• Tighten the fuel filter cartridge with a final half turn using commercial tool.
•Open fuel stopcock.

•Check for leaks.
•Fuel system bleeding is not required.
Keep naked flames away when working on they fuel system. Do not smoke while
working with fuel system.
D7.2.2 Changing Fuel Filter - Element Type
•Close fuel valve.

•Unscrew the plug at bottom of bowls and collect the fuel in tray.
D-40
Diesel Genset
•Unscrew the center bolt of bowls and remove bowls and fuel inserts.
•Clean the bowl with diesel.
•Change Pre-filter insert only. Do not change Pre-filter insert & Micro filter insert at a time.
•Discard the removed insert.
Figure D - 41: Changing Fuel Filter - Element Type

•Check the condition of sealing ring, change if required.
•Assemble the bowls and tighten centre bolts firmly.
•Bleed the fuel system before starting engine.
•For changing Micro filter insert follow the same procedure.
Do not clean fuel filter inserts. Always replace the insert with new one at recommended
intervals.
D7.2.3 Fuel Strainer
Figure D - 42: Fuel Strainer

•Remove banjo bolt at inlet of feed pump.
D-41
Diesel Genset
•Unscrew the strainer fitted inside the banjo bolt.

•Clean the fuel strainer in fuel & blow it with compressed air. Replace if necessary.
•Refit the fuel strainer in banjo bolt.
•Refit the banjo bolt to feed pump with new copper washer.
•Bleed the fuel system.
No naked flames when working on the fuel system. Do not smoke in the vicinity.
D7.3 Cooling System
D7.3.1 Cleaning Intervals
•The amount of contamination in the cooling system depends on the engine application.
•Oil or fuel leakages on the engine increase the risk of contamination. Be careful and avoid
leakage when engine is used in dusty environment.
•Serious contamination can occur, for example - on construction sites where there is a high
level of air - borne dust. - in harvesting application where there are high concentrations of
chaff and chopped straw in the vicinity of the machine.
•Because applications vary, cleaning intervals have to be determined from case to case.
•The cleaning intervals given in the table below can be used as a guide.
Table 18: Cleaning Intervals
Recommended
Inspection
and Engine application
Clearing
Intervals
Operating Hours
2000 Ships, Gensets in enclosed areas, pumps

1000 Vehicles on reinforced highways
500 Tractors, fork-lift trucks, mobile electrical units.
250 Vehicles on construction sites and on roads with loose surfaces, construction
machinery, compressors, mining equipment.
125 Agricultural machinery, tractor used for harvesting purpose.
D-40
Diesel Genset
D7.4 Combustion Air Filter
D7.4.1 Air Cleaner Service Intervals
Figure D - 43: Restriction Indicator

•The soiling of air cleaner depends on the dust in air, operating environment and size of air
cleaner used.
•Cyclone type pre-cleaner is recommended in dusty environment.
•Cleaning intervals will have to be determined from case to case.
•If dry-type air cleaners are used, it should be cleaned only in accordance with the restriction
indicator.
•Air cleaner servicing is needed when the red flag is visible on the restriction indicator and
coincides with level indicated.
• After completing the service work, reset the red flag by operating the button on the indicator.
D7.4.2 Dry Type Air Cleaner
Figure D - 44: Cleaning Dust Ejector Valve

•Empty dust ejector valve by pressing apart lips of discharge slot as indicated.
•Clean discharge slot from time to time.
•Remove any caked dirt by pressing together the upper section of the valve.
•Inspect the dust ejector valve, replace if necessary.
D-41
Diesel Genset
Figure D - 45: Filter Element

• Loosen the mounting clamp of dust cup / top cover assembly.
• Take out the element for cleaning.
•Use damp cloth to wipe out dust in the air cleaner.
Figure D - 46: Cleaning Filter Element

•Clean the element by dry compressed air (air pressure 3 kg/cm 2 maximum).
•Blow the air from inside to outside for cleaning the element.
•Replace main element after two cleaning intervals.
•Replace outer element at least once in a year.
Never clean air cleaner with petrol.
Figure D - 47: Checking Element with Light Test

•Check cleaned/new element for damage before installing.
•Check for cracks by passing a light through element.
D-42
Diesel Genset
•Any crack in the element will show up due to leakage of light.

•Replace element if found cracked.
Figure D - 48: Checking Sealing Ring

•Check rubber sealing ring for damage.
•Replace if necessary.
•Inner / Safety Element element should be replaced after every two changes of outer element.
•Repeat same procedure as outer element while replacing inner element.
Never clean the inner element, always replace it.
D7.5 Belt Drives
•Inspect complete belt for damage, refer section D7.5.1

•Replace damaged V-belts.
•After installing new, belts, run engine for 15 minutes, then check belt tension as mentioned in
section D7.5.3.
Check tension and change belts only when engine is at standstill. Refit belt guard, if
provided. When new V-belts are fitted, check the belt tension after 15 minutes running time.
D7.5.1 Checking V-Belts
Figure D - 49: V-Belts
D-43
Diesel Genset
D7.5.2 Replacing Fan V- Belt
Figure D - 50: Replacing Fan V- Belt

• To replace V-belts, press in tension unit using a commercial tool and remove the old V-belts.
•Fit new V-belts.
D7.5.3 Tensioning Alternator Belt
Figure D - 51: Tensioning Alternator Belt

• Loosen bolts which fix alternator on mounting bracket. Also loosen bolts of tension adjusting
lever.
•Pull out alternator until correct belt tension is achieved.
•Retighten all bolts firmly.
Check/ tension/ replace V-belts only when the engine is at a standstill. Replace V-belt
cover before restarting the engine.
D-44
Diesel Genset
D7.5.4 Changing Alternator Belt
Figure D - 52: Changing Alternator Belt

•Remove fan V-belts as described in D7.5.2.
• Loosen alternator mounting bolts.
•Push alternator inwards.

•Remove old V-belt and replace with new belt.
•Pull alternator out until desired belt tension is achieved.
•Retighten alternator mounting. bolts.
•Fit fan V-belts covers.
Retighten new V-belts after 15 minutes running time
D7.5.5 V-belt Failure Warning System
Figure D - 53: V-belt Failure Warning System

•If the V-belts fails, the Failure Warning System actives an electrical switch.
•This switch initiates a warning or shutdown through the engine’s safety system.
• * To do a functional check, press switch actuator and simulate V-Belt failure.
Check belt only when the engine is at a standstill.
D-45
Diesel Genset
D7.5.6 Visual Inspection of V-Belts
Figure D - 54: Cracked V belt

Check V belts (Blower and Alternator) for cracks and wear along entire length. Replace belt if
excessive wear and cracks are observed. Replace belt if any other abnormalities like cords
coming loose or fraying of belt exteriors.
Figure D - 55: Excessive wear of V belt
D7.5.7 Re-tensioning of Alternator Belt
Figure D - 56: Belt Tensioning Device

Appropriate belt tensioning device should be used to measure the belt tension.
Belt tension should be between 60 to 50 Hz (190 to 130N). If the belt tension value of
falls below 50 Hz, (130N) Re-tension to 60±2 Hz (190±20N). Applicable for HA air cooled
engines series only.
D7.6 Adjustments
D7.6.1 Checking Valve Clearance
•Check and adjust valve clearance when engine is in cold condition.
D-46
Diesel Genset
•Remove the rocker cover.

• Turn crankshaft until the valves of cylinder (on which clearance is being checked) are
overlapping.
•Then turn the engine by 360 degree.
•Check valve clearance between rocker arm toe and valve stem with feeler gauge.
•Feeler gauge of 0.15mm should pass with slight resistance. Failing this, adjust valve
clearance. Refer D7.6.1. For permissible valve clearance, see D10.1.
Figure D - 57: Checking Valve Clearance
D7.6.2 Adjusting Valve Clearance
Figure D - 58: Adjusting Valve Clearance

• Loosen lock nut of adjusting screw.
•Use screw driver to loosen setscrew so that feeler gauge of 0.15mm can be inserted and
removed with slight resistance.
• Tighten the lock nut.
•Check and adjust valve clearance on all remaining cylinders.

•Reassemble rocker cover. (use new gasket if needed).
D-47
Diesel Genset
D7.7 Accessories
D7.7.1 Checking Battery and Cable Connectors
Figure D - 59: Battery and Terminations

•Keep the battery clean and dry.
•Ensure the cable terminals tightly fitted on the battery posts.
•Secure the battery firmly on the cradle.
•Ensure battery earth. Use rubber or wooden strip between battery & cradle.
•Clean the terminals (+ve and -ve) and clamps with ammonia solution. Mix in the ratio of 115
grams of ammonia for 1 litre of water.
•Apply petroleum jelly / vaseline on terminals & posts. Never apply grease.
•Ensure good contacts of terminals.
D7.7.2 Checking Electrolyte Level
Figure D - 60: Removing Battery Vent Caps

•Remove cell caps.
• Top up only with distilled water.
•Maintain level corresponding to the maximum level.
•Do not add Acid.
D-48
Diesel Genset
•Keep vent plugs tightly closed.

•Ensure the holes in battery caps are open. Choked vent holes could lead to bursting of the
battery.
D7.7.3 Checking Electrolyte Density
Figure D - 61: Checking Electrolyte Density

•Check the specific gravity of individual cell with hydrometer.
•Check specific gravity if battery has been topped up with distilled water. Check 5 minutes
after topping up.
•The measured values indicate state of charge of battery.
•Charge the battery if necessary.
• Avoid measuring specific gravity when battery is warm.
Table 19: Specific Gravity of a Battery
Specific Gravity (kg/1) State of Charge
Normal Tropics
1.28 1.23 Fully charged
1.20 1.12 Half charged, Recharge
1.12 1.08 Discharged, Charge up immediately.
-The gases emitted by the battery are explosive!

-Keep spark and naked flames away from the battery.
-Do not allow battery acid to come into contact with skin or clothing.
-Wear protective goggles.
-Do not rest tools on the battery
D-49
Diesel Genset
D7.7.4 Lifting Tackle
Figure D - 62: Lifting Tackle

•Always use proper lifting tackle when transporting and lifting the engine.
•After transportation / lifting engine, remove lifting tackle before starting the engine.
Figure D - 63: Do not lift without tackle
Use only the correct lifting tackle.
D7.8 Engine Cleaning
D7.8.1 Cleaning the engine with Compressed Air
• Stop the engine.
•Release the cowling clamps and remove cowling.

•Remove baffle on exhaust side.
•Cover electrical / electronic components. (Starter, alternator, stop solenoid etc.)
•Blow the compressed air through the engine starting from exhaust side.
•Be careful with cooling fins and cooler.
•Remove dirt blown inside engine compartment.
D-50
Diesel Genset
•Reassemble the cowling.
Figure D - 64: Cleaning the Engine with Compressed Air
D7.8.2 Cleaning the engine with Cold Cleaning Agent
Figure D - 65: Cleaning the Engine with Cold Cleaning Agent

•Cover inlet & exhaust ports.
• Spray the engine with cold cleaning agent and allow it to soak for 10 minutes.
•Clean the engine with pressurized water jet. Repeat the process if necessary.
•Blow the engine with compressed air to remove water.
D-51
Diesel Genset
D7.8.3 Cleaning the engine with High Pressure Steam Jet
Figure D - 66: Cleaning the Engine with High Pressure Steam Jet

•Cover inlet and exhaust ports.
•Clean the engine with steam jet. (Steam pressure - 60 bar and temperature 90 deg.C)
• Loosen pipe connection 1.
•Rotate engine with starter, key switch in START position.

•Fuel must be emitted at loosened pipe connect ion.
•Otherwise have the system, solenoid 3, checked by a specialist.
Test stage 3:
• Loosen pipe connection 1.
•Remove flame glow plug 2 and reconnect pipe.
•Rotate engine with starter, key switch in START position.
•Fuel must be emitted at flame glow plug 2, replace plug 2 if necessary
•Use heat resistant sealant when fitting flame glow plug 2.
•Refit flame glow plug 2 on fuel line.
•Keep away from rotating parts.
Collect any leaked fuel and dispose off as per approved environmental policy.
D8. Faults, Causes & Remedies

Most common faults and solutions are listed in the diagnosis chart on next page..
D-52
wear
Excessive fuel injection equipment
Battery runs down frequently
starting
Engine rotates very slowly during
Excessive vibration
Mechanical knock
Diesel knock
Breaking of valve springs
Excessive valve & valve guide wear
Excessive liner & piston ring wear
Bearing wear
Low lube oil pressure
Excessive oil consumption
Mixing of diesel with lube oil
Excessive fuel consumption
Engine gives out white smoke
Engine gives out blue smoke
Engine overheat
Excessive smoke at full load
Excessive smoke at no load
speed
Engine does not reach governed
constant
Engine speed does not remain
Engine misfires during operation
Engine lacks power
time
Engine starts but stops after some
Engine has starting difficulty
Engine fails to rotate
Engine will not start
Complaints
Dust entry in air inlet system
•
•
•
•
•
•
•
Air /Exhaust
Dirty / clogged air cleaner
•
•
•
•
• •
• •
•
•
• • • •
•
• •
• •
System
High exhaust back pressure
• • Derating due to altitude
Derating due to temperature
No fuel
• • • • • •
Poor quality of fuel
•
• •
Air in the fuel line
• •
Choked fuel line
•
Fuel System
External / Internal fuel leakage
•
•
• • •
Choked fuel injector holes
• •
• •
• •
•
• Damaged or dribbling nozzle
•
Loose HR pipe connections

• • • • •
• • • •
Dirty / Choked fuel filter
•
• •
Control lever settings wrong

• •
Faulty fuel pump

•
•
•
•
• •
• •
Water mixed with fuel

•
Wrong grade of lube oil used

•
•
•
•
•
Lubricating System
Dirty / Choked suction tube strainer
•
Lube oil dilution

Dirty / Clogged lube oil filter
•
•
•
Clogged oil passage

•
Excessive oil in the sump

• •
External / internal leakages

Faulty oil pump
• • •
•
•
Radiator fins choked

• • • • •
• •
Cooling
System Operation
Loose V - Belt
Air leakages through radiator &
No coolant in radiator/Coolant level
• •
• •
Engine overloading
•
Engine used after a long time Maint.

•
•
•
• •
Wrongly adjusted valve clearances

•
• •
• •
• •
•
•
•
Prolonged oil change period

•
•
•
Blown cylinder head gasket

• • •
• •
• • •
•
• •
Valve leakages
• •
Broken / worn out piston rings

• • •
•
•
•
• • •
• • •
Excessive end play in crankshaft

Worn out cylinder liner & piston
•
•
•
•
Mechanical System
Incorrect bearing clearances

• •
• •
• •
• •
• • • • •
Damaged main & connecting rod

•
•
Worn out valves & valve guides

•
•
Incorrect valve & fuel timing

•
• •
• •
• •
• •
Injector needs adjustment

•
•
Engine seized
•
•
•
Faulty governor setting

• •
• •
• •
One or more cylinders not working

• • •
Loose mounting bolts

• •
Loose flywheel / wrong alignment

Engine needs overhauling
•
•
•
•
•
•
•
• • • • •
Fuel pump rack stuck in stop

Battery run down / under rated
• • •
• • •
• • •
Electrical
System
Faulty starter
Battery of wrong capacity
Loose or dislodged wiring
•
•
•
•
Diesel Genset
D9. Engine Preservation
D9.1 About Preservation
If the engine is to remain idle for an extended period of time, it is necessary to take protective
measures to prevent rust formation. The preservative measures described here will protect the
engine up to 12 months.
Table 20: Recommended Preservatives for Lube and Fuel system
Manufacturer Brand
Indian Oil Corp. Servo Preserve 30
Bharat Petroleum Bharat Preserve Oil 30

Hindustan Petroleum Autoprun T120
Veedol Tide Oil Co. Veedol 30/40
Table 21: Recommended Preservatives for External Surfaces
Manufacturer Brand
Indian Oil Corp. Servo RP 125
Bharat Petroleum Bharat Rustrol 152
Hindustan Petroleum Rustop 274
Veedol Tide Oil Co. Veedol Ruspro IT

Castrol India Rustilo DW-904 or DW-901
Recommended cleansing agent to remove preservatives when recommissioning engine : NC

Thinner.
D9.2 Preserving Engine
•Clean the engine preferably using thinner and compressed air.

•Run the engine until warm and stop.
•Drain the lube oil.
• Fill the engine with preservative oil.
•Clean the oil bath air cleaner, fill oil bowl with preservative oil.
•Drain the fuel tank.
•Prepare mixture of Diesel + Preservative, ratio 5 :1. Refill the fuel tank with mixture.
•Run the engine for 5 minutes at low speed / fix speed engine at No Load.
• Turn the engine manually several times to preserve the cylinders and combustion chamber.
D-54
Diesel Genset
• While rotating with starter, stop lever of fuel pump to be in stop condition.
•Drain the preservative oil from engine
•Drain the Diesel + Preservative oil from fuel tank.
•Remove the V-belts.
•External unpainted surfaces to be treated with rust preventive oil
•Plug all the openings, vents of the engine.
•Disconnect the battery and store it in a safe place.
•Cover the engine with polyethylene bag if possible.
•Procedure to be repeated if engine is to be stored for more than 12 months.
D9.3 Commissioning Preserved Engine
•Remove plugs, tapes from inlet port, exhaust port and vent.
•Remove the rust preventive coating from all external surfaces.
•Install V- belts.Retension belts after brief operation if required.
•Set the engine in operation. Refer D4.1.
D10. Technical Specifications
D10.1 Engine Specifications for CPCB II
Table 22: Engine Specifications
HA394TCI HA494TCI HA694TCI

Sr No Specification Unit HA294 G1
G1 G1 G1
1 Number of Cylinder 2 3 4 6
Cylinder
2 Vertical In-line
arrangement
3 Bore mm 100
4 Stroke mm 120
5 Total displacement cc 1885 2827 3770 5655

6 Compression ratio 17:1
7 Working Cycle 4-Stroke Diesel Engine
8 Combustion System Direct Injection

9 Direction of rotation Counter-clockwise, looking from flywheel end
Starting
10 Electric start
arrangement
11 Firing order 1-2 1-3-2 1-3-4-2 1-5-3-6-2-4
D-55
Diesel Genset
Table 22: Engine Specifications (Continued)
HA394TCI HA494TCI HA694TCI

Sr No Specification Unit HA294 G1
G1 G1 G1
12 Power Refer 9.2.1 / 9.2.2

13 Speed Refer 9.2.1 / 9.2.2
14 Lubrication Forced feed Gerotor pump

15 SAE Oil K-OIL PREMIUM SAE 15 W 40 CI4
Lube Oil oC
16 90-125
temperature
Minimum Oil
17
Pressure at idle kg/cm2 1.5
Minimum Oil
18 Pressure at rated kg/cm2 3.0 to 4.5
Speed
Sump Capacity-w/o
19 Liter 5 8 11 13.5
Lube filter
20 Sump + Lube filter Liter 6.5 9 12.5 15.5

Valve clearance in
21 mm 0.15
cold condition
Injector Opening
22
Pressure kg/cm2 260 ± 10
23 Fuel timing degrees 8±1 °BTDC 8.5±1.5 °BTDC

24 Bumping Clearance mm 0.8-0.9
25 Dry weight of engine Kg 243 300 370 450
Dry engine weight

26 with flywheel and Kg 338 370 440 520
housing
D10.2 Power Output for CPCB II
Table 23: Power Output
Engine Model Speed Continuous Power As Per Iso 3046
Rating
RPM
KW BHP
HA294 G1 1500 15.1 20.5

HA394TCI G1 1500 23.5 32
HA494TCI G1 1500 41.2 56
D-56
Diesel Genset
Footnotes:
1. Total angle torque 165 degree for cylinder head with steel gasket.
2. During replacement of piston, piston rings and bearings it is recommended to change main
bearing cap bolts, connecting rod cap bolts and cylinder head bolts.
D-5
SECTION -E ALTERNATOR
----------- EruichingLives ------------------------------- --·

Diesel Genset
Kirloskar Green AC Alternator

E1. General ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ E‐1
E1.1 Introduction ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ E‐1 E1.2
Standards ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ E‐1 E1.3
Enclosures and Mounting ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ E‐1 E2.
Design of AC Generator ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ E‐1 E2.1
Stator ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ E‐1 E2.2
Rotor‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ E‐2 E2.3
Exciter Stator ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ E‐2 E2.4
Exciter Rotor‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ E‐2 E2.5
Rotating Rectifier Assembly‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ E‐2 E2.6
Impregnation ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ E‐2 E2.7
Balancing ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ E‐2 E2.8
Terminal Box‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ E‐3 E2.9
Bearings ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ E‐3 E2.10
Ventilation ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ E‐3 E2.11
Earthing ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ E‐3 E2.12 Space
Heater ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ E‐3 E2.13 Voltage
Regulator ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ E‐3 E2.14 Optional
Accessories ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ E‐4
E3. Operating Principle ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ E‐4
E3.1 Standard Brushless AC Generator‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ E‐4
E3.2 Brushless AC Generator with PMG ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ E‐5 E3.3
Advantages Of PMG Excitation System: ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ E‐5 E4.
Kirloskar Green (KG) AC Generators ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ E‐6 E4.1
Electrical Performance ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ E‐6 E4.2
Process‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ E‐6 E5.
Automatic Voltage Regulator ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ E‐7 E5.1
Features ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ E‐7 E5.2 AVR
Models ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ E‐7 E6. Derating
Factors ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ E‐8 E6.1
Temperature‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ E‐8 E6.2
Altitude ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ E‐8 E6.3
Power Factor ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ E‐9 E7.
Selection of AC Generators ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ E‐9 E7.1
Linear Loads ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ E‐9 E7.2 Linear
Loads ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ E‐10 E7.3 Power
Factor ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ E‐10
Diesel Genset
E7.4 Motor Loads‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ E‐10 E7.5

Non Linear Loads ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ E‐11 E7.6
Characteristics of Non Linear Loads ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ E‐11 E7.7 Effects
Of Non Linear Loads‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ E‐11 E7.8 Deration
for Non Linear Loads ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ E‐11
ii
Diesel Genset
Brushless A C Generators
E1. General
E1.1 Introduction
Kirloskar Green (KG) Brushless AC Generators are of salient pole, revolving field, brushless,
horizontally foot mounted, and single/double bearing type. These AC Generators are available
with and without PMG generators Standard Voltage of operation i.e., 415/460 V at 50/60 Hz for
3Ø and 230/240 V at 50/60 Hz for 1Ø.
E1.2 Standards
The Kirloskar Green (KG) AC Generators generally comply with various national and
international standards such as IS: 4722, IS: 13364, BS: 5000 Part3 and IEC 6034-1 (34-1) and
specifications mutually agreed upon at the time of order.
E1.3 Enclosures and Mounting
The AC Generators have degree of protection of IP 23 with B15(SB)/B3(DB) type of Mounting.

Other types of protection and mounting can also be offered on request.
Figure E - 1: Alternator Designation
E2. Design of AC Generator
E2.1 Stator
Stator of the AC Generator is made of high quality, low loss high permeability steel stamping
built rigidly to with stand all types of forces due to static, dynamic and transient loading
conditions. The armature coils are made up of enameled high conductivity copper wires with
E--1
Diesel Genset
class ‘H’ insulation, 2/3 pitch winding to eliminate triple and its multiple harmonics in the
generated output voltage. Windings are subjected to vacuum pressure impregnation for better
consolidation and the overhangs are provided with epoxy gel coating to protect against ingress
of dust, moisture and others. The winding leads themselves form the output terminals directly
from the armature without any joints on the overhang. All the 6/12 leads are brought out sleeved
and terminated with suitable crimping sockets.
E2.2 Rotor
The main rotor is made of low loss high permeability steel stamping, built directly on to the shaft,
which is then wound with field coils using high conductivity enameled copper for Class ‘H’
insulation. A set of completely interconnected damper winding cage is provided in the rotor for
compensation for any unbalance and during transient condition. Coil support blocks are
provided for adequate supporting of the coils from high centrifugal forces.
E2.3 Exciter Stator
Exciter stator built up of high quality laminated steel stampings carries the field coils mounted
on the Non- Driving End shield of the machine. The coils are made up of high conductivity
enameled copper with class ‘H’ insulation. The coils are firmly supported by suitable epoxy
wedges inserted in between the pole shoes.
E2.4 Exciter Rotor
Exciter rotor built up of thin laminations in the form of riveted core carries three phase armature
windings and is mounted on to the shaft. The winding is made of high conductivity enabled
copper with class ‘H’ Insulation. The output winding leads are terminated at the rotating rectifier
assembly.
E2.5 Rotating Rectifier Assembly
Rotating Rectifier Assembly is a three-phase bridge rectifier mounted on two Aluminum heat
sinks. Provisions are made in the rectifier assembly for connecting the main rotor leads and
surge suppressor provided to protect the diodes from surge voltages.
E2.6 Impregnation
All the windings are impregnated with Class ‘H’ resin and taken through the temperature curing
cycle to form a rigid winding. The overhangs are protected with a coat of epoxy gel application
against ingress of dust, moisture and others particles.
E2.7 Balancing
All generators rotors are dynamically balanced to better than Grade 2.5 (BS 6861: Part 1) for
minimum vibration in operation.
E-2
Diesel Genset
E2.8 Terminal Box
The sheet metal/cast Aluminum terminal box having ample space is fixed on the top of the NDE
end shield. 6/12 output terminals are terminated. It is possible to terminate the customer cables
on either side, depending on the customer’s choice. The Voltage Regulator is also mounted
inside the terminal box and terminated.
E2.9 Bearings
Two nos. of anti-friction double shielded ball bearings are provided one each at NDE and DE in
double bearing machine and only one at NDE in case of Single/double Bearing machine.
Adequate care is taken in the design of the Single/double Bearing machine to accommodate for
possible axial differences in the close coupling system.
E2.10 Ventilation
The AC Generators are self-cooled. The centrifugal Aluminum/Steel fan fitted on the shaft at the
driving end of the rotor draws the fresh air through the opening provided at the NDE cover and
discharges through ventilating ducts provided in the DE End Shield in double bearing machines
and adaptor in Single Bearing machines. The method of cooling is IC 01 as per IS:6362.
E2.11 Earthing
Two earthling screws provided on the feet ribs are used for grounding of the AC Generator.
E2.12 Space Heater
Two space heaters (optional) suitable for 230 V / 24 V, single phase/ DC are provided on each
overhang of the main stator winding of AC Generator on request.
E2.13 Voltage Regulator
Automatic Voltage Regulator provided is compact, high performance encapsulated unit mounted
inside the terminal box. This unit senses the voltage between lines and controls the generator
output voltage automatically to be with in the specified regulation band. AVR consists of separate
potentiometers for adjusting the voltage, stability, frequency roll off and quadrature droop
adjustment (Optional).
The following are the features of the AVR.
•Build up from a very low residual voltage -about 2.5 V (L-N).

• Voltage regulation within +/- 0.8%of pre-set value.
•Fast response to the load changes.
•Remote V-trim pot for voltage adjustment up to ± 10%of nominal terminal voltage.
E- 3
Diesel Genset
•QDC pot for Quadrature droop adjustment during parallel operation (Optional).
• Stability pot for adjustment of the response.
• Frequency-Roll-Off pot to set the frequency range.
•Over excitation limit pot to set the excitation limit
E2.14 Optional Accessories
These optional accessories are provided on the customer requirement. These are basically for
the protection of the machine while working on the extreme conditions. The following
accessories are provided.
• Winding temperature detectors (RTD/Thermistor).

•Bearing temperature detectors (BTD).
•Current transformers for differential protection.
•Permanent magnet generator.
•Auxiliary winding facility.
•Filters for dusty environment.
•Filters for harmonics.
E3. Operating Principle
E3.1 Standard Brushless AC Generator
1.In this generator there is a separate source to AVR from a small permanent magnet A.C.
generator mounted on the same shaft as the main machine. Refer Figure E - 2 on page 5.
2.The permanent magnet produces an output voltage that is only dependent on speed and is
independent of load conditions. This constant output voltage is fed to the exciter field winding
through the AVR.
3. By comparing the main output ‘sensed’ voltage with the ‘set reference’ voltage, the AVR
decides on the proportion of permanent magnet machine output to rectify and feed to the exciter
field.
4. The exciter rotor output would then increase, established a strong main field and therefore a
marked increase in main output voltage.

5. The AVR senses and compares voltages and adjusts exciter field excitation until desired
output voltage is developed. In this way the main stator voltage is progressively built up until the
‘sensed’ voltage is the same as the ‘set reference’ voltage.
E-4
Diesel Genset
Figure E - 2: Standard Alternator
E3.2 Brushless AC Generator with PMG
PMG = Permanent Magnet Generator
Figure E - 3: PMG Alternator
E3.3 Advantages Of PMG Excitation System:
E- 5
Diesel Genset
•Better motor starting characteristics with lower transient voltage dips.

•Better co-ordination with relay under sustained short circuit condition.
•Since the Power to AVR is supplied from the PMG, isolation from AC Generator output
terminals, harmonic currents from the load are prevented from passing to the AVR. This
reduces output voltage distortion.
• The process of initial voltage build up is very positive in this system, as residual magnetism is
no longer continually depended upon.
E4. Kirloskar Green (KG) AC Generators
E4.1 Electrical Performance
1. AVR used on the machine is of proven design, reliability and performance. These are unique
encapsulated against moisture, sand, salt, humidity and corrosive atmosphere ensuring trouble
free operations under the most demanding conditions. The voltage regulation offered is +/-
0.8%.
• Transient voltage dips are lower.
• Wave-form distortion on no-load is less than 1.8%. Total harmonic distortion and the
telephonic interference is less than 4% in distorting balanced linear load.

•All stators are wound to 2/3rd pitch, which along with PMG excitation system as optional and
2 line sensed as standard AVR and 3 line sensing as optional to provide better system
performance.
•Damper winding on poles ensure smooth parallel operation with similar and dissimilar
machines and with the grid. Power factor controller is recommended when balancing with
gird.
•Liberally rated diode used in rotating rectifier assembly ensures high reliability.
•The rotating diodes are protected by a surge suppresser which has the ability to chop the
transients.
•Short Circuit Current with stand capability is up to 3 times the rated current for 3 seconds.
•Excellent motor starting capacity 2.5 times rated kVA.
E4.2 Process
•Gel coat application is a standard feature which enhances the mechanical strength of the
winding overhang and ensures trouble free performance in humid and corrosive atmosphere.
•Burr free stamping pack construction and file free winding results in excellent quality of
winding and also better machine life.
•Hammer free assembly and sealed bearing increase bearing life.
•Dynamically balanced rotor to minimize vibration.
E-6
Diesel Genset
Table 23: Power Output (Continued)
Engine Model Speed Continuous Power As Per Iso 3046
HA694TCI G1 1500 61 83
D10.3 Torque Wrench Setting
Table 24: Torque Wrench Setting
Total
Remark
Description Size Initial Torque Tightening Angle In Degree Angle
Nm (kgm) 1st 2nd 3rd 4th

Stage Stage Stage Stage
Cylinder M12x1. See

30 (3.1) 45 45 45 30 165
Head Bolt 75x211 Footnote 1
Connecting M12x1.
30 (3.1) 60 30 .... .... 90
Rod Bolt 5x55
Bearing Cap M14x1 See

30 (3.1) 60 45 .... .... 105
Bolt 10 Footnote 2
Intermediate M10x6
30 (3.1) 60 .... .... .... 60
Gear Bolt 0
Balance M12x6
30 (3.1) 30 30 .... .... 60
Weight Bolt 0
Crank M24x2 Left Hand

50 (5.1) 210 .... .... .... 210
Pulley x110 Threads
Cooling
Blower Bolt M12x1
30 (3.1) .... .... .... .... 90
(HA294 G1/ 40
394/494)
Cooling
M12x1
Blower Bolt 30 (3.1) 90
80
(HA694)
M 10
Flywheel x1x
30 (3.1) 30 60 90
Bolt 35/40/
45/50
25-30Nm
Fuel Injector M 10
- - - (2.5-3.1
Nut x1.5
kgm)
Footnotes on next page.
D-57
Diesel Genset
E5. Automatic Voltage Regulator

Kirloskar Green (KG) regulators are in wide range for wide application. Our regulators have the
following specifications.
•Encapsulated components for weather protection.
•Compact and rugged construction.
•Solid state.
•Fast response to the load changes.
•Build up from a very low residual voltage – about 2.5 V (L-N)
E5.1 Features
• Voltage adjustment: The V trimmer is provided in the AVR for voltage adjustment up to +/-
10% of rated voltage.

• Stability Adjustment: The AVR include stability circuit to provide the good steady state and
transient performance of the generator.

•Under frequency Roll off (UFRO): The AVR incorporates an under speed protect circuit which
gives a Volts/ Hz characteristics when the generator speed falls below a presentable value
the red LED gives indication that the UFRO circuit is operating.
•Droop Adjustment: Generator intended for parallel operation are fitted with a quadrature
droop CT. CT is connected to Q1, Q2 on the AVR with ratios of rated current: 5Amps, 1%
accuracy, 5/2.5 VA burden.
•Accessory Input: for 250 kVA and above AC Generators
•An analog input (A1& A2 is provided to connect to the DC current source device. It is
designed to accept DC signal up to +/- 4.5 Volts.
E5.2 AVR Models

Table 1: AVR Models
Number Parameter TAVR -20 TAVR -30 TAVR -18 (PMG) DSR
1 Voltageadjustment Yes Yes Yes Yes
Stability Yes Yes Yes Yes

2
adjustment
Under frequency No Yes Yes Yes

3
roll off adjustment
Remote voltage Yes Yes Yes Yes

4
adjustment
Over Excitation Yes Yes Yes Yes

5
adjustment
Accessory ( DC No Yes No Yes

6
input)
E- 8
Diesel Genset
Table 1: AVR Models

Number Parameter TAVR -20 TAVR -30 TAVR -18 (PMG) DSR
7 Quadrature Droop No Yes Yes Yes

Sense Loss Yes Yes Yes No
8
indication
Over excitation Yes Yes Yes No
9
indication
Under frequency Yes Yes Yes Yes

10
roll off
Frequency roll of Yes Yes Yes Yes
11
indicator
12 Used on frames KG 164 - 254 KG 284 - 354 KG 284 - 354 KG3-28-32-34
13 Ratings 5 - 200 kVA 250 - 750 kVA 250 - 750 kVA 5 - 160 kVA
E6. Derating Factors
E6.1 Temperature
These AC Generators are designed for an ambient temperature of 40°C. For other applications
where the ambient temperature is greater than 40°C, the AC Generators must be de-rated to
ensure that the actual temperature does not exceed the specified limit.
Outputs are normally quoted at 40°C. These outputs must be multiplied by the following factors
for higher ambient temperatures.
Table 2: Derating for Temperature
TEMPERATURE (°C) MULTIPLIER
45 0.97
50 0.94
55 0.91
60 0.88
E6.2 Altitude
Above 1000 m the effectiveness of the air is reduced sufficiently to make de-rating necessary.
For altitudes above 1000 m outputs must be multiplied by the following factors.
Table 3: Derating for Altitude
Altitudes Multiplier
1500 0.97
2000 0.94
Diesel Genset
Table 3: Derating for Altitude
Altitudes Multiplier
2500 0.91
3000 0.88
3500 0.85
4000 0.82
E6.3 Power Factor
Standard AC Generators are suitable for 0.8 pf lag to UPF loads. Power factor below 0.8 lag
causes heating of the AC Generator. The A C Generator output must be multiplied by the
following factors for lower PF.
Table 4: Multiplier for Power Factor
P.f(Lag) Multiplier
0.7 0.95
0.6 0.91
0.5 0.88
0.4 0.86
0.3 0.85
0.2 0.84
0.1 0.84
0.0 0.84
Leading pf loads cause rise in terminal voltage which may subsequently harm the AVR and the
loads. Please refer to works in case of leading pf loads.
E7. Selection of AC Generators

This section deals with selection of AC Generators to suit various loads.
The different types of load encountered by an AC Generators can be broadly classified as

a) Linear Loads.
b) Motor Loads (part of linear loads, considered separately).
c) Non-linear Loads.
E7.1 Linear Loads
•Constant load impedance regardless of applied voltage.
E-
Diesel Genset
•he load current increases proportionately as the voltage increases and decreases as the
voltage decreases.
Examples of linear loads are motor, incandescent lamp and heating loads.
E7.2 Linear Loads
To select the rating of AC Generator for linear loads the maximum connected load and the base
load which is always connected has to be considered. In arriving at a total load figure is always
wise to select the standard rating larger than that estimated. This despite the fact that all the
loads may not be operating at the same time hence a smaller machine could have been
selected. Future operating conditions and future growth are very difficult to estimate. An
allowance of 15% to 20% excess capacity designed into a set now is a small price to pay
compared with the cost of completely new larger unit that may be required to drive additional
loads in a few years time.
E7.3 Power Factor
It is the nature of the applied load that dictates the system power factor.
1. The loads which operate at or very close to unity (1.0) power factor include most forms of
lighting, all heating elements, rectifier and thyristor type loads & all domestic loads which are
fractional hp motors (washing machine, refrigerator, etc.).
2. For all remaining load types, some knowledge of operating power factor is required, which for
motors depends a great deal on their size and power rating.

Kirloskar Green (KG) A C Generators perform satisfactorily at any power factor in the range of
0.8 p.f lag to unity. For p.f operation at leading low power factor Please refer back to works.
E7.4 Motor Loads
During the starting of an induction motor, a very large current is demanded from the power
source, which is known as the starting or locked rotor current. For better sizing of AC
Generators, the following guidelines can be referred to.
Table 5: Motor Loads
Method Of Starting Current Starting Current as I rated times full load
Direct On Line 6-7
Star Delta 3-3.5
Rotor Resistance 1.5-2

Auto Transformer: At 40% Tapping 1.1
At 60% Tapping 2.5
At 80% Tapping 4.5

Diesel Genset
For motor applications the following information should be furnished:
a) Rating of the motor/ motors.

b) Type of the motor (slip ring / squirrel cage).
c) Method of starting.
d) Rated full load current.
e) Starting power factor.
f) Any restriction on Transient Voltage Dip? (Details of the same).
g) Frequency at starting.
h) Base load at the time of starting induction motor.
i) Any other load apart from the motor loads? (Details there of).
j) Sequence of starting of motors.
E7.5 Non Linear Loads
Over a period of time the loads applied to AC generators have become more complex and more
care has to be exercised in the sizing of the generators to ensure satisfactory performance.
E7.6 Characteristics of Non Linear Loads
a) A non linear load is one in which the load current is not proportional to the instantaneous
voltage. Often the load current is not continuous.
b) These are essentially electronic loads such as computers, UPS equipments and variable
speed motor drives.
E7.7 Effects Of Non Linear Loads
a) Non linear loads generate harmonics in their current waveform which in turn leads to
distortion of the AC generator waveform. Depending upon the degree of voltage waveform
distortion this can lead to instability of the excitation systems and impact on other loads being
supplied by the generator.
b) Odd order harmonics cause heating of neutral conductors.
E7.8 Deration for Non Linear Loads
The above percentage figures are guidelines. There may be a problem with electronic load,
trying to cope with distorted waveform if distortion levels are unacceptable to the load.
Table 6: Non Linear Loads
Loads Derating Factors
Fluorescent lighting load No derate required.
UPS & Telecom load controlled by a 12 Non linear load should not exceed 90% of AC Generator
pulse Thyristor bridge plus a filter. rating
Diesel Genset
Table 6: Non Linear Loads
Loads Derating Factors
UPS & Telecom load controlled by 6 pulse Non linear load should not exceed 60% of AC Generator
Thyristor Bridge plus a filter. rating
UPS & Telecom load controlled by3 pulse Non linear should not exceed 50% of AC Generator rating.
thyristor bridge pulse a filter
Variable speed 6 pulse thyristor Non linear load should not exceed 35% of AC
controlled drive. Generator rating
Better sizing of machine is possible on furnishing following information:

a) Number of pulses of Thyristor drive: 3, 6, or 12.
b) Level of harmonic distortion produced by the non-linear load.
c) What is the maximum acceptable level of voltage distortion the Non-linear load can accept?
d) Operating voltage and frequency.
e) If Non-linear load power requirement is stated in kW, then some guidance regarding
operating power factor & system efficiency is required to establish the AC Generator load.
With the information, guidance should be sought from the factory regarding AC Generator
sizing for compatible equipment operation.
E - 12
HELP DESK CONTACT NUMBER - +91 880 63 344 33
HELP DESK TOLL FREE NUMBER - 1800 233 3344
email ID - koel.helpdesk@kirloskar.com Drawing: 04.536.30.0.00
www.koel.co.in
INTRODUCTION
Intec Corporation is promoted by Mr. Ronsher Singh Sidhu who is a graduate in mechanical engineering
from State University of New York at Stony Brook. The firm was started in 1996 after his graduation and
now after 14 years is a reputed supplier of air conditioning equipment to Indian Railways for
Conventional and LHB type RMPU. INTEC is an ISO 9001:2015 Certified Company and an RDSO
approved Part-I regular source for supply of RMPUs with Control Panels as per their latest specification
and RMPUs with Microprocessor Controller for LHB Type Coaches for Indian Railways.
Intec is the second largest supplier of Roof Mounted Rail Coach Air Conditioners for passenger coaches
in India. Intec thus far has supplied more than 2400 such air conditioners duly tested and approved by
RDSO to Indian Railways since 1997 and enjoying an excellent reputation. Intec has supplied more than
370 RMPUs with Microprocessor Controller to RCF for LHB Type I & II coaches. Intec also has an after
sales service network throughout India to provide technical support and service back up to its products
during and after warrantee through annual maintenance contracts for AC coaches.
Intec has a modern factory at Kala Amb, Himachal Pradesh, 250 km from Delhi, in a one acre plot with
over 20,000 square feet covered area. A brand new factory has been established in Selaqui,
Uttarakhand, with 12,000 square feet covered area. The manufacturing unit is approved by RDSO, RCF
and ICF. Intec has in house sheet metal fabrication, dynamic balancing of rotating axial and centrifugal
fans, TIG, MIG, and electric arc welding machines, electronic leak detectors, charging stations and
controlled ambient test chambers. Thus enabling us to manufacture components in house to increase
reliability.
Through extensive development and research, Intec has produced excellent products and services them
as well. The dynamic team of engineers and technicians has successfully developed and supplied
quality equipment including deep freezers, food warmers, pantry equipment, and electric panels to Indian
Railways in addition to the Roof Mounted Rail Coach Air Conditioner which remains the heart of Intec’s
core competency.
Made from the best raw materials and manufactured under stringent quality norms carried out right from
the receipt of raw material to the final testing in controlled ambient test rooms and shower tested under
60 mm per minute of simulated rain water conditions to ensure no water ingress in the passenger area
while the unit is running.
Intec has complete design capability, trained manpower and latest plant & machinery to manufacture any
type of Roof Mounted AC Package Units for Indian Railways.
Description Date : Issue

Technical Manual of RMPU for LHB 20-11-2013 00 Page 1
Design Coach with R407C refrigerant
INTEC
1 Safety Instructions
1. Range of hazards
1.1 No hazards to passengers/personnel may be expected, if the system is
properly installed. Use the snap closures to open the system for repairs and
maintenance.
When opening the plant (cleaning or maintenance work), ensure not to

touch the heater or compressor.
Risk of burn!
1.2 Operators/maintenance personnel

These are staff who are in charge of handling, assembling, installing,
operating, setting up, servicing and cleaning the system, and who are also
responsible for troubleshooting.
The system may only be operated by skilled personnel
To avoid disputes over respective areas of authorities, there must be a clear
delimitation of responsibilities to which all operating personnel should adhere.
The shutdown of over headline should be observed during operation,,
maintenance, repairs etc.
The description of cleaning, maintenance and repair jobs given in these
operating instructions will be understood by persons who are skilled in the
following fields:
 Refrigerant handling
 Mechanics, maintenance, cleaning
 Electrical engineering/electronics
The required tools/test equipment must be made available to the personnel in

question.
System operators must ensure that only qualified staff as described above
carry out any work on the system.
Operators must avoid any practices, which put the safety of the system at risk.
Operating staff must notify INTEC immediately of any modifications, which

impair the safety of the system.

INTEC
1 Safety Instruction
Installation of spares/wearing parts

Spares / accessories supplied by companies other than INTEC have not been
tested/authorised for use by INTEC.
INTEC accepts no liability for damage resulting from the use of non authorised
spares / accessories.
The enclosed parts lists contain all essential components used in the system.
Air conditioning unit consisting off

 Compressors Steel, casting
 Evaporators Copper, aluminum coated
 Condensers Copper, aluminum coated
 Fans Aluminum with FRP blade
 Electric heater Steel
 Electrical motors Casting copper
 Electrical cable Copper, plastic
 Refrigerant R 407C
 Refrigerant lines Copper
 Air filters Synthetic fibres
 Housings Steel

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2 Technical data
2. Technical data
2.1 General
The compact air conditioner unit has been designed for the air conditioning of 2 tier, 3 tier & chair car for
Indian Railways. A rack consists of cars and a generator car.
The coach is provided with 2 compact air conditioning units each and the generator car with 1 air
conditioning unit each.
The units used in the different cars types are identical.
2.2 Air conditioning system

2.3 Compact air conditioning unit
Specifications Remarks
Cooling capacity 22.5 kW (to=5°C, tk=60°C
Heating capacity 6.0 kW
Air delivery
Supply air flow 4000 m3/h±10% ( pstat = 200 Pa)
3
Of this fresh air 820 m /h
Power input
Compressor motors 2x 5.4 KW
Condenser fan 2x 0.75 KW
Supply air fan 1.1 KW
Operating voltages
Compressors motors 415 V AC 3~50Hz
Condenser fan 415 V AC 3~50Hz
Supply air fan 415 V AC 3~50Hz
Electric heater 415 V AC 3~50Hz
Control voltage 24V DC
Control Voltage 110V DC
Dimensions
Length 2220 mm
Width 2200mm Max
Height 500 mm

INTEC
2 Technical data
Specifications Remarks
Weight 635 kg
Refrigerant 407C
Refrigerant charge 4.2 Kg. X2
Interfaces
Power plugs X1 415 V AC
Power plugs X2 415 V AC
Control plugs X3 110 V DC
Control plugs X4 24 V DC
2.4 Safety devices provides

Specifications
Temperature switch
Motor protection
Compressor motor 1
Compressor motor 2
Condenser fan motor 1
Condenser fan motor 2
Supply air fan
Electric heater
Thermostat
Fusible link
Pressure switch / -sensor
High pressure switch 30-23 bar Auto Reset
Low pressure switch 3.2 – 2.2 bar Auto Reset
Control pressure switch 20-16 bar Auto Reset

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3 Construction
3. Construction
The seat cars & 3 tire’s are provided with 2 compact air-conditioning units
each and the generator cars with one air- conditioning unit each.
The units used in the different car type are identical.
The AC system for the cars consists of the following assemblies:

 Compact air conditioning unit
 Duct system
 Exhaust air system
- exhaust air unit
- WC/WC exhaust fan
- WC/switch cabinet exhaust fan
 Circulating air duct system
 Fresh air screen
 Open/closed-loop control devices
 Sensors

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3 Construction
The AC system for the generators cars consists of the following assemblies:
 Compact air conditioning unit

 Duct system
 Exhaust air system
 Circulating air duct system
 Fresh air screen
 Open/closed-loop control devices
 Sensors

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3 Construction
3.1 Compact air conditioning unit
The compact air conditioning unit has two separate cooling circuits
consisting of the following components:
 two hermetic refrigeration compressors

 two condenser with Cu pipes and pre coated Aluminum fins
 two axil fans for cooling the condensers
 two evaporators
 two twin-sucking radial fans for the supply air (driven by the motor)
 three maintenance covers
 two air inlets for circulating air
 one air outlet for supply air
 control and safety devices
 pipelines/fittings
 two mixed air filters

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3 Construction
(Figure 3-3)

INTEC
3 Construction
(Compact air-conditioning Unit – Interfaces)

(Figure 3-4)

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3 Construction
3.2 Fresh air screens

In each car four air screens are installed at the coach ends parallel to the
air conditioning unit.
In the generator car also four fresh air screen are installed at the coach
ends parallel to the air conditioning unit.
These screens are fitted with exchangeable air filters (fig-3-5) out side air
filters.
(Figure 3-5)

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4 Functional description
4. Functional description
General functions of AC system

The AC system for all type of coaches and generator cars of Indian railways service AC system
for
 Ventilation
 Air heater
 Air cooling
 Air dehumidification
 Air filtering
In all rooms used by either the train staff of passengers, such as the passenger
compartment, staff compartment, WC, kitchen and rooms accommodating the
switchgear.
The condenser fans concurrently suck fresh via ventilation slots provided on both Condenser
sides to cool the compressor-condenser section. fan
The supply air is first carried via silencers into the thermally insulated supply air duct,
which is diagonally split in the longitudinal direction. The air is then supplied via
openings in the bottom into a compensating chamber and from there via the
perforated ceiling into the passenger compartment.

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5 Control
5.1.1 Control in passenger compartment
In controlled service, the air-conditioning units are controlled by a microcomputer. This
is a fully automatic operating mode. Depending on the ambient temperature, the
available modes of heating, ventilating, cooling and dehumidifying are controlled. The
existing temperature causes the various mode of the HVAC system to overlap.
The system adopts a non-dangerous status if a functional defect occurs.
5.2 Air-conditioning control
5.2.1 General control
5.2.2 Operating switch
(Figure 5-1)
Switch S1U1S1 (Fig. 5-1) (A4I2=K15) on the switch panel turns the HVAC system on.
At first 24V must be supplied. The computer adopts the operating mode. In addition,
the „ 400V OK” signal must be available on input A4I3=K16. In this state the system is
ready for controlled operation.
Switch S1U1S1 when set to position 0 turns the system off. All components enter a safe status.
5.2.2.1 Set point generator(Push button type at display Board)

Set point generator S1U1R1 (Fig. 5-1) with 7 switch positions is also mounted on the
switch panel. Details of set point evaluation are described in chapters 5.2.3.1.
5.2.2.2 Measuring Instruments (for information only)
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5 Control
The switch panel contains two indicating instruments for suction pressure and high
pressure. Switch S1U1S2 (Fig. 5-1) sets these instruments to the required refrigerating
circuit. The switch has four positions.
5.2.3 Air-conditioning unit
5.2.3.1 Fan operation
When the air-conditioning system is turned on with switch S1U4S1 band the 400V level is
available at K48 then output activates contactor K20. This turns on the supply air fan in
CACU1. Similarly, the same input conditions enable contactor K27. The supply air fan in
CACU2 starts running. Together with the supply air fans the three exhaust fans must turn
on. This is achieved by activating contactor K24 .
Two conditions must be met for ventilation mode:
1. The indoor temperature exceeds the set point temperature by at least 1K in heating
mode or falls short of the set point temperature by at least 1K in cooling mode. Ventilation
service
2. With the HVAC system turned on, the controller fails due to a defect. The signal on
output causes control contactor K22 to drop out. This is the signal for the
emergency ventilation mode to be turned on.
Pre-
heating
5.2.2.3 Temperature regulation in heating, ventilation and cooling modes.

The room temperature is exclusively controlled by the microcomputer in a similar way as
specified in EDTS075 Rev ‘A’.
CACU1 : Coach air-conditioning unit-1 CACU2 : Coach air-conditioning unit-2

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5 Control
5.2.2.3.1 Room set point temperature in cooling mode / Heating Mode
Switch S1U1R1 Set point generator 7 point temp. selector switch (Fig. 5-
1)
Summer Winter
1. 20.0°C 17.0°C
2. 20.5 °C 17.5°C
3. 21.2 °C 18.2°C
4. 21.9 °C 18.9°C
5. 22.6°C 19.6°C
6. 24.3 °C 20.3°C
7. 25.0 °C 21.0°C
5.2.2.4 Control of the heating coil in the air treatment unit
The heating coil in the passenger compartment is supplied with 415V-3~50Hz. The
heating output is controlled by the two heating contactors K35 and K40, which can be
actuated separately by one output each. The heating coil in CACU2 heating coil.
The heater is cycled as per specification No- RDSO/PE/SPEC/AC/0139-2009 (rev 1)
Several safety requirements must be met for switching the heater coils:
The supply air fans of the unit must be running. This means that output must be set for
the fans and the feed back signal of the contactors (thermal contact OK) must also be
supplied to the controller (input K13 and K14).
Heating
In addition of this, before supplying the make signal to the heater contactors, it must be coil
checked that monitoring thermostats of the heating coils (K17=1L and K18=1l,
respectively) have not tripped.
The heater must not start running in the following conditions exist:
When operating switch S1U4S1 (Fig. 5-1) is turned off;
At a duct temperature over 65°C (overtemperature protection at C6S2 and C7S2, resp.);
 When the appropriate duct temperature sensor (C6S2 and C7S2, resp.) is not
working properly;
 At the second step in cooling mode (see chapter 5.2.2.6 Dehumidification)
 If an error message of the appropriate supply air fan (K13 and K14, resp.) exists.
 If an error message of the heating coil thermostat exist;
 If there is no 400V feed (K16
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5 Control
5.2.2.5 Cooling circuit control
If a cooling power request is received, a safety check is made before the compressor is Cooling
turned on. The following information is available and should be observed: request
 Thermal monitoring of the condenser fan

 Suction pressure message
 High pressure message
At first a check is made whether the supply air fans are running (K13) and K4). Then
thermal contacts M3F1 and M7F1 are to sample the function of the condenser fans. This
requires that inputs K1, K2, K3 and K4 are logic1.
As a next step the pressure states are to be sampled. The low- pressure pressostats
also in each refrigerating circuit connected to in puts K6, K8, K10 and K12 is used. The
high pressure pressostats use logic 0 as the OK signal. If erroneously the pressostats
should switch, the 1L signal on input K5, K7, K9 or K11 and the respective contacts are
disabled by the pressstat. To test the function of a released pressostat, the compressor
output must be actuated two more times after 6 min each to enable a signal to be read at
the input. The procedure must be repeated after 12 hours.
Now the compressor of the appropriate circuit can be started via output K101, K102,
K103 & K104. These outputs also turn on the each a/c unit has a by-pass valve installed
in the first refrigerating circuit, which can be actuated via outputs K107 and K108.
The following parameters must be met for compressor operation:
Minimum on period 1 min
Minimum off period 1 min
Max. number of switching operations per hour: 10 times
To achieve equal load distribution on both refrigeration sets in either unit, if a step 2
request is received, the compressors are either controlled to run for the duration of the
second –step request.
Each refrigeration set contains two condenser fans. These fans are controlled individually Condenser
by the controller via dedicated output. The procedure is to turn on the first fan (M3) to run fan
continuously in cooling mode. The second fans in the
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5 Control
refrigeration circuits will only turn on if one of the two control pressure pressostats sends
a signal to input of controller. The fans are turn off again when these signals are reset.
The fans are actuated via outputs of controller.
The refrigerating system (compressor) is blocked / switched off in the following conditions
 When operating switch S1U4S1 is turned off;
 When an error message exists in the safety chain (high pressure K5, K7, K9,
K11=1L)
 When a suction pressure error message exists (K6, K8, K10 K12=0L) and this Compressor
message is not reset within 120s while the compressor is switched on
 When the switching frequency limit is exceeds (C6S2, C7S2)
 When the duct temperature sensor (AA005, AA007) is not working properly;
 At duct temperature below 10°C (C6S1, C7S2)
 If a suction pressure error occur three times in 30 minutes in cooling mode, the
compressor is blocked continuously.
5.2.2.6 Dehumidification
The dehumidification function is available at cooling mode step 2. It is used if the relative
humidity of the room air rises to 60%. This condition is monitoring by the moisture sensor
in input C7S3. If the relative humidity is less than 60%, a simulated temperature of below
60°C is measured (appr. 10 k ). When the sensor switches, this resistance is reduced
via a measuring bridge so as to enable measurement over (appr.1 k ).
During dehumidification, the room temperature is controlled by the extra heater. Extra
heating is maintained until
Dehumidification
 The cooling power of the second step becomes insufficient to maintain the
room temperature even at maximum cooling output, or
 The moisture sensor relative humidity of less than 60%.
In dehumidification service, a max 50% of the cooling output is allowed to ensure that the
combined power consumption of the refrigerating and heating units does not exceed the
maximum cooling output. This is ensured by limiting the dehumidification function to
cooling step 2. The higher power consumption that would be needed if 2 compressors
were turned on simultaneously is avoided by delaying the start of the second compressor
by 5s.
When the heating coils, observe the safety instructions in chapter 5.2.2.4 control of the
heating coil in the air treatment unit.
Air flap

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5 Control
5.2.3 Component control

5.2.3.1 Computer OK
Output controller OK of Digital Controller signal is indicates the controller is ready for
service or working. When 24V is supplied, the computer is operating even if the air
conditioning unit is turned off, this means that in turned off condition the LED shows
readiness for service, in regular operation contractor K22 picks up and changes from
emergency operation to normal operation. The output must not be enabled if regular
operation is not possible because an internal error has occurred.

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5 Control
5.2.3.3 Supply air fan normal operation

The supply air fans must be running if the system is turned on by switch S1U1S1. This
condition is controlled, in emergency mode when the controller is defective, by dropped
out contactor K22, for one, or directly by the computer, for another, The dedicated
outputs for this are output BY003 for the supply air fan in CACU1 and output BY013 for
the supply air fan in CACU2. The signals routed via these outputs control the respective
contactor (K20, K23) via thermal contact. Supply
air fan
The functional control is indirect. as the thermal contacts are directly integrated in the
control circuit, their function is sampled by the feedback signal of the connector. As in the
case monitoring high pressure, if an error occurs, the failing fan must be actuated
repeatedly to find out if the thermal contact has closed again. If the same error occurs
three times in one hour, the failing fan is blocked permanently and entered in the error
memory (see chapter 9.5 Error memory)
5.2.3.4 Condenser fan
Each refrigerating set contains two condenser fans. these fans are controlled directly by
the computer via dedicated outputs. The fans are switched on or off as required by the
pressure conditions in the refrigerating circuit. The fan motor (M3) is switched on
permanently in cooling mode.
Fan
The second fan (M7) in either refrigerating circuit is started when one of the two control
pressure pressostats (which are set to 20/2016 bar) has sent a signal to inputs K19 and
K20=1L, resp. When this signal is reset, the fans are turned off again.
Both fans are monitoring separately by thermal contacts and can be turned off separately
if an error occurs. If an error message is received, the failing fan is blocked and the
cooling output reduced. This is achieved by allowing only one refrigerating circuit to
remain in operation. The thermal contacts must be monitored further and the fan turned
on again after the return of the signal. If a thermal error occurs error memory (see
chapter 9.5 error memory)
5.2.3.5 Compressor and by pass
See description of the refrigerating circuit start up in 5.2.2.5 Cooling circuit control.
5.2.3.6 Heating coil
See description of the heater start up in chapter 5.2.2.4 Control of the heating coil in the
air treatment unit.

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5 Control
Pilot lamp
5.2.3.7 Pilot lamp
Connected to output K119 is a pilot lamp mounted on the switch panel. The pilot
should light if an error disrupts the function of the air conditioning system to the degree
that regular operation is no longer possible. For a description of errors indicated by the
pilot, see the list of error number in chapter 9.5
The pilot should extinguish automatically if the case which made it light no longer. The
lamp is reset either by turning off the air conditioning system (K118=0L) and starting it
again after cleaning the error or by resetting the error memory.
5.2.3.8 Safety devices
5.2.3.8.1 Heating coil thermal contacts
The two coils of the high voltage heater have a thermal contact which sends a signal
to the computer (input K17 and K18=0L, resp.) if an error occurs. The failing heating
coil must be turned off by the computer immediately.
The heating coil must not be started again unless the thermal contacts close gain Thermal
when the coil has cooled down. If the coil is turned off 5 times in one hour, the heater contact
is blocked permanently The same happens if the thermostat is not reset 3 minutes
after it tripped.
The error is entered in the error memory and the pilot lamp lights.
5.2.3.8.2 Supply air fan thermal contacts
The supply air fans are protected from over temperature by thermal contacts. These
contacts are integrated in the control circuit of the contactor. If a thermal contact fails,
an error message is sent to the contactor via the auxiliary contact.
The function control is indirect. As the thermal contacts are directly integrated in the
control circuit, their function is sampled by the feedback signal of the contactor. If an
error occurs, the failing fan must be actuated reputedly to find out if the thermal
contact has closed again. If same error occur three times in one hour, the failing fan is
blocked permanently and entered in the error memory (see chapter 9.5 Error memory)
The pilot lights

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5 Control
.
5.2.3.8.3 Condenser fan thermal contacts

Th condenser fan motors also have thermal motor protection in the form of
thermal contacts. The contacts are connected to inputs K6, K8, K10 K12. If a
thermal error signal is sent (segnal=01), the failing motor must be switched off
immediately. If the first condenser fan (M3) fails, the second fan (M7) must start
running when the required control pressure is available. The system in this state Thermal
is only partly ready for service and must not operate at full cooling output (see the
contact
description of condenser fan operation in chapter 5.2.3.4 Condenser fan). If the
second condenser fan also fails, the refrigerating set of the involved a/c unit must
be turned off.
If the same error occurs three times in one hour, the failing fan is blocked
permanently and entered in the error memory (see chapter 8, Page-42, Error
memory)
5.2.3.9 Low pressure pressostat
Each refrigerant circuit has low-pressure pressostat. The LP pressostat are
connected to inputs BA006, BA007, BA016 and BA017. Message 1L exists if no pressostat
low pressure error is detected. If the signal is 0L, the involved refrigerating circuit
must be blocked and the compressor stopped. When the low pressure
disappears, the refrigerating circuit can be started again. If the same error occurs
three times in 30 minutes, the involved refrigerating circuit is blocked permanently
and entered in the error memory (see chapter 8, Page-42, Error memory)
and the pilot lamp lights.
5.2.3.10 High pressure pressostat

Each refrigerating circuit has a high-pressure pressostat. The pressostats are
integrated in the circuit that actuates the compressor contactor. If a high-pressure pressostat
pressostat trips, the compressor contactor is switched off immediately and an
error message sent to the computer. Depending on which refrigerating circuit is
involved inputs K5, K7, K9 and K11 are available for this. The compressor is
turned off
To test the function of a tripped pressostat, the compressor output must be
actuated two times after every 6 min to enable a signal to be read at the input an
the procedure repeated after 12 hours.
The error is entered in the error memory (see chapter 8, Page-42, Error memory)
and the pilot lights.
For information:
If a high pressure error exists, the pressostat is interlocked mechanically and
cannot be restarted by the controller. The pressostat resets automatically if the
pressure drops below the minimum level. The purpose of the test routine is to
identify a functional error of the pressostats.

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5 Control
5.3 Diagnosis
5.3.1 Functional description
The diagnostic concept of the Indian Railways requires the following monitoring
functions.
 Monitoring all analog inputs for idling and short circuit
 Monitoring by integrated thermal contacts all motors for winding over

temperature.
 Monitoring the refrigerating circuit for low pressure and high pressure.
 Monitoring the heating coils for over temperature.
In addition to the monitoring functions, the train and maintenance staff can read
the current pressure values at the switch panel.
5.3.1.1 Monitoring of inputs and outputs
The following inputs and outputs are monitored for idling and short circuit. If an
error occurs, an entry is made in the error memory. For a description of sensor
error priority and the action to be taken, see chapter 5.1.2.
Disruption of service
All errors contained in the list (next page) cause the pilot to light. The pilot lights
for as long as the error exists, the computer is turned off (by F11 interruption of
voltage supply) or the error memory is deleted.

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6 Safety devices
6. Safety devices
6.1 Equipment earthing
All current –carrying components such as motors, heaters and the like are
earthed with respect to the coach body.
6.2 Motor protection / Thermal protection
All motors of the fans Klixon). If a motor heats up impermissibly, the thermal
protection system switches of the motor via the controller.
The electric heaters are protected in two ways against over temperature. If the
supply air temperatures reach an impermissible level, a Klixon device switches
the heater off via the control system. If this safety feature fails, the heater is
finally switched off by a relief device(ESTI).
(Figure 6-1)

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6 Safety devices
6.3 Cooling circuit pressure protection
To prevent overpressure or under pressure in the two parallel connected cooling circuits of an air
conditioning unit, a high pressure switch and a control pressure switch are used. Pressure gauges
can be connected via a Schrader valve in the pressure line and in the suction line to determine
refrigerant pressures.

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7 Installation
7. Installation
7.1 Transport/shipment/storage
7.1.1 Transportation/shipment
All assemblies of the air conditioning system (compact air conditioning unit,
on skid are supplied preassembled on truck frame . The air conditioning
units are fastened with bolts to the truck frame. All assemblies are carefully
tested and packed prior to shipment. The refrigerant circuit is filled.
Caution Caution
For loading and unloading, over head crane shall be used. It
enables the unit to be transported safety.
7.1.2 Storage
The system components shall be stored in their undamaged transport

skids. Do not store them in the open. Make sure that they cannot become
damaged.
7.2 Installation
Install the assemblies of the AC system from above in the roof space of the
coach at both ends of the coach
-the compact air conditioning units at the extreme coach end Caution
Caution
For transporting the air conditioning unit to the coach for the
purpose of installation, overhead crane shall be used.
The duct connections for the supply air and circulating air point in the Caution
direction of the coach.
Caution
Lift the air conditions for the specified lifting points. Mind the
center of gravity when lifting.

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7 Installation
7.2.1 Installing the compact air conditioning unit
Sr. No. Component Activity Note

1 AC unit Remove packing Do not throw away
Perform visual check for transit damage Damage report
Undo transport screws used for fixing unit to frame
Sling lifting tackle For lifting points
Lift unit with crane into coach
Lower unit into installation trough
Adjust unit in position
Tighten fastening screws
Connect earthing connections
Establish plug-and-socket connections for voltage Fig. 3-4
supply
Connect duct system
Caution
Caution
When equipment is handled manually, Lifter shall observe
national legal regulations concerning lifting of items. Mind
center of gravity..
7.3. Commissioning
7.3.1 Tests to be performed prior to commissioning

The functional test is designed to thoroughly test the AC system in the installed condition.
Conditions: Ambient temperature abt. 25°C
Voltage of coach electrical system
Caution
Fully open all shut-off valves of the cooling circuits, except the
filling valve.

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7 Installation
Sr. No. Component Activity Note

1 Earthing cables check for firm fit and retighten, if necessary
2 Fan motors/ Check sensor of rotation Air must be sucked via
Air conditioning unit condenser and
evaporator
3 Cooling circuit Check site glass for presence of bubbles Dry Anzeige
4 Water outlets Check for unobstructed drainage
5 Heater Functional test
6 Cooler Functional test
Test to be performed prior to commissioning

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8 Maintenance
8 Maintenance
8.1 Maintenance steps
8.2 Maintenance plan
Interval 1) D I1 I2 I3
Peroid 2) 1D 4W 6M 12 M
1)
means I Interval
2) means D daily
W Weeks
M Months
Table 8-1 Maintenance plan
Maintenance work on the refrigerating circuit should be completed

before the refrigerating season.
Caution
Before starting any inspection or maintenance work on live
components, turn off the power supply and secure against
turning on, then start work.
.
8.3 Maintenance operations
8.3.1 Compact air conditioning unit
S.NO. COMPONENT MAINTENANCE OPERATION 1
1 Fresh air filter Visual inspection for dirt accumulation
Remove dirt if necessary
2 Air inlet on condenser Visual inspection for dirt accumulation
Remove dirt if necessary
3 Mixed air filter Replace air filter
- open the maintenance side covers
- take out the filter mats and clean the mats
- replace mats whose fibre structure is damaged
- close the maintenance covers
4 Refrigerant sight Check for bubbles
glasses - open the maintenance side covers
- inspect the moisture meters
- - close the maintenance covers

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8 Maintenance

5 Condenser Visual inspection for air-side dirt accumulation through protective
grate
- remove the grate if dirt has accumulated
- remove the dirt
Table 8-2 Maintenance step 1
Caution
If the coach is servicing areas with heavy air pollution, the filter Caution
requires more frequent inspection than indicated in the table
above.

1 Condenser water drain Inspection of water drain
- visual inspection of the drain
- rinse, if necessary
- close the roof panels
2 Rain water drain Inspection of after drain
- open the condenser maintenance cover
- inspect the water drain
- remove the collected sludge if necessary
- rinse the drains
- close the maintenance cover
Table 8-3 Maintenance step I2
Caution Caution
The water drains are cleaned regularly with the overall system of
the coach

1 Condenser Clean
- Remove both protective grates
- Clean the condenser with compressed air
- Install the protective grates and tighten the screws
2 Electrical connection Inspection the plugs for proper seating
- - Inspect the plugs
-
3 Refrigerating circuit Inspect the connections
piping - Open the maintenance cover
- Inspect all pipe connections
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- Tightened the connections if necessary
- Close the maintenance cover
4 Pressostats Inspection of switching points

- Open the condenser maintenance cover
- Check the switching points of the high-pressure
presssotats
- Check the switching points of the high pressure sensors of
the condenser fans
- Close the maintenance cover
5 Lid gasket Inspect for leaks
- Visually inspect all gaskets
- Replace damaged seals
- Close the maintenance side covers
6 Evaporator Inspect for accumulation of dirt

- Make visual inspection
- Clean with compressed air if necessary
- Close the maintenance
7 Supply air fans Mechanical inspection
- Remove the cover
- Inspect the fans
- Install cover and tighten the screws
- Clean with compressed air if necessary
- Close the maintenance covers
8. Condenser fans Mechanical inspection

- Open the maintenance covers
- Inspect the fans
- Close the maintenance covers
9. Electric heater Inspect the terminals for proper seating

- Open the maintenance side covers
- Inspect for proper seating
- Close the maintenance side covers
- Inspect the safety element 8.3.2
Table 8-4 Maintenance step 3

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8 Maintenance
8.3.2 Inspecting the electric heater safety elements

the heating coil (shown removed in the illustration) is controlled by a
thermostat and protected from overheating by a temperature protection
switch (ESTI)
THERMOSTAT PROTECTION SWITCHING HEAD
THERMAL PROTECTION
(Figure 8-1)
8.3.2.1 maintenance
the switching head is practically maintenance-free
the inspection if for the motion of the release linkage 4 of the sensor.
process as follows:
When carriage carrier 1 is unscrewed together with the undamaged esti cartridge 2 over temperature
is simulated which release the switching head
EST1
(Figure 8-2)

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8 Maintenance
If this is not the case, the temperature protection must be removed and the cause of the
failure located and repaired.
8.3.2.2 Failure of the safety elements

if the temperature of the heating coil is too high, the thermostats send a signal to the a/c
computer, which turns off the heating coil.
If this fail and the temperature continuous to rise, the temperature protection switch
interrupts the power supply mechanically.
Heating
coil
The temperature protection switch contains a small, clear glass ball with a liquid. the glass
ball bursts at a certain temperature. this releases a spring-loaded pin which opens the
contacts.
Glass ball
the broken glass ball must be removed and a new ball installed in the temperature
protection switch. the cause of the overheating must be located and repaired.
Repairing the temperature protection switch

Remove split pin 3. screw out cartridge holders 1.
Remove the broken glass pieces of the old ball and install a new ball 2 of the same type in
the cap. inspect the motion of the spring loaded release rod 4. (if it is reluctant to move,
install a new temperature switch). slowly screw in cap 1 (the release rod is pressed down
when the cap is screwed in place) and secure with a new split pin.
Installing the temperature protection switch

Install the temperature protection switch in the holder and secure it with cap nut 5. Connect
the electrical lines according to their marking.
When the cartridge bursts, carefully remove all glass pieces from the cartridge before a
new cartridge is installed.
The cartridge carrier with the installed cartridge must be secured with a split pin.
8.3.4 Fresh air filter
The fresh air filter should be cleaned daily
.
S.NO. COMPONENT MAINTENANCE OPERATION D

1 Fresh air filter Visual inspection for dirt accumulation
Remove the accumulated dirt
Maintenance step D fresh air filter
8.3.4.1 Maintenance
The filter can be washed 4 or 5 times
For maintenance, open the closure of the fresh air grate and fold them up. The fresh air grate is retained
by a spring.

INTEC
8 Maintenance
Pull out the filter frame, take out and clean the filter mat
(Figure 8-3)

INTEC
8 Maintenance
Mat replacement
If the filter mat is worn (mar with holes) install a new mat.
8.4 Trouble shouting
Note
Prior to opening units containing live components make sure
power is disconnected and can not be reconnected during Caution
inspection
SL. NO. TROUBLE CAUSE REMEDY

1 Plant is switched on but No voltage Check 400V
does not start
2 Condenser fan does not No voltage applied to Check fuses, thermal relays
start motor
Ventilator motor defect Measure motor windings, if
necessary replace motor
3 Compressor does not start No voltage applied to Check fuses, thermal relay
even through indoor motor
temperature is high Compressor motor Measure motor windings, if
defective necessary replace compressor
4 Compressor starts and stop Suction pressure Refrigerant shortage, top up if
but preset temperature is protector goes on necessary
not reached Air filter clogged, clean or change
Check sense of rotation of fan
Solenoid valve in liquid line
defective, replace coil or valve
High pressure protector Condenser contaminated, clean
goes on Condenser defective
Check fuses thermal relays
5 Supply air handling unit fan No voltage Check incoming voltage, fuse,
not running power connection
Motor defective Measure motor winding, if
necessary replace motor
Trouble shouting

INTEC
8 Maintenance
8.6 Repair
Most components of the compact air conditioner unit will be replaced when defective
8.7 Dismantling
Note Caution
Prior to opening units containing live components for
dismantling make sure power is disconnect and can not be
reconnected
Environment
ECO Friendly R22 refrigerant
S.NO. UNIT REMEDY

1 Condenser fan motor - Open protective grill of compressor-condenser unit
- Loosen electrical connection
- Loosen screw joints
2 Compressor - Open (central) cover of compressor-condenser
- Loosen compressor clamp
- Loosen power connection
- Loosen refrigerant piping
Loosen screw joints
3 Filter drier - Open air handling unit cover
- Drain refrigerant
- Dismantle solenoid valve
6 Expansion valve - Open air handling unit cover
- Drain refrigerant
Dismantle expansion valve
7 Mixed air filter - Open r.h/l.h. cover on air handling unit
Take out filter
8 Motor for supply air - Open cover
- Loosen CONNECTION TO RADIAL FANS
- Loosen electrical connections
Take out motor
Dismantling of components

INTEC
9 Spare parts
SPARE PARTS OF LHB TYPE AIR CONDITIONER :
Sl. DESCRIPTION INTEC PART NO.

NO
1 Hartige(Couplers) Connector 24 Pin IC-075-1001
2 Hartige(Couplers) Connector 16 Pin IC-075-1002
4 Protection Hose VCSG29B NW/29 IC-075-1004
5 Connection fitting NVAV-P29G PG29 IC-075-1005
6 Elbow screw joint NWW P299G PG229 IC-075-1006
7 Nut Din 46320 PG29 IC-075-1007
8 Connection fitting BFIO P-299 PG29 IC-075-1008
9 Enlarger, PG Brass Part No. 2129M IC-075-1009
10 Pressure transmeter (0-10 bar) IC-075-1010
11 Pressure transmeter (0-40 bar) IC-075-1011
12 Protection for heater. IC-075-1014
13 Cartrige + 130° IC-075-1015
17 Drier Filter (1/2” Solder type) IC-075-1019
18 Air Heater 400 Watt IC-075-1020
19 Liquid level cum moisture indicator(sight glass) IC-075-1021
20 Hygrostat 35-100% IC-075-1022
21 Vibration Mounting Pad (Conical mount) IC-075-1023
22 PVC Cable Gland PG-11 with nut (Coupler) ) IC-075-1024
23 PVC Cable Gland PG-13 with nut (Coupler) ) IC-075-1025
24 Electric motor 1.0 HP 1400 RPM with top IC-075-1026
25 Electric motor 1.5 HP 1400 RPM with top & Al. IC-075-1027
26 Brass distributor 10 hole, IC-075-1028
27 Connectors 2.5 mm² IC-075-1029

INTEC
NO
28 Wago connectors 4 mm² IC-075-1030
29 End plate 2.5 mm² connector IC-075-1031
30 End plate 4mm² connector IC-075-1032
31 End lock for 2.5 mm² IC-075-1033
32 Filter Media Mix Air IC-075-1034
33 Filter Cassette Fresh Air IC-075-1035
34 FRP Fan with Al. Hub IC-075-1036
35 Low Pressure Control IC-075-1037
36 High Pressure Control IC-075-1038
37 Expension Valve IC-075-1039
38 Gas Compressor ZR-61KCE-2TFD 522 IC-075-1040
39 SS Welded Round Gaurd IC-075-1041
40 Evaporator Coil Left IC-075-1042
41 Evaporator Coil Right IC-075-1043
42 Condensor Coil Left IC-075-1044
43 Condensor Coil Right IC-075-1045
44 Male Female Plug & Socket for damper actuator IC-075-1046
45 Switch Control Pannel IC-075-1047
46 ON/OFF Rotary switch (S1 U1 S1) IC-075-1048
47 Set point generator (S1 U1 R1) (Switch) IC-075-1049
48 Pressure measuring switch IC-075-1050
49 Fault Indication IC-075-1051
50 Suction pressure gauge (LP) 0-10 micro bar IC-075-1052
51 High pressure gauge (HP) 0-40 micro bar IC-075-1053

INTEC
NO
52 Fresh air bellow connection IC-075-1054
53 Return air bellow connection IC-075-1055
54 Supply air bellow connection IC-075-1056
55 Microprocessor controller with display unit. IC-075-1057
56 Temperature sensor 5K IC-075-1058

INTEC
INTRODUCTION GENERAL DESCRIPTION
These pumps are used on Indian Railways coaching stock for lifting
water from under frame mounted main tank to auxiliary tank located Motor and Pump
at the ceiling of the coaches to supply water in toilets & wash basins. Motor body, pump casing, rear
These are horizontal centrifugal self-priming mono set pumps which cover and front-end bracket are
are driven by 3- phase, 50 Hz. 415 V ac supply. molded out of high-quality cast
iron. Pump casing is hydrostatic
TECHNICAL DATA pressure tested at 1.5 times the
(Ref: Amendment no. 1 to RDSO/PE/SPEC/AC/0022-(Rev.0)-2002 dated 13.01.2004) maximum discharge pressure. The
stator is constructed with
electrical grade silicon steel
laminated stamping. The rotor is
made of high conductivity aluminum by pressure die casting.
Pump Shaft
The shaft for rotating rotor is
dynamically balanced, (with
impeller) to minimize vibration at
Type Squirrel cage induction motor TEFC the highest allowed speed and to
ensure smooth running and
Rated Output 0.5 HP/0.37 kW increased life of the bearings. It is
Rated Voltage 415 V ± 6 %, 3 Phase AC made of stainless steel of AISI 410
Rated Frequency 50 Hz ± 3 %. Grade or as per IS: 6603.
Load Current 1.1 Amps Impeller
Speed 2800 RPM Impeller is the rotary part of the
pump fitted on a shaft mounted with
Insulation Class F
suitable bearings. The material of the
Winding Connection Y (Star) impeller is LTB-2 grade and is
Duty Continuous (S1 duty a per IS: 325) properly balanced for the long life of
Type of mounting Foot mounted bearings.
Rubber Seal Operational Instructions:
The entry of water from pump to motor is prevented by providing The following points shall be checked:
high quality Nitrile rubber seal.  Ensure that the main tanks are filled with water
 Ensure that pump selector switch of pump controller is on 'Auto'
Ball Bearing
mode
Only sealed low friction RZ type bearings from SKF/FAG make are  Ensure that the outlet valve of main tank to pump is in open
used. The L-10 life of these type bearings is 1,00,000 Hrs. condition
Earthing  Ensure that motor rotates in correct direction as painted/embossed
Motor casing is provided with two independent earthing terminals arrow as a sign of rotation.
which are connected to the coach body.  Ensure that pump runs smoothly and does not make any unpleasant
Non-Return Valve noise.
 Ensure the availability of the water in the tank from the pump has
Non return valve is provided on each pump at out let pipe to avoid to lift the water.
back flow while pump is not working.
Dismantling and Re-assembly Procedure:
Terminal box & Connections:
Isolate supply connections and dismantle the pump from the pipe
The terminal connection for supply is brought out in lines and foundation.
a terminal box on the motor and clearly marked RYB
(embossed) on terminal plate to ensure correct Remove the bolts, which are holding the casing to remove casing
direction of rotation. The terminal plate is made of from the assembly and slide out the impeller.
epoxy reinforced glass fiber material conforming to Remove the screws of the fan to remove it. Remove bolts of the end
BS-3815 and it is also anti-absorbent and free from porosity. cover and pull out the end cover. The shaft with stuffing box can be
Ingress Protection: taken out from the frame.
The entire motor portion have ingress protection IP55 as per IS 4691. All parts are to be checked and replace if damaged and worn out.
Pump Controller Checking bearing condition and replace it, if necessary.
Pump controller is provided in AC coach power Replace rubber seals and gaskets before re-assembly and ensure that
panel. It has a selector switch to operate the pump there are no dust / foreign particles between the seal while re-
either in auto or manual mode. In auto mode pump assembling.
change over takes place automatically after 4 hrs. It While re-assembly, follow the reverse procedure of dis-assembly, if
also displays run time elapsed of pump – motor and the impeller is tight, tap the shaft at the non-driving end.
LED displays are provided for working status / faulty
Shaft should rotate freely after assembly.
condition for individual pump.
Problems, Causes and their Remedies: - Monoblock By changing any one phase of the
S. pump electrical connection the direction
Problem Causes Remedial Action running in can be changed
No.
opposite
1 Motor does No power Ensure uninterrupted 3-phase power
direction
not rotate / supply supply to the pumps.
fails to start
Over Remove fan cover and check for free 3 Leaking Running Lap the running face or replace it
heating rotation of motor shaft along with Mechanical face is
fan and allow the motor to cool & seal damaged
switch on 4 Insufficient Strainer Clean the strainer
discharge / clogged
Impeller Rotate the shaft by hand/with the capacity
stuck due to help of screwdriver to ensure free decrease Wrong Interchange any two phase to correct
keeping idle rotation direction of the direction
for a longer rotation
time 5 Pump Defective Replace defective bearings
Motor Check winding for open circuit draws bearings
winding excess
defective current Dirty water Ensure clean & clear water supply
2 Pump does Priming not Fill water till it flows continuously
not lift sufficient without air lock 6 Pump set Wrong Interchange any two phase for
water making direction of correct direction
Air leak in Use proper sealing to arrest leak or noise rotation
suction pipe use Teflon tape at joints
Defective Replace defective bearings
bearings
Blocked Clean the suction pipe & remove any
suction pipe blockage & foreign bodies in the
7 Motor starts Pump Switch off the supply and rotate the
pipe line
with a jammed shaft with the help of the screw
humming driver/ by hand. A slot is provided on
Leakage in Replace seal
sound. the non-driving end of the pump
seal
Does not shaft.
Air cock Tighten the air cock, renew if rotate and
side leakage required then trip
Routine Maintenance Activities
S. No. Activities
1 Check functioning of water pumping arrangement in

auto mode/ manual through pump controller
2 Visual checking the mounting arrangement for any
abnormality
3 Check running of pump for any abnormal sound, water
leakage from pipe lines, joints Etc.
4 Check cable connections on terminal box for tightness
and for sign of overheating etc.
5 Check rubber seal / gasket for any damage/water
leakage
Disclaimer:
It is clarified that this pamphlet does not supersede any existing
provisions laid down by RDSO, Railway Board or Zonal Railways.
The pamphlet is for guidance only and it is not a statutory document.
KALSI METAL WORKS PRIVATE LIMITED

Kapurthla Road, Jalandhar – 144021 (Pb.)
Ph.: 0181-2651704, Fax : 2651705
Email : kalsi@kalsigroup.com
Model :
Name of Purchaser :
Date of Purchase :
Serial No. of Unit :
Name and Address of the Seller :

R
Seller’s Stamp & Signature :
Manufactured by:
THE VENDING COMPANY
PLOT NO - 28, SECTOR- 4,
IIE, SIDCUL, PANTNAGAR,
RUDRAPUR, UTTARAKHAND CUSTOMER COPY
INDIA - 263153
Model :
Name of Purchaser :
Date of Purchase :
Serial No. of Unit :
Name and Address of the Seller :
Seller’s Stamp & Signature :
Manufactured by:
THE VENDING COMPANY
PLOT NO - 28, SECTOR- 4, Please read the instructions carefully prior to using the product.
IIE, SIDCUL, PANTNAGAR, Actual design and color may vary from the images shown.
The pictures are used for representation purposes only.
RUDRAPUR, UTTARAKHAND MERCHANT COPY Note:- The machine specications are subject to change without notice.
INDIA - 263153
USER’S MANUAL HOT BEVERAGE DISPENSER
Dear Customer, . INSTALLATION

Congratulations on your purchase of the new Atlantis Hot Beverage Vendor. Installation Required at Site
This Product is guaranteed to be free from facts in workmanship and material,
under normal use and service, for a period of 12 months from date of original Free space required Refer m/c dimensions given in technical
purchase. data. Apart from space covered by the
m/c, 6” free space required all around
SPECIAL FEATURES OF THE ATLANTIS HOT BEVERAGE VENDOR the m/c. for maintenance purpose.
24 Volts DC motor
Power Supply 230V, 50Hz, 15Amps power socket with
Fully programmable proper earthing & within 1.5 mtrs. distance
Password protected from m/c.
Magnetic sealing door to ensure that cockroaches do not get into the machine
IN CUP TEMPERATURE AS HIGH AT 85 DEGREE CAN BE OBTAINED Quality of Water Portable Drinking Water
Manually adjustable solenoid valves
SS heating element Unpacking
Waste tray with optional drain facility
Unpacking the m/c carefully at the installation site and securely place the
Membrane switches for easy accessibility machine on a platform. Check contents of the packaging which consists of : -
Float valve with buzzer for low water level indication
Adjustable temperature through controller card a. Machine 1 Nos.
Compact and easy to maintain. b. Drip Tray Jali 1 Set
Easy to service
c. User Manual with Warranty Card. 1 Nos.
GENERAL SAFETY INSTRUCTIONS
d. Machine Key 2 Nos.
Before using this machine, this manual must be read carefully. e. Main Lead 15Amp 1 Nos.
The machine should not be installed in place that may exposed to sprayed
water and they likewise should not be cleaned using sprayed water.
TECHNICAL SPECIFICATION
The user or person responsible for relling & cleaning the machine must follow
the instructions set forth in this manual. Descriptions 2 Lane 3 Lane 4 Lane
Weight (Kg.) 16 20 21
Do not touch the product with your hands & prevent liquids from falling inside
the product canisters. Dimensions (HxWxD) mm 640x320x350 640x320x470 640x320x470
Power (Watts)
If any maintenance task needs to performed & the machine is going to be 2000 Watts 2000 Watts 2000 Watts
disconnected for a long time period, the boiler and canisters must be empty. Power Source 220V/1p/50Hv 220V/1p/50Hv 220V/1p/50Hv
Only trained service technician are authorised service/dismantle any component Operating Voltage 24 V DC 24 V DC 24 V DC
of the m/c. Start Up Time 8 Minutes 8 Minutes 8 Minutes
Appropriate ELCB is be provided by the outlet before installation of the m/c. Premix Canister /Capacity 2 Nos. of 1.2 Kg. each 3 Nos. of 1.2 Kg. each 4 Nos. of 1.2 Kg. each
Dispensing Rate 4 cups per minutes 4 cups per minutes 4 cups per minutes
Proper earthing is must with 3 pin, 15A supply socket at the outlet.
Front Door ABS Moulded ABS Moulded ABS Moulded
Switch off the power supply and unplug the main supply cord before carrying Steam Dispersion
out any cleaning and maintenance operations. Exhaust Fan Exhaust Fan Exhaust Fan
Hot Water Tank Material/Capacity SS 304 Stainless Steel SS 304 Stainless Steel SS 304 Stainless Steel
Do not touch the machine with wet or humid hands.
3.0 Ltr. 3.0 Ltr. 3.0 Ltr.
Do not unplug the machine from the source by pulling the power supply cable.
* Actual design, colour and specications may very from the images shown.
Do not allow children or untrained people to play with machine.
PARTS IDENTIFICATION
59
60 49 64 65 66 67 68 69 70 71 72
61 62 63 48
USER’S MANUAL
47
46
45
50 51 52 53 54 55 56 57 58
31
36 37 38 39 40 41 42 43 44
30
35
29
34 28
27
33
26
32
25
24
23
22
1
21
2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
PART IDENTIFICATION
PART PART PART

PART NAME PART NAME PART NAME
NO. NO. NO.
1. Membrane Switch 25. Hot Tank Drain 49. Flexible Pipe
2. Lock With Key 26. Hot Tank - 2,3,4 Lane 50. Canister Outlet Cover
3. PCB 2,3,4 Lane 27. Hot Tank Inlet 51. Canister Bush Front
4. Drip Tray 28. Thermostat 90 52. Canister Front Nut
5. Drip Tray Jali 29. Steam Pipe 53. Canister Elbow
6. Door Hinge Lower 30. Sensor 54. Whipper Cover
7. Overflow Nozzle 31. EDP Foam 55. O Ring
8. Outlet Nozzle Cap 32. Main Lead Socket 15amp 56. Whipper Button
9. Outlet Nozzle 3, 4 Way 33. NRV - Washer, Jali 57. Whipper Base
10. Door Supporter 34. Sensor Rubber 58. Whipper Washer
11. Metal Body 35. Silicon Pipe (6x8, 8x12, 7x13) mm 59. Canister Cap
12. Whipper Motor 36. Front Door 60. Canister Gear
13. Rubber Feet 37. Supply SMPS 61. Canister Body
14. Fuse Holder 38. Fiber Washer 62. Canister Worm
15. Indicator 39. Main Switch 63. Canister Back Nut
16. Gear Motor- 90 rpm 40. Door Sheet 64. Fan Cover
17. Main Lead 15 amp 41. Gasket 65. Exhaust Fan
18. Drain Set 42. Mixing Bowl-lower 66. Float Valve
19. Relay 24DC-40 amp 43. Mixing Bowl-upper 67. Steam Elbow Box
20. Steam Trap 44. Water Inlet 68. Steam Box Washer
21. Lock Patti -SS 45. Hinge Upper 69. Steam Elbow Box Nut
22. Solenoid Valve (DV) 46. Funnel Black 70. Clamp Strip
23. Impeller 47. Puncturing Tube Black 71. Storage Tank
24. Hot Tank Stand 48. Back Plate 72. Fuse-15 amp
HOT BEVERAGE DISPENSER
PROGRAMMING INSTRUCTIONS – CAFÉ MINI

USAGE INSTRUCTIONS FOR THE CAFÉ MINI
The Atlantis Café mini is a fully programmable machine which can be customized
Please read the instructions below prior to using the machine. to the customer's requirements. Please follow the simple instructions below to
Remove the machine form its outer packing and place the machine on a flat even program your machine. .
surface. .
Overturn a bottle of water (2 ltrs to 25 ltrs) over the machine . Press the STOP switch for 3 sec. and the machine enters the programming mode
DO NOT TURN THE MACHINE ON TILL THE WATER HAS COMPLETELY Now we would be using the COFFEE TEA and HALF switches to program the
FILLED UP INSIDE THE MACHINE. THIS POSITION IS REACHED WHEN machine. .
THE BUBBLES STOP APPEARING INSIDE THE BOTTLE. .
Immediately as we enter the programming mode, the display would show PREMIX1
Switch the machine on from the mains and then from the switch behind the 3.75. This indicates the dispensing time in seconds for the powder from the coffee
front door. . canister. There would also be a cursor under the number before the decimal
The Display would indicate “Please wait – heating” . (3 in the above case). The COFFEE and TEA switches can be used to increase or
The display would toggle between the above sign and the temperature on the front decrease this number. Once done, press the HALF switch and the cursor would then
display. . move to the digit after the decimal point. The HALF switch would henceforth play
The cup counter comes on the screen after you push the half cup button for the role of an ENTER/SAVE button .
3 seconds. .
The machine would not dispense till such time as the set water temperature is reached The increase or decrease would change in direct proportion to the settings. So a
Fill us the canisters with the premix (coffee in the left canister and tea in the right one) setting at 5.0 would mean that 10% more powder is dispensed than at 4.5 sec.
Once the desired temperature has been reached, the machine is ready for dispensing
Make the desired choice from the membrane panel at the base of the door. Press HALF (enter) again and the display would show WATER1 5.0. The cursor
Please note that the first cup of coffee and tea would have less powder as the would be under the number 5. Follow the procedure to change the quantity of water
machine has not yet been “primed”. . in the coffee side as above. .
PLEASE NOTE THAT THE MACHINE ARRIVES WITH DEFAULT SETTINGS Press HALF and the display would show PREMIX2 3.75. This refers to the quantity
OF 12.7 GMS OF PREMIX AND 90 ml OF WATER. YOU CAN CUSTOMIZE of tea powder dispensed. Changes can be made as above. .
T H E S A M E T O Y O U R TA S T E B Y F O L L O W I N G T H E S I M P L E
INSTRUCTIONS BELOW. . Press HALF again for WATER 2 (water from the tea side). Make changes as above.
Note that the setting for WATER would always be 1.0 sec more than the respective
For half cup, please press the HALF switch and then your choice of either premix. This would ensure that the water would always flow more than powder and
COFFEE or TEA. . not allow accumulation of powder in the mixing bowl. .
Similarly for just hot water, press HOT WATER followed by COFFEE or TEA.
This feature can also be used for flushing out the system at the beginning of the Press HALF button again and the display shows HOT WATER 5.0. This is the
day for cleaning purposes. . quantity of water which is dispensed when we push the HOT WATER button .
The STOP switch is used when an incorrect choice has been made and we would The quantity can be adjusted by using the COFFEE and TEA buttons and saved by
like to abort the operation midway . pressing the HALF button as above. .
In case the temperature of the water is less than 10 degree C, of set temperature
the machine would not dispense any premix or water . Press HALF again and the display shows TEMP 85. Again this can be adjusted (to a
In case the water level in the container is low, the display would show maximum of 89 degree) by using the coffee and tea (up and down) switches.
WATER LEVEL LOW and the buzzer would sound. The machine would not
dispense in this mode. THE DEFAULT PASSWORD IS CURRENTLY ENTERED BY PRESSING HALF 5
TIMES. NO NUMBER NEEDS TO BE ENTERED. .
Press HALF again and the display would show ENABLE COIN. Only applicable
to coin operated machine. Using the COFFEE and TEA we can enable – YES or
disable the coin mechanism - NO. .
Press Half again and we now enter the SET FLUSH mode. Here we have the following TROUBLESHOOT
options (all available using the COFFEE/TEA switches). If we want to flush the machine
at regular intervals, specially when not in use, then we should enable – YES, this option.
Specific fault message will be displayed when the m/c stops dispensing.
We recommend this as well, because it not only cleans the water pathways, but also keeps
List of fault messages, their possible cause and remedial action are listed blow.
them warm. If you choose YES, then you can set the flush time interval to 10/ 30/60/90 mins
depending upon usage of the machine. If the machine is used extensively, then a higher
interval is recommended. .
Next mode on pressing HALF is the SET DEFAULT option. In you enable the same 1. If display show “Heating....” 1. Check heater fuse. If fuse has blown off, replace it.
by imputing YES, then all settings of water, powder, temp etc would be restored to the for more than 10 minutes 2. Check loose connections continuity at heater/
factory settings. . fuse/holder/relay/terminals
3. Check loose connections at main PCB connector
Press HALF and the screen would show CNTR RESET. Pressing TEA would show and rectify.
YES. Then you have to enter the password and the counters of coffee and tea would 4. Check 230 volt AC supply across heater terminal,
be reset to 0. . if power supply not detected replace heater.
Press HALF again and we have the USER MESSAGE change option. Using the 5. If power supply not detected, check DC signal
COFFEE TEA and HALF buttons (for saving) you can actually change the name on the across relay terminals.
display to your choice. A unique feature only on ATLANTIS machines. a.) If power supply not detected replace relay.
Lastly pressing HALF would show CHANGE PASSWORD. Press TEA and the YES b.) If power supply not detected, then replace PCB.
option appears. Press HALF again and ENTER the old password followed by the new
password twice. .
Press HALF again and the machine display shows “returns to the regular MAKE 2. If display shows 1. Check water level in bottle top
YOUR CHOICE mode. “Water tank empty” 2. Check continuity of sensor wire from PCB to tank
PROGRAMMING INSTRUCTIONS – CAFÉ PLUS 3. Overheating in boiler tank 1. check loose connection of temperature sensor on
the boiler.
The 3 and 4 lane machines are programmed in a very similar manner to the Café mini. 2. Check DC signal across heater relay terminal
The main differences have been highlighted . a) If power supply not detected, replace repay.
The five buttons are named BEV 1, BEV 2, BEV 3, BEV 4, STOP. . b) if power supply not detected, replace
BEV 1 and BEV 2 buttons does the same function as the COFFEE button to temperature sensor.
increase/decrease time and toggle to enable or disable functions. BEV 3 is the
4. Electric shock 1. Check earthing / polarity in supply socket.
equivalent of the HOT WATER button in the 2 lane Café mini and is primarily for
2. Check water leaking inside the machine and
saving and moving on to next mode. .
rectify it.
IN the Café Plus, to get hot water or half cup, just press the STOP button once and
3. Ch loose connection of earthing wire with
then the BEV button of your choice to get hot water/half cup of drink from that lane.
machine body.
A longer press of the STOP button and you can enter the MENU mode and follow the
4. check continuity between machine body & earth
same instructions as the Café Mini programming. .
pin on 15 Amp power plug. if continuity is not there
NOTE THAT THE ATLANTIS MACHINES HAVE A LOT OF OTHER FEATURES replace power cord
LIKE LANGUAGE CHANGE AND CALIBRATION WHICH CAN BE ENABLED
UNDER SUPERVISION OF AN AUTHORISED ENGINEER FROM THE COMPANY. 5. As soon as machine is 1. Check correct rating of MCB.
switched on power supply
trips. 2. Remove 15 Amp fuse & switch on. If it is tripping
again, reconnect the same & if it not tripping,
replace heater.
4. The warranty is void if : .
3. Remove SMPS AC supply connector & switch on. a) It is found that the unit has been subject of unauthorized installation or repair.
If it is tripping, reconnect the same & if it is not b) The voltage of the power supply is not within the specified limited .
(230 V 50Hz + _ 10%) .
tripping, replace SMPS.
c) The damage is caused during transit, due to accident, flood, fire, other natural
4. Remove Exhaust fan wire & switch on. If it is not hazards, neglect of misuse.
tripping, replace exhaust fan. 5. Any liquid except water in the container.
6. machine is shipped (out side premises) without prior information.
6. Bubble top is full, no 1. Check loose connection & continuity between WARRANTY INSTRUCTIONS FOR USER
dispensation of water while main PCB & water level sensor.
1. This warranty card has 2 parts. kindly ensure that the Merchant fills all parts correctly
pressing dispensing button 2. Replace level sensor. 2. Part A is the customer’s copy. It should be retained by you for your record.
only premix is dispensing 3. Replace main board 3. Part B must be torn and mailed to the company’s address (mentioned there itself.)
4. In the event of a defect developing in the product, contact the Merchant. .
7. Variation in end cup volume 1. Check scaling in value & clean it. of company for obtaining warranty service by informing defect, Model & Serial No.
2. replace dispense valve. 5. On your loading a complaint, trained technician will call on your promptly. In the
unlikely event of the technician deciding that the product requires attention at
8. Premix clotting in canister 1. Check exhaust fan whether working or not. customer care center, kindly arrange to deliver the Machine to the customer care
elbow 2. If exhaust fan working, check exhaust pipe center for further action.
connected properly between fan & duct. Connect
it properly. If it is not working, check loose
connections at exhaust fan.
3. Replace exhaust fan.
9. Variation in end cup taste 1. Check level of ingredient inside the canister.
Rell if it is below minimum level.
2. Check whipper motor whether working or not.
If it is not working, check the voltage across
motor terminal.
a) If power supply detected, replace whipper motor.
b) If power supply not detected, check loose connection.
c) Replace main board.
WARRANTY CONDITIONS
This product is covered under a one year warranty to be free from defects is
workmanship and material under normal use and service for a period of 12 months
from the date of purchase.
1. The guarantee extended herein is limited to the repair and/or replacement of defective
part (s), and the manufacturer would not be responsible for any consequential liability/
damage/ loss arising due to such defects .
2. Warranty card duly filled in and stamped by the dealer, along with a copy of the invoice
should be produced for and warranty claims. All expenses incurred in sending and
collecting the unit or part thereof from the authorized service center will be payable
by the customer .
3. This warranty dose not cover accessories such as main cord, relay, membrane
switch, funnel and plastic parts. .
MC28H5025**
Microwave Oven imagine the possibilities

Thank you for purchasing this Samsung product.
Owner’s instructions & Cooking guide
Please be advised that the Samsung warranty does NOT cover service
calls to explain product operation, correct improper installation, or
perform normal cleaning or maintenance.
This manual is made with 100 % recycled paper.
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contents safety information
Safety information........................................................................................ 2
Using this instruction booklet
Quick look-up guide..................................................................................... 11
Oven features................................................................................................ 12 You have just purchased a SAMSUNG microwave oven. Your Owner’s
Oven........................................................................................................... 12 Instructions contains valuable information on cooking with your microwave
Control panel............................................................................................... 13 oven:
Accessories................................................................................................. 13 • Safety precautions
Oven use........................................................................................................ 14 • Suitable accessories and cookware
How a microwave oven works..................................................................... 14 • Useful cooking tips
Checking that your oven is operating correctly............................................. 14
Setting the time........................................................................................... 15 • Cooking tips
Cooking/Reheating...................................................................................... 15
Legend for symbols and icons
Power levels and time variations.................................................................. 16
Adjusting the cooking time.......................................................................... 16
Stopping the cooking.................................................................................. 16 Hazards or unsafe practices that may result in severe
Setting the energy save mode..................................................................... 16 WARNING personal injury or death.
Using the slim fry cook features................................................................... 17
Using the indian recipe features................................................................... 22 Hazards or unsafe practices that may result in minor
Using the curd/dough proof features........................................................... 42 CAUTION personal injury or property damage.
Using the power defrost features................................................................. 43
Using the roti/naan features......................................................................... 44
Convection.................................................................................................. 45 Warning; Fire hazard Warning; Hot surface
Grilling......................................................................................................... 45
Combining microwave and grill.................................................................... 46 Warning; Electricity Warning; Explosive material
Combining microwave and convection........................................................ 46
Choosing the accessories........................................................................... 47
Do NOT attempt. Do NOT touch.
Using the child lock features........................................................................ 47
Using the manual crusty cook function........................................................ 48
Spit-roasting................................................................................................ 49 Do NOT disassemble. Follow directions explicitly.
Using the vertical multi-spit.......................................................................... 50
Make sure the machine is
Using the deodorisation features................................................................. 50 Unplug the power plug
grounded to prevent electric
Switching the beeper off.............................................................................. 50 from the wall socket.
shock.
Cookware guide........................................................................................... 51
Cooking guide............................................................................................... 52 Call the service center for
Note
Troubleshooting and information code...................................................... 61 help.
Checkpoints................................................................................................ 61
Important
Information codes ...................................................................................... 64
Technical specifications.............................................................................. 64
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Important safety instructions WARNING: Only allow children to use
READ CAREFULLY AND KEEP FOR the oven without supervision when
FUTURE REFERENCE. adequate instructions have been given
Make sure that these safety precautions are so that the child is able to use the oven
obeyed at all times. in a safe way and understands the
01 SAFETY INFORMATION
Before using the oven, confirm that the hazards of improper use.
following instructions are followed. WARNING: This appliance can be
WARNING used by children aged from 8 years
(Microwave function only) and above and persons with reduced
physical, sensory or mental capabilities
WARNING: If the door or door seals or lack of experience and knowledge
are damaged, the oven must not be if they have been given supervision
operated until it has been repaired by a or instruction concerning use of the
competent person. appliance in a safe way and understand
WARNING: It is hazardous for anyone the hazards involved. Children shall not
other than a competent person to carry play with the appliance. Cleaning and
out any service or repair operation that user maintenance shall not be made by
involves the removal of a cover which children unless they are aged from 8
gives protection against exposure to years and above and supervised.
microwave energy. Only use utensils that are suitable for use
This appliance is intended to be used in in microwave ovens.
household only. When heating food in plastic or paper
containers, keep an eye on the oven due
to the possibility of ignition.
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The microwave oven is intended for Failure to maintain the oven in a clean
heating food and beverages. Drying of condition could lead to deterioration of
food or clothing and heating of warming the surface that could adversely affect
pads, slippers, sponges, damp cloth and the life of the appliance and possibly
similar may lead to risk of injury, ignition result in a hazardous situation.
or fire. The appliance is not intended for
If smoke is emitted, switch off or unplug installing in road vehicles, caravans and
the appliance and keep the door closed similar vehicles etc.
in order to stifle any flames. This appliance is not intended for use by
WARNING: Microwave heating of persons (including children) with reduced
beverages can result in delayed eruptive physical, sensory or mental capabilities,
boiling, therefore care must be taken or lack of experience and knowledge,
when handling the container. unless they have been given supervision
WARNING: The contents of feeding or instruction concerning use of the
bottles and baby food jars shall be appliance by a person responsible for
stirred or shaken and the temperature their safety.
checked before consumption, in order to Children should be supervised to ensure
avoid burns. that they do not play with the appliance.
Eggs in their shell and whole hard-boiled If the supply cord is damaged, it must be
eggs should not be heated in microwave replaced by the manufacturer, its service
ovens since they may explode, even agent or similarly qualified persons in
after microwave heating has ended. order to avoid a hazard.
The oven should be cleaned regularly WARNING: Liquids and other foods
and any food deposits removed. must not be heated in sealed containers
since they are liable to explode.
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The appliance should not be cleaned During use the appliance becomes hot.
with a water jet. Care should be taken to avoid touching
This oven should be positioned proper heating elements inside the oven.
direction and height permitting easy WARNING: Accessible parts may
access to cavity and control area. become hot during use. Young children
Before using the your oven first time, should be kept away.
oven should be operated with the water A steam cleaner is not to be used.
during 10 minute and then used. WARNING: Ensure that the appliance is
If the oven generates a strange noise, switched off before replacing the lamp to
a burning smell, or smoke is emitted, avoid the possibility of electric shock.
unplug the power plug immediately and WARNING: The appliance and its
contact your nearest service center. accessible parts become hot during use.
The microwave oven has to be Care should be taken to avoid touching
positioned so that plug is accessible. heating elements.
The microwave oven is intended to be Children less than 8 years of age shall
used on the counter or counter top use be kept away unless continuously
only, the microwave oven shall not be supervised.
placed in a cabinet. The temperature of accessible surfaces
may be high when the appliance is
WARNING operating.
(Oven function only) - Optional The door or the outer surface may get
WARNING: When the appliance is hot when the appliance is operating.
operated in the combination mode, Keep the appliance and its cord out of
children should only use the oven reach of children less than 8 years.
under adult supervision due to the
temperatures generated.
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This appliance can be used by Installing your microwave oven
children aged from 8 years and above Place the oven on a flat level surface 85 cm
and persons with reduced physical, above the floor. The surface should be strong
sensory or mental capabilities or lack of enough to safety bear the weight of the oven.
experience and knowledge if they have 1.When you install your oven, 20 cm 10 cm
been given supervision or instruction make sure there is adequate
above behind
concerning use of the appliance in a

safe way and understand the hazards ventilation for your oven by 85 cm of 10 cm on
involved. Children shall not play with leaving at least 10 cm (4 inches) the floor the side
the appliance. Cleaning and user of space behind and, on the sides of the
maintenance shall not be made by oven and 20 cm (8 inches) of space above.
children without supervision. 2.Remove all packing materials inside the oven.
Do not use harsh abrasive cleaners or 3.Install the roller ring and turntable. Check
sharp metal scrapers to clean the oven that the turntable rotates freely.
door glass since they can scratch the (Turntable type model only)
surface, which may result in shattering of
the glass. 4.This microwave oven has to be positioned
Appliances are not intended to be so that plug is accessible.
operated by means of an external timer If the supply cord is damaged, it must be
or separate remote-control system. replaced by the manufacturer, its service
agent or similarly qualified persons in
order to avoid a hazard.
For your personal safety, plug the cable
into a proper AC earthed socket.
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Do not install the microwave oven in hot or 1.Clean the outside surfaces with a soft cloth
damp surroundings like next to a traditional and warm, soapy water. Rinse and dry.
oven or radiator. The power supply 2.Remove any splashes or stains on the
specifications of the oven must be respected inside surfaces of oven with a soapy cloth.
and any extension cable used must be Rinse and dry.
of the same standard as the power cable
supplied with the oven. Wipe the interior and 3.To loosen hardened food particles and
the door seal with a damp cloth before using remove smells, place a cup of diluted
your microwave oven for the first time. lemon juice in the oven and heat for ten
minutes at maximum power.
Cleaning your microwave oven 4.Wash the dishwasher-safe plate whenever
The following parts of your microwave oven necessary.
should be cleaned regularly to prevent DO NOT spill water in the vents. NEVER
grease and food particles from building up: use any abrasive products or chemical
• Inside and outside surfaces solvents. Take particular care when
• Door and door seals cleaning the door seals to ensure that no
• Turntable and Roller rings particles:
(Turntable type model only) • Accumulate
ALWAYS ensure that the door seals are • Prevent the door from closing correctly
clean and the door closes properly. Clean the microwave oven cavity right after
Failure to maintain the oven in a clean each use with a mild detergent solution, but
condition could lead to deterioration of the let the microwave oven cool down before
surface that could adversely affect the life cleaning in order to avoid injury.
of the appliance and possibly result in a
hazardous situation.
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When cleaning the upper If you wish to store your oven away
part inside the cavity, it will temporarily, choose a dry, dustfree place.
be convenient to turn heater Reason : Dust and damp may adversely
downward by 45 ° and clean it. affect the working parts in the oven.
(Swing heater model only) This microwave oven is not intended for
Storing and repairing your commercial use.
microwave oven The Light bulb should not be replaced in
A few simple precautions should be taken person for safety reasons.
when storing or having your microwave oven Please contact nearest authorised
serviced. Samsung customer care centre to arrange
The oven must not be used if the door or for a qualified engineer to replace the bulb.
door seals are damaged:
WARNING
• Broken hinge
Only qualified staff should be allowed to modify or
• Deteriorated seals repair the appliance.
• Distorted or bent oven casing Do not heat liquids and other food in sealed
containers for microwave function.
Only a qualified microwave service technician
For your safety, do not use high-pressure water
should perform repair. cleaners or steam jet cleaners.
NEVER remove the outer casing from Do not install this appliance; near heater,
inflammable material; in a humid, oily or dusty
the oven. If the oven is faulty and needs location, in a location exposed to direct sunlight and
servicing or you are in doubt about its water or where gas may leak; on un level ground.
condition: This appliance must be properly grounded in
accordance with local and national codes.
• Unplug it from the wall socket Remove all foreign substances such as dust or
• Contact the nearest after-sales service water from the power plug terminals and contact
centre points using a dry cloth on a regular basis.
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Do not pull or excessively bend or place heavy Do not pour or directly spray water onto the oven.
objecton the power cord.
In the event of a gas leak (such as propane gas, LP Do not place objects on the oven, inside or on the
gas, etc.), ventilate immediately without touching the door of the oven.
power plug. Do not spray volatile material such as insecticide
onto the surface of the oven.
Do not touch the power plug with wet hands.
Do not store flammable materials in the oven. Take
Do not turn the appliance off by unplugging the special care when heating dishes or drinks that
power plug while an operation is in progress. contain alcohol as alcohol vapours may contact a
hot part of the oven.
Do not insert fingers or foreign substances, If any
foreign substance such as water has entered the Keep children away from the door when opening or
appliance, unplug the power plug and contact your closing it as they may bump themselves on the door
nearest service centre. or catch their fingers in the door.
Do not apply excessive pressure or impact to the WARNING: Microwave heating of beverages can
appliance. result in delayed eruptive boiling, therefore care must
be taken when handling the container; To prevent
Do not place the oven over a fragile object such as a
this situation ALWAYS allow a standing time of at
sink or glass object.
least 20 seconds after the oven has been switched
Do not use benzene, thinner, alcohol, steam cleaner off so that the temperature can equalize. Stir during
or high pressure cleaner to clean the appliance. heating, if necessary, and ALWAYS stir after heating.
Ensure that the power voltage, frequency and In the event of scalding, follow these FIRST AID
current are the same as those of the product instructions:
specifications. • Immerse the scalded area in cold water for at
least 10 minutes.
Plug the power plug into the wall socket firmly. Do • Cover with a clean, dry dressing.
not use a multiple plug adapter, an extension cord or
• Do not apply any creams, oils or lotions.
an electric transformer.
Do not put the tray or rack in water shortly after
Do not hook the power cord on a metal object,
cooking because it may cause breakage or damage
insert the power cord between the objects or behind
of the tray or rack.
the oven.
Do not operate the microwave oven for deep
Do not use a damaged power plug, damaged power
fat frying because the oil temperature cannot be
cord or loose wall socket. When the power plug
controlled. This could result in a sudden boil over of
or power cord is damaged, contact your nearest
the hot liquid.
service centre.
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CAUTION Do not operate the microwave oven when it is
empty. The microwave oven will automatically
Only use utensils that are suitable for use in shut down for 30 minutes for safety purposes. We
microwave ovens; DO NOT use any metallic recommend placing a glass of water inside the oven
containers, Dinnerware with gold or silver trimmings, at all times to absorb microwave energy in case the
Skewers, forks, etc. microwave oven is started accidentally.
Remove wire twist ties from paper or plastic bags. Install the oven in compliance with the clearances stated
Reason: Electric arcing or sparking may occur and in this manual. (See installing your microwave oven.)
may damage the oven.
Take care when connecting other electrical
Do not use your microwave oven to dry papers or appliances to sockets near the oven.
clothes.
Use shorter times for smaller amounts of food to Precautions to avoid possible exposure to excessive
prevent overheating and burning food. microwave energy.(microwave function only)
Do not immerse the power cable or power plug in Failure to observe the following safety precautions may result in harmful
water and keep the power cable away from heat. exposure to microwave energy.
(a) Under no circumstances should any attempt be made to operate the
Eggs in their shell and whole hard-boiled eggs
oven with the door open or to tamper with the safety interlocks (door
should not be heated in microwave ovens since they
latches) or to insert anything into the safety interlock holes.
may explode, even after microwave heating has
ended; Also do not heat airtight or vacuum-sealed (b) Do NOT place any object between the oven door and front face or
bottles, jars, containers, nuts inshells, tomatoes etc. allow food or cleaner residues to accumulate on sealing surfaces.
Ensure that the door and door sealing surfaces are kept clean by
Do not cover the ventilation slots with cloth or paper. wiping after use first with a damp cloth and then with a soft dry cloth.
They may catch fire as hot air escapes from the
(c) Do NOT operate the oven if it is damaged until it has been
oven. The oven may also overheat and switch itself
repaired by a qualified microwave service technician trained by the
off automatically, and will remain off until it cools
manufacturer. It is particularly important that the oven door closes
sufficiently.
properly and that there is no damage to the:
Always use oven mitts when removing a dish from (1) door (bent)
the oven to avoid unintentional burns. (2) door hinges (broken or loose)
Stir liquids halfway during heating or after heating (3) door seals and sealing surfaces
ends and allow the liquid stand at least 20 seconds (d) The oven should not be adjusted or repaired by anyone other than
after heating to prevent eruptive boiling. a properly qualified microwave service technician trained by the
Stand at arms length from the oven when opening manufacturer.
the door to avoid getting scalded by escaping hot air
or steam.
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Samsung will charge a repair fee for replacing an accessory or repairing
a cosmetic defect if the damage to the unit and/or damage to or loss of quick look-up guide
the accessory was caused by the customer. Items this stipulation covers I want to cook some food.
include:
(a) A Dented, Scratched, or Broken Door, Handle, Out-Panel, or Control 1. Place the food in the oven. Press the START/+30s button.
Panel. Result: When cooking has finished, the oven will beep
and flash “End” 4 times. The oven will then beep
(b) A Broken or missing Tray, Guide Roller, Coupler, or Wire Rack.
02 QUICK LOOK-UP GUIDE

one time per minute.
• Use this appliance only for its intended purpose as described in this
instruction manual. Warnings and Important Safety Instructions in this I want to add an extra 30 seconds.
manual do not cover all possible conditions and situations that may
occur. It is your responsibility to use common sense, caution, and Press the START/+30s button one or more times for each extra
care when installing, maintaining, and operating your appliance. 30 seconds that you wish to add.
• Because these following operating instructions cover various models,
the characteristics of your microwave oven may differ slightly from
By pressing the Up and Down Button, You can set the time as
those described in this manual and not all warning signs may be
you want.
applicable. If you have any questions or concerns, contact your
nearest service centre or find help and information online at www.
samsung.com.
• This microwave oven is supposed for heating food. It is intended for
domestic home-use only. Do not heat any type of textiles or cushions
filled with grains, which could cause burns and fire. The manufacturer
cannot be held liable for damage caused by improper or incorrect
use of the appliance.
• Failure to maintain the oven in a clean condition could lead to
deterioration of the surface that could adversely affect the life of the
appliance and possible result in a hazardous situation.
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I want to Power Defrost some food.
oven features
1. Press the Power Defrost button.
Oven
1 2 3 4 5
2. Set the cooking category by pressing the Up or Down
button. Press the Select button to set desired.
3. Select the weight by pressing the Up or Down button as

required.
4. Press the START/+30s button.

Result: Defrosting starts.
• When cooking has finished, the oven will
beep and flash “End” 4 times. The oven will
then beep one time per minute.
6 7 8 9 10 11
1. DOOR HANDLE 7. TURNTABLE

2. DOOR 8. COUPLER
3. VENTILATION HOLES 9. ROLLER RING
4. HEATING ELEMENT 10. SAFETY INTERLOCK HOLES
5. LIGHT 11. CONTROL PANEL
6. DOOR LATCHES
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Control panel Accessories
Depending on the model that you have purchased, you are supplied with several
accessories that can be used in a variety of ways.
1. Roller ring, to be placed in the centre of the oven.

Purpose: The roller ring supports the turntable.
03 OVEN FEATURES
2. Turntable, to be placed on the roller ring with the centre
fitting on to the coupler.
Purpose: The turntable serves as the main cooking
surface; it can be easily removed for cleaning.
3. High rack, Low rack, to be placed on the turntable.
Purpose: The metal racks can be used to cook two dishes
at the same time. A small dish may be placed
on the turntable and a second dish on the
rack. The metal racks can be used in grill,
convection and combination cooking.
4. Crust plate, to be placed on the turntable.

Purpose: The crust plate is used to brown botton of food
by using the microwave or grill combination
cooking modes and to keep pastry and pizza
dough crispy.
5. Roasting spit, coupler barbecue and Skewer to be
placed in the glass bowl.
1. SLIM FRY BUTTON 9. MICROWAVE BUTTON Purpose: The roasting spit is a convenient of barbecuing
2. ROTI/NAAN BUTTON 10. COMBI BUTTON a chicken, as the meat does not have to be
3. CURD/DOUGH PROOF BUTTON 11. CLOCK BUTTON turned over. It can be used for grill combination
cooking.
4. INDIAN RECIPE BUTTON 12. SELECT BUTTON
6. Glass bowl, to be placed on the turntable.
5. POWER DEFROST BUTTON 13. DOWN BUTTON
Purpose: Roasting stand is placed on the glass bowl.
6. DEODORISATION BUTTON 14. UP BUTTON
7. CONVECTION BUTTON 15. STOP/ECO BUTTON
DO NOT operate the microwave oven without the roller ring and turntable.
8. GRILL BUTTON 16. START/+30s BUTTON
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oven use Checking that your oven is operating
How a microwave oven works correctly
Microwaves are high-frequency electromagnetic waves; the energy released enables The following simple procedure enables you to check that your oven is working correctly
food to be cooked or reheated without changing either the form or the colour. at all times. If you are in doubt, refer to the section entitled “Troubleshooting” on the
You can use your microwave oven to: page 61-64.
• Defrost The oven must be plugged into an appropriate wall socket. The turntable must be
• Reheat in position in the oven. If a power level other than the maximum (100 % - 900 W) is
• Cook used, the water takes longer to boil.
Cooking principle. Open the oven door by pulling the handle on the right side of the door.
Place a glass of water on the turntable. Close the door.
1. The microwaves generated by the magnetron reflected at
cavity and are distributed uniformly as the food rotates on Press the START/+30s button and set the time to 4 or
the turntable. The food is thus cooked evenly. 5 minutes, by pressing the START/+30s button the appropriate
number of times.
2. The microwaves are absorbed by the food up to a depth of Result: The oven heats the water for 4 or 5 minutes.
about 1 inch (2.5 cm). Cooking then continues as the heat is The water should then be boiling.
dissipated within the food.
3. Cooking times vary according to the container used and the
properties of the food:
• Quantity and density
• Water content
• Initial temperature (refrigerated or not)
As the centre of the food is cooked by heat dissipation, cooking continues even
when you have taken the food out of the oven. Standing times specified in recipes
and in this booklet must therefore be respected to ensure:
• Even cooking of the food right to the centre.
• The same temperature throughout the food.
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Setting the time Cooking/Reheating
Your microwave oven has an inbuilt clock. When power is supplied, “88:88” and then The following procedure explains how to cook or reheat food.
“12:00” is automatically displayed on the display.
ALWAYS check your cooking settings before leaving the oven unattended.
Please set the current time. The time can be displayed in either the 24-hour or 12-hour
notation. You must set the clock: Open the door. Place the food in the centre of the turntable. Close the door. Never switch
• When you first install your microwave oven the microwave oven on when it is empty.
• After a power failure
04 OVEN USE
1. Press the Microwave button.
Do not forget to reset the clock when you switch to and from summer and winter time. Result: The following indications are displayed:
(microwave mode)
1. Press the Clock button.
2. Press the Up or Down button until the appropriate power
level is displayed.
At that time, press the Select button to set the power level.
2. Press the Up or Down button to set time display type (12H • If don't set the power level within 5 seconds,
or 24H). At that time, press the Select button to set the Automatically changes to the cooking time setting stage.
display type.
3. Set the Cooking time by pressing the Up or Down button.
Result: The cooking time is displayed.
3. Press the Up or Down button to set the hour.

Result: The oven light comes on and the turntable starts
4. Press the Select button.
rotating. Cooking starts and when it has finished:
• The oven beep and flash “End” 4 times.
The oven will then beep one time per minute.
5. Press the Up or Down button to set the minute.
6. When the right time is displayed, press the Select button to

start the clock.
Result: The time is displayed whenever you are not
using the microwave oven.
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Power levels and time variations Stopping the cooking
The power level function enables you to adapt the amount of energy dissipated and thus You can stop cooking at any time so that you can:
the time required to cook or reheat your food, according to its type and quantity. • Check the food
You can choose between six power levels. • Turn the food over or stir it
• Leave it to stand
Power level Percentage Output
To stop the cooking... Then...
HIGH 100 % 900 W
MEDIUM HIGH 67 % 600 W Temporarily Open the door or Press the STOP/ECO button once.
Result: Cooking stops.
MEDIUM 50 % 450 W
MEDIUM LOW 33 % 300 W To resume cooking, close the door again and press
the START/+30s button.
DEFROST 20 % 180 W
Completely Press the STOP/ECO button once.
LOW 11 % 100 W Result: Cooking stops.
The cooking times given in recipes and in this booklet correspond to the specific power If you wish to cancel the cooking settings, press the
level indicated. STOP/ECO button again.
If you select a... Then the cooking time must be... Setting the energy save mode
Higher power level Decreased The oven has an energy save mode.
Lower power level Increased
• Press the STOP/ECO button. (During Standby mode.)
Result : Display off.
Adjusting the cooking time
• To remove energy save mode, open the door or press the
You can adjust the cooking time by pressing the START/+30s. STOP/ECO button and then display shows current time.
• Check how cooking is progressing at any time simply by opening the door The oven is ready for use.
• Increase the remaining cooking time
Auto energy saving function
To adjust the cooking time of your food during cooking, press If you do not select any function when appliance is in the middle of setting or
the START/+30s button once for each 30 seconds that you operating with temporary stop condition, function is canceled and clock will be
wish to add. displayed after 25 minutes.
• Example: To add three minutes, press the START/+30s Oven Lamp will be turned off after 5 minutes with door open condition.
button six times.
To adjust the cooking time of press the Up and Down button
that you wish to add.
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Using the slim fry cook features
The 22 Slim Fry cook features include/provide pre-programmed cooking times. The following table presents the 22 Slim Fry auto programmes for frying. It contains its
You do not need to set either the cooking times or the power level. quantities and appropriate instructions.
You can adjust the slim fry cook category by press the Slim Fry button. You will use less oil compared to frying with oil fryer, while you will get tasty results.
First, place the food in the centre of the turntable and close the door. Programmes are running with a combination of convection, top heater and microwave
energy.
ALWAYS use microwave-safe and oven-proof cookware. Glass or ceramic dishes
04 OVEN USE
are ideal as they allow the microwaves to penetrate the food evenly. ALWAYS use 1. Indian Slim Fry
oven gloves when touching the recipients in the oven, as they will be very hot. Serving
Code/Food Ingredients
Size
1. Press the Slim Fry button.
1-1 4 pieces Maida (all-purpose flour) - 1 cup, Oil - 2 tbsp., Ajwain
Samosa (optional) - large pinch, Water - enough to knead the
Pockets maida, Salt to taste, Oil for brushing
2. Select the category of food by pressing the Up and Down
For the filling:
button and press Select button.
Boiled potatoes (crumbled) - 2, Boiled peas - ¼ cup,
1) Indian Slim Fry
Grated ginger - ¼ tsp., Red chilli powder - 1 tsp.,
2) Potatoes/Vegetables
Coriander powder - ½ tsp., Cumin powder - a pinch,
3) Seafood
Kasuri methi - a pinch, Lemon juice - dash, Garam
4) Chicken
masala - a pinch, Chopped coriander leaves, Salt to
3. Select the type of food that you are cooking by pressing the taste
Up and Down button. Refer to the table on the following Instructions
page for a description of the various pre-programmed Mix the maida with salt, oil, ghee and ajwain, combine to form a
settings. At that time, press the Select button to select the crumbly mixture. Now slowly add enough water to make pliable
type of food. dough, not too soft. Divide the dough and shape into balls. Keep
4. Select the size of the serving by pressing the Up and Down aside covered with moist cloth for 15-20 minutes. Now prepare the
button. filing for the samosa by mixing all the ingredients for filling. Divide
• The serving size differs depending on the menu, and the dough into 4 equal parts and make into balls. Roll each ball into
some menus do not provide a serving size. 6-inch diameter circles and cut each circle in half. Spread the paste
• You can skip this step for a menu that does not provide lightly all along the edge of one semicircle. Spread potato filling
a serving size. in centre leaving the edges fold it into triangle shape pockets or
desired shape seal the edges with a little water. Continue filling the
rest of the Samosa Pockets. Now Keep the 4 Samosa Pockets on
the crusty plate and brush all sides with vegetable oil. Put the crusty
plate on high rack and press start. When beep, turn the side over
and press start button.
(continued)
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Serving Serving
Code/Food Ingredients Code/Food Ingredients
Size Size
1-2 6 pieces Potatoes - 2 medium (300 g), Boiled and shredded, 1-3 4 pieces Bread slices - 4, Salt to taste, Green chilli (chopped)
Veg. Cutlets Mixed vegetables - 2 cups (250 g) : peas, carrots, Bread Pakora - 1, Coriander powder - ¼ tsp., Red chilli powder -
green beans, corn, Paneer - 3~4 oz (100 g), Onions - ¼ tsp., Roasted cumin powder - ½ tsp.
¼ medium (75 g), Green chillies (chopped) - to taste, For the batter:
Cilantro (Coriander leaves), chopped - 10 sprigs, Gram flour (besan) - 1 cups, Salt to taste, Red chilli
Assorted nuts(chopped) - 1 Tbsp. (example: walnuts, powder ¼ teaspoon, Dry mango powder (amchur)
peanuts, etc), Salt to taste, Chaat masala - 1 tsp., - ¼ tsp., Garam masala powder - ⅛ tsp., Oil for
Dried mango powder (Amchur) - 1 tsp., Red chilli brushing
powder - ½ tsp. or to taste, Roasted cumin powder -
Instructions
½ tsp., Bread crumbs for coating, Oil for brushing
Mix gram flour, salt, soda bicarbonate, red chilli powder, amchur,
Instructions garam masala powder in a bowl. Add sufficient water to make thick
Finely chop all the Mixed Vegetables and put them in a bowl. Do and smooth batter. Cut the slices into desired shape. Brush little
the same with the Paneer and pour into a bowl. Into the bowl, Oil on the crusty plate. Dip the bread slices in the batter. Keep the
add in Potatoes, Onions, Green Chillies, Cilantro, and Mixed Nuts. 4 pieces on the crusty plate and brush all sides with vegetables
Mix gently but well. Add in the dry spices: Salt, Chaat Masala, Dry oil. Put the crusty plate on high rack and press start button. When
Mango Powder, Roasted Cumin Powder and Red Chilli Powder. beep, turn the side over and press start button.
Again mix well but gently. Put the bread crumbs in a plate. Make
1-4 30 to 35 Potatoes - 2, Chaat masala powder - ¾ tsp.,
cutlets to the size desired, roll in the crumbs and coat well with the
Masala pieces Red chilli flakes - ½ tsp., Black pepper powder -
bread crumbs. Brush a little Oil on the crusty plate. Now Keep the
French Fries ½ tsp., Oil to brush. Salt to taste
4 Veg Cutlets on the crusty plate and brush all sides with vegetable
oil. Put the crusty plate on high rack and press start. When beep, Instructions
turn the side over and press start button. Wash and peel the potatoes. Slice the potato into thin, long pieces
put them in salt water. In a small bowl, prepare the masala spice
mix salt, chaat masala powder, red chilli flakes & black pepper
powder. Now drain the salt water and dry the potatoes using a
paper towel. Grease the crusty plate with a little vegetable oil, Place
fries on crusty plate and spread evenly, brush them up with oil. Put
the crusty plate on high rack and press start. When beep, transfer
the fries to a bowl and sprinkle spice mix evenly and serve.
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Serving Serving
Size Size
1-5 12 pieces Chickpea flour - 1 cup, Salt - 1 tsp., Turmeric - ¼ tsp., 1-7 4 pieces White bread or brown bread - 5~6 slices, Potatoes - 2
Mix Veg. Ground cumin - ½ tsp., Green chilli - ¼ tsp., Potato - Flat Bread (medium size), Dry pomegranate seeds - ½ tsp. or
Pakora 1, Onion - 1, Olive oil Roll dry mango powder - ½ tsp,, Crushed black pepper
Instructions - ½ tsp. or black pepper powder ¼ tsp., Red chilli
04 OVEN USE
Mix the chickpea flour with the salt, green chillies and the spices. powder - ¼ tsp., Green chilli - 1 (chopped), Garam
Stirring with a whisk, add 200 ml (1 cup) of water. Finely chop the masala powder - ¼ tsp., Cumin powder - ¼ tsp.,
Potatoes and onions. Add them to the water-chickpea batter. Brush Chaat masala - ½ tsp., Coriander leaves - 2 to 3 tsp.
a little oil on the crusty plate. Put one-one tbsp of batter on the (chopped), Salt as required, Oil for brushing
crusty plate and brush them with cooking oil. Put the crusty plate Instructions
on high rack and press the start button. When beep, turn the side Boil the potatoes. When they are still warm, peel and mash them
over and press start button. and keep aside. Add the pomegranate powder, crushed black
1-6 6 pieces Mashed aloo (potatoes) - 2 (large boiled), Green chilies pepper, red chili powder, chopped green chilies, coriander leaves,
Aloo Bonda (chopped) - 1~2, Coriander leaves (finely chopped) garam masala powder, cumin powder and chaat masala powder
Flip Overs - 1 tbsp., Gram flour - 1cup, Salt to taste, Red chilli and salt. Mix the whole filling well. Make small to medium rolls of
powder to taste, Garam masala powder - ¼ tsp., the filling depending on the size of the bread and how many you
Turmeric powder - ¼ tsp., Oil for brushing are going to use. Take a slice of bread and dampen it with water,
Instructions squeeze the water from the bread. Place the filling in the center of
Add salt, chili powder, garam masala, coriander, and green chilies the bread. Roll the bread and close the edges so as to get an even
to the mashed aloo (potatoes) and mix well. In a bowl take a cup outer cover and to cook them evenly gently press them to make
of gram flour; add turmeric powder, little salt and chili powder to them flat. Make all bread rolls this way and keep aside. Brush little
it. Add little water bit by bit and mixing with hand make a batter oil on the crusty plate. Now Keep the 4 bread rolls on the crusty
(neither too thick nor too loses). Make small balls of aloo (potato) plate and brush all sides with olive oil. Put the crusty plate on high
mixture and flatten them to make turnovers. Brush little oil on the rack and press start. When beep, turn the side over and press start
crusty plate. Dip each ball in the batter and keep it on the crusty button. Serve the bread rolls with tomato sauce or green chutney.
plate and brush it with oil. Put the crusty plate on high rack and (continued)
press start. When beep, turn the side over and press start button.
Serve aloo bonda hot with chutney.
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Serving Serving
Size Size
1-8 10 pieces Paneer - 150 g (10 square pieces), Gram/ besan flour 1-10 6 pieces Boiled, peeled and mashed potatoes - 2, Boiled
Paneer - 1 cup, Red chilly powder - 1 tsp., Mango powder Aloo Tikki and coarsely crushed green peas - ¼ cup, Finely,
Pakora - ½ tsp., Roasted cumin powder - ½ tsp., Garam chopped coriander (dhania) - ⅓ tbsp., Chaat masala
masala powder - ½ tsp., Oil to brush, Salt to taste - ⅓ tsp., Chilli powder - ⅛ tsp., Lemon juice - ½ tsp.,
Instructions Salt to taste, Olive oil
Cut paneer into thick medium sized square shaped pieces. Sprinkle Combine all the ingredients in a bowl (except green peas) and
salt , red chilli and cumin powder over the paneer pieces and mix mix well. Divide the mixture into 6 equal portions and shape each
well. In a bowl, mix, gram flour, red chilli powder, mango powder, portion into a round. Fill the crushed green peas in the potato ball
roasted cumin powder, garam masala powder and salt. Add little and make it flat. Brush little oil on the crusty plate. Keep the tikki on
water and beat the mixture to form a thick & smooth batter. Brush the crusty plate and brush both sides with olive oil. Put crusty plate
little oil on the crusty plate. Dip the paneer pieces, into the batter on high rack and press start button. When beep, turn the side over
and keep on the crusty plate. Brush all sides of paneer pieces with and press start button.
olive oil. Put the crusty plate on high rack and press start. When
beep, turn the side over and press start button. Serve the paneer 2. Potatoes/Vegetables
pakora with tomato sauce or green chutney. Code/Food Serving Size Instructions
1-9 6 pieces Besan/chickpea flour - 1 ½ cup, Chilli powder -
2-1 300-350 g Distribute frozen oven chips evenly on the
Mirchi Pakora ½ tsp., Turmeric powder - ½ tsp., Garam masala
Frozen Oven 450-500 g crusty plate. Set plate on low rack.
powder - ¼ tsp., a pinch of asafoetida mango
Chips Turnover after beep sounds. Press start to
(Amchoor) powder, Salt as required, Water, Green
continue. (The oven keeps operating if you do
chilies - 6, oil, Rice flour - 1 tbsp.
not turn over). Stand for 1-2 minutes.
For the filling:
2-2 200-250 g Distribute frozen potato croquettes evenly on
Boiled potato - 1 (medium), Salt, Red chilli powder, 300-350 g the crusty plate. Set plate on low rack.
Frozen Potato
Chaat masala Stand for 1-2 minutes.
Croquettes
Instructions
Add all the dry ingredients to the batter. Add little water so as to 2-3 300-350 g Use hard to medium type of potatoes and wash
form a thick batter. Give 1 vertical slits on the green chillies and Homemade 450-500 g them. Peel potatoes and cut into sticks with a
deseed them. in a small bowl mash boiled potato and add dry French Fries thickness of 10 x 10 mm.
spices. Fill the chillies with potato filling. Brush, little oil on the crusty Soak in cold water (for 30 min.).
plate .Dip them in the batter. Evenly coat the mirch (chillies) with Dry them with a towel, weigh them and brush
batter. Put the mirchi pakora on the crusty plate and brush them with 5 g olive oil. Distribute homemade fries
with oil. Put the crusty plate on high rack and press the start button. evenly on the crusty plate. Set plate on low
When beep, turn the side over and press start button. rack. Turnover after beep sounds. Press start to
continue. (The oven keeps operating if you do
not turn over). Stand for 1-2 minutes.
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4. Chicken
Code/Food Serving Size Instructions Code/Food Serving Size Instructions
2-4 200-250 g Wash normal sized potatoes and cut them into 4-1 200-250 g Distribute frozen chicken nuggets evenly on
Potato Wedges 300-350 g wedges. Brush with olive oil and spices. Frozen Chicken 300-350 g the crusty plate. Set plate on low rack.
400-450 g Put them with the cut side on the crusty plate. Nuggets Turnover after beep sounds. Press start to
Set plate on high rack. Stand for 1-3 minutes. continue. (The oven keeps operating if you do
04 OVEN USE
2-5 100-150 g Put frozen breaded onion rings or frozen not turn over). Stand for 1-2 minutes.
Frozen Onion 200-250 g breaded squid rings evenly on the crusty plate. 4-2 200-250 g Weigh drumsticks and brush with oil and
Ring Set plate on low rack. Stand for 1-2 minutes. Chicken 300-350 g spices. Place them evenly on high rack.
2-6 100-150 g Rinse and slice courgettes. Brush with 5 g Drumsticks 400-450 g Turnover after beep sounds, oven will stop
200-250 g olive oil and add spices. Put slices evenly on process. Press start to continue. Stand for
Sliced
the crusty plate and set plate on high rack. 1-3 minutes.
Courgettes
Turnover after beep sounds. Press start to 4-3 200-250 g Weigh chicken wings and brush with oil and
continue. (The oven keeps operating if you do Chicken Wings 300-350 g spices. Place them evenly on high rack.
not turn over). Stand for 1-2 minutes. Turnover after beep sounds, oven will stop
process. Press start to continue. Stand for
3. Seafood 1-2 minutes.
Code/Food Serving Size Instructions
3-1 200-250 g Distribute frozen breaded prawns evenly on
Frozen Prawns 300-350 g the crusty plate. Set plate on low rack.
Stand for 1-2 minutes.
3-2 200-250 g Distribute breaded fish cutlets evenly on the
Fish Cutlets 300-350 g crusty plate. Set plate on low rack.
3-3 100-150 g Distribute breaded squid rings evenly on the
Fried Squid 200-250 g crusty plate. Set plate on low rack.
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Using the indian recipe features
The 100 Indian Recipe features provide pre-programmed cooking times. You do not The following table presents the various Indian Recipe (Veggie) programmes and
need to set either the cooking times or the power level. appropriate Instructions.
Use only recipients that are microwave-safe. Use oven gloves when taking out food.
Open the door. Place the food in the centre of the turntable. Close the door. 1. Soups & Snacks
1. Press the Indian Recipe button. Serving
Size
1-1 400-500 g Tomato - 6 ea (medium size), Garlic - 7~8 Cloves,
2. Press the Up or Down button to select cook category. Tomato Soup Carrot - 1 ea (small size), Celery - 1 stalk, Onion - 1 ea
(medium size), Pepper corns - 5~6 , Oil - 1 tbsp.,
Butter - 1 tbsp., Salt & sugar as per your taste, Cream
- 2 tbsp., Water - 2 cups
3. Select the cook category by pressing the Select button. Instructions
Wash all vegetables. Cut tomatoes into quarters. Peel & chop
garlic. Peel & cut carrots in rounds. Chop celery, slice onion & crush
4. Press the Up or Down button to select cook type. pepper corns. In microwave safe glass bowl put oil onion, carrot,
celery and garlic. Add 2 cups of water & cook. When beep, let it be
cool and then blend in blender. Pour them in microwave safe glass
bowl and add butter, tomato puree, salt and sugar. Stir well and
5. Press the START/+30s button. cook. After cook strain and add cream and serve it hot.
Result: The food is cooked according to the pre- 1-2 400-450 g Potato - 1 ea, Cabbage - 50 g, Onion - 1 ea (small
programmed setting selected. Mushroom size), Mushroom - 100 g, Tomato sauce - 2 tbsp.,
• When cooking has finished, the oven will Oil - 2 tbsp., Water - 2 cups, Salt, Sugar, Pepper as
Soup
beep and flash “End” 4 times. per taste
The oven will then beep one time per minute.
Instructions
Chop all vegetables. In microwave safe glass bowl put potato,
cabbage, onion, 2 cups of water and cook. When beep, grind the
stalk with some water and then add oil, chopped mushroom, salt,
black pepper, sugar and tomato sauce. Mix well and press start.
Serve hot and garnish with grated cheese.
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Serving Serving
Size Size
1-3 300-350 g Mushroom - 6~7 (chopped), Fresh coriander leaves 1-6 300-400 g Poha - 0.3 kg, Oil - 3 tbsp., Onion - 1 cup (chopped),
Tom Yum a few spring, Green or fresh red chili - 3~4, Lemon Poha Green chili - 4 ea, Mustered, Cumin, Asafetida,
Soup grass - 4 inches stalk, Lime leaves - 4~5, Salt as per Turmeric, Curry leaves for tempering, Grated Coconut
your taste, Thai red curry paste - 2 tbsp., Lemon juice & Coriander for garnishing
04 OVEN USE
- 2 tbsp., Water - 4 cups Instructions
Instructions In microwave safe bowl put oil mustered, cumin, green chili, onions,
In microwave safe glass bowl add 4 cups of water, lemon grass, turmeric powder curry leaves. Mix well and cook. When beep add
lime leaves, 2 red or green chilies and salt. Mix well and cook. When washed poha, salt and sugar to taste. Mix well and press start.
beep, grind the stalk with some water and then add oil, chopped Garnish coconut and coriander. Serve hot.
mushroom and Thai red curry paste. Serve hot with Lemon juice & 1-7 300-400 g Rava/ Suji (Semolina) - 1 cup or 100 g, Oil - 2 tbsp.,
red or green chili. Upama Mustard seeds - 2 tsp., Cumin - 2 tsp., Urad Dal
1-4 300-400 g Bread (French) - 3 slices, Butter - 3 tbsp., Garlic (Black Gram) - ½ tsp., Green Chilies - 2 ea, Curry
Garlic Bread - 2 tbsp., Grated cheese - 3 tbsp., Salt, Pepper, Leaves - 7~8, Water - 200 ml, Sugar & Salt as per
Oregano, Chili flakes as per taste. your taste, Lemon Juice - 1 tsp.
Instructions Instructions
Pre-heat the oven 200 °C with the convection function. Mix butter, In microwave safe bowl put oil, mustard seeds, cumin, black gram,
garlic, salt, pepper, oregano and make a paste. Apply this paste on green chilies, curry leaves, and rava suji/semolina. Mix well and
both sides of the bread and sprinkle grated cheese and chili flakes. cook. When beeps add water, sugar and salt to taste, lemon juice,
Put these breads on crusty plate and put in on low rack. When mix well and then press start. Garnish with coriander and bhujiya.
beep, select menu and cook. 1-8 200 g Mix Vegetable (Carrot, Muter, Corn, Cauliflower,
1-5 200 g Gram flour - 200 g, Warm water - 75 ml, Curd - Chili Honey French Beans etc : cut small pieces) - 200 g, Honey -
Dhokla 3 tbsp., Green chili-ginger paste - 1½ tsp., Fruit salt Vegetables 2 tbsp., Salt, Lemon juice, Pepper powder as per your
- 1½ tsp., Salt, Sugar as per your taste test, Water as required
Grease the microwave safe flat dish, with little oil. Mix gram flour, In microwave safe bowl take vegetables and some water. When
curd, sugar, salt, water, ginger-green chili paste, yellow color, fruit beeps drain water and add honey, salt, lemon juice, pepper powder
salt together. Pour the mixture in greased dish and cook. Cut it into mix well and then press start.
pieces, garnish with grated coconut and coriander and serve with 1-9 200-250 g Pasta - 200 g, Oil - 1 tbsp., Grated Cheese - 3 tbsp.,
sauce or chutney. Vegetable Pasta Sauce, Spring Onion, Water as per your taste,
Pasta Salt as required
Instructions
In microwave safe bowl add pasta and water and cook. When beep
strain Pasta and mix with all the ingredients and then press start.
Serve hot.
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2. Vegetables & Rice
Serving Serving
Size Size
2-1 400-500 g Boiled Mutter - 100 g, Paneer - 200 g, Onions - 2 2-4 400-500 g Soaked Arhar Dal (Soaked for 1 hr) - 200 g, Water -
Mutter (paste), Tomato - 2 (puree), Garlic-ginger paste - Dal Tadaka 300 g, Oil - 2 tbsp., Cumin - 1 tbsp., Green Chilies
Paneer 1 tsp., Oil - 2 tbsp., Red chili powder, Garam masala, - 2~3 ea, Curry Leaves - 5~6 ea, Salt, Coriander,
Fresh Cream, Salt, Turmeric, Sugar, Kasoori methi, Cumin Powder, Turmeric, Asafetida, Kasoori methi,
Coriander as per your taste, Cream - 2 tbsp. Lemon juice as per your taste
In microwave safe bowl add oil, onions and ginger-garlic paste and In microwave safe bowl take dal, water, turmeric, asafetida. Cover
cook. When beep add tomato puree, cream, salt, turmeric, sugar, and cook. When beep take oil, cumin, chopped green chilies, curry
boiled mutter, paneer, kasoori methi (except masala) and then press leaves, salt, coriander, cumin powder, kasurimethi, lemon juice,
start. water and then press start. Garnish with tomato.
2-2 300-400 g Cut Potatoes - 200 g, Cut Cauliflower - 200 g, 2-5 400-500 g Palak Leaves (Spinach) (Boiled & Grinded) - 300 g,
Aloo Ghobi Cut Tomatoes - 100 g, Oil - 2 tbsp., Turmeric powder, Palak Paneer Onion (Chopped) - 2 ea, Tomato (Chopped) - 2 ea,
Coriander powder, Red chili powder, Cumin seeds, Ginger Garlic Paste - 2 tbsp., Paneer - 150 g, Oil -
Salt, Garam masala, Water as per your taste 3 tbsp., Garam Masala, Coriander, Cumin Powder,
Instructions Salt, Fresh Cream as per your taste
In microwave safe glass bowl take oil, potatoes, cauliflower. Mix well Instructions
and cook. When beep, add tomatoes, other ingredients, water and In microwave safe glass bowl take oil, chopped onion, ginger garlic
then press start. paste and cook. When beep add tomato and all the masala, palak
2-3 400-500 g Ghee - 2 tbsp., Gram Flour - 3 tbsp., Curd - 200 g, paste, paneer and cream. Mix it well and then press start.
Kadhi Water - 300 ml, Salt, Sugar, Cumin, Green Chili, 2-6 400-500 g Arhar Dal/ Red Gram - 100 g, Oil - 2 tbsp., Onion
Pakoda Ginger, Curry Leaves as per your taste, Gram flour for Sambhar - 1 ea (Chopped), Tomato - 1 ea (Chopped), Mix
Pakoda - 100 g, Red Chili powder, Turmeric, Ajwain, vegetables (drumsticks, ghia/bottle gourd, red
Salt as per your taste pumpkin, brinjal, ladies finger) - 1 cup, Mustard Seeds
Instructions - 1 tsp., Asafetida - ¼ tsp., Tamarind pulp, Cumin
In bowl take gram flour and add salt, ajwain, red chili powder, seeds, Green chili, Sambhar masala, Salt as required
little oil to it and make soft dough and make small ball form it. In Instructions
microwave safe glass bowl add ghee, cumin, curry leave, curd, In microwave safe glass bowl put dal, turmeric powder, onions,
water, gram flour, sugar, salt, green chili, ginger. Mix well and cook. green chilies, tomatoes, mixed vegetables and add some water.
When beep, add kadhi mixture to prepared ball dough and then Cover and cook. When beep, add oil, asafetida, cumin, curry
press start. Serve hot with rice. leaves, red chilies, sambhar masala, tamarind pulp, salt, water and
then press start.
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Serving Serving
Size Size
2-7 400-500 g Soaked Rice 200 g, Corn 50 g, Chopped Simla Mirch 2-10 400-500 g Soaked Rice - 150 g., Mustard seeds - ½ tsp., Urad
Corn & - 1 ea, Oil - 2 tbsp., Black cardamom - 2 or 3, Cumin Lemon Rice dal - ½ tsp., Grated ginger - 1 tsp., Roasted Daria -
Shimla Mirch seeds - ½ tsp., Onions - 2 ea (Chopped), Green chili & 1 tsp., Dry red chili – 2, Curry leaves – 7~8., Turmeric
04 OVEN USE
Rice salt as per your taste powder - ½ tsp., Lemon juice - 1 tsp., Oil - 2 tbsp.,
Instructions Salt as per your taste, Chopped coriander - 1 tbsp.,
In microwave safe glass bowl take oil, black cardamom, cumin Water - 350 ml
seeds, chopped onions, green chili & salt, soaked rice and cook. Instructions
When beep add water and salt. Mix well and cover and then press In microwave safe glass bowl take oil, mustard seeds, urad dal,
start. grated ginger, roasted daria, dry red chili, curry leaves, turmeric
2-8 400-500 g Boiled potato peeled & chop 300 g., Chopped Onion powder, lemon juice, salt, soaked rice and cook. When beep add
Dosa Sabji 2 Nos., Green chili salt, turmeric powder as per your water and salt, mix it well, cover it and press start. Garnish with
taste, Oil 2 tbsp., Mustard Seeds, Cumin seeds, Curry chopped coriander & serve hot.
leaves for tempering
3. Sweets & Tandoori
Instructions
In micro wave safe glass bowl take oil, mustard seeds, cumin Serving
seeds, curry leaves, green chili, turmeric powder, onion and cook. Size
When beep mix it well and add chopped potato. Mix it well and 3-1 200-250 g Suji - 150 g, Ghee - 4 tbsp., Sugar - ¾ cup., Water -
press start. Garnish with coriander leaves. Suji Halwa 3 cup, Dry Fruit, Cardamom Powder as per your test
2-9 400-500 g Soaked Basamati Rice 200 g, Water - 400 ml, Ghee - Instructions
Vegetable 2 tbsp., Cloves, Cinnamon, Black pepper, Cardamom In microwave safe glass bowl take suji, ghee and cook. When beep,
Biryani - 2 pieces, Salt & Sugar as per your taste, Mixed add water, sugar, dry fruit & cardamom powder, mix well and press
vegetables (cauliflower, peas, french beans & carrot : start.
chopped) - 1 cup
3-2 300-350 g Besan (Bengal Gram flour) - 2 cups , Ghee - 100 g,
Instructions Besan Powder Sugar - 75 g, Cardamom powder - 1 tbsp.,
In microwave safe glass bowl add ghee, vegetables, all masalas (Bengal Almonds (Chopped) - ¼ cup
and soaked basamati rice, mix it well and cook. When beep, add
Gram Flour) Instructions
water, salt & sugar. Cover it and press start. Serve hot.
Laddoo In microwave safe glass bowl add besan and ghee, mix well
and cook. When beep stir well and press start. When cool and
cardamom powder, sugar powder, mix well and make ladoo.
(continued)
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Serving Serving
Size Size
3-3 450-500 g Grated carrot - 400 g, Milk - 100 g, Khoya - 50 g, 3-7 250-300 g Gobhi (Cut big flowers) - 200 g, Marinate : Hung
Gajar (Carrot) Sugar - 100 g, Milk Powder - 50 g, Cardamom Tandoori Curd - 4 tbsp., Ginger Garlic Paste - 1½ tbsp.,
ka Halwa powder - 1 tsp., Almonds & resins - 2 tbsp. Gobhi Red Chili Powder, Garam Masala as per your taste,
Instructions Lemon Juice - 1 tbsp., Edible Red Color - 1 pinch,
In microwave safe glass bowl add grated carrot, milk, khoya, milk Oil - 1 tbsp.
powder, mix it well and cook. When beep stir well and add sugar, Instructions
cardamom powder, mix it well and press start. Decorate it with Mix all the ingredients of marinate thoroughly. Add gobhi pieces and
almonds & resins. Serve hot or cold. keep it for 2 hrs in a refrigerator. Keep the pieces on crusty plate at
3-4 450-500 g Rice (soaked in 200 ml. milk for 1 hr.) - 0.3 kg, Milk high rack. Apply little oil on it and cook. When beep, turn the pieces
Phirani - 300 ml, Sugar - 200 g, Saffron - 1 tsp., Cardamom and press start. Serve hot with chutney.
powder - 1 tsp., Pista pieces - 1 tbsp. 3-8 8 Kababs Boiled vegetables - Potato, Cauliflower, Carrot, Green
Instructions Vegetable peas - 0.1 kg, Water - 3 tbsp., Cornflour – 1~2 tbsp.,
Blend soaked rice with milk. Pour this microwave safe bowl and Kabab Bread crumbs - 1 tbsp., Ginger-Garlic paste - ½ tsp.,
cook. When beep adds sugar, saffron, cardamom powder, mix it Chili paste - ½ tsp., Garam Masala - ¼ tsp., Lemon
well & press start. Take it out, stir it. When cool, decorate with pista juice, salt, sugar as per your taste
pieces and serve cool. Instructions
3-5 250-300 g Paneer - 200 g, Marinate : Hung Curd - 4 tbsp., Mix boiled vegetables and strained bengal gram, ginger-garlic
Paneer Tikka Ginger Garlic Paste - 1½ tbsp., Red Chili Powder, paste, red chili powder, garam masala, coriander-cumin powder,
Garam Masala as per your taste, Lemon Juice - salt, bread crumbs, coriander leaves together. Apply little oil to your
1 tbsp., Edible Red Color - 1 pinch, Oil - 1 tbsp. palms and shape as desired like tikki balls and roll over with corn
Instructions flour. Cutlet rolls, brush with little oil. Place kebabs on crusty plate at
Mix all the ingredients of marinate thoroughly. Add paneer pieces high rack and cook. When beep, turn kababs and press start. Serve
and keep it for 2 hrs in a refrigerator. Keep the pieces on crusty it with chutney and salads.
plate at high rack. Apply little oil on it and cook. When beep, turn
the pieces and then press start. Serve hot with chutney.
3-6 400-500 g Baby Potato (peeled) - 400 g Curd - ½ cup Ginger
Aloo Tikka garlic paste - ½ tbsp., Coriander powder, cumin
powder, red chili powder, kasoori methi, salt & oil as
per your test
Instructions
Take peeled aloo, add curd, ginger garlic paste, other spices and
salt. Mix them well and put them on crusty plate at high rack,
Sprinkle oil and cook. When beep turn potato and press start.
Serve hot.
English - 26
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Serving Serving
Size Size
3-9 200-250 g Mushroom - 150 g, cottage cheese- 3 tbsp., Grated 4-2 300-400 g Chopped tomato - 4 ea, Fresh basil leaves -20~25,
Stuffed cheese - 2 tbsp., corns – 1 tbsp., corn flour- 2 tbsp., Tomato Basil Crushed peppercorns - 10~15, Chopped onion
Mushroom lemon juice- 1 tbsp., red chilli powder- ¼ tsp, garam Soup - 1 ea, Chopped garlic - 7~8, Celery sticks finely
masala- ¼ tsp, Salt as per your taste, Butter - 2 tbsp. chopped - 2 tbsp., Corn flour - 2 tbsp. (dissolve in
04 OVEN USE
Instructions 1 cup of water), Salt and Sugar as per your taste,
Hollow the mushrooms and marinate with lemon juice, salt, red chilli Water - 3 cups, Olive oil - 2 tbsp.
powder, butter and garam masala, keep aside for 15 minutes. Instructions
In another bowl mix cottage cheese, grated cheese and corn and In microwave safe glass bowl add tomato, basil leaves, onion,
season as per tatse. garlic, celery sticks and water, mix well and cook. When beep add
Stuffed the mushrooms with cottage cheese mixture and coat with all other ingredients, mix well and press start. Serve hot.
corn. (flour mixed in very less water.) 4-3 400-450 g Noodles - 200 g, Water - 2 cups, Mix Vegetables
Grease the crusty plate with some butter and place the mushrooms Vegetable - 100 g, Soya Sauce, Chili Sauce, Viengar, Salt &
on it, brush up a little butter on mushrooms and put the crusty plate Chowmein Pepper as per your taste, Oil as required
on high rack and cook. When beep brush up a little more butter Instructions
and cook. In microwave safe glass bowl take noodles and 2 cups water and
4. Continental cook. When beep, drain all the water from it & keep noodles a side.
In other microwave safe glass bowl take oil & vegetables and press
Serving start. After done add all ingredients with noodles mix well & serve
Size hot.
4-1 8 ea Potatoes - 4 ea (boiled), Cottage cheese - 200 g, 4-4 450-500 g Basmati Rice (soaked) - 150 g, Spinach (chopped)
Cheese Chopped coriander - 2 tbsp., Chopped green chili Risotto Rice - 100 g, Butter - 3 tbsp., Chopped onion - 2 ea,
Cutlet - 1 tsp., Chopped onion - 1 ea, Chopped cabbage - Chopped Garlic - 2 tsp., Grated cheese - 3 tbsp., Salt
2 tbsp., Bread crumbs - 4 tbsp., Oil for applying, Salt & Pepper as per your taste, Water - 300 ml
as per your taste Instructions
Instructions In microwave safe glass bowl take butter, onion, garlic and cook.
Mash the potatoes very well, add all ingredients, mix it well and When beep add spinach (chopped) soaked rice, water, salt &
shape the cutlet as you wish. Take it on crusty plate at high rack, pepper and mix well. Cover and press start. Garnish with grated
applying oil and cook. When beep, turn the pieces and press start. cheese and serve hot.
(continued)
English - 27
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Serving Serving
Size Size
4-5 350-400 g Half boiled vegetables (carrot, cauliflower, french 4-8 400-450 g Penne Pasta - 200 g, Chopped onion - 2 tbsp.,
Baked beans - cut into small pieces, sweet corn & green Pasta Chopped garlic - 2 tsp., Chopped spinach - 75 g,
Vegetables peas etc.) - 300 g, Plain flour - 2 tbsp., Butter - Cream - 1 cup, Grated cheese - 3 tbsp., Butter -
2 tbsp., Milk - 2 cups, Water - ½ cup, Grated cheese 2 tbsp., Nutmeg Powder - 1 pinch, Oregano - ½ tsp.,
- 5 tbsp., Salt, sugar, pepper as per your taste Salt & pepper as per your taste, Oil - 1 tbsp., Water
Instructions - 3 cups
In microwave safe glass dish take butter, vegetables, plain flour, Instructions
milk, water, salt, sugar and pepper, mix well and cook. When beep In microwave safe glass bowl take pasta, water, oil and When
mix it well & spread grated cheese on it. Keep the dish on high rack beep drain the water & keep a side. In another bowl add butter,
and press start. Serve hot. chopped onion, chopped garlic, spinach, cream, nutmeg powder,
4-6 400-450 g Ribbon noodles - 250 g, Tomato sauce - ½ cup, Pizza salt, pepper powder, oregano, mix it well and press start. After done
Noodles sauce - ½ cup, Cheese sauce - 1 cup, Oil - 2 tbsp., pasta & cheese, mix it well & serve hot.
with Tomato Grated cheese - 2 tbsp., Salt, sugar & pepper as per 4-9 300-350 g Boiled sweet corn - 100 g, Boiled Potatoes - 2 ea,
and Cheese your taste, Fresh Cream - 2 tbsp., Oregano - ½ tsp., Corn & Finely chopped onion - 1 ea, Finely chopped green
Sauce Water - 4 cups Potato Baked chili - 2 ea, Grated cheese - 4 tbsp., White sauce -
Instructions 1 cup, Fresh cream - 2 tbsp., Butter - 2 tbsp., Salt &
In microwave safe glass bowl add noodles, oil and cook. When Pepper as per you taste
beep drain & keep a side. In another bowl add tomato sauce, pizza Instructions
sauce, cheese sauce, fresh cream, salt, sugar & pepper, mix it well In microwave safe glass dish take butter, onion, green chili and
and add boiled noodles, sprinkle cheese and press start. Serve hot. cook. When beep add white sauce, chopped potatoes, sweet corn,
4-7 250-300 g Shell Macaroni - 200 g, Chopped Onion - 2 ea, fresh cream, salt, pepper, mix it well and sprinkle cheese. Transfer it
Macaroni Hot Chopped capsicum - 1 ea, Chopped Tomato - 2 ea, on high rack and press start. Serve hot.
Pot Chopped Garlic - 1 tsp., Red chili powder - ½ tsp.,
One small can baked beans - 200 g, Tomato ketchup
- 6 tbsp., Grated cheese - 4 tbsp., Butter - 1 tbsp.,
Salt as per your taste, Oil - 1 tbsp., Water - 4 cups
Instructions
In microwave safe glass bowl add shell macaroni, oil, water and
cook. When beep drain & keep a side. In another bowl add butter,
salt, onion, capsicum, tomato, garlic cloves, chili powder, cheese,
baked beans and press start. When beep add macaroni, mix it well
and serve hot.
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5. Cake & Confectionery
Serving Serving
Size Size
4-10 500-600 g For green paste : Green chillies - 6~8, Spring 5-1 450-500 g Refined flour - 120 g, Margarine - 90 g, Egg - 2 ea,
Vegetable in onions - 3 ea (chopped along with the green part), Butter Powder Sugar - 120 g, Baking Powder - 1 tsp., Milk
Thai Curry Lemon grass leaves - 4 (optional), Ginger - 2" piece, Sponge as required, Vanilla essence - ¼ tsp.
04 OVEN USE
Coriander leaves - 3 tbsp., For main dish : Coconut Instructions
milk - 1½ cups, Salt - 1½ tsp., A tiny piece of jaggery, Pre-heat the oven 200 °C with the convection function. Grease
Coriander powder - 1 tbsp., Cumin powder - 1 tbsp., and dust 8" cake tin. Sieve flour with baking powder thrice. Cream
Oil - 2 tbsp., Chopped mix vegetable (carrot, margarine and powdered sugar until light and fluffy. Beat egg
cabbage, peas ) - 1 cup and add to the creamed mixture little by little beating thoroughly
Instructions between each addition. Fold in the shifted flour a little at a time.
In grinder prepare green paste. Churn grated one coconut in mixer. Adjust consistency of the batter with milk to get a dropping
In microwave safe glass bowl add vegetables, oil and cook. When consistency. Put it in cake tin at low rack, when beep select menu
beep add salt jaggery and coconut milk. Mix well & press start. and cook.
4-11 500-550 g Mushrooms quartered (cut into 4 pieces each) - 5-2 450-500 g Refined flour - 115 g, Margarine - 55 g, Egg - 2 ea,
Mushroom 200 g, Oil or butter - 2 tbsp., Maida (flour) - 2 tbsp., Chocolate Powder Sugar - 85 g, Baking Powder - 1 tsp., Soda
Gratin Salt - 1 tsp., Pepper - 1 tsp., Rum or sherry (optional) Cake Bicarb - ½ tsp., Milk as required, Cocoa powder -
- 1 tsp., Cream - 100 g (½ cup), Water - ½ cup, Some 2 tbsp., Chocolate essence - 1 tsp.
chopped celery or coriander leaves for garnishing Instructions
Instructions Pre-heat the oven 200 °C with the convection function. Grease and
In microwave safe plate butter, maida and cook. When beep add all dust 8" cake tin. Sieve flour with baking powder, cocoa powder
other ingredients, mix well and press start. Sprinkle chopped celery & soda bicarb. Cream butter & sugar until light & fluffy. Add egg &
or coriander and serve hot. beat in well. Add essence & fold in refined flour with sufficient milk
4-12 400-450 g Fussily Pasta - 200 g, Oil - 1 tbsp., Cream - 1 cup, to make a soft consistency. Pour in a greased & lined cake tin. Put it
Pasta in Grated cheese - 3 tbsp., Butter - 2 tbsp., Oregano on low rack, when beep select menu and cook.
Pesto Sauce - ½ tsp., Salt & pepper as per your taste, Olive Oil - (continued)
1 tbsp., Pesto Sauce - 4 tbsp., Water - 3 cups
Instructions
In microwave safe glass bowl take Pasta with water, oil and cook.
When beep drain the water & keep a side. In another bowl add
butter, olive oil, pasta, cream, salt, pepper powder, oregano,
cheese, pesto sauce. Mix it well & press start. Serve hot.
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Serving Serving
Size Size
5-3 450 g Refined flour - 225 g, Margarine - 125 g, Egg - 2 ea, 5-5 450-500 g Refined flour - 150 g, Condensed Milk - 200 g,
Banana Powder Sugar - 200 g, Baking Powder - ½ tsp., Soda Marble Cake Butter - 100 g, Soda Bicarb - ½ tsp., Baking Powder
Bread Bicarb - 1 tsp., Riped Banana - 3 ea, Walnut - 50 g, - 1 tsp., Vanilla essence - 1 tsp., Cocoa Powder -
Milk as required, Vanilla essence - 1 tsp. 2 tbsp., Milk or water as required
Pre-heat the oven 180 °C with the convection function. Grease and Pre-heat the oven 200 °C with the convection function. Sieve
dust 10" cake tin, Sieve flour with baking powder & soda bicarb. refined flour, baking powder & soda. In a bowl add condensed milk
Cream butter & sugar until light & fluffy. Beat egg separately. Add & butter & beat well. Add refind flour, essence & mix. For spoon
gradually to creamed mixture, beating well all the time. Add mashed dropping consistency add milk or water. Divide the mixture in two
banana with 1 table spoon of flour. Mix well. Fold in flour. Add parts. Add cocoa powder in one part. Put the plain batter & cocoa
chopped walnuts. Pour into a greased loaf tin. Put it on low rack, batter alternately in the tin. Run a spoon through the batter, put it on
When beep, select menu and cook. low rack, when beep select menu and cook.
5-4 400-450 g Refined flour - 100 g, Butter - 75 g, Egg - 2 ea, 5-6 300-350 g Condensed Milk - 200 g, Fresh grated coconut -
Brownie Chopped Almonds - 3 tbsp., Powder Sugar - 80 g, Coconut 1 cup, Chopped walnut - 100 g, Ghee - 2 tbsp.
Baking Powder - 1 tsp., Milk - ¼ cup, Chocolate Toffee Instructions
essence - 1 tsp., Cocoa powder - 2 tbsp., Water - In microwave safe glass bowl mix the condensed milk, coconut and
½ cup cook. When beep, add ghee and press start. After done add the
Instructions chopped walnuts & mix well. Spread the mixture on a well greased
Pre-heat the oven 200 °C with the convection function. Grease and tin. Press & level by pressing with a wet cloth. After 5 min. mark into
dust 8" cake tin. Sieve flour with baking powder. Mix cocoa powder small pieces. Remove when cold.
with half cup of hot water. In a bowl add powder sugar & butter 5-7 400-450 g Refined flour - 170 g, Butter - 115 g, Powder sugar
& beat well. Add egg & essence & again beat well. Add almonds German - 60 g, Cashew nut powder - 60 g, Almond essence
to Refined flour, mix well, add maida mix with butter mixture. Biscuits - ¼ tsp.
Add cocoa solution to it & again mix well. For spoon dropping Instructions
consistency add milk. Pour the mixture in a greased tin. Put it on Pre-heat the oven 180 °C with the convection function. Sieve the
low rack, When beep, select menu and cook. flour, cream butter & sugar very well until light & creamy. Add the
Almond essence & beat. Add cashew nut & sieved refined flour &
mix well. The mixture will form into a dough. Roll into sticks & shape
into a circle. Arrange this on baking tray. Put it on low rack, When
beep, select menu and cook. Cool the biscuits. Serve them.
English - 30
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Serving Serving
Size Size
5-8 200-225 g Refined flour - 115 g, Margarine or butter - 60 g, 5-10 400 g Refined flour - 100 g, Powder sugar - 100 g, Ghee -
Chocolate Powder sugar - 60 g, Vanilla essence - ½ tsp., Baking Kesar 100 g, Semolina - 100 g, Cardamom powder - ½ tsp.,
Cookies powder - ½ tsp., Cocoa powder - 1 tbsp., Golden Nankatai Nutmeg powder - ½ tsp., Fresh curd - 1 tsp., Soda
syrup - 1 tbsp. Bicarb - ¼ tsp., Saffron - ¼ tsp., Milk - 1 tsp.
04 OVEN USE
Pre-heat the oven 160 °C with the convection function. Sieve the Pre-heat the oven 180 °C with the convection function. Sieve the
flour with cocoa & baking powder together. Cream the margarine flour. Cream the ghee & sugar very well until light & creamy. Add the
& sugar very well until light & creamy. Add the vanilla essence & cardamom & nutmeg powder & cream it again. The saffron dissolve
golden syrup & beat very well. Add the flour to the mixture & mix it in a 1 tsp. of milk. Add the curd, soda bicarb & prepared saffron.
well. Shape the biscuit as you wish. Arrange them on a baking tray. Mix well. Add the flour & semolina & knead well. Make a small
Put it on low rack, When beep, select menu and cook. round. Arrange them on a baking tray. Put it on low rack, When
5-9 250-300 g Refined flour - 115 g, Margarine or butter - 50 g, beep, select menu and cook. Cool the biscuits. Serve them.
Almond Powder sugar - 50 g., Cardamom powder - ¼ tsp.,
Nutmeg powder - ¼ tsp., Chopped almond - 1 tbsp., The following table presents the various Indian Recipe (Non-Veggie) programmes and
Cookies
Chopped Pistachio - 1 tbsp., Little saffron, Milk as appropriate Instructions.
(Pistachio)
required 6. Soups & Snacks
Instructions
Serving
Pre-heat the oven 180 °C with the convection function. Sieve the Code/Food Ingredients
Size
flour. Cream the margarine & sugar very well until light & creamy.
Add the saffron, cardamom & nutmeg powder & mix very well. Add 6-1 300-400 g Boneless Chicken - 100 g, Chopped Onion - 1
the sieved flour & make a dough. Roll out the dough using a little Chicken (medium size), Chopped Garlic - 4~5 cloves, Oil
flour. Sprinkle a few nuts & give a light final roll. Cut into desired Shorba - 1 tbsp., Cumin Seeds - ½ tsp., Water - 1 cup,
shape. Put it on cookie tray at low rack, When beep, select menu Coconut Milk - 1 cup, Peppercorns - 5~6, Salt as per
and cook. Cool the biscuits. Serve them. taste, Cream - ¼ cup, Chopped Coriander Leaves -
2 tbsp.
Instructions
In microwave safe glass bowl add oil, chopped onion, garlic cloves,
cumin seeds & chicken, peppercorns. Mix well and cook. When
beep add all the other ingredients, mix it well and press start.
(continued)
English - 31
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Serving Serving
Size Size
6-2 350-400 g Boneless Chicken - 150 g, Ginger paste - 1 tsp., 6-6 350-400 g Boneless Chicken - 150 g, Chopped Celery - 1 tbsp.,
Chicken Garlic paste - 1 tsp. , Salt & Pepper powder as per Herb Chicken Chopped Parsley - 1 tbsp., Oregano - ½ tsp.,
Soup your taste, Corn Flour Paste - 2 tbsp.(dissolve in Soup Chopped Coriander - 1 tbsp., Ginger Paste - 1 tsp.,
½ cup of water), Oil - 2 tbsp., Water - 300 ml Garlic Paste - 1 tsp., Salt & Pepper powder as per
Instructions your taste, Corn Flour Paste - 2 tbsp.(dissolve in
In microwave safe glass bowl add oil, chicken in small pieces, ½ cup of water), Oil - 2 tbsp., Water - 300 ml
ginger paste, garlic paste, corn flour paste & water, mix it well and Instructions
cook. Serve hot. In microwave safe glass bowl add oil, chicken in small pieces,
6-3 400-450 g Crab - 150 g, Ginger paste - 1 tsp., Garlic paste - ginger paste, garlic paste, chopped celery, chopped parsley,
Crab Soup 1 tsp., Salt & Pepper powder as per your taste, Corn oregano, chopped coriander, corn flour paste & water, mix it well
Flour Paste - 2 tbsp.(dissolve in ½ cup of water), Oil and cook. Serve hot.
- 2 tbsp., Water - 350 ml 6-7 300-350 g Chopped Boneless Chicken - 150 g, Fresh Coriander
Instructions Tom Yum Leaves a few springs, Green or Fresh red chili - 3~4,
In microwave safe glass bowl add oil, crab, ginger paste, garlic Chicken Lemon Grass - 4 inches stalk, Lime leaves - 4~5,
paste, corn flour paste & water, mix it well. Mix it well and cook. Soup Salt as per your taste, Thai red curry paste - 2 tbsp.,
Serve hot. Lemon juice - 2 tbsp., Water - 350 ml
6-4 450-500 g Boneless Chicken - 150 g, Ginger, Garlic, Green Instructions
Chicken Chili - 1 tbsp.(small pieces), Salt & Pepper Powder as In microwave safe glass bowl add water, boneless chicken, lemon
Manchow per your taste, Corn Flour Paste - 2 tbsp.(dissolve in grass, lime leaves & 2 red or green chili, salt, oil, thai red curry
½ cup of water), Vinegar - 1 tsp., Chili sauce - ½ tsp., paste, lemon juice & cook. Serve hot.
Soup
Soya sauce - ½ tbsp., Oil - 2 tbsp., Water - 350 ml 6-8 350-400 g Fish slice - 300 g, Salt, Lemon juice, Pepper powder
Instructions Fish Pepper as per your taste, Oil - 3 tbsp., Chopped Onion -
In microwave safe glass bowl add oil, chicken in small pieces, 4 tbsp., Chopped Tomato - 3 tbsp., Chopped Garlic -
ginger, garlic, green chili pieces, corn flour paste & chili sauce, soya 2 tsp., Water as required, Coriander leaves - 1 tbsp.
sauce & vinegar, water, mix it well and cook. Serve hot. Instructions
6-5 300-350 g Boneless Mutton - 150 g, Ginger paste - 1 tsp., Garlic Marinate fish slice with salt, lemon juice & pepper powder for one
Mutton Soup Paste - 1 tsp., Salt & Pepper powder as per your hour. In microwave safe bowl put oil, chopped onion, chopped
taste, Corn Flour Paste - 2 tbsp.(dissolve in ½ cup of tomato, chopped garlic & cook. When beep add marinated fish, salt
water), Oil - 2 tbsp., Water - 300 ml to taste & ¼ cup of water and press start. Garnish with chopped
Instructions coriander leaves.
In microwave safe glass bowl add oil, mutton in small pieces, ginger
paste, garlic paste, corn flour paste & water, mix it well, cook. Serve
hot.
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Serving Serving
Size Size
6-9 400-450 g Boneless Chicken - 300 g, Lemon juice - 3 tbsp., Salt 6-12 300-350 g Boneless Chicken - cut into small pieces, Soya sauce
Lemon as per your taste, Honey - 3 tsp., Pepper powder - Ginger - 3 tbsp., Grated Ginger - 1 tbsp., Thinly sliced Ginger
Chicken 1 tsp., Olive Oil - 2 tbsp., Corn Flour - 2 tbsp., Corn Chicken - 1 tbsp., Spring onion - 3~4 (chopped with green
Flour Paste - 2 tbsp.(dissolve in ½ cup of water), part), Sherry - 2 tbsp., Ajinomoto - ½ tsp., Salt as per
04 OVEN USE
Chopped Coriander leaves - 1 tbsp. your taste, Pepper powder - 1 tsp., Corn Flour - 2 tsp.
Instructions (dissolve in ½ of water), Oil - 2 tbsp.
Marinate chicken with pepper powder, salt, lemon juice & keep Instructions
for one hour in refrigerator. In microwave safe bowl take olive oil, In microwave safe glass bowl mix oil, chicken, grated ginger, sherry,
marinated chicken & mix it well, and cook. When beep, add honey, spring onion & soya sauce. Mix it well & cover it & cook. When beep
corn flour paste & press start. add salt, pepper & sliced ginger. Mix it well, add corn flour paste,
6-10 300-350 g Boiled Chicken Kheema - 175 g, Boiled & Mashed ¼ cup of water, mix it well and press start. Serve hot.
Kheema Ball Potato - 3 ea, Ginger, Garlic paste, Salt, Garam 6-13 500-550 g Boneless Chicken - 400 g, Grind red chili - 10, Oil -
Masala, Coriander, Lemon juice as per your taste, Schezwan 3 tbsp., Garlic paste - 1 tbsp., Garlic finely - 1 tbsp.
Bengali Gram powder - 2 tbsp. Chicken (chopped), Tomato sauce - 4 tbsp., Vinegar - 1 tbsp,
Instructions Red Chili Sauce - 2 tbsp., Soya Sauce -1½ tbsp.,
Mix all the ingredients together. Make balls from it. Place the balls Salt & Sugar as per your taste, Corn flour - 1 tbsp.,
greased microwave multiple pan on 2nd level and cook. When beep Ajinomoto - ¼ tsp., Orange color - 1 pinch
turn over the balls and cook, serve hot. Instructions
6-11 300-350 g Boneless Chicken - 250 g, Chopped Ginger - ½ tsp., In microwave safe glass bowl add oil, chopped garlic, grind red chili
Chili Chicken Chopped Garlic - ½ tsp., Vinegar - 1 tbsp., Soya and cook. When beep add garlic paste & all other ingredients. Mix it
sauce - 2 tbsp., Ajinomoto - ½ tsp., Green chili - well & press start.
4~5 ea (slit length ways), One medium capsicum : 6-14 400-450 g Boneless Chicken - 250 g (cut into bite size pieces),
cut into thin strips, One small onion - cut into ½” thin Chicken Cashew nut - 15~20, Dried broken red chilies - 6,
strips, Onion leaves - 2~3 (cut into long strips), Sugar Hong Kong Fresh garlic - 4~5 (chopped), Sherry - 2 tbsp., Salt
- 1 tsp., Salt as per your taste, Sherry - 2 tsp., Corn & Sugar as per your taste, Oil - 2 tbsp., Ajinomoto -
Flour - 2 tsp.(dissolve in ½ of water), Oil - 2 tbsp. ½ tsp., Cornflour - 2 tsp.(dissolve in 1 cup of water)
In microwave safe glass bowl mix oil, ajinomoto, ginger-garlic, chili, In microwave safe glass bowl add oil, ginger, soya sauce, sherry,
soya sauce & chicken and cook. When beep add all ingredients & ajinomoto, salt, sugar, chicken and cook. When beep add broken
¼ cup of water, mix it well, cover it & press start. Serve hot. dried red chili powder, garlic, corn flour, cashew nut, all other
ingredients. Mix it well and press start.
English - 33
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7. Indian Special Chicken Dishes
Serving Serving
Size Size
7-1 400-450 g Chicken legs - 5~6, Chopped coriander leaves - 7-3 500-600 g Boneless Chicken - 450 g, Chopped Mushroom
Mirchi 2 tbsp., Oil - 4 tbsp., Tomato puree - 1 cup, Sugar Chicken & - 8~10, Spring onion - 3~4, Finley chopped Garlic
Chicken & salt as per your taste, Onion paste - 4 tbsp, Mushroom - 5~6, Chopped red chili - 1 tbsp., Pepper powder
Ginger-garlic & green chili paste - 2 tbsp., Lemon juice with Tomato - ¼ tsp., Tomato puree - ½ cup, Honey - 2 tsp.,
- 2 tsp., Garam Masala - 1 tsp. Oregano - ¼ tsp., Butter - 2 tbsp., Salt as per your
Instructions taste
Marinate chicken with onion, ginger-garlic & green chili paste. Place Instructions
it in refrigerator for 2-3 hrs. In microwave safe glass bowl add oil, In microwave safe glass bowl take oil, garlic, chicken, salt and cook.
marinated chicken & cook. When beep add tomato puree, salt, When beep add mushroom, tomato puree & all other ingredients,
sugar, garam masala & press start. Garnish with coriander leaves & mix it well. Cover it and press start. Sprinkle spring onion & serve
serve hot. hot.
7-2 500-550 g Boneless Chicken - 400 g, Lemon juice - 1 tbsp., 7-4 500-600 g Chicken - 500 g (medium size pieces), Onion - 1
Butter Kashmiri red chili powder - 1 tsp., Salt & sugar - as Chicken (chopped), Garlic - 4~5 flakes, Tomato Puree - 4 ea,
Chicken per your taste, Butter - 4 tbsp., Ginger-garlic paste Jalfreji Grated Ginger - 1 tsp., Garam Masala - 1 tsp., Cumin
- 2 tbsp., Garam Masala - 1 tsp., Yogurt - ½ cup, Powder - 1 tsp., Red Chili Powder - 1 tsp., Lemon
Dried fenugreek leaves - 1 tsp., Mustard oil - 2 tsp., Juice - ½ tsp., Turmeric powder - 1 tsp., Oil - 3 tbsp.,
Chopped onion paste - 1 cup, Tomato puree - ½ cup, Capsicum - 1 ea, Cream - 1 cup
Chopped coriander - 1 tbsp., Fresh cream - ½ cup & Instructions
orange-red color - 1 pinch In microwave safe glass bowl add oil, onion, ginger, garlic,
Instructions haldi, chicken and cook. When beep add capsicum & all other
Marinate chicken with yogurt, mustard oil, lemon juice, ginger-garlic ingredients, all spices & lemon juice except cream. Mix well and
paste & place it in refrigerator for 1 hr. In microwave safe glass press start. After done add cream, mix it well & serve hot.
bowl add butter, onion paste, chicken & cook. When beep add all 7-5 500-600 g Chicken - 500 g, Yogurt - 1 cup, Finely chopped mint
other ingredients, mix it well & cover it & press start. Garnish with Yogurt leaves - 1 tbsp., Corn flour - 1 tbsp.(mix in 2 tbsp.
chopped coriander. Chicken water), Oil - 2 tbsp., Chopped onion - 1 ea, Chopped
green chili - 2~3, Chopped ginger - 1 tbsp., Garam
Masala - 1 tsp., Dried fenugreek leaves - 1 tsp., Salt
as per your taste, Chopped coriander - 1 tbsp.
Instructions
In microwave safe glass bowl add oil, onion, green chili, ginger &
chicken, mix it well & cook. When beep add all other ingredients,
½ cup of water. Cover it and press start. Sprinkle chopped mint &
coriander leaves. Serve hot.
English - 34
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Serving Serving
Size Size
7-6 700-800 g Chicken - 500 g (cut into pieces of your choice), 7-8 700-800 g Chicken - 600 g (cut into pieces of your choice),
Green Chopped green chili - 3~4, Chopped coriander - Hyderabadi Ginger-garlic paste - each 1 tsp., Tomato puree -
Chicken ½ cup, Chopped mint - ¼ cup, Two sticks chopped Chicken ½ cup, Finely chopped onion - 2 ea, Finely Chopped
04 OVEN USE
celery, Chopped spring onion - 2 ea, Garlic paste - tomato - 2 ea, Oil - 4 tbsp., Water - 1 cup, Cream -
1 tsp., Ginger paste - 1 tsp., Cumin powder - 1 tsp., 4 tbsp., Salt as per taste, Chopped coriander leaves.
Oil - 3 tbsp., Salt - 1 tsp. For paste : Red chili - 4~5, Cashew nut - 10~12,
Instructions Magaj - 2 tbsp., Poppy seeds - 1 tbsp., Almond -
Grind together mint, coriander, celery, green chili to a paste. 7~8, Cloves - 4 ea, Cinnamon - 2 sticks, Cardamom
In microwave safe glass bowl take oil, green paste & all other - 2 ea, Make a fine paste of all these ingredients.
ingredients. Mix well and cook. When beep add ½ cup water, mix it Instructions
well and press start. Serve hot. In microwave safe glass bowl add oil, finely chopped onion, chicken
7-7 600-700 g Chicken - 400 g (cut into pieces of your choice), with given paste and cook. When beep add all other ingredients,
Kadhai Ginger-garlic paste - each 1 tsp., Tomato puree - water, mix it well and press start. Garnish with coriander leaves.
Chicken ½ cup, Red chili powder - ½ tsp., Coriander powder Serve hot.
- 1 tsp., Garam masala - 1 tsp., Sugar - 1 tsp., Two
large capsicum cut into strips, Corn flour - 2 tbsp.
8. Tandoori
(dissolve in 3 cups of water), Oil - 4 tbsp., Dried Serving
fenugreek leaves - 1 tsp.
Size
Instructions 8-1 600-700 g Prawns - 500 g, Chopped onion - 2 ea, Chopped
In microwave safe glass bowl take oil, ginger-garlic, onion, chicken, Roasted tomato - 2 ea, Oil - 2 tbsp., Red Chili powder - 1 tsp.,
red chili powder and cook. When beep add 3 cup water, all other Prawns Turmeric powder - ½ tsp., Ginger-garlic paste - each
ingredients, mix it well and press start. Garnish with coriander 1 tsp., Garam Masala - 1 tsp., Cumin powder - 1 tsp.,
leaves & serve hot. Coriander powder - 1 tsp., Chopped coriander leaves
- 2 tbsp.
Little water
Instructions
In microwave safe glass bowl add oil, finely chopped onion,
chopped tomato, ginger-garlic paste, red chili powder, turmeric
powder and cook. When beep add prawns, all other ingredients mix
it well, and press start. Garnish with coriander leaves. Serve hot.
(continued)
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Serving Serving
Size Size
8-2 500 g Fish (pomfert) - 400 g, Thick yogurt - ½ cup, Chat 8-5 400-450 g Boneless chicken - 300 g, Garlic paste - 1 tsp.,
Fish Tikka Masala - 1 tsp., Ginger-garlic paste - each 1 tsp., Chicken Anissed powder - 1 tsp., Dry mango powder - 1 tsp.,
Orange red colour - 1 pinch, Oil - 2 tbsp., Semolina Malai Kabab Red chili powder - 1 tsp., Cream - 4 tbsp., Oil - 2 tbsp.,
- 2 tbsp., Red chili powder - 1 tsp., Salt as per your Salt as per your taste, Coriander leaves - 1 tbsp.
taste, Coriander leaves - 2 tbsp. Instructions
Instructions Place chicken in a bowl. Add all the ingredients & mix well. Let it
Marinate fish slice with salt, thick yogurt, ginger-garlic paste, marinate for 2 hrs. at refrigerator. Place kebab on crusty plate at
orange-red colour, red chili powder, mix it well & keep it in high rack, put some oil around kebabs and cook. When beep, turn
refrigerator for ½ hr. Roll it in semolina. Put them on crusty plate at them over and press start. Garnish with coriander leaves. Serve hot.
high rack, put some oil around, and cook. When beep, turn them 8-6 350-400 g Boiled Kheema - 250 g, Boiled potato - 2 ea, Bread
over and press start. Garnish with coriander leaves. Serve hot. Chicken crumbs - 1 cup, Oil - 2 tbsp., Red chili powder -
8-3 400-500 g Surmai (Goanese fish) - 300 g (cut into pieces), Tamarind Kheema 1 tsp., Turmeric powder - 1 tsp., Ginger-garlic paste
Goanese Fish juice - 2 tbsp., Red chili powder - 1 tsp., Turmeric Cutlet - 1 tsp., Salt as per your taste, Garam Masala - 1 tsp.,
Kabab powder - ½ tsp., Cumin powder - ½ tsp., Coconut Coriander leaves - 2 tbsp.
oil - 1 tbsp., Rice flour - 1 tbsp., Chopped peppercorn - Instructions
1 tsp., Salt as per your taste, Coriander leaves - 1 tbsp. In bowl take chicken kheema, all other ingredients except oil & mix
Instructions well. Make cutlets. Put them on a metal tray, put some oil around
Place fish in a bowl. Add all the ingredients & mix well. Let it the cutlets. Keep this on crusty plate at high rack, put some oil
marinate for 1 hr. at refrigerator. Place kebab on crusty plate at high around the cutlets and cook. When beep, turn them over and press
rack, put some oil around kebabs and cook. When beep, turn them start. Garnish with coriander leaves. Serve hot.
over and press start. Garnish with coriander leaves. Serve hot. 8-7 400-500 g Boneless chicken - 400 g (cut into pieces), Dry mango
8-4 400-500 g Fish (pomfert) - 400 g (cut into pieces), Ginger- garlic Sesame powder - 1 tsp., Red chili powder - 1 tsp., Turmeric
Coconut Fish paste - each 1 tsp., Pepper powder - ½ tsp., Cumin Chicken powder - ½ tsp., Garam Masala - 1 tsp., Ginger-garlic
Kabab powder - ½ tsp., Lemon juice - 2 tbsp., Corn flour paste - 1 tsp. each, Coconut oil - 2 tbsp., Rice flour -
- 1 tsp., Powdered coconut (desiccated coconut) - 1 tbsp., Salt as per your taste, Sesame seeds - 4~5,
4 tbsp., Salt as per your taste Coriander leaves - 1 tbsp.
In a bowl add fish pieces & all other ingredients except coconut. In a bowl add chicken, all the other ingredients except sesame
Mix well, late it marinate for 2-3 hrs. at room temperature. Pick fish seeds and mix well, let marinate for 2 hrs. at room temperature. Lift
pieces one by one & roll into the coconut so that fully coated with one piece at a time, roll in sesame seed so that it is fully covered.
it. Place fish on crusty plate at high rack, put some oil around the Place fish on crusty plate at high rack , put some oil around chicken
kebabs and cook. When beep, turn them over and press start. and cook. When beep, turn them over and press start. Garnish with
Garnish with coriander leaves. Serve hot. coriander leaves. Serve hot.
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9. All Time Favorite
Serving Serving
Size Size
8-8 500-600 g Boneless Mutton - 500 g, Garlic paste - 1 tsp, Ginger 9-1 550-600 g Boneless chicken - 500 g, French beans - 18~20
Tandoori paste-1 tsp., Red chili powder - 1 tsp., Coriander, Chicken a'la (cut into 1 piece), Carrots - 2 (medium size, cut into
Mutton cumin powder - 1 tsp. each, Yogurt - 1 cup, Orange- Kiev 1 piece), Sticky celery - 2 (chopped), Capsicums - 2
04 OVEN USE
red colour - 1 pinch, Corn flour - 2 tbsp., Salt - to (cut into ¼" pieces), Milk - ½ cup, Maida - 2 tbsp.,
taste, Oil - 2 tbsp., Garnish with onion ring & lemon Pepper - 1 tsp., Mustard powder - 1 tsp., Salt - 1 tsp.,
pieces Grated cheese (Amul) - 4 tbsp.
In a bowl mix all ingredients except oil. Add mutton & mix well. Let it In microwave safe glass bowl mix chicken, carrots, celery, french
marinate for 2-3 hrs. in refrigerator. Place mutton on crusty plate at beans, 2-3 tbsp. water, cover it and cook. When beep add all
hogh rack in microwave, put some oil around and cook. ingredients and press start. Add grated cheese. Garnish with
When beep, turn them over and press start. Garnish with onion ring parsley or coriander.
& lemon pieces. Serve hot. 9-2 500-550 g Boneless chicken - 200 g (cut into bite size pieces),
8-9 450-500 g Surmai fillets - 300 g (cut into 2" pieces), Lemon juice Chicken & Mushrooms quartered (cut into 4 pieces each) -
Fish Tikka - 2 tbsp., Ginger-garlic paste - 1 tsp. each, Turmeric Mushroom 200 g, Oil or butter - 2 tbsp., Maida (flour) - 2 tbsp.,
Achari powder - ½ tsp., Kashmiri red chili powder - 2 tsp., Gratin Salt - 1 tsp., Pepper - 1 tsp., Rum or sherry (optional)
Mustard seed powder - 1 tsp., Onion seeds powder - 1 tsp., Cream - 100 g (½ cup), Water - ½ cup, some
- 1 tsp., Fenugreek seed powder - ½ tsp., Black salt - chopped celery or coriander leaves for garnishing,
½ tsp., Mustard oil - 2 tbsp., Yogurt whisked - 1 cup, grated cheese-4 tbsp.
Butter - 2 tbsp. Instructions
Instructions In microwave safe glass dish, add chicken, mushroom and all the
Place the fish in a bowl, add salt, lemon juice, ginger-garlic paste, ingredients except cheese and cook. When beep, spread grated
turmeric powder, chili powder, mustard seed powder, fenugreek cheese and put it on high rack and press start. Sprinkle chopped
seed powder, onion seed powder, mix it well & take it refrigerator celery or coriander and serve hot.
for 2 hrs. Arrange the fish pieces and brush the oil, put it on crusty (continued)
plate at high rack in microwave, put some oil around tikkas and
cook. When beep turn the pieces, apply little oil and press start.
Serve hot.
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Serving Serving
Size Size
9-3 500-550 g Keema - 500 g (Meanced meat), Curd - ¾ cup, 9-5 350-400 g Keema - 200 g, Basmati Rice - 1 cup, Ghee - 4 tbsp,
Meat Loaf 2 eggs, Garlic paste - 1 tsp., Ginger paste - 1 tsp., Keema Pulav Cloves - 5 laung, Green cardamoms (broken) - 4,
Garam masala powder - 1 tsp., Lemon juice - 2 tbsp., Ginger paste - 1 tbsp., Cinnamon - 1" piece, Bay leaf
Chopped coriander leaves - 2 tbsp., Salt - 1 tsp., - 1, Onion - 1 (sliced thinly), Red chili powder - 1 tsp.,
Pepper - 1 tsp.(adjust to taste), Bread slices - 3 pieces Salt - 1 tsp., Garam masala - 1 tsp.
(soaked in water, squeezed & crumbled) Instructions
For sauce : Maida - 1 tsp., Mustard powder - ½ tsp., In microwave safe glass bowl mix ghee, laung, dalchini, bay leaf,
Worcestershire sauce - 1 tbsp., Tomato sauce - cardmoms, rice, onion and cook. When beep, add keema, rice,
1 tbsp., Chili sauce - 1 tbsp. water, mix it well and press start. Serve hot.
Instructions 9-6 400-450 g Boneless Chicken - 500 g, Pineapple juice - ½ cup,
Mix all ingredients given under loaf. Grease the dish & put keema Chicken with Baby corns (cut into lengthwise) - 3~4, Broccoli/
in it and cook. To the juices, add all ingredients given under sauce. Sweet & Sour cauliflower - 4~5, Mushrooms - 3~4 (cut into pieces),
When beep, pour the sauce on a loaf and put it on crusty plate Vegetables Slices of pineapple - 2 ea, Small capsicum - 1 ea (cut
at high rack, and press start. Serve with sauce & decorate with into pieces), Red chili paste - ½ tsp., Crushed garlic
coriander. - 1½ tsp., Spring onion white - 2-3 (cut into slices),
9-4 900 g For green paste : Green chillies - 6~8, Spring onions Tomato ketchup - ¼ cup, Vinegar - 3 tbsp., Ajinomoto
Thai Chicken - 3 ea (chopped along with the green part) , Lemon - ¼ tsp., Sugar - 4 tsp., Soya sauce - 1 tsp., Salt to
grass leaves - 4(optional), Ginger - 2" piece, Coriander taste, Stock cube - 1 crushed, Corn flour - 4 tbsp.
leaves - 3 tbsp. (mixed in ¼ cup of water)
For main dish : Boneless chicken - 700~800 g (cut Instructions
into pieces), Coconut milk - 1½ cups, Salt - 1½ tsp., In microwave safe glass bowl add 1 ½ cups water, pineapple juice,
Jaggery - a tiny piece, Coriander powder - 1 tbsp., baby corn, florets, mushrooms and cook. When beep add chicken,
Cumin powder - 1 tbsp., Oil - 2 tbsp. all other ingredients. Mix it well and press start. Serve hot.
Instructions
In grinder prepare green paste. Churn grated one coconut in mixer.
In microwave safe glass bowl add chicken, oil and cook. When
beep, add salt jaggery and coconut milk. Mix well and press start.
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Serving Serving
Size Size
9-7 500-550 g Boneless chicken - 400 g, Kashmiri red chili - 4~5 dry, 9-9 550-600 g Boneless chicken - 150 g, Soaked rice - 1 cup,
Chicken in Onion - ½, Garlic - 8~10 flakes, Chopped ginger - Chicken with Sprouted green gram - ½ cup, Finely chopped carrot
Thai Red 1 tsp., Lemon grass - 1 , Coriander seeds - 1½ tsp., Tomato Rice - ½ cup, Finely chopped French beans - ½ cup, Oil -
Curry Cumin seeds - 1 tsp., Saboot kali mirch - 6, Soya 2 tbsp., Peanuts - 3 tbsp., Cumin - ½ tsp., Slices of
04 OVEN USE
sauce - ½ tsp., Lemon juice - 1 tbsp., Salt & sugar Onion - 1 small, Tomato puree - 4 tbsp., Tomatoes -
- each 1 tsp., Baby corns - 4~5, Small carrot - 1 ea, 2 ea, Turmeric - 1 pinch, Garlic paste - ½ tsp., Garam
Cauliflower - ½ cup, Mushrooms - 2 ea, Basil leaves - Masala - ½ tsp, Salt - 1 tsp.
8~10, Coconut milk - 2 cups Instructions
Instructions In microwave safe glass bowl take oil, add soaked rice, chicken,
Make fine paste of red chili, water. In microwave safe glass bowl onion, sprouted green gram and cook. When beep add all other
add oil, red curry paste, onion, ginger-garlic paste and cook. When ingredients, 3 cups of water and press start. Serve hot.
beep add coconut milk, all vegetables, all other ingredients with 9-10 450-500 g Chicken - 250 g, Beat in Egg - 1 ea, Salt - ¼ tsp.,
chicken and press start. Add salt, sugar, add basil leaves. Serve hot Crispy Red chili powder - ¼ tsp., Bread crumbs - ½ cup,
with steamed rice. Chicken Oil - 1-2 tbsp.
9-8 500-550 g Boneless chicken - 250 g, Capsicum - 1 ea (cut into For Marinade : Butter - 2 tbsp., Garlic paste - 2 tsp.,
Chicken in pieces), Oil - 3 tbsp., Garlic - 1 tbsp.(chopped), Dry Chili powder - 1 ½ tsp., Cumin seeds powder - 1 tsp.,
Hot Garlic red chili - 1 ea (cut into thin slices), Red chili paste - Coriander powder - 2 tsp., Cinnamon - 1 tsp., Salt -
Sauce 1 tsp., Spring onion - 1 ea, Tomato ketchup - 3 tbsp., 1½ tsp.
Red chili sauce - 1 tbsp., Soya sauce - 2 tsp., Vinegar Instructions
- 1 tbsp., Pepper - ½ tsp., Sugar - ½ tsp., Corn flour - Marinated chicken with all marinade ingredients & put it in
4 tbsp. (dissolve in ½ cup of water) refrigerator for 1 hr. Roll out the marinated chicken in bread crumbs
Instructions and place them over crusty plate, grease them with a little oil and
In microwave safe glass bowl put chicken, capsicum, oil, chopped put the crusty plate on high rack and press start. Serve hot.
ginger-garlic, ½ cup of water and cook. When beep add all other
ingredients, ¼ cup of water, cover it and press start.
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0. Indian Famous Variety
Serving Serving
Size Size
0-1 200-250 g Refine flour - 200 g, Curd - 2 tbsp, yeast- 1 tsp, 0-3 800-900 g Boneless Mutton - 600 g, Cashewnuts - ½ cup, Green
Naan Badami sugar- 1 pinch, blanched & sliced almonds- 1 tsp, Mutton chillies - 2~3, Fresh coriander leaves - 1 few springs,
oil - 1 tsp, luke warm water - enough to make dough, Mirchi Yogurt - 1 cup, Ginger-garlic paste - 2 tsps., Red chilli
salt as per taste powder - 1 tsp., Coriander powder - 2 tsp., Salt to
Instructions taste, Oil - 2 tbsp., Bay leaf - 1, Cloves - 4~5, Green
In a small bowl add yeast, 2 tbsp. luke warm water, sugar and cardamoms - 4~5, Garam masala powder - 1 tsp,
½ tsp. oil, keep aside for 20 min. After 20 min in a bowl add all the White pepper powder - ¼ tsp., Fresh cream - ⅓ cup
ingredients and yeast except almonds. Make a dough and keep Instructions
aside for 2 to 3 hours to double its size. Preheat microwave at Make a paste of green chili, coriander and spring onion. In microwave
200 °C along with crusty plate on low rack. Divide the dough into 6 safe glass bowl add oil, boneless mutton, green paste, ½ cup of
equal portions. Roll out each ball into oval shape naan and spread water and cook. When beep add all other ingredients and press strat.
blanched almonds. Put it on crusty plate on low rack and cook on 0-4 700-750 g Prawns - 500 g, Ginger-garlic - each 1 tsp., Cumin
combination mode (micro 300w + convection200 °C) for 4 minutes Bombay seeds - 1 tsp., Red chilies whole - 12~15, Cloves -
after beep cook again at convection mode at 200 °C for 5 min. Prawn 7~8, Cinnamon - 2 inch stick, Mustard seeds - 1 tsp.,
Brush up with oil or ghee and serve hot. Vinegar - 4 tbsp., Chopped Onions - 2 medium size,
0-2 500-550 g Mutton - 250 g, Spaghetti - 100 g, Oil - 2 tbsp., Green Chopped tomato - 4 medium size, Oil - ½ cup, Sugar
Mutton capsicum - 1 small sized, Red capsicum - 1 small - 2 tbsp., Salt to taste
Tetrazini sized, Yellow capsicum - 1 small sized, Mushrooms - Instructions
4~5, Onion - 1 large sized, Garlic - 5-6 cloves, Basil In microwave safe glass bowl take oil, chopped onion, chopped
Leaves - 5~6, Tomatoes - 4 medium size, Olive oil - tomato, cumin seeds, ginger-garlic paste, cloves, cinnamon, cumin
4 tbsp., Pepper powder - ½ tsp., Salt to taste, Grated seeds, mustard seeds, chili, prawns and cook. When beep add
Cheese - ⅓ cup vinegar, salt, sugar, mix it well and press start. Serve hot.
Instructions 0-5 650-700 g Boneless Chicken - 500 g (cut into pieces), Dry red
In microwave safe bowl mix oil, salt, mutton, 1 cup of water, cover it Chicken chilies - 6~7, Vinegar - 3 tbsp., Chopped Onion -
and cook. When beep add chopped capsicum, mushroom, onion, Vindaloo 2 ea, Garlic & ginger paste - each 1 tsp., Tomato
garlic, basil, tomato, pepper powder, salt, grated cheese and press puree - ¼ cup, Potato - 1 ea, Oil - 3 tbsp., Stick
start. Serve hot. cinnamon - 2", Cumin powder - 1 tsp., Turmeric
powder - ½ tsp., Salt - 1 ½ tsp., Water - ½ cup
Instructions
In microwave safe glass bowl take oil, stick cinnamon, turmeric
powder, garlic-ginger paste, chopped onion, chicken and cook.
When beep add potato, tomato puree, cumin powder & half cup of
water. Mix it well and press start. Serve hot.
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Serving Serving
Size Size
0-6 600-650 g Chicken - 400 g (cut into 8 pieces) 0-8 350-400 g Chicken - 100 g (cut into 2-3 pieces), Water - 4 cups,
Dum Chicken Marinade : Thick yogurt - ½ cup, Almonds - 8~10 Chicken Hot Salt as per your taste.
Kali Mirch (ground to powder), Ginger-garlic paste - 1 tbsp., & Sour Soup Other ingredients : Oil - 1 tbsp., Crushed garlic
04 OVEN USE
Oil - 1 tbsp., Red chili powder - ½ tsp., Salt - ¾ tsp., -¾ tsp., Red chili paste - ½ tsp., Chopped cabbage
Garama masala powder - ½ tsp. - 2 tbsp., Grated carrot - 2 tbsp., 1 Chicken soup
Other ingredients : Oil - 3 tbsp., Peppercorns - ½ tsp., cubes crushed, Sugar - 1 tsp., Pepper - ¼ tsp. Soya
Onion paste - 2 ea, Coriander powder - 1 tsp. sauce - ½ tsp., Tomato ketchup - 1 tbsp., White
Instructions vinegar - 1 tbsp., Corn flour (dissolve ¼ cup of water)
In microwave safe glass bowl take oil, chicken & marinated - 4 tbsp.
ingredients. Mix it well & keep it in refrigerator for 1 hr. and cook. Instructions
When beep mix it well and press start. Serve hot. In microwave safe glass bowl take chicken, water, salt and cook.
0-7 550-600 g Drumsticks - 5 (500 g chicken legs) When beep add all other ingredients and press start. Serve hot.
Badami First marinade : Lemon juice - 2 tbsp., Oil - 1 tbsp., 0-9 450-500 g Prawns - 200 g, Red chili paste - 2 tbsp., Tomato
Tangri Salt - ½ tsp., Red chili powder - ½ tsp. Schezwan sauce - 4 tbsp., Soya sauce - 1 tbsp., Ajinomoto -
Second Marinade : Yogurt - ½ cup, Oil - 2 tbsp., Prawns ¼ tsp., Sugar - 2 tsp., Salt as per your taste, Water -
Ginger-garlic paste - 2 tbsp., Almonds ground to 1 cup, Oil - 2 tbsp., Pepper powder - ¼ tsp., 1" ginger
powder - 8~10, Thick cream - ¼ cup, Corn flour - chopped, Garlic - 5~6 (chopped), Green chili - 1 tsp.,
1 tbsp., Salt - ¾ tsp., Chopped coriander - 2 tbsp., Spring onion - 2 tbsp. (chopped), Water - ½ cup,
Dry fenugreek leaves - 2 tsp. Corn flour - 2 tbsp. (dissolve in 1 cup water), Vinegar
Instructions - 1 tbsp.
In microwave safe glass bowl take drum stick & add 1st marinade Instructions
material, mix it well & keep it in refrigerator for 1 hr. After 1 hr. take In microwave safe glass bowl take prawns, ginger, garlic, green
2nd marinatde & keep it in refrigerator for 1 hr. Arrange drum stick chili, water and cook. When beep add all other ingredients. Mix it
in metal tray. Apply little oil & place it on crusty plate at high rack, well and press start.
put some oil around, and cook. When beep turn it and press start.
Serve hot.
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Using the curd/dough proof features
The 5 Curd/Dough Proof features provide pre-programmed cooking times. The following table presents how to use the auto programmes for rising yeast dough or
You do not need to set either the cooking times or the power level. curd.
You can adjust the Curd / Dough Proof category by pressing the Up or Down button
1. Curd
after press the Curd/Dough Proof button.
First, place the food in the centre of the turntable and close the door. Code/Food Serving Size Instructions
1-1 500 g Distribute 150 g curd into 5 ceramic cups or small
1. Press the Curd/Dough Proof button. glass jars evenly (30 g each). Add 100 ml milk into
Large Glass
Bowl each cup. Use long-life milk (room-temperature;
3,5 % fat). Cover each with cling film and set in a
2. Select the type of food that you are cooking by Up or Down circle on turntable. After finish, keep 6 hours in a
button. No.1 is Curd and No.2 is Dough Proof. You have refrigerator.
to choose the number that you want to use for cooking For the first time we recommend to use dried yoghurt
by pressing the Up or Down button. Refer to the table bacteria ferment.
on the following page for a description of the various pre- 1-2 500 g Mix 150 g curd with 500 ml long-life milk (room-
programmed settings. At that time, press the Select button Clay Pots temperature; 3,5 % fat). Pour evenly into large glass
to select the type of food. bowl. Cover with cling film and set on turntable. After
finish, keep 6 hours in a refrigerator.
3. Select the food by pressing the Up or Down button.
For the first time we recommend to use dried yoghurt
bacteria ferment.
2. Dough Proof
Code/Food Serving Size Instructions
2-1 300-500 g Put dough in suitable sized bowl and set on the low
Turntable is not operating during curd cooking. Pizza Dough rack. Cover with aluminium foil.
Cake Dough rack. Cover with aluminium foil.
Bread Dough rack. Cover with aluminium foil.
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Using the power defrost features
The 5 Power Defrost features enables you to defrost meat, poultry, fish, bread, cake The following table presents the various Power Defrost programmes, quantities and
and fruit. The defrost time and power level are set automatically. appropriate instructions. Remove all kind of package material before defrosting.
You simply select the programme and the weight. Place meat, poultry and fish on a flat glass plate or on a ceramic plate, arrange bread,
Use only containers that are microwave-safe. cake and fruit on kitchen paper.
Open the door. Place the frozen food on a ceramic in the centre of the turntable. Close Code/Food Serving Size Instructions
04 OVEN USE
the door. 1 200-1500 g Shield the edges with aluminium foil. Turn the meat
1. Press the Power Defrost button. Meat over, when the oven beeps. This programme is
suitable for lamb, pork, steaks, chops, minced
meat. Stand for 20-90 minutes.
2 200-1500 g Shield the leg and wing tips with aluminium foil.
2. Select the type of food that you are cooking by pressing Poultry Turn the poultry over, when the oven beeps. This
the Up or Down button. Refer to the table on the following programme is suitable for whole chicken as well as
page for a description of the various pre-programmed for chicken portions. Stand for 20-90 minutes.
settings. At that time, press the Select button to select the
3 200-1500 g Shield the tail of a whole fish with aluminium foil.
type of food.
Fish Turn the fish over, when the oven beeps. This
3. Select the size of the serving by pressing the Up or Down programme is suitable for whole fishes as well as for
button. fish fillets. Stand for 20-80 minutes.
4 125-1000 g Put bread horizontally on a piece of kitchen paper
4. Press the START/+30s button. Bread/Cake and turn over, as soon as the oven beeps. Place
Result: cake on a ceramic plate and if possible, turn over,
• Defrosting begins. as soon as the oven beeps. (Oven keeps operating
• The oven beeps through defrosting to and is stopped, when you open the door.)
remind you to turn the food over. (except This programme is suitable for all kinds of bread,
fruit) sliced or whole, as well as for bread rolls and
baguettes. Arrange bread rolls in a circle.
5. If oven will beep and operate stop, must turn the food over This programme is suitable for all kinds of yeast
(ex: Meat, Poultry, Fish). And press the START/+30s button cake, biscuit, cheese cake and puff pastry. It is not
again to finish defrosting. suitable for short/crust pastry, fruit and cream cakes
Result: When cooking has finished, the oven will beep as well as for cake with chocolate topping.
and flash “End” 4 times. The oven will then beep Stand for 10-60 minutes.
one time per minute.
5 100-600 g Spread fruits evenly into a flat glass dish.
Fruit This programme is suitable for all kind of fruits.
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Using the roti/naan features
The 2 Roti/Naan features provide pre-programmed cooking times. You do not need to
Serving
set either the cooking times or the power level. Code/Food Ingredients
Size
Use only recipients that are microwave-safe.
1 8 pieces Whole wheat flour - 4 cups, Water as required for
Open the door. Place the food in the centre of the turntable. Close the door. Roti dough, Ghee - 50 g, Salt to taste
Instructions
1. Press the Roti/Naan button.
Preheat oven and crusty plate with high rack. In a bowl add flour, C
salt and ghee. Kneadwith sufficient water and make smooth dough. r
Cover and leave for ½ hour. Divide into 8 equal balls, roll out with the
2. Press the Up or Down button to select cook category. help of a rolling pin and make rotis. When beep, apply a little water
at one side of roti and place that side down on the crusty plate and
cook. Serve hot with butter. Repeat the same process until all the
naan has been prepared.
Result: The food is cooked according to the pre- 2 8 pieces All-purpose flour - 4 cups, Sugar - 1 tbsp., Hot water
programmed setting selected. Naan (but not boiling, just hot tap water) - ¼ cup, Active dry
• When cooking has finished, the oven will yeast - ¾ tsp., Warm milk - ¾ cup, Melted butter for
beep and flash “End” 4 times. brushing (may use olive oil), Fresh garlic or other herbs
The oven will then beep one time per minute. for topping
Preheat oven and crusty plate with high rack. Combine the warm
water with the sugar and yeast. Let sit for 10 minutes until foamy.
It should smell like bread. In a bowl add the flour, warm milk and
yeast mixture. Mix with a wooden spoon until dough starts to come
together and then finish mixing the dough with your hands until a
smooth but still sticky ball forms. Cover the dough with a damp towel
or plastic wrap and let sit in a warm place for 2 to 3 hour. After 2
to 3 hours dough will be double to its size, punch the dough down
and divide into eight equal balls. Using a rolling-pin, roll each piece
of dough into an oval shape. The dough should be about 6-8 inches
long and about ¼-inch thick, but no thinner. Repeat this method with
the rest of the dough. When beep, place the dough on the hot crusty
plate and cook. Take out cooked naan after 4 min. Serve hot with
butter. Repeat the same process until all the naan has been prepared.
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Convection Grilling
The convection mode enables you to cook food in the same way as in a traditional oven. The grill enables you to heat and brown food quickly, without using microwaves.
The microwave mode is not used. You can set the temperature, as required, in a range • Always use oven gloves when touching the recipients in the oven, as they will be
varying from 40 °C to 200 °C. The maximum cooking time is 60 minutes. very hot.
• Always use oven gloves when touching the recipients in the oven, as they will be • You can get better cooking and grilling results, if you use the high rack.
very hot.
1. Open the door and place the food on the rack.
04 OVEN USE
• You can get better cooking and browning, if you use the low rack.
Check that the heating element is in the horizontal position. Open the door and place the
recipient on the low rack and set on turntable.
1. Press the Convection button. 2. Press the Grill button.

Result: The following indications are displayed: Result: The following indications are displayed:
(convection mode) (grill mode)
180 °C (temperature) • You cannot set the temperature of the grill.
3. Set the grilling time by pressing the Up or Down button.
2. Set the temperature by pressing the Up or Down button.
• The maximum grilling time is 60 minutes.
(Temperature : 40~200 °C, 10 °C interval)
• If don't set the temperature within 5 seconds,
Automatically changes to the cooking time setting stage. 4. Press the START/+30s button.
3. Press the Select button. Result: Grilling starts.
4. Set the cooking time by pressing the Up or Down button.
(If you want to preheat the oven, omit this step.)

Result: Cooking starts.
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Combining microwave and grill Combining microwave and convection
You can also combine microwave cooking with the grill, to cook quickly and brown at the Combination cooking uses both microwave energy and convection heating. No
same time. preheating is required as the microwave energy is immediately available.
ALWAYS use microwave-safe and oven-proof cookware. Glass or ceramic dishes Many foods can be cooked in combination mode, particularly:
are ideal as they allow the microwaves to penetrate the food evenly. • Roast meats and poultry
ALWAYS use oven gloves when touching the recipients in the oven, as they will be • Pies and cakes
very hot. • Egg and cheese dishes
You can improve cooking and grilling, if you use the high rack. ALWAYS use microwave-safe and oven-proof cookware. Glass or ceramic dishes
Open the door. Place the food on the rack best suited to the type of food to be cooked. are ideal as they allow the microwaves to penetrate the food evenly.
Place the rack on the turntable. Close the door. ALWAYS use oven gloves when touching the recipients in the oven, as they will be
very hot.
1. Press the Combi button. You can get better cooking and browning, if you use the low rack.
Result: The following indications are displayed:
Open the door. Place the food on the turntable or on the low rack which should then be
Cb - 1 (Microwave + Grill)
placed on the turntable. Close the door. The heating element must be in the horizontal
2. Make the display indicating Cb - 1 by pressing the Up or position.
Down button, and then press the Select button.
Result: The following indications are displayed: 1. Press the Combi button.
Result: The following indications are displayed:
(microwave & grill combi mode)
600 W (output power)
2. Make the display indicating Cb - 2 by pressing the Up or
3. Select the appropriate power level by pressing the Up Down button, and then press the Select button.
or Down button until the corresponding output power is Result: The following indications are displayed:
displayed (600, 450, 300 W). At that time, press the Select
button to set the power level. (microwave & convection combi
• You cannot set the temperature of the grill. mode)
• If don't set the power level within 5 seconds, 600 W (output power)
Automatically changes to the cooking time setting stage. 3. Select the appropriate power level by pressing the Up
4. Set the cooking time by pressing the Up or Down button. or Down button until the corresponding output power is
• The maximum cooking time is 60 minutes. displayed (600, 450, 300, 180, 100 W). At that time, press
the Select button to set the power level.
• If don't set the power level within 5 seconds,
Automatically changes to the cooking time setting stage.
Result:
(Default: 180 °C )
• Combination cooking starts.
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Choosing the accessories
4. Select the appropriate temperature by pressing the Up or Traditional convection cooking does require cookware. You
Down button. (Temperature : 200~40 °C) At that time, press should, however, use only cookware that you would use in your
the Select button to set the temperature. normal oven.
• If don't set the temperature within 5 seconds, Microwave-safe containers are not usually suitable for
Automatically changes to the cooking time setting stage. convection cooking; don’t use plastic containers, dishes, paper
04 OVEN USE
5. Set the cooking time by pressing the Up or Down button. cups, towels, etc.
• The maximum cooking time is 60 minutes. If you wish to select a combined cooking mode (microwave and grill or convection), use
only recipients that are microwave-safe and oven-proof.
6. Press the START/+30s button. For further details on suitable cookware and utensils, refer to the Cookware Guide
Result: on page 51.
• Combination cooking starts.
• The oven is heated to the required Using the child lock features
temperature and then microwave cooking
continues until the cooking time is over. Your microwave oven is fitted with a special child lock programme, which enables
• When cooking has finished, the oven will the oven to be “locked” so that children or anyone unfamiliar with it cannot operate it
beep and flash “End” 4 times. The oven will accidentally.
then beep one time per minute. 1. Press the Up and Down button at the same time.
(One second)
Result :
• The oven is locked (no functions can be
selected).
• The display shows “L”.
2. To unlock the oven, press the Up and Down button at the

same time. (One second)
Result : The oven can be used normally.
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Using the manual crusty cook function
Normally when cooking in microwave oven, using grill or microwave mode in grill/
8. Select the cooking time by press Up and Down button until
convection ovens, foods like pastries and pizza become soggy from button side. Using
the appropriate cooking time is displayed.
the Samsung Crusty plate helps to gain a crispy cookde result of your food.
The crusty plate can also be used for bacon, eggs, sausages, etc.
or Result: Cooking starts.
beep and flash “End” four times. The oven
Crusty plate Low rack High rack will then beep one time per minute.
1. Preheat the crusty plate, as described above. Before using the crusty plate, preheat it by selecting the combination mode for 3 to
5 minutes:
2. Brush the plate with oil if you are cooking food, such as
bacon and eggs, in order to brown the food nicely. • Combination of convection (200 ºC) and microwaves. (600 W power level)
• Combination of grill and microwaves. (600 W power level)
3. Place the food on the crusty plate.
Use oven gloves at all times as the crusty plate will become very hot.
4. Place the crusty plate on the metal rack (or turntable) in the
microwave. Please note that the crusty plate has a teflon layer which is not scratch-resistant. Do
5. Press the Combi Button. Select the combi mode by not use any sharp objects like a knife to cut on the crusty plate.
pressing Up and Down button. After then Press the Select
Use plastic accessories to avoid scratches on the surface of the crusty plate or
button.
remove the food from the plate before cutting.
Cb - 2 (Microwave + Convection) Do not place any recipients on the crusty plate that are not heat-resistant (plastic
bowls for example).
6. Select the appropriate power level by pressing the Up or
Down button until the appropriate output power. At that Never place the crusty plate in the oven without the turntable.
time, press the Select button to set the power level.
• If don't set the power level within 5 seconds, How to clean the Crusty Plate
Automatically changes to the cooking time setting stage. Clean the crusty plate with warm water and detergent and rinse off with clean water.
7. If use the MW+Convection mode, select the appropriate Do not use a scrubbing brush or a hard sponge otherwise the top layer will be
temperature by pressing the Up and Down button. At that damaged.
time, press the Select button to set temperature.
• If don't set the power level within 5 seconds, Please note
Automatically changes to the cooking time setting stage. The crusty plate is not dishwasher-safe.
(Default: 180 °C )
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Spit-roasting
The barbecue spit is useful for grilling, as you do not need to turn the meat over. It can be 5. Select the appropriate temperature by pressing the Up or
used for combined microwave and Convection cooking. Down button. (Temperature : 200~40 °C) At that time, press
Make sure that the weight of the meat is evenly distributed on the spit and that the the Select button to set the temperature.
spit rotates evenly. • If don't set the temperature within 5 seconds,
Always use oven gloves when touching the recipients in the oven, as they will be Automatically changes to the cooking time setting stage.
04 OVEN USE
very hot. 6. Set the cooking time by pressing the Up or Down button.
1. Push the roasting spit through the centre of the meat. • The maximum cooking time is 60 minutes.
Example: Push the spit between the backbone and breast
of a chicken. 7. Press the START/+30s button.
Place the spit on its upright on the glass bowl Result:
the glass bowl and the glass bowl onto the • Combination cooking starts.
turntable. To help brown the meat, brush it with • The oven is heated to the required
spices and oil. temperature and then microwave cooking
2. Press the Combi button. continues until the cooking time is over.
Result: The following indications are displayed: • When cooking has finished, the oven will
Cb - 1 (Microwave + Grill) beep and flash “End” 4 times. The oven will
3. Make the display indicating Cb - 2 by pressing the Up or • When the meat has been fully cooked,
Down button, and then press the Select button. carefully remove the spit, using oven gloves
Result: The following indications are displayed: to protect your hands.
(microwave & convection combi
mode)
600 W (output power)
4. Select the appropriate power level by pressing the Up

or Down button until the corresponding output power is
displayed (600, 450, 300, 180, 100 W). At that time, press
the Select button to set the power level.
• If don't set the power level within 5 seconds,
Automatically changes to the cooking time setting stage.
(Default: 180 °C )
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Using the vertical multi-spit Using the deodorisation features
Use the feature after cooking odorous food or when there is a lot of smoke in the oven
MULTI-SPIT FOR KEBAB interior. First clean the oven interior.
Using the multi-spit with 6 kebab skewers you can easily barbecue meat, poultry, fish,
1. Press the Deodorisation button than it will start
vegetables (like onions, peppers or courgettes) and fruit which have been cut into pieces.
automatically, after you have finished cleaning.
You can prepare the above food with the kebab skewers by using convection or
combination mode.
The deodorisation time has been specified as 5 minutes.
You can also adjust Deodorisation time by pressing the START/+30s button.
The maximum deodorisation time is 15 minutes.
Coupler Kebab,
Multi-Spit Barbecue Spit Glass Bowl
Skewer
Switching the beeper off
USE OF THE MULTI-SPIT WITH KEBAB SKEWERS You can switch the beeper off whenever you want.
1. Press the START/+30s and STOP/ECO button at the same
1. For preparing kebabs with the multi-spit use the 6 skewers.
time. (One second)
2. Put the same amount of food on each skewer. Result: The oven does not beep to indicate the end of a
3. Place the roasting-spit into the glass bowl and insert the multi-spit into it. function.
4. Put the glass bowl with the multi-spit in the centre of the turntable. 2. To switch the beeper back on, press the START/+30s and
STOP/ECO buttons again at the same time. (One second)
Make sure that the grill heating element is in the right position at the back wall of the Result: The oven operates normally.
cavity and not at the top before starting the grilling process.
REMOVING THE MULTI-SPIT FROM THE OVEN AFTER

GRILLING
1. Use oven gloves for taking for glass bowl with the multi-spit out of the oven,
because it will be very hot.
2. Remove multi-spit out of the spit stand by using oven gloves as well.
3. Carefully remove the skewers and use a fork for removing the food pieces from the
skewers.
The multi--is not suitable for cleaning in the dishwasher. Therefore clean it with warm
water and washing up liquid by hand. Remove the vertical multi-spit from the oven,
after use.
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cookware guide
To cook food in the microwave oven, the microwaves must be able to penetrate the food,
Cookware Microwave-safe Comments
without being reflected or absorbed by the dish used.
Care must therefore be taken when choosing the cookware. If the cookware is marked Glassware
microwave-safe, you do not need to worry. • Oven-to-tableware ✓ Can be used, unless decorated with
The following table lists various types of cookware and indicates whether and how they a metal trim.
05 COOKWARE GUIDE
should be used in a microwave oven. • Fine glassware ✓ Can be used to warm foods or
liquids. Delicate glass may break or
Cookware Microwave-safe Comments crack if heated suddenly.
Aluminum foil ✓✗ Can be used in small quantities to • Glass jars ✓ Must remove the lid. Suitable for
protect areas against overcooking. warming only.
Arcing can occur if the foil is too
Metal
close to the oven wall or if too much
foil is used. • Dishes ✗ May cause arcing or fire.
Crust plate ✓ Do not preheat for more than • Freezer bag twist ✗
8 minutes. ties
China and ✓ Porcelain, pottery, glazed Paper
earthenware earthenware and bone china are • Plates, cups, ✓ For short cooking times and
usually suitable, unless decorated napkins and kitchen warming. Also to absorb excess
with a metal trim. paper moisture.
Disposable ✓ Some frozen foods are packaged in • Recycled paper ✗ May cause arcing.
polyester cardboard these dishes. Plastic
dishes • Containers ✓ Particularly if heat-resistant
Fast-food packaging thermoplastic. Some other plastics
• Polystyrene cups ✓ Can be used to warm food. may warp or discolour at high
containers Overheating may cause the temperatures. Do not use Melamine
polystyrene to melt. plastic.
• Paper bags or ✗ May catch fire. • Cling film ✓ Can be used to retain moisture.
newspaper Should not touch the food. Take care
when removing the film as hot steam
• Recycled paper or ✗ May cause arcing.
will escape.
metal trims
• Freezer bags ✓✗ Only if boilable or oven-proof. Should
not be airtight. Prick with a fork, if
necessary.
Wax or grease-proof ✓ Can be used to retain moisture and
paper prevent spattering.
✓ : Recommended ✓✗ : Use caution ✗ : Unsafe

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cooking guide Cooking Guide for frozen vegetables
Use a suitable glass pyrex bowl with lid. Cook covered for the minimum time – see table.
MICROWAVES Continue cooking to get the result you prefer.
Stir twice during cooking and once after cooking. Add salt, herbs or butter after cooking.
Microwave energy actually penetrates food, attracted and absorbed by its water, fat and
Cover during standing time.
sugar content.
The microwaves cause the molecules in the food to move rapidly. The rapid movement of Food Serving Size Power Time (min.)
these molecules creates friction and the resulting heat cooks the food.
Spinach 150 g 600 W 5-6
COOKING Instructions
Add 15 ml (1 tbsp.) cold water. Serve after 2-3 minutes standing.
Cookware for microwave cooking:
Broccoli 300 g 600 W 8-9
Cookware must allow microwave energy to pass through it for maximum efficiency.
Microwaves are reflected by metal, such as stainless steel, aluminium and copper, but Instructions
they can penetrate through ceramic, glass, porcelain and plastic as well as paper and Add 30 ml (2 tbsp.) cold water. Serve after 2-3 minutes standing.
wood. So food must never be cooked in metal containers. Peas 300 g 600 W 7-8
Food suitable for microwave cooking: Instructions
Many kinds of food are suitable for microwave cooking, including fresh or frozen Add 15 ml (1 tbsp.) cold water. Serve after 2-3 minutes standing.
vegetables, fruit, pasta, rice, grains, beans, fish, and meat. Sauces, custard, soups, Green Beans 300 g 600 W 7½-8½
steamed puddings, preserves, and chutneys can also be cooked in a microwave oven. Instructions
Generally speaking, microwave cooking is ideal for any food that would normally be Add 30 ml (2 tbsp.) cold water. Serve after 2-3 minutes standing.
prepared on a hob. Melting butter or chocolate, for example (see the chapter with tips, Mixed 300 g 600 W 7-8
techniques and hints). Vegetables Instructions
Covering during cooking (Carrots/Peas/ Add 15 ml (1 tbsp.) cold water. Serve after 2-3 minutes standing.
To cover the food during cooking is very important, as the evaporated water rises as Corn)
steam and contributes to cooking process. Food can be covered in different ways: e.g.
Mixed 300 g 600 W 7½-8½
with a ceramic plate, plastic cover or microwave suitable cling film.
Vegetables Instructions
Standing times (Chinese style) Add 15 ml (1 tbsp.) cold water. Serve after 2-3 minutes standing.
After cooking is over food the standing time is important to allow the temperature to even
out within the food.
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Cooking Guide for fresh vegetables
Use a suitable glass pyrex bowl with lid. Add 30-45 ml cold water (2-3 tbsp.) for every
Food Serving Size Power Time (min.)
250 g unless another water quantity is recommended – see table. Cook covered for the
minimum time – see table. Continue cooking to get the result you prefer. Stir once during Leeks 250 g 900 W 4-4½
and once after cooking. Add salt, herbs or butter after cooking. Cover during a standing Instructions
time of 3 minutes. Cut leeks into thick slices. Serve after 3 minutes standing.
Hint: Cut the fresh vegetables into even sized pieces. The smaller they are cut,
06 COOKING GUIDE
Mushrooms 125 g 900 W 1½-2
the quicker they will cook. 250 g 2½-3
Food Serving Size Power Time (min.) Instructions
Prepare small whole or sliced mushrooms. Do not add any water.
Broccoli 250 g 900 W 4½-5
Sprinkle with lemon juice. Spice with salt and pepper. Drain before
500 g 7-8
serving. Serve after 3 minutes standing.
Instructions
Prepare even sized florets. Arrange the stems to the centre. Serve Onions 250 g 900 W 5-5½
after 3 minutes standing. Instructions
Cut onions into slices or halves. Add only 15 ml (1 tbsp.) water.
Brussels 250 g 900 W 6-6½
Serve after 3 minutes standing.
Sprouts Instructions
Add 60-75 ml (5-6 tbsp.) water. Serve after 3 minutes standing. Pepper 250 g 900 W 4½-5
Cut pepper into small slices.
Carrots 250 g 900 W 4½-5
Instructions Potatoes 250 g 900 W 4-5
Cut carrots into even sized slices. Serve after 3 minutes standing. 500 g 7-8
Instructions
Cauliflower 250 g 900 W 5-5½
500 g 7½-8½ Weigh the peeled potatoes and cut them into similar sized halves
Instructions or quarters. Serve after 3 minutes standing.
Prepare even sized florets. Cut big florets into halves. Arrange Turnip 250 g 900 W 5½-6
stems to the centre. Serve after 3 minutes standing. Cabbage Instructions
Courgettes 250 g 900 W 4-4½ Cut turnip cabbage into small cubes. Serve after 3 minutes
Instructions standing.
Cut courgettes into slices. Add 30 ml (2 tbsp.) water or a knob of
butter. Cook until just tender. Serve after 3 minutes standing.
Egg Plants 250 g 900 W 3½-4
Instructions
Cut egg plants into small slices and sprinkle with 1 tablespoon
lemon juice. Serve after 3 minutes standing.
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Cooking Guide for rice and pasta REHEATING
Rice: Use a large glass pyrex bowl with lid - rice doubles in volume during Your microwave oven will reheat food in a fraction of the time that conventional ovens
cooking. Cook covered. hobs normally take.
After the cooking time is over, stir before standing time and salt or add Use the power levels and reheating times in the following chart as a guide. The times in
herbs and butter. the chart consider liquids with a room temperature of about +18 to +20 °C or a chilled
Remark: the rice may not have absorbed all water after the cooking time food with a temperature of about +5 to +7 °C.
is finished. Arranging and covering
Pasta: Use a large glass pyrex bowl. Add boiling water, a pinch of salt and stir Avoid reheating large items such as joint of meat - they tend to overcook and dry out
well. Cook uncovered. before the centre is piping hot. Reheating small pieces will be more successful.
Stir occasionally during and after cooking. Cover during standing time
and drain thoroughly afterwards. Power levels and stirring
Some foods can be reheated using 900 W power while others should be reheated using
Food Serving Size Power Time (min.) 600 W, 450 W or even 300 W.
White Rice 250 g 900 W 15-16 Check the tables for guidance.
(Parboiled) 375 g 17½-18½ In general, it is better to reheat food using a lower power level, if the food is delicate, in
large quantities, or if it is likely to heat up very quickly (mince pies, for example).
Instructions
Stir well or turn food over during reheating for best results. When possible, stir again
Add cold water of double quantity. Serve after 5 minutes standing.
before serving.
Brown Rice 250 g 900 W 20-21 Take particular care when heating liquids and baby foods. To prevent eruptive boiling
(Parboiled) 375 g 22-23 of liquids and possible scalding, stir before, during and after heating. Keep them in the
Instructions microwave oven during standing time. We recommend putting a plastic spoon or glass
Add cold water of double quantity. Serve after 5 minutes standing. stick into the liquids. Avoid overheating (and therefore spoiling) the food. It is preferable to
Mixed Rice 250 g 900 W 16-17 underestimate cooking time and add extra heating time, if necessary.
(Rice + Wild Instructions Heating and standing times
Rice) Add 500 ml cold water. Serve after 5 minutes standing. When reheating food for the first time, it is helpful to make a note of the time taken - for
Mixed Corn 250 g 900 W 17-18 future reference.
(Rice + Grain) Instructions Always make sure that the reheated food is piping hot throughout.
Add 400 ml cold water. Serve after 5 minutes standing. Allow food to stand for a short time after reheating - to let the temperature even out.
The recommended standing time after reheating is 2-4 minutes, unless another time is
Pasta 250 g 900 W 10-11
recommended in the chart.
Instructions Take particular care when heating liquids and baby food. See also the chapter with the
Add 1000 ml hot water. Serve after 5 minutes standing. safety precautions.
REHEATING LIQUIDS
Always allow a standing time of at least 20 seconds after the oven has been switched off
to allow the temperature to even out. Stir during heating, if necessary, and ALWAYS stir
after heating. To prevent eruptive boiling and possible scalding, you should put a spoon
or glass stick into the beverages and stir before, during and after heating.
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REHEATING BABY FOOD
BABY FOOD:
Empty into a deep ceramic plate. Cover with plastic lid. Stir well after reheating! Let stand
for 2-3 minutes before serving. Stir again and check the temperature. Recommended
serving temperature: between 30-40 °C. Stew (Chilled) 350 g 600 W 4½-5½
BABY MILK: Instructions
Put stew in a deep ceramic plate. Cover with plastic lid. Stir
06 COOKING GUIDE
Pour milk into a sterilised glass bottle. Reheat uncovered. Never heat a baby’s bottle with
teat on, as the bottle may explode if overheated. Shake well before standing time and occasionally during reheating and again before standing and
again before serving ! Always carefully check the temperature of baby milk or food before serving.
giving it to the baby. Recommended serving temperature: ca. 37 °C. Serve after 2-3 minutes standing.
Pasta with 350 g 600 W 3½-4½
REMARK: Sauce (Chilled) Instructions
Baby food particularly needs to be checked carefully before serving to prevent burns. Put pasta (e.g. spaghetti or egg noodles) on a flat ceramic plate.
Use the power levels and times in the next table as a guide lines for reheating. Cover with microwave cling film. Stir before serving.
Serve after 3 minutes standing.
Reheating Liquids and Food
Filled Pasta 350 g 600 W 4-5
Use the power levels and times in this table as a guide lines for reheating.
with Sauce Instructions
Food Serving Size Power Time (min.) (Chilled) Put filled pasta (e.g. ravioli, tortellini) in a deep ceramic plate.
Drinks (Coffee, 150 ml (1 cup) 900 W 1-1½ Cover with plastic lid. Stir occasionally during reheating and again
Tea and Water) before standing and serving. Serve after 3 minutes standing.
300 ml (2 cups) 2-2½
450 ml (3 cups) 3-3½
Plated Meal 350 g 600 W 4½-5
(Chilled) 450 g 5½-6½
600 ml (4 cups) 3½-4
Instructions
Instructions Plate a meal of 2-3 chilled components on a ceramic dish. Cover
Pour into cups and reheat uncovered: 1 cup in the centre, 2 cups with microwave cling-film. Serve after 3 minutes standing.
opposite of each other, 3 cups in a circle. Keep in microwave
oven during standing time and stir well. Serve after 1-2 minutes
Cheese Fondue 400 g 600 W 6-7
standing. Ready-To-Serve Instructions
(Chilled) Put the ready-to-serve cheese fondue in a suitable sized glass
Soup (Chilled) 250 g 900 W 2½-3
350 g 3-3½ pyrex bowl with lid. Stir occasionally during and after reheating.
450 g 3½-4 Stir well before serving. Serve after 1-2 minutes standing.
550 g 4½-5
Instructions
Pour into a deep ceramic plate or deep ceramic bowl. Cover with
plastic lid. Stir well after reheating. Stir again before serving.
Serve after 2-3 minutes standing.
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Reheating Baby Food and Milk DEFROSTING
Use the power levels and times in this table as guide lines for reheating. Microwaves are an excellent way of defrosting frozen food. Microwaves gently defrost
Food Serving Size Power Time frozen food in a short period of time. This can be of great advantage, if unexpected
guests suddenly show up.
Baby Food 190 g 600 W 30 sec.
Frozen poultry must be thoroughly thawed before cooking. Remove any metal ties and
(Vegetables + Instructions take it out of any wrapping to allow thawed liquid to drain away.
Meat) Empty into ceramic deep plate. Cook covered. Stir after cooking
time. Before serving, stir well and check the temperature carefully. Put the frozen food on a dish without cover. Turn over half way, drain off any liquid and
Serve after 2-3 minutes standing. remove any giblets as soon as possible. Check the food occasionally to make sure that it
does not feel warm.
Baby Porridge 190 g 600 W 20 sec.
If smaller and thinner parts of the frozen food start to warm up, they can be shield by
(Grain + Milk + Instructions wrapping very small strips of aluminium foil around them during defrosting.
Fruit) Empty into ceramic deep plate. Cook covered. Stir after cooking
time. Before serving, stir well and check the temperature carefully. Should poultry start to warm up on the outer surface, stop thawing and allow it to stand
Serve after 2-3 minutes standing. for 20 minutes before continuing.
Baby Milk 100 ml 300 W 30-40 sec. Leave the fish, meat and poultry to stand in order to complete defrosting. The standing
time for complete defrosting will vary depending on the quantity defrosted. Please refer to
200 ml 1 min. to 1 min.
the table below.
10 sec.
Hint: Flat food defrosts better than thick and smaller quantities need less time
Instructions
than bigger ones. Remember this hint while freezing and defrosting food.
Stir or shake well and pour into a sterilized glass bottle. Place into
the centre of turntable. Cook uncovered. Before serving, shake For defrosting of frozen food with a temperature of about -18 to -20 °C, use the following
well and check the temperature carefully. Serve after 2-3 minutes table as a guide.
standing.
Meat
Minced Meat 250 g 180 W 6-7
500 g 8-13
Pork Steaks 250 g 180 W 7-8
Instructions
Place the meat on turntable. Shield thinner edges with
aluminium foil. Turn over after half of defrosting time!
Serve after 15-30 minutes standing.
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GRILL
The grill-heating element is located underneath the ceiling of the cavity. It operates while
the door is closed and the turntable is rotating. The turntable’s rotation makes the food
Poultry brown more evenly. Preheating the grill for 3-5 minutes will make the food brown more
Chicken Pieces 500 g (2 pcs) 180 W 14-15 quickly.
Whole Chicken 1200 g 180 W 32-34 Cookware for grilling:
06 COOKING GUIDE
Should be flameproof and may include metal. Do not use any type of plastic cookware,
Instructions
as it can melt.
First, put chicken pieces first skin-side down, whole chicken
first breast-side-down on a flat ceramic plate. Shield the Food suitable for grilling:
thinner parts like wings and ends with aluminium foil. Turn Chops, sausages, steaks, hamburgers, bacon and gammon rashers, thin fish portions,
over after half of defrosting time! sandwiches and all kinds of toast with toppings.
Serve after 15-60 minutes standing. Important remark:
Fish Whenever the grill only mode is used, please remember that food must be placed on the
Fish Fillets 200 g 180 W 6-7 high rack, unless another instruction is recommended.
Whole Fish 400 g 180 W 11-13 MICROWAVE + GRILL

Instructions This cooking mode combines the radiant heat that is coming from the grill with the speed
Put frozen fish in the middle of a flat ceramic plate. Arrange of microwave cooking. It operates only while the door is closed and the turntable is
the thinner parts under the thicker parts. Shield narrow ends rotating. Due to the rotation of the turntable, the food browns evenly. Three combination
of fillets and tail of whole fish with aluminium foil. Turn over modes are available with this model:
after half of defrosting time! 600 W + Grill, 450 W + Grill and 300 W + Grill.
Serve after 10-25 minutes standing. Cookware for cooking with microwave + grill
Fruits Please use cookware that microwaves can pass through. Cookware should be
Berries 300 g 180 W 6-7 flameproof. Do not use metal cookware with combination mode. Do not use any type of
plastic cookware, as it can melt.
Instructions
Spread fruit on a flat, round glass dish (with a large diameter). Food suitable for microwave + grill cooking:
Serve after 5-10 minutes standing. Food suitable for combination mode cooking include all kinds of cooked food which
need reheating and browning (e.g. baked pasta), as well as foods which require a short
Bread
cooking time to brown the top of the food. Also, this mode can be used for thick food
Bread Rolls 2 pcs 180 W 1-1½ portions that benefit from a browned and crispy top (e.g. chicken pieces, turning them
(Each ca. 50 g) 4 pcs 2½-3 over half way through cooking). Please refer to the grill table for further details.
Toast/Sandwich 250 g 180 W 4-4½ Important remark:
Instructions Whenever the combination mode (microwave + grill) is used, the food should be placed
Arrange rolls in a circle or bread horizontally on kitchen paper on the high rack, unless another instruction is recommended. Please refer to the
in the middle of turntable. Turn over after half of defrosting instructions in the following chart.
time! Serve after 5-20 minutes standing. The food must be turned over, if it is to be browned on both sides.
English - 57
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Grill Guide for Fresh Food
Preheat the grill with the grill-function for 2-3 minutes.
Fresh Food Serving Size Power 1 step (min.) 2 step (min.)
Use the power levels and times in this table as guide lines for grilling.
Use oven gloves when taking out. Baked Apples 2 apples 300 W + Grill 7-8 -
(ca. 400 g)
Fresh Food Serving Size Power 1 step (min.) 2 step (min.) Instructions
Toast Slices 4 pcs Grill only 3-4 2-3 Core the apples and fill them with raisins and jam. Put some
(each 25 g) almond slices on top. Put apples on a flat glass pyrex dish. Place
Instructions the dish directly on the low rack.
Put toast slices side by side on the high rack. Chicken 500 g (2 pcs) 300 W + Grill 8-10 6-8
Grilled 400 g (2 pcs) 300 W + Grill 5-6 - Pieces Instructions
Tomatoes Instructions Brush chicken pieces with oil and spices. Put them in a circle on
Cut tomatoes into halves. Put some cheese on top. Arrange in a the high rack. After grilling stand for 2-3 minutes.
circle in a flat glass pyrex dish. Place it on the high rack. Stand for Roast Chicken 1200 g 450 W + Grill 18-19 17
2-3 minutes. Instructions
Tomato- 4 pcs (300 g) 300 W + Grill 4-5 - Brush the chicken oil and spices. Put the chicken on the low rack.
Cheese Toast Instructions After grilling stand for 5 minutes.
Toast the bread slices first. Put the toast with topping on the high Roast Fish 400-500 g 300 W + Grill 5-7 5½-6½
rack. Stand for 2-3 minutes. Instructions
Toast Hawaii 4 pcs (500 g) 300 W + Grill 5-6 - Brush skin of whole fish with oil and add herbs and spices. Put two
(Ham, Instructions fishes side by side (head to tail) on the high rack. After grilling stand
Pineapple, Toast the bread slices first. Put the toast with topping on the high for 2-3 minutes.
Cheese Slices) rack. Stand for 2-3 minutes.
Baked 500 g 600 W + Grill 7-8 -
Potatoes Instructions
Cut potatoes into halves. Put them in a circle on the high rack with
the cut side to the grill.
Gratin 450 g 450 W + Grill 9-11 -
Potatoes/ Instructions
Vegetables Put the fresh gratin into a small glass pyrex dish. Put the dish on
(Chilled) the high rack. After cooking stand for 2-3 minutes.
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CONVECTION Convection Guide for fresh and frozen food
Cooking with convection is the traditional and well known method of cooking food in a Preheat the convection with the auto pre-heat function to the desired temperature. Use
traditional oven with hot air. the power levels and times in this table as guide lines for convection cooking. Use oven
The heating element and the fan position is at the back-wall, so that the hot air is gloves when taking out.
circulating. This mode is supported by the top heating element.
1 step 2 step
Cookware for convection cooking: Fresh Food Serving Size Power
(min.) (min.)
06 COOKING GUIDE
All conventional ovenproof cookware, baking tins and sheets – anything you would
normally use in a traditional convection oven – can be used. Pizza
Food suitable for convection cooking: Frozen Pizza 300 g 1 step 300 W + 200 °C 11-12 2-3
All biscuits, individual scones, rolls and cakes should be made by this mode as well as (Ready Baked) 2 step Grill
rich fruit cakes, choux pastry and soufflés. Instructions
Place the pizza on the low rack.
MICROWAVE + CONVECTION After baking stand for 2-3 minutes.
This mode combines the microwave energy with the hot air and is therefore reducing the Pasta
cooking time while giving the food a brown and crispy surface.
Cooking with convection is the traditional and well known method of cooking food in an Frozen Lasagne 400 g 1 step 450 W + 200 °C 15-16 5-6
2 step Convt. 200 °C
oven with hot air circulated by a fan on the back-wall.
Instructions
Cookware for cooking with microwaves + convection:
Put into a suitable sized glass pyrex dish or leave in the original
Should be able to let the microwaves pass through. Should be ovenproof (like glass,
packaging (take care that this is suitable for microwaves and oven
pottery or china without metal trims); similar to the cookware described under Microwave
heat). Put frozen pasta gratin on the low rack. After cooking stand
+ Grill.
for 2-3 minutes.
Food suitable for Microwave + Convection cooking: Meat
All kinds of meats and poultry as well as casseroles and gratin dishes, sponge cakes and
light fruit cakes, pies and crumbles, roast vegetables, scones and breads. Roast Lamb 1200-1300 g 600 W + 180 °C 20-23 10-13
(Medium) Instructions
Brush lamb with oil and spice it with pepper, salt and paprika. Put
it on the low rack, first with the fat side down. After cooking wrap
in aluminium foil and stand for 10-15 minutes.
Roast Chicken 1000-1100 g 450 W + 200 °C 20-22 20
Instructions
Brush chicken with oil and spices. Put chicken first breast side
down, second side breast side up on the low rack. Stand for
5 minutes.
(continued)
English - 59
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TIPS AND TRICKS
MELTING BUTTER
1 step 2 step
Fresh Food Serving Size Power Put 50 g butter into a small deep glass dish. Cover with plastic lid.
(min.) (min.)
Heat for 30-40 seconds using 900 W, until butter is melted.
Bread MELTING CHOCOLATE
Fresh Bread 6 pcs (350 g) 100 W + 180 °C 8-10 - Put 100 g chocolate into a small deep glass dish.
Rolls Instructions Heat for 3-5 minutes, using 450 W until chocolate is melted.
Put bread rolls in a circle on the low rack. Stand for 2-3 minutes. Stir once or twice during melting. Use oven gloves while taking out!
Garlic Bread 200 g (1 pc) 180 W + 200 °C 8-10 - MELTING CRYSTALLIZED HONEY
(Chilled, Instructions Put 20 g crystallized honey into a small deep glass dish.
Prebaked) Put the chilled baguette on baking paper on the low rack. After Heat for 20-30 seconds using 300 W, until honey is melted.
baking stand for 2-3 minutes. MELTING GELATINE
Cake Lay dry gelatine sheets (10 g) for 5 minutes into cold water.
Marble Cake 500 g Only 180 °C 38-43 - Put drained gelatine into a small glass pyrex bowl.
(Fresh Dough) Instructions Heat for 1 minute using 300 W. Stir after melting.
Put the fresh dough in a small rectangular black metal baking dish COOKING GLAZE/ICING (FOR CAKE AND GATEAUX)
(length 25 cm). Put the cake on the low rack. After baking stand Mix instant glaze (approximately 14 g) with 40 g sugar and 250 ml cold water. Cook
for 5-10 minutes. uncovered in a glass pyrex bowl for 3½ to 4½ minutes using 900 W, until glaze/icing is
Small Cakes 10 x 28 g Only 160 °C 26-28 - transparent. Stir twice during cooking.
(Fresh Dough) Instructions COOKING JAM
Fill the fresh dough evenly in paper cups and set on baking tray Put 600 g fruits (for example mixed berries) in a suitable sized glass pyrex bowl with lid.
on the low rack. Add 300 g preserving sugar and stir well.
After baking stand for 5 minutes. Cook covered for 10-12 minutes using 900 W.
Cookies 200-250 g Only 200 °C 15-20 - Stir several times during cooking. Empty directly into small jam glasses with twist-off lids.
Stand on lid for 5 minutes.
(Fresh Dough) Instructions
Put the chilled croissants on baking paper on the low rack. COOKING PUDDING
Mix pudding powder with sugar and milk (500 ml) by following the manufacturers
Frozen Cake 1000 g 180 W + 180 °C 18-20 -
instructions and stir well. Use a suitable sized glass pyrex bowl with lid. Cook covered for
Instructions
6½ to 7½ minutes using 900 W.
Put the frozen cake directly on the low rack. After defrost and
Stir several times well during cooking.
warming stand for 15-20 minutes.
BROWNING ALMOND SLICES
Spread 30 g sliced almonds evenly on a medium sized ceramic plate.
Stir several times during browning for 3½ to 4½ minutes using 600 W.
Let it stand for 2-3 minutes in the oven. Use oven gloves while taking out!
English - 60
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troubleshooting and information code
You may encounter a problem using the oven. In that case, first check the table below Problem Cause Action
and try the suggestions. If a problem persists, or if any information code keeps appearing
on the display, contact a local Samsung service centre. The power turns off The oven has been cooking After cooking for an
during operation. for an extended period of extended period of time, let
Checkpoints time. the oven cool.
07 troubleshooting and Information code

If you encounter a problem with the oven, first check the table below and try the The cooling fan is not working. Listen for the sound of the
suggestions. cooling fan.
Trying to operate the oven Put food in the oven.
Problem Cause Action without food inside.
General There is not sufficient There are intake/exhaust
The buttons Foreign matter may be caught Remove the foreign matter ventilation space for the oven. outlets on the front and rear
cannot be pressed between the buttons. and try again. of the oven for ventilation.
properly. For touch models: Moisture is Wipe the moisture from the Keep the gaps specified
on the exterior. exterior. in the product installation
guide.
Child lock is activated. Deactivate Child lock.
Several power plugs are being Designate only one socket to
The time is not Power is not supplied. Make sure power is supplied.
used in the same socket. be used for the oven.
displayed. The Eco (power-saving) Turn off the Eco function.
There is no power Power is not supplied. Make sure power is supplied.
function is set.
to the oven.
The oven does not Power is not supplied. Make sure power is supplied.
There is a popping Cooking sealed food or using Do not use sealed containers
work. The door is open. Close the door and try again.
sound during a container with a lid may as they may burst during
The door open safety Remove the foreign matter operation, and the causes popping sounds. cooking due to expansion of
mechanisms are covered in and try again. the contents.
oven doesn't work.
foreign matter.
The oven exterior There is not sufficient Keep the gaps specified
The oven stops The user has opened the door After turning over the food,
ventilation space for the oven. in the product installation
to turn food over. press the Start button again
is too hot during
while in operation. There are intake/exhaust guide.
to start operation. operation.
outlets on the front and rear of
the oven for ventilation.
Objects are on top of the Remove all objects on the
oven. top of the oven.
The door cannot be Food residue is stuck between Clean the oven and then
opened properly. the door and oven interior. open the door.
(continued)
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Problem Cause Action Problem Cause Action
The oven does not The oven may not work, too Put one cup of water in a The interior light The door has been left open The interior light may
heat. much food is being cooked, microwave-safe container is dim or does not for a long time. automatically turn off when
or improper cookware is being and run the microwave turn on. the Eco function operates.
used. for 1-2 minutes to check Close and reopen the door
whether the water is heated. or press the "Cancel" button.
Reduce the amount of food The interior light is covered by Clean the inside of the oven
and start the function again. foreign matter. and check again.
Use a cooking container with A beeping sound If the Auto Cook function After turning over the food,
a flat bottom. occurs during is being used, this beeping press the Start button again
Heating is weak or The oven may not work, too Put one cup of water in a cooking. sound means it's time to turn to restart operation.
slow. much food is being cooked, microwave-safe container over the food during thawing.
or improper cookware is being and run the microwave The oven is not The oven is installed on an Make sure the oven is installed
used. for 1-2 minutes to check level. uneven surface. on flat, stable surface.
whether the water is heated.
Reduce the amount of food There are sparks Metal containers are used Do not use metal containers.
and start the function again. during cooking. during the oven/thawing
functions.
Use a cooking container with
a flat bottom. When power is The door is not properly Close the door and check
The warm function The oven may not work, too Put one cup of water in a connected, the closed. again.
does not work. much food is being cooked, microwave-safe container oven immediately
or improper cookware is being and run the microwave starts to work.
used. for 1-2 minutes to check There is electricity The power or power socket is Make sure the power and
whether the water is heated. coming from the not properly grounded. power socket are properly
Reduce the amount of food oven. grounded.
and start the function again. There is water There may be water or steam Let the oven cool and then
Use a cooking container with dripping. in some cases depending on wipe with a dry dish towel.
a flat bottom. the food. This is not an oven
The thaw function The oven may not work, too Put one cup of water in a malfunction.
does not work. much food is being cooked, microwave-safe container Steam leaks from There may be water or steam Let the oven cool and then
or improper cookware is being and run the microwave the door. in some cases depending on wipe with a dry dish towel.
used. for 1-2 minutes to check the food. This is not an oven
whether the water is heated. malfunction.
Reduce the amount of food There is water left There may be water or steam Let the oven cool and then
and start the function again. in the oven. in some cases depending on wipe with a dry dish towel.
Use a cooking container with the food. This is not an oven
a flat bottom. malfunction.
English - 62
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Problem Cause Action Problem Cause Action
The brightness Brightness changes Power output changes Grill
inside the oven depending on power output during cooking are not Smoke comes out During initial operation, smoke This is not a malfunction, and
varies. changes according to malfunctions. during operation. may come from the heating if you run the oven 2-3 times,
function. This is not an oven elements when you first use it should stop.
malfunction. the oven.
07 troubleshooting and Information code

Cooking is finished, To ventilate the oven, the This is not an oven Food is on the heating Let the oven cool and then
but the cooling fan cooling fan continues to run malfunction. elements. remove the food from the
is still running. for about 5 minutes after heating elements.
cooking is complete. Food is too close to the grill. Put the food a suitable
Pressing the This happens when the oven The microwave oven is distance away while cooking.
+30sec button was not operating. designed to operate by Food is not properly prepared Make sure food is properly
operates the oven. pressing the +30 sec button and/or arranged. prepared and arranged.
when it was not operating.
Oven
Turntable
The oven does not The door is open. Close the door and try again.
While turning, the There is no roller ring, or the Install the roller ring and then
heat.
turntable comes roller ring is not properly in try again.
place. Smoke comes out During initial operation, smoke This is not a malfunction, and
out of place or
during preheating. may come from the heating if you run the oven 2-3 times,
stops turning. elements when you first use it should stop.
The turn table The roller ring is not properly Adjust the amount of food the oven.
drags while turning. in place, there is too much and do not use containers
Food is on the heating Let the oven cool and then
food, or the container is too that are too large.
elements. remove the food from the
large and touches the inside
heating elements.
of the microwave.
There is a burning Plastic or non heat-resistant Use glass cookware suitable
The turn table Food residue is stuck to the Remove any food residue
cookware is used. for high temperatures.
or plastic smell
rattles while turning bottom of the oven. stuck to the bottom of the
oven. when using the
and is noisy.
oven.
There is a bad Food residue or plastic has Use the steam function and
smell coming from melted and stuck to the then wipe with a dry cloth.
inside the oven. interior. You can put a lemon slice
inside and run the oven to
remove the odour more
quickly.
(continued)
English - 63
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technical specifications
SAMSUNG strives to improve its products at all times. Both the design specifications and
Problem Cause Action
these user instructions are thus subject to change without notice.
The oven does not The oven door is frequently Do not frequently open
cook properly. opened during cooking. the door unless you are Model MC28H5025**
cooking things that need
to be turned. If you open Power source 230 V ~ 50 Hz AC
the door often, the interior
temperature will be lowered Power consumption
and this may affect the Maximum power 2900 W
results of your cooking. Microwave 1400 W
The oven controls are not Correctly set the oven Grill (heating element) 1500 W
correctly set. controls and try again. Convection (heating element) Max. 2100 W
The grill or other accessories Correctly insert the
are not correctly inserted. accessories. Output power 100 W / 900 W - 6 levels (IEC-705)
The wrong type or size of Reset the oven controls or Operating frequency 2450 MHz
cookware is used. use suitable cookware with
flat bottoms. Dimensions (W x H x D)
Outside 517 x 310 x 474.8 mm
Information codes
Oven cavity 358 x 235.5 x 327 mm
If the oven fails to operate, you may see an information code on the display. Check the
table below and try the suggestions. Volume 28 liter
Code Description Action Weight
C-20 The temperature sensor is open. Unplug the power cord of the oven, Net 17.5 kg approx.
The temperature sensor is short. and contact a local Samsung service
centre.
C-21 This code appears when the oven Unplug the power cord for cooling
temperature high. In case the enough time, and restart the
temperature rises over the limit microwave oven.
temperature during operation of
each mode. (Fire sensed.)
C-d0 The touch key is malfunction. Unplug the power cord for cooling
enough time, and clean the button.
(Dust, Water) When appear same
problem, contact a local Samsung
service centre.
English - 64
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MEMO MEMO
08 technical specifications
MC28H5025_TL_DE68-04351A-00_EN_150112.indd 65 2015-01-12 �� 3:47:37
MEMO MEMO
MC28H5025_TL_DE68-04351A-00_EN_150112.indd 66 2015-01-12 �� 3:47:38

MEMO MEMO
MC28H5025_TL_DE68-04351A-00_EN_150112.indd 67 2015-01-12 �� 3:47:38

QUESTIONS OR COMMENTS
COUNTRY CALL OR VISIT US ONLINE AT

AUSTRALIA 1300 362 603 www.samsung.com/au/support
NEW ZEALAND 0800 726 786 www.samsung.com/nz/support
CHINA 400-810-5858 www.samsung.com/cn/support
www.samsung.com/hk/support (Chinese)
HONG KONG (852) 3698 4698 www.samsung.com/hk_en/support (English)
INDIA 1800 3000 8282 - Toll Free

1800 266 8282 - Toll Free www.samsung.com/in/support
BANGLADESH 9612300300
021-56997777
INDONESIA www.samsung.com/id/support
08001128888
JAPAN 0120-363-905 www.samsung.com/jp/support
1800-88-9999
MALAYSIA www.samsung.com/my/support
603-77137477 (Overseas contact)
1-800-10-7267864 [PLDT]
PHILIPPINES 1-800-8-7267864 [Globe landline and Mobile] www.samsung.com/ph/support
02-4222111 [Other landline]
SINGAPORE 1800-SAMSUNG(726-7864) www.samsung.com/sg/support
0-2689-3232,
THAILAND www.samsung.com/th/support
1800-29-3232
TAIWAN 0800-329999 www.samsung.com/tw/support
VIETNAM 1800 588 889 www.samsung.com/vn/support
MACAU 0800 333
MYANMAR 01-2399888 www.samsung.com/support
0094117540540
SRI LANKA
0094115900000
This product is RoHS compliant
DE68-04351A-00
MC28H5025_TL_DE68-04351A-00_EN_150112.indd 68 2015-01-12 �� 3:47:38

SPIC Volume 3 Part-2

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केवऱ कायााऱयीन उपयोग हे तु

(For Official Use Only)

भारत सरकार GOVERNMENT OF INDIA

VOLUME – 3[PART – II]

THIS PAGE IS INTENTIONALLY LEFT BLANK

OEM Documentation [PART – II] – Electrical Equipment

Content in this document is compiled with the inputs provided by ICF

Amendments and Revisions

IRCAMTECH/GWL/MECH/2020-21/SPIC/MM/1.0# XX date .......

Version Date Corrections Remarks

1. Amendments and Revisions ........................................................................................... 4

Propulsion and Control Equipment

3. OPERATION AND MAINTENANCE MANUAL /8 WHEELER SELF‐PROPELLED INSPECTION

4. USER MANUAL /DA SET/ KOEL

5. TECHNICAL MANUAL/ LHB DESIGN COACH WITH R407C REFRIGERANT/ INTEC

6. USER AND MAINTENANCE MANUAL / MONOBLOCK PUMPS/ KALSI

7. INSTALLATION AND OPERATING MANUAL / VRLA BATTERIES/ AMARA RAJA

8. INSTRUCTION MANUAL / INDUCTION OVEN (IC3616)/ USHA

8 WHEELER SELF‐PROPELLED INSPECTION CAR

CUSTOMER INTEGRAL COACH FACTORY, CHENNAI

CG Power & Industrial Solutions Ltd.

Issued By TRACTION MACHINES DESIGN DEPARTMENT, CG

The instructions contain adequate details/information required for maintenance of equipment.

CG POWER AND INDUSTRIAL SOLUTIONS LTD.

MAINTENANCE MANUAL FOR SPIC‐AC/US

2. POWER PACK ARRANGEMENT

7. CONTROL GEAR EQUIPMENT

8. MAINTENANCE INSTRUCTIONS FOR CONTROL GEAR EQP

10. SPIC DRAWINGS

11. RECOMMENDED SPARES

MAINTENANCE MANUAL FOR SPIC‐AC/US

1.0 PERFORMANCE AND GENERAL DATA

2.0 LIST OF ABBREVIATIONS

Salient features of SELF-PROPELLED INSPECTION CAR:

i. Fully air conditioned self-propelled coach.

MAINTENANCE MANUAL FOR SPIC‐AC/US

Each power pack consists of following major components:

1. Under floor mounted:

2. Equipment’s installed over board;

3. Over the roof

 Engine Radiator Unit.

MAINTENANCE MANUAL FOR SPIC‐AC/US

The bypass safety function is not permitted to use on a regular basis or

The manual contains following information:

MAINTENANCE MANUAL FOR SPIC‐AC/US

1.0 PERFORMANCE AND GENERAL DATA

GENERAL DESIGN FEATURES

1. Track Gauge : 1676 mm

MAINTENANCE MANUAL FOR SPIC‐AC/US

2.0 LIST OF ABBREVIATIONS

MAINTENANCE MANUAL FOR SPIC‐AC/US

 RCD1 - REVERSE CURRENT DIODES

 SYS CTRL - SYSTEM CONTROL MCB 30A

 ENG-1 PROT - ENGINE –1 PROTECTION MCB 15A

MAINTENANCE MANUAL FOR SPIC‐AC/US

POWER PACK ARRANGEMENT

MAINTENANCE MANUAL FOR SPIC‐AC/US

2. Major components of power pack

2.2 Traction Alternator

MAINTENANCE MANUAL FOR SPIC‐AC/US