Alimar Manuel Ingilizce

ALIMAR GENERATOR
OPERATING MANUAL
> Your Solution Partner in Energy
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Dear Customer,
Thank you for choosing our product.
Thanks to its years of experience in the sector, Alimar Generator manufactures efficient,
reliable and high quality generators.
In the light of our long years of experience, your generator was manufactured in our factory
located in Balıkesir Organized Industrial Zone in accordance with ISO 9001 Quality
Management Systems, ISO 14001 Environmental Management Systems and OHSAS 18001
Occupational Health and Safety Management System and CE norms and by fulfilling the
requirements set out in TS ISO 8528-4, TS ISO 8528-5 and TS ISO 8528-8 standards.
This manual describes the operating, inspection and maintenance procedures for Alimar
Generators. Before using your generator, please read these procedures carefully and follow
these instructions during operation.
Please do not operate, maintain or repair your generator without taking general safety
precautions. By following the instructions set out in this manual, you will avoid serious
accidents with potentially serious consequences.
Periodical inspections and maintenance of your generator by authorized service centers will
allow you to use your generator for extended periods of time.
If you wish to contribute to our product and service quality, please e-mail your suggestions to
[email protected] and report maintenance and malfunction-related issues to
[email protected] or contact us at 444 54 59.
ALIMAR GENERATOR OPERATING MANUAL 2

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Contents
1. Introduction .................................................................................................................................... 4
2. Safety and Health ............................................................................................................................ 6
3. General Definitions ....................................................................................................................... 11
4. Storage, Lifting, Installation, Assembly ........................................................................................ 13
5. Periodic Maintenance ................................................................................................................... 33
6. Generator Startup and Panel ........................................................................................................ 35
7. Troubleshooting ............................................................................................................................ 47
8. Quality Standards ......................................................................................................................... 52
9. Warranty Conditions / User's Obligations.................................................................................... 53
10. Customer Service ...................................................................................................................... 55

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1. Introduction
Safety Information
The warnings and safety precautions related
to potential hazards that may occur in the
genset are provided in this operating manual
and on the genset. Failure to observe the
warnings in these operating instructions and
to comply with the safety precautions may
result in material damage, serious personal
injury or even death.
Potential hazards can be prevented by
anticipating them in advance and taking
precautions. Also, children and unauthorized
persons should not be allowed to approach
the genset.
The following methods are intended to
identify potential hazards:
 "Danger" and "Warning" labels on the

genset
 The following warning indications in
the user manual as classified below;
DANGER
Refers to situations of potential danger that, if not avoided, could result in death or serious
injury.
WARNING
Refers to potentially hazardous conditions that, if not avoided, could result in serious injury or
damage.
Make sure that all danger and warning labels are clearly legible. In case of any problems in
the legibility of the label, please contact the manufacturer for replacement of the label.
Please note that the manufacturer cannot predict and provide warnings about all possible
hazards associated with the device. If tools, accessories or working techniques not
specifically recommended by the manufacturer are to be used, then the general safety
precautions must be observed and consideration must be given as to whether the work will
cause damage to the genset and its surroundings.
To avoid accidents, please do not perform any procedures other than those described in this
manual nor use the device for purposes other than those authorized.

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The contents of this manual are subject to change without prior notice owing to the further
development of the device.
SAFETY
For engine-related safety precautions, please refer to the safety instructions section of the
respective engine manual.

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2. Safety and Health

Overview
! Please read the operating manual carefully.

To ensure optimum performance and safe operation of the genset, read the operating manual
carefully before use. Improper use may result in death or serious injury.
! Never start the generator if there is an unsafe condition.
 If you identify an unsafe condition related to the generator malfunction, please

contact our authorized services or sales department.
 Never start the generator in an unsafe condition. By disconnecting the "-" pole of
the battery, you may prevent the generator from starting until the unfavorable
situation is corrected.
 Operating the generator without eliminating the unusual condition may result in a
major malfunction and/or a serious accident.
 Find out where the Emergency Stop Button is positioned. Emergency Shutdown
Buttons should only be used in case of emergency.
! Leak Precautions
 During maintenance or repair of the generator, care must be taken to prevent the
fluids inside the generator from leaking. To prevent the risk of leakage, you
should make the necessary containers and cleaning agents ready before
opening the parts containing liquids.
 Improper disposal of wastes causes enormous damage to the environment. All
residual chemical liquids should be disposed of in accordance with the relevant
regulations. When disposing of liquids, you should use leak-proof containers. The
chemical liquid wastes must not be poured on the ground, down drains or into
water sources.
! Avoid standing or leaning on parts that cannot support your weight.

Never stand or lean on parts that cannot support your weight. Always use a ladder during
assembly/disassembly. Failure to do so may result in material damage and injury.
! Do not operate the genset in a wet or humid environment.

Operating the generator in a wet or damp environment may result in electric shock. Keep the
genset away from damp, rainy and snowy conditions. Never operate the device with wet or
damp hands.
! Battery electrolyte contains acid.

 The battery fluid contains electrolyzed acid and can cause injury. Avoid contact of
battery fluid with skin and eyes.

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 Always wash your hands after touching the battery and connection terminals.
Wearing gloves is recommended.
 Wear protective goggles when handling the battery.
! Prolonged exposure to more than 85 dB of noise can lead to hearing loss.

 At 7 meters distance, noise levels in generators are 100-110 dB for those without
sound insulation and 70-80 dB for those with sound insulation.
 To reduce the noise level of the genset, various equipment such as custom
sound insulation cabinets, special exhaust silencers, etc. can be used.
When lifting and transporting the genset, use the lifting lugs on the frame.
 The lifting lugs on the genset frame are specially designed for easy handling of
the genset. Improper lifting and handling may result in serious personal injury or
material damage.
 You may use a hoist or forklift of suitable capacity to lift the generator. In case a
hoist is used for lifting, ropes and chains of suitable length and lifting capacity
must be used. For enclosed generators, care should be taken to use silk
ropes/cloth ropes.
 Do not lift the generator using the engine or alternator lifting eyes.
 Do not lift the generator using the lifting eyes on the enclosure. Use them only for
lifting the empty enclosure.
! Ensure that the generator's electrical wiring is connected by trained and

authorized personnel.
 The electrical wiring of the generator must be made by trained and authorized
personnel as per the cable section table recommended in this operating manual.
 The generator's electrical cables and connections must be isolated. Failure to do
so may result in electric shock.
 The generator must be started after making sure that the genset ground
connection is made. Failure to do so may result in electric shock.
 Never touch the output terminals when the device is in operation, as this may
cause electric shock. In cases where you need to touch the output terminals for
power connections, make sure that the device is not in operation.
 Make sure that the power cables are not damaged. Damaged power cords may
result in electric shock.
 Electrical connections must be made as per the relevant standards. Attention
should be paid to grounding.
! Check the circuit breaker before starting the generator.

Before starting the generator, please check the circuit breaker and make sure that it is OFF
(in the on position). Failure to do so may result in electric shock.
! Protect your body and garments from Moving Parts.

 Make sure that no one is near the engine or its rotating parts before starting the
generator.

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 Loose clothing, long hair and hanging accessories can get caught in the moving
and rotating parts of the engine. And this may cause serious injuries.
 Make sure that the protective casings are closed except during maintenance.
Check for potential hazards before starting the device.
 Before starting the genset, check the control panel for warning alarms. Do not
start the generator if there is a fault alarm.
 Operate the genset as described in this manual.
The exhaust gas produced by the generator is hazardous to health. Run the genset outdoors
or in well-ventilated areas and, if operating indoors, make sure that exhaust gases are
exhausted to the outside.
! Fire and Explosion Hazard

 Generators use fuels and oils that are easily ignitable. Do not get close to the
generator with flammable materials.
 A fire that starts in a generator is classified as BC and ABC type fire.
 Therefore, a BC and ABC powder type fire extinguisher should be available
around the genset.
 Refuel the generator in a well-ventilated area with the engine shut off.
Immediately stop the generator if you notice fuel leaking from the engine fuel
tank or fuel system.
 No flammable materials should be deposited in the areas where your generator
is located. Any spilled liquids should be cleaned up immediately.
 All electrical cables must be neatly and tightly connected. In case of loose and
frayed cables, you should contact an authorized service center. Sparks and arcs
may lead to fire.
 If lubricating oil and fuel spray onto hot surfaces, this may cause a fire. Always
check the oil and fuel pipes for leaks. Tighten all connections using the
recommended torque.
 Never bend high pressure pipes. Avoid using damaged or bent oil and fuel pipes
and hoses.
 Batteries give off flammable vapors. Always ensure that batteries placed indoors
are well ventilated.
 Avoid smoking while checking the battery electrolyte level.
 Frozen batteries may lead to an explosion. Always properly warm up frozen
batteries before starting them.
! Hot Surface Hazard
The exhaust pipes and muffler get hot during the operation of the generator and remain hot
for a while after the engine is stopped. Avoid touching the exhaust pipes and muffler when
they are hot.
! Toxic Substances

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Fuels, oils and coolants used in the genset contain acids and heavy metals. Their contact
with skin or eyes or ingestion can cause serious injury. In case of skin contact, wash the
affected area with soap and water. In case of ingestion, seek medical advice immediately.
! Do not open the radiator cap until after the engine has cooled down.
 The coolant is hot and under pressure when the engine is running. All hoses to
the radiator and heater contain hot water. The hot water turns into steam when
the pressure is reduced.
 Allow the engine to cool down before draining the coolant. Serious injury may
occur upon contact with hot water or steam.
 Check the coolant level after the engine is stopped and once the filler cap is cool
enough to be opened with bare hands.
 Remove the radiator cap slowly due to the risk of high pressure.
 Drain the coolant through the drain pipe or coolant drain valves.
 Avoid the discharge of used coolant into the environment, sewage and/or storm
water lines.
Other Labels on the Genset
Refueling Point
 Refuel the generator where you see the refueling label.

 Drain the fuel using the drain plugs on the fuel tank.
Oil Replenishment Point
 Replenish the generator oil from the section where you see the oil replenishment
label.
 Drain the oil using oil drain valves.
 Avoid the discharge of used engine oil into the environment, sewage and/or
storm water lines.
Oil Level Dipstick
 Check the oil level of the genset using the oil level dipstick. Complete if missing.
 Never add oil and fuel while the generator is running.
 Avoid operating the heater and generator when the cooling system is empty or
lacking coolant.
General Information about Generator
 Inhaling the exhaust gas produced by the engine is hazardous to human health.
Therefore, the genset should not be started indoors without an exhaust outlet.
 Replace the oil and fuel filter at regular periods as recommended in the operating
manuals of diesel engines. Failure to replace the oil and fuel filter on time will
cause damage to diesel engines and result in your generator being out of
warranty.
Safety Instructions for Electricity

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Careful attention should be paid to the following issues related to the electrical system in the
generator set:
a) The electrical equipment (including connection lines and plug connections) must be
free of faults.
b) The genset must not be connected to any other power generation line. In specific
cases where a redundant connection to existing electrical systems is required, such
connection should only be carried out by the authorized personnel.
c) The protection against electric shock is connected to circuit breakers compatible with
the generator set. In cases where it is necessary to replace current breakers, a
current breaker with the same rated values and performance conditions must be
selected.
d) Only hard rubber covered flexible cables (as per IEC 60245-4) or equivalent must be
used due to high mechanical stresses.
e) Where extension lines or mobile distribution networks are used, the total cable length
should not exceed 60 meters for a cable section of 1.5mm² and 100 meters for a
cable section of 2.5mm².

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3. General Definitions
DESCRIPTIONS
1 Diesel Engine 9 Exhaust Pipe Outlet

2 Alternator 10 Turbocharger
3 Fuel Tank 11 Air Suction Pipe
4 Frame Lifting Plate 12 Air Filter
5 Cable Entry (with Moulded Case 13 Engine Cylinders
Circuit Breaker)
6 Crankcase 14 Radiator
7 Expansion Tank 15 Rubber Chocks
8 Control Panel 16 Charge Alternator

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4. Storage, Lifting, Installation, Assembly

Storing the Generator
During long-term storage of the engine and the alternator, a number of side effects may
occur. We should follow some protection methods during the storage of the generator in
order to minimize such side effects. In cases beyond 1 month storage period, please request
support from our authorized service centers.
Storing the Engine
In case of long-term storage, a procedure for engine protection, including engine cleaning
and preservation fluids, can be followed for the engine. The rate of corrosion that may occur
on the engine without proper protection procedures will depend on the climatic conditions in
which the engine is stored.
Short-term Storage
This type of storage is intended for an engine storage period of 1 month to 6 months.
 Run the engine at high speed until the engine coolant reaches 70°C.
 Stop the engine.
 Disconnect the fuel filter and the fuel return line.
 Use a Daubert Chemilcal NoxRust NO: 518 or equivalent preservation oil.
 Fill one container with diesel oil and the other with preservation oil. Immerse both fuel
hoses into the diesel tank.
 Start the engine.
 Transfer the fuel supply line from the container with diesel oil to the container with
preservation oil while the engine is running.
 Remove the fuel return line from the diesel tank, stop the engine when the
preservation oil flows out of the fuel return line.
 Connect the fuel filter and the fuel return line.
 Drain the preservation oil from the crankcase and oil filter.
 Insert the blind plugs. Until the engine is restarted, the crankcase may remain empty.
 Disconnect the fuel solenoid from the mains.
 Spray engine oil into the intake manifold. Seal all open areas of the engine with a
tape to prevent moisture and dirt.
 Attach a warning label to the engine. The label should indicate the following.
There is no oil in the engine.
Do not start the engine.
 Store the engine in a dry area with a constant temperature.

 Rotate the motor 2-3 times every 3-4 weeks.
Remark: If the coolant contains antifreeze and rust inhibitor, there is no need to drain the
cooling system.

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Engine start-up following short-term storage
 Remove the tapes and warning labels on the engine.

 Fill the oil filters with clean 15w-40 oil and then pre-lubricate the oil system.
 Remove the preservation oil from inside the fuel system using clean diesel. Refill the
fuel filters.
 Adjust the belt tension.
Long-term Storage
The long-term storage includes a period between 6 months and 12 months. At the end of 12
months of storage, the engine cooling system should be flushed using a suitable solvent or
hot light mineral oil. And the following procedures should be repeated.
 Run the engine until the engine coolant reaches 70°C.

 Stop the engine.
 Drain the engine oil. Put the blind plugs in place. Use Shell 66202 or a suitable
preservation oil. Fill the engine's crankcase dipstick to the high level mark.
 Disconnect the fuel filter and the fuel return line.
 Use a Daubert Chemilcal NoxRust No: 518 or equivalent preservation oil.
 Fill one container with diesel oil and the other with preservation oil. Immerse both fuel
hoses into the diesel tank.
 Start the engine.
 Transfer the fuel supply line from the container with diesel oil to the container with
preservation oil while the engine is running.
 Remove the fuel return line from the diesel tank, stop the engine when the
preservation oil flows out of the fuel return line.
 Connect the fuel filter and the fuel return line.
 Drain the preservation oil from the crankcase, oil filter (in the air compressor in
turbocharged engines). Insert the blind plugs.
 Remove the intake and exhaust manifolds. Spray preservation oil into the intake and
exhaust ports, inside the manifold and on the cylinder heads.
 Spray preservation oil into the inlet port of the air compressor (on turbocharged
engines).
 Apply anti-rust agent to all unpainted surfaces by brushing or spraying.
 Lift the rocker (depressor arm) cover. Spray preservation oil on the rockers, valve
stems, springs, valve guides, cross heads (if equipped) and rocker arms. Seal the
rocker cover.
 Seal all openings using a sealing paper to prevent ingress of dirt and moisture into
the engine.
 Attach warning labels to the engine, like the one below:
 The motor has been treated with a preservation oil.
 Do not rotate the crankshaft.
 The coolant has been drained.
 Date of protective treatment.
 Do not start the engine.

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 Store the engine in a dry place with a constant temperature.

Engine start-up after long-term storage
 Remove all the tapes and warning labels on the engine.

 Flush the fuel system with clean diesel oil to remove the preservation oil from the fuel
system.
 Flush the oil system with thin mineral oil by removing a blind plug attached to the oil
line.
Remark: Rotate the motor 3 - 4 times while the motor is being flushed.
 Drain and flush the water system.

 Install a new oil filter, fuel filter and water filter on the engine. Fill the cooling system.
 Pre-lubricate the oil system.
 Adjust the belt tension.
 Adjust the valve and the injector.
 If necessary, check all connections for looseness and tighten them.
Start-up of engines that have been kept without preservation
 Check the fan belt.

 Perform pre-start checks.
 For turbo-charged engines, lubricate the turbocharger before start-up.
 Rotate the engine 3-4 times without using the starter.
 Remove the cylinder head covers.
 Crank the engine for 15 seconds (without letting the engine run) to make sure that all
bearing surfaces are sufficiently lubricated. Allow 2 minutes, then crank the engine for
another 15 seconds.
 Run the engine at idle for a while. Warm up the engine and then check all gauges
before loading.
 When starting the engine for the first time after prolonged storage, check the entire
engine for leaks.
Storing the Alternator
There may occur moisture in the windings during storage of the alternator. The generator
should be stored in a dry place to reduce the build-up of such moisture. Warm up the ambient
air if possible to keep the windings dry. Alternators that are not in use for extended periods of
time must undergo insulation tests.
Storing the Battery
During storage, the battery should be fully charged once every 4 weeks.
Mounting
Supplying the space where the generator will operate with fresh air is important for the
engine. If the hot air in the generator room cannot be exhausted outside, this may cause poor
performance of the generator or overheating of the engine. Also, the engine exhaust pipes

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cause an increase in the ambient temperature of the generator room. This makes it important
that the room gets enough air circulation.
It is also important that there is sufficient amount of hot air coming out of the room as well as
air entering the room. We recommend that the windows that allow fresh air into the room and
those that allow hot air to escape should be at least 2 times the size of the radiator in the
generator.
It is also advisable to install louvers to prevent the intake windows from being closed.
Grounding/Grounding Requirements
Failures and damages that may occur in the insulation system of electrical devices cause the
metal parts of the devices that are not related to the energy system outside the main circuit to
be under voltage. In some cases, as the voltage level reaches extreme values, the insulation
is punctured due to the exposure of the device to puncture voltage, causing these insulating
parts to be under voltage. Grounding is necessary to protect both human life and the
equipment.
A proper grounding should be:
 Uninterrupted and continuous,

 Capable of carrying excess currents at the time of failure,
 Have low impedance capable of keeping the voltage drop at a limited level,
 Have a grounding resistance at a low value,
 Have a small soil resistivity.
There are various grounding techniques used in different parts of the world. Companies
usually deploy TT, TN and IT techniques, choosing the one that suits them.
Today, the most widely used type of grid is the TN-type grid. In such grids, the star point of
the grid is earthed. The casing and metal parts of the devices are connected to the protective
conductor PE. PE is also connected to the earthed part at the star point.
In case of phase-to-earth contact, the voltage to earth of the PE or PEN protection lines and
connected devices increases. The magnitude of these voltages can be kept below the
permissible contact voltage by keeping the RB resistor less than 2 Ohms.

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In the project design of the grounding system
 First, the location of the grounding system is determined.

 Necessary measurement procedures are performed to identify the soil resistivity.
 The type of electrode to be used in grounding is identified.
 Then, the system's short circuit current and the tripping time of the protection
elements, which will be connected to the system, are identified.
 The grounding resistance is calculated.
 Then, the cross section of the grounding conductor is calculated.
 Whether the selected and calculated values are correct or not is checked.
 The step voltage and the contact potentials are calculated to check the suitability of
the intended request.
All conductors and connection points are visually and manually inspected before
commissioning. Resistance between neutral and earth
• Soil with low resistance <1 Ohm (ideal soil resistance)
• Soil with high resistance <5 Ohm (Max 20 Ohm)
The most crucial point to consider while grounding in the generator system is that the mains
grounding and the grounding areas for the generator should be at least 20 m away from each
other. This distance serves to prevent the earthing systems from being affected by each
other.
In grounding systems using grounding rods, which are most commonly used, the lengths of
the grounding rods and the distances between them are important. In grounding systems
using more than one grounding rod, the distances of the rods should be at least the distance
of two rods. In a grounding system using a 1.5 m long earthing rod, the distance between the
other rod and the driven rod should be 3 meters.
The grounding cables must be capable of carrying the full load current. In particular, the
generator casing must be earthed. To avoid ruptures due to vibration, a flexible earthing
connection should be deployed.
Coolant
 In our radiators, we aim for maximum protection by using a mixture of water and
antifreeze.
 Antifreeze refers to agents that are mixed into the radiator fluid to prevent the water
from freezing at 0º C or at "-" degrees below 0º.
 The amount of antifreeze and water in the radiator should be well adjusted for engine
protection.
 In coolant systems involving carbon steel pipes, the "pH" of the fluid is maintained
high (between 8-9) to prevent corrosion of the metal parts.
 The reference values for coolant quality include: chlorides -40 mg/liter maximum,
sulphates -100 mg/liter maximum, total hardness 170 mg/liter maximum, total solids
340 mg/liter maximum.
 Avoid operating the preheater when the radiator lacks fluid.

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 Under pressure, coolant boils at temperatures higher than that of water. Do not open
the radiator cap while the engine is running.
 Remove the radiator cap carefully after the diesel engine has cooled down.
 Under conditions prevailing in our country, the maximum protection is achieved with
an antifreeze mixture of 33% to 50%.
 Frost resistance performance of pure antifreeze: Filling the radiator with antifreeze at
100% will not ensure protection and may damage the steel pipes.
 Filling the radiator only with mains water may lead to freezing of the cooling system
below zero degrees Celsius, as well as calcification and clogging of the radiator
cores.
 Besides preventing water from freezing, the additives in antifreeze also ensure
protection against corrosion.
Renewing the Coolant
Never change the coolant while the engine is running. The system runs under pressure and
the coolant is extremely hot. It may cause harm to you and the surrounding environment.
 Make sure that the application is on a flat surface.

 Remove the filler cap of the cooling system.
 To drain the engine, remove the drain plug from the side of the cylinder block. Make
sure that the drain opening is not restricted.
 Open the drain cock or remove the drain plug at the bottom of the radiator to drain the
radiator. If there is no radiator drain cock or drain plug on the radiator, disconnect the
hose at the bottom of the radiator.
 Flush the coolant system with fresh water.
 Install the drain plugs and close the radiator drain cock. Fit the radiator hose if the
radiator hose was previously removed.
 Fill up the system with an approved antifreeze mixture. Install the filler cap.
 Start the engine and check whether the coolant is leaking.
Diesel Fuel
It is essential to use fuel that is free of water and impurities. Any impurities in the fuel can
cause damage to the fuel injection system. Any water in the fuel can cause rust and
corrosion of parts in the fuel equipment. Please refer to the engine manual for the
specifications of the fuel to be used.
Lubrication
Lubricating oil
In diesel engines, the lubrication system is one of the most important parts of the engine.
Proper maintenance extends the engine's service life and reduces operating costs.
In generators, high quality SAE 15W/40 heavy duty engine oil should be used as lubricating
oil for engines operating at an ambient temperature above -15°C.

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Minimum API oil quality level for generator engines: CF4 oil may be used where CH/CI-4 oils
are not available, but the oil should be changed every 250 operating hours. The oil categories
API CA, CB, CC, CD, CE are not recommended. Avoid using.
Ambient
Temperature F
All Seasons
All Seasons
Winter Conditions
Winter Conditions
Arctic Conditions
Unmaintained Battery
The accumulator's main functions on a generator are to supply the electric current required
for the starter motor during the initial starting of the engine, to provide the necessary energy
when the energy requirement cannot be met by the charging alternator, and to protect the
electrical system by serving as a voltage regulator in the generator's auto electrical system.
Battery state of charge Electrolyte density Voltage
50% 1.20 12.24
25% 1.17 12.06

DISCHARGE 1.14 11.89
Automatic generator systems use buffer battery charger rectifiers to keep the battery charged
continuously.
Partially charged batteries are unlikely to crank well in low ambient temperatures. This is
because more power is needed to start the engine in cold temperatures than in normally hot
conditions. Especially in winter, partially charged batteries are exposed to another danger.
The specific gravity of the electrolyte will decrease during discharge and will approach the
freezing temperature of water. This will put the electrolyte at risk of freezing.
Battery state of charge Electrolyte density Voltage

100% 1.28gr/cm -70

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75% 1.24gr/cm -45

50% 1.20gr/cm -25
25% 1.17gr/cm -15
DISCHARGE 1.14gr/cm -7,2
Replacing the Battery
 Turn the engine OFF. Remove all electrical charges.

 Switch off all battery chargers. Disconnect all battery chargers.
 The NEGATIVE "-" cable connects the NEGATIVE "-" battery terminal to the
NEGATIVE "-" end connector on the starter motor. Disconnect the cable from the
NEGATIVE "-" battery terminal.
 The POSITIVE "+" cable connects the POSITIVE "+" battery terminal to the
POSITIVE "+" end connector on the starter motor. Disconnect the cable from the
POSITIVE "+" battery terminal.
 Now you can replace the battery.
CABLE SECTION TABLE
NYY-Cable Section (mm²)

Power (kVA) Prime Current (A)
In Air
10 14.45 4x2.5
20 28.86 4x4
25 36.075 4x6
30 43.29 4x6
36 51.948 4x10
45 57.72 4x16
50 72.15 4x16
63 90.909 3x25+16
75 108.225 3x35+16
100 144.3 3x50+25

125 180.375 3x70+35
150 216.45 3x95+50

175 252.525 3x120+70
200 288.6 3x120+70

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NYY-Cable Section (mm²)

Power (kVA) Prime Current (A)
In Air
225 324.625 3x150+70
250 360.75 3x185+95
275 396.825 2x(3x70+35)
300 432.9 3x240+120
325 468.975 2x(3x95+50)
350 505.05 2x(3x120+70)
375 541.125 2x(3x120+70)
400 577.20 2x(3x150+70)

425 613.275 2x(3x150+70)
450 649.35 2x(3x150+70)

475 685.425 2x(3x185+95)
500 721.5 2x(3x+185+95)
575 829.725 2x(3x240+120)

625 901.875 3x(3x150+70)
700 1010.1 3x(3x185+95)
750 1082.25 3x(3x185+95)

825 1190.475 4x(3x+150+95)
925 1334.775 4x(3x185+95)
1000 1443 4x(3x185+95)

1250 1803.72 5x(3x185+95)
1500 2164.5 5x(3x240+120)
1600 2308.8 6x(3x+240+120)

1750 2525.25 6x(3x+240+120)
2000 2886 8x(3x185+95)
Layout
Installing the Generator

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Room layout plan
 In confined spaces, it should be checked whether the generator can operate properly.
 It should also be checked whether the room is of a suitable size for the generator.
 The vent window area must be at least 1.5 times the radiator area.
 The generator should be provided with at least 1 meter of running space on the sides.
 You should install the generator set where it can be protected against corrosive
materials as well as conductive materials such as exhaust fumes, vapors, oil mist,
dust, lint, yarn, etc.
 The room entrance should be wide enough to allow the generator to enter the room
for installation purposes and to be taken out when necessary, and the door should
open outwards.
 The fire extinguishers should be easily visible and in places where they can be easily
picked up to fight the fire.
 For multiple generator applications, multiple exhaust ducts should be used.
 The floor on which the generator will be positioned must be slope-free, flat (level) and
strong enough to carry the generator's weight and the live load that the generator will
produce.
A simple room layout design for the generator

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Synchrono
us Control
Basement layout plan
 The exhaust gas should be vented out of the ambient as soon as possible.
 The exhaust air released from the radiator must be prevented from returning by
means of a bellows.
Floor -1
Areaway
Floor -2
Rooftop Installation
This form of installation is only possible when a suitable space is not available on the ground
floor or in the basement.
Advantages

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 No air flow problem.

 Requires no costly duct work.
 No need to lay long exhaust pipes.
 No problems with exhaust fumes.
 Less noise problems.
 No problems such as limited space.
Disadvantages
 Roof structure may need reinforcement.

 There may be a need for a big crane.
 Plans may require permits.
 A longer cable installation is required.
 Only a limited amount of fuel can be stored.
 The generator set must be of enclosed type.
BASE STABILITY, VIBRATION
To ensure proper operation of the generator, vibration should be minimized.
The generator should be vibration-isolated in order to minimize the effect of the vibration of
the generator on the piping required for the installation of the generator.
 Plumbing pipes
 Fuel piping
 Exhaust pipes
Improper use
Proper use
Therefore, when mounting suspended piping, care should be taken to ensure that the
distances between the transport clamps are not even so that the installation does not
resonate from the vibration and intensify its effect. Also, these clamps should be of spring or
rubber type to prevent vibration.
Evenly spaced suspended pipes can resonate, especially with low frequency vibrations,
causing the effect of the vibration to be transmitted over greater distances.

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 The muffler housing must be securely mounted. It must be clamped tightly on the
housing.
 The pipe and exhaust assembly in the exhaust system must be of ball bearing type. It
should not resist the movements that occur during warming up and cooling down.
 All fasteners should be of a type that prevents transmission of vibration.
 The muffler and piping in the generator room should be heat insulated. The customer
should be informed of this issue, with the necessary explanations on this requirement,
and should not be provided with guidance.
 Mufflers of several different make or model groups cannot be combined. You may get
technical support from the factory to combine silencers of the same make and model
groups.
 The offtake of the muffler system must be designed in such a way that neither rain nor
birds can ingress. As with enclosed groups, a flap or cap should be used for this
purpose.
 Sideways offtake should not be preferred. If so, the offtake should be in such a way
that people are not affected by the smoke.
Anti-vibration chocks
 As standard, all our gensets are equipped with anti-vibration chocks between the
frame and the generator set.
 Also, if necessary, groups can be equipped with base chocks.
 No base chocks should be supplied in case of a concrete base.
 Alimar generator sets are manufactured as per ISO8528-9 vibration standard.
 To minimize the vibration transferred to the floor, your generator set is equipped with
rubber dampers.
Floor Assembly
 Make sure that the surface on which the generator is to be mounted is leveled.
 The floor leveling should be performed by the customer.
 Where this is not possible, the generator should be supported underneath with block
gages. The whole group should be leveled.
 The group must be anchored to the floor (unless a base chock is used).
 Never install the group on soil or poorly concreted surfaces outdoors.
 Failure to follow these practices, especially in groups with double bearing alternators,
can lead to serious failures in a short time.
 Unleveled groups should not be started.
Placing the generator on concrete floor
 A space of at least 1 meter around the generator and at least 2 meters above the
generator should be allowed for cooling, service and maintenance of the generator
following operation.

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Concrete Base 1m
1m Generator 1m
Set
1m
Top View
Ceiling
2m (minimum)
t Concrete Base
Floor
Side View
Concrete Base
A preferred practice is to install the generator set on a concrete base. The concrete base
must be engineered to support the weight of the generator set. Its height should be around
200-300 mm. For more details, ask a professional for advice.
The floor on which the generator is mounted must be resistant to static weight and to
vibration caused by the operation of the engine.
The concrete base should be designed by a civil engineer (customer)
Where there is the possibility of occasional ponding of water in the selected floorage, the
concrete base height should be increased depending on the extent of the risk.
The concrete base should ideally be in a sandbox.

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Concrete's Load Carrying

Capacity
Concrete Base
Concrete Thickness
T: Concrete thickness (m) SBL: Load carrying capacity of concrete

2
(kg/m )
WT: Wet weight of the generator set (m) TW: Total weight of the generator set and
3
*2403: Density of the concrete (kg/m ) equipment (kg)
L: Length of concrete (m) W: Width of concrete (m)
W: Width of concrete (m) L: Length of concrete (m)
2403 kg/m³ : Aggregate properties of concrete are prescribed in TS 706 EN 12620 standard
(normal aggregate, 2000-3000 kg/m3).
Aggregate: Materials used in concrete such as crushed stone, sand and gravel, making up
approximately 60-80% of concrete.
GENERATOR ROOM
Ventilation of the Generator Room
 To ensure healthy operation of the generator, the heat emitted to the ambient by the
engine and alternator should be exhausted out of the room and the generator room
should be ventilated.
 The air offtake and intake window's surface area must be at least 1.5 times the
radiator's surface area.
 Depending on the wind direction, a wind barrier should be used.
 The distance to the barrier should be at least the width of the radiator.
 The air taken off should be prevented from escaping into the generator room, and
there should be a sealed bellows attachment between the air takeoff window and the
radiator frame.
 There should be no blockage in front of the air takeoff and intake window. An opening
of sufficient width should be allowed.
 In cases where the air is taken in and off through an areaway, the areaway's size
should not be smaller than that of the air takeoff. Areaway should be free of sharp
corners or column-like architectural structures that would create resistance.
 The windows facing outwards should be equipped with shutters to prevent the
generator from being affected by external weather conditions. The shutters should be
of "L" profile. Under no circumstances should manual opening and closing systems be
used.

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 For remote systems, the "Total Air Requirement Table" should be used. In cases
where necessary, the Engineering Department should be contacted.
INSTALLATION OF EXHAUST SYSTEM
 First, the route of the exhaust system should be

determined.
 Whether the mounting wall is suitable for the
clamps should be verified.
 The route should not pass through the walls of
living spaces.
 If multiple elbows are to be used, the elbow
Scale-free
diameter should be 50% larger than the pipe
diameter.
 The exhaust should be supported by suspending
it in a way to support the weight of the outlet
elbow and the turbocharger.
 Attention should be paid to ensure that the exhaust outlet pipe and the fresh air inlet
are not situated in the same place. Oxygen-poor air degrades the efficiency of the
engine.
 For 90° bends in the exhaust pipe system, the turning radius should be 3 times the
pipe diameter.
Recommendations on pipe size

Exhaust outlet size
6m to 12m 12m to 18m 18m to 24m
mm (inch)
6m (20ft) (20 to 40ft) (40 to 60ft) (60 to 80ft)
Remark: These sizes are intended for reference only. Technical specifications and custom
silencer applications may result in variations in pipe sizes.
Exhaust back pressure
Adverse effects caused by high levels of
exhaust back pressure;
 Excessive fuel consumption

 High exhaust temperature and related
failures

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 Reduced engine performance

 Shorter engine service life
P: Exhaust back pressure (psi)

L: Exhaust pipe length (m)
Q: Exhaust gas flow (m3/min.)
D: Exhaust pipe inner diameter (mm)
S: Specific exhaust gas weight (kg/m3)
Lifting
Lifting / Handling the Generator
The generator frame is specially designed to ensure easy handling of the generator.
Improper lifting of the generator may cause serious damage to components.
The generator can be lifted using a forklift truck, and can be cautiously pushed or towed by
the frame. If requested by the customer, the frame can be equipped with forklift brackets,
which are optional.

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Improper handling may damage parts of the generator and the generator may tip over due to
loss of balance.
Transporting the generator
 In enclosed groups, the generator should be handled by the frame. During lifting,
lifting lugs should not be used.
 The generator should be lifted using a lifting equipment that supports the weight of
the generator.
 Keep personnel away from the generator when it is lifted for transportation.
 Use guide ropes to prevent the generator set from skidding when lifted from the
ground.
 Ensure that the steel rope or chain to be used for lifting the genset does not cause
any damage to the parts where it contacts the genset.
 Before lifting, check the connection points for cracked welds or loose nuts and bolts.
 Attention should be paid to use proper equipment for horizontal transportation.
 Check that the crane equipment does not damage the generator set.
 Never place the generator set hard on the floor. This may damage the vibration
chocks.
 Do not place the generator set directly on the base chocks. Place base chocks once
the group is in place, lifting it slightly.
 Avoid lifting/placing the generator under strong windy weather conditions.
Towing
Trailer mounted generator
Preparation steps for towing
Check all fasteners on the tow truck and the trailer mounted generator for loose nuts, bent
metal, cracks, wear, etc.
Check the condition of all tires. Verify that all flash lamps and headlamps are in working
order.
Important: When towing a trailer mounted generator, the trailer weight may adversely affect
the maneuverability and braking distance.
 Observe all traffic rules, standards and other regulations when towing trailer mounted
generators. These include the required equipment and speed limits, which are clearly
specified in the regulations.
 Never allow personnel to climb on the generator while it is being towed.
 Ensure that no personnel stands on the towbar or between the mobile generator and
the towing vehicle.
 Avoid sloping and soft terrain and any other obstacles such as potholes, stones, etc.
 When maneuvering backwards, make sure that the ground behind and under the
mobile generator is free of debris.

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Parking
 Park the trailer mounted generator on a dry surface that supports its weight. If the
generator is to be parked on a slope, park the generator diagonally across the slope
and use chocks to prevent it from sliding downward. Do not park the generator on a
slope exceeding 15°.
Remark: The tires are subject to the warranty of the tire manufacturer.

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5. Periodic Maintenance
PERIODIC MAINTENANCE
Disconnect the system breaker switch and the battery during servicing.
A) DAILY CHECKS:
1. Check the engine, alternator, control and transfer panels visually.
2. Check the oil, water and fuel circuits for leaks.
3. Check the engine lubricating oil level. Complete if missing.
4. Check the fuel level in the fuel tank. Complete if missing.
5. Check the water level in the radiator and expansion tank, if any. Complete if
missing.
6. Check the battery, and add distilled water if necessary. Battery eyelids and gas
outlets should be open.
7. Check the air filter if the generator group is operating in a dusty environment.
B) MAINTENANCE AFTER THE FIRST 50 HOURS OF OPERATION:

1. Replace the engine oil, oil filters and by-pass filter.
2. Check the fasteners on the engine. If loose, tighten them.
3. Check the condition of the air filter. Replace if necessary. Check the pipes and
clamps.
4. Check the charge and electrolyte level of the battery.
5. Drain the contents of the fuel filter's water drain.
C) PERIODIC MAINTENANCE AT 250 HOURS OR 6 MONTHS OF OPERATION:

1. Repeat checks B.
2. Check the radiator fan belt for proper condition and tension.
3. Check the radiator cores. Clean if dirty.
4. Check the engine installation and connections, tighten if necessary.
5. Replace the engine's water filter, if fitted.
D) PERIODIC MAINTENANCE AT EVERY 500 HOURS OR 1 YEAR OF OPERATION:

1. Repeat checks B and C.
2. Drain the deposits from the fuel tank by unscrewing the fuel tank's deposit plug.
3. Check the oil, fuel and coolant pipes and clamps and replace if necessary.
4. Check the valves for proper adjustment. If necessary, adjust according to the
engine manual or request service from an authorized dealer.
E) PERIODIC MAINTENANCE AT EVERY 1000 HOURS OR 2 YEARS OF

OPERATION:
1. Repeat checks B, C and D.
2. Check the alternator.
3. Check the starter motor.
4. Replace the coolant with fresh one.
5. Check the fan blades.

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6. Check and then clean the turbocharger bearings, blades and diffuser.
7. Check and then clean the contacts of the transfer panel switch.
 Run the generator for at least 10 minutes a week.
 Following the oil change, crank the engine 3 times for at least 10 seconds before
starting the engine and ensure that the engine is lubricated. Then check the oil level
again 10 minutes after the last cranking.
 Allow the engine to reach ambient temperature when adding coolant. Never add
water to a hot engine.
The scheduled maintenance on the genset must be performed by authorized service centers
or trained personnel. Unqualified personnel should refrain from performing any interventions
other than cleaning. Take all necessary precautions before starting maintenance to prevent
the generator from starting during maintenance.

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6. Generator Startup and Panel
Checks and Operations Required Before Starting the Generator

 Make a thorough visual inspection of the generator and its equipment before starting
the generator. Check whether there are any fractures, cracks, breaks, leaks or loose
parts. In case of a fault, do not attempt to start the generator until the fault is
corrected.
 Make sure that there are no foreign objects on the generator.
 Check the fuel level in the daily fuel tank. Refuel if in short supply.
 Check the oil in the engine. If lacking, add the recommended oil up to the maximum
level.
 Unscrew the radiator cap and check the water level in the radiator. If not enough, add
water. The water level should be 25-30mm below the water refilling neck.
 Use antifreeze taking into account the coldest weather conditions of the location
where the generator will be used. A mixture of 50% antifreeze and 50% water will
provide a suitable mixture in every region in Turkey. Refer to the related graph for
extremely cold regions.
 Check the radiator's air outlet hood, remove anything that may obstruct the exhaust,
check the air intake, offtake and exhaust gas outlets in general.
 Check the air filter's impurity indicator and replace the air filter if necessary.
 Always tighten loose battery terminals using a wrench and keep the terminals clean.
 Check if the circuit breaker output switches, if any, are in the OFF position.
 Verify that the emergency stop button is not pressed.
Procedures to follow after the generator starts

 Check if there is any unusual noise or vibration in the generator.
 Check the exhaust system for leaks.
 Check the fuel system for fuel leaks.
 Check the engine temperature and oil pressure on the panel. The oil pressure should
be at its normal value within 8 to 12 seconds after the generator starts.
 Monitor the generator output voltage and frequency from the displays on the panel.
Check if the voltage between phases is 400 V and the voltage between phase-neutral
is 230 V. The output voltage is adjusted at the factory, so do not attempt to adjust the
voltage settings.
 Check if the no-load frequency is at 51 to 52 Hz for generators with mechanical
governors and at 50 Hz for models with electronic governors.
 Where there is no preheater, run the generator idle for 3 to 5 minutes to warm it up
and then put it on load (manual models).
Loading for Manual Models
 Turn ON the Alternator Output Switch on the panel.

 Set the Load Switches (or fuses) on the distribution panel to ON position one by one.
This prevents the generator from being suddenly loaded with full load. Failure to do

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so may cause the engine to stall or the alternator winding insulation to degrade or
even burn out.
 Before stopping the generator, turn the Alternator Output Switch OFF.
 Allow the engine to run without load for two minutes after unloading to allow the
engine to cool down.
 Never start the genset in case of any fault before such fault is corrected.
 With the engine running, check for oil, fuel and/or water leaks.
 Avoid running the engine at low load (<30%) or no load for long periods.
 Distribute single-phase loads evenly on each phase (U, V, W).
 In Automatic Generators, the load will be switched on automatically.
Panel
Generator's control systems
The generator uses electronic control systems to control and monitor the generator
operation. Depending on the needs of the generator, one of the standard control systems can
be applied. The control panel allows starting and stopping the generator, monitoring its
operation as well as the output voltage. In addition, it automatically stops the generator in
case of low oil pressure, high engine temperature and various fault conditions.
Requirements for operation in automatic mode
 Press the AUTO button to turn the automatic transfer device on the front panel of the
genset to Automatic mode.
 The generator is in standby mode when the mains voltage is within normal limits.
Even when one of the mains phases is interrupted or if the mains voltage drops or
rises excessively, the generator comes into operation within 14 to 15 seconds and
starts to supply the installation. In cases where the mains voltage is restored or
reaches within normal limits, the system starts to be fed from the mains within 1
minute. In such case, the generator's engine will run for another 2 minutes to cool
down and then stop.
Automatic Controller
ALM 929
This device can be programmed using the buttons and LCD display on the control panel or
by using PC interface software.
ALM - 929 is a multi-functional, reliable and cost-effective next generation generator
controller with a wide range of communication capabilities.
The device meets the world's most stringent safety, vibration, EMC and environmental
standards in the industrial category.
The software can be easily updated via the USB port.
The Windows-based computer software allows monitoring and programming via USB, RS -
485 and GPRS.

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The software Rainbow Scada allows you to remotely monitor and control multiple generators
from a single centralized location.
Specifications
 GSM – GPRS
 Built-in GPRS modem (optional)
 GSM – SMS
 E-mail
 Modbus
 USB Port
 RS – 485
 RS – 232
 J1939 – CANBUS
Functions
AMF device with seamless transition
ATS device with seamless transition
Remote actuation device
Manual actuation device
Motor controller
Remote monitoring & control
V & I waveform oscilloscope display

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V & I harmonic analysis

Current transformer by generator or load
Key Functions
Key Function
Switch to TEST mode. The generator starts and takes the load.
Switch to RUN mode. The generator starts and stands by without taking
the load.
Switch to AUTO mode. The generator starts and takes the load if
necessary.
Switch to OFF mode. The generator stops.
Switch to the next screen in the same group. LAMP TEST key
Switch to the previous screen group.
Switch to the next screen group.
Switch to the previous screen in the same group. The ALARM RELAY is
reset.
Manual check of the MAINS CONTACTOR in RUN mode.
Manual check of the GENERATOR CONTACTOR in RUN mode.
Holding down these two buttons for 5 seconds enables the

PROGRAMMING mode.
Reset to factory settings.
Holding down these two buttons simultaneously for 5 seconds resets the
service time counters.

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ComAp – Alimar
Key Function
1. Allows you to move left on the screen or switch modes. If in the
current display screen, you can switch between modes.
2. Allows you to move right on the screen or switch modes. If in the
current display screen, you can switch between modes.
3. Horn Reset: Resets the horn when pressed.
4. Error Code Reset: Deactivates the confirmation alarm and outputs

when pressed.
5. Up Key: Allows upward movement on the screen or increments the
value.
6. Page Key: Switches between screen pages.
7. Down Key: Allows downward movement on the screen or decreases

the value.
8. Enter Key: Confirms the adjustment or switches to the previous page.
9. Start Key: Use only in manual mode. Press this key to start the
running procedure of the engine.
10. Stop Key: Use only in manual mode. Switches the engine to cooling
mode (runs for 120 seconds and stops) at the first press.
When pressed for the second time, the engine immediately stops.

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11. GCB: Test mode only. Switches the generator contactor on or off.
MCB 12: Test mode only. Switches the contactor of the mains generator
on or off.
13. Genset status indicator
14. Mains status indicator
15. Display: 132x63 pixel screen
16. GCB ON: Generator contactor activated

17. MCB ON: Generator contactor activated

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Manual Operation
 Set the ignition switch from position "0" to position
"1".
 Meanwhile, the manual controller's warning lamps
will illuminate.
 Then press the "start" button once to start the
engine. This will start the engine of the generator.
 Check to see whether the warning lamps on the
panel are illuminated and whether the readings on
the indicators are normal.
 Run the generator idle for 1 minute. During this time
the generator will warm up.
 Meanwhile, the receivers (loads) in the installation
must be in the off position.
 Switch the main switch to position "1".
 Set the inverter switch in the installation from "MAINS" to "GENERATOR" position.
 Switch on the receivers one by one.
 Check the phases' current and voltage using the commutator of the ammeter and
voltmeter.
 When the mains is connected, set the inverted switch to the "MAINS" position.
 Run the generator idle for 1 minute to cool down the engine. Then press the stop
button and wait for the engine to stop. Finally, set the ignition switch to the "0"
position.
1. On / Off Switch: Is used to switch the device on and off. When the switch is set
to the "0" position, the device is off and consumes no power.
2. Start Button: Is used to start the generator and to adjust the program

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parameters.
3. Start LED: This LED allows to monitor the operation of the engine from the start
until the engine is stopped.
4. Stop Button: This LED is used to monitor when the engine is not running and/or
stops.
5. Stop LED: This LED indicates that the engine is not running and/or has
stopped.
6. Enter Button: When pressed for 5 seconds, the program menus are accessed.
Each time the button is pressed briefly, the engine speed, alternator frequency
and operating hours are displayed on the display (7).
7. Value Display: This screen displays program parameters, measured values and
fault codes.
8. Failure to Start: If the engine still has not started after the number of starting
attempts defined in parameter P10, this LED flashes and the panel trips. The
fault is reset by setting the On/Off switch (1) to the "0" (off) position and back to
the "1" (on) position.
9. High Temperature Fault: This LED flashes and the panel trips when the oil
pressure drops. The fault is reset by setting the On/Off switch (1) to the "0" (off)
position and back to the "1" (on) position.
10. Low Oil Pressure Fault: This LED flashes and the panel trips when the oil
pressure drops. The fault is reset by setting the On/Off switch (1) to the "0" (off)
position and back to the "1" (on) position.
11. Generator Frequency and Speed: This LED is lit when the alternator frequency
and engine speed are displayed in the value display (7). For accessing the
values, the ENTER Button (6) is used.
12. Engine Running Time: This LED illuminates when the engine operating hours
are displayed in the value display (7). For accessing the values, the ENTER
Button (6) is used. The engine running time is displayed on the screen with
EA0M - 36.R, increasing in hours each time the engine starts.
13. Speed Fault: The LED flashes and the panel trips when the alternator frequency
and engine speed exceed the set limits. The fault is reset by setting the On/Off
switch (1) to the "0" (off) position and back to the "1" (on) position.
14. Charging Alternator Fault: Once the charging alternator voltage exceeds the set
class values, the LED flashes and the panel trips. The fault is reset by setting
the On/Off switch (1) to the "0" (off) position and back to the "1" (on) position.
15. Generic Alarm: This LED flashes for all alarms other than those mentioned
above. Scrolling over this LED with the ENTER button (6) displays the code of
the alarm on the value display (7).
Maintenance of the Device

The device should be repaired by trained personnel. Disconnect the device from the power
supply before accessing internal parts of the device.
Do not clean the device using hydrocarbon-containing solutions (such as Petroleum,
Trichlorenthylene). Using such solutions to clean the device reduces the mechanical
reliability of the device.

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Clean the outer plastic part of the device with a cloth dampened with ethyl alcohol or water.
The device has an average lifetime of 10 years.
Things to Consider Before Starting Up

A balanced load distribution in phases is essential for trouble-free operation of your generator
in both manually and automatically controlled generators. Keeping the load distribution
between phases within the tolerance values of -/+ 15% is the responsibility of the user. Any
failure due to inadequate and/or incomplete maintenance shall be out of the scope of the
warranty.

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7. Troubleshooting
FAULTS THAT MAY OCCUR IN MANUAL GENERATORS

a- The diesel engine doesn't crank:
 The battery may be discharged and not supplying the required voltage. If there
are no problems with the battery voltage, check the battery terminals and
tighten if loose. The battery terminals may be loose or oxidized. If the
terminals are oxidized, clean them. Check the voltage level of the battery
using a voltmeter. Charge if the battery voltage is low. Check the battery acid
level. Complete if missing.
 The ignition switch may be faulty. Replace the ignition switch with a new one if
there is no (+) DC voltage at the start terminal when the ignition switch is set
to the start position even though there is (+) DC voltage at the battery
terminal.
 The starter motor may be faulty. Check the starter motor ( + / ) battery cables.
Check whether a DC voltage is supplied to the start terminal ( + ) when the
ignition key is set to the start position. Contact our after-sales service
department for replacement of the starter motor if the starter motor still does
not operate even though a DC voltage (+) is applied to the starter motor start
terminal.
b- Diesel engine cranks but does not start:

 The diesel engine may be out of fuel. Purge the air from the fuel passages and
refuel the diesel engine to start the engine.
 The fuel system of the diesel engine may have a blockage or air in it. Clean
the diesel fuel system. After having unblocked the fuel lines, bleed the air from
the fuel passages.
terminal.
c- While supplying the load, the switch opens and cuts off the supply:
 The generator may be drawing excessive current. Check that the generator
power is not drawn more than the rated current. Monitor the current in the load
ammeters. Reduce the loads if the current is high.
FAULTS THAT MAY OCCUR IN AUTOMATIC GENERATORS
a- No supply from the mains even though the mains is available:
 The mains voltage may be out of the lower and upper limit range set by the
parameters. Check the mains voltage at the automatic controller.

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 There may be no 220 V AC voltage at the mains contactor coil end. Refer to
the electrical controller connection diagram, power line and measuring circuit
diagrams and check whether 220 V AC is supplied to the contactor coil.
 The mains contactor coil may be burnt out. The contactor's failure to draw
although 220 V AC is supplied to the mains contactor indicates that the
contactor coil is burnt out. Replace with a new one.
 The operation mode of the panel may not be automatic. Set the switch on the
control panel to the automatic position.
b- The generator doesn't switch on when the mains go down:

 The battery may be discharged and not supplying the required voltage. If there
are no problems with the battery voltage, check the battery terminals and
tighten if loose. The battery terminals may be loose or oxidized. If the
terminals are oxidized, clean them. Check the voltage level of the battery
using a voltmeter. Charge if the battery voltage is low. Check the battery acid
level. Complete if missing.
 The starter on the generator may be faulty. Check whether the starter motor is
energized. The starter's failure to start the diesel even though the power is
supplied indicates that the starter motor is faulty. Contact the authorized
service center.
 The operation mode of the panel may not be automatic. Set the switch on the
control panel to the automatic position.
c- When the mains is cut, the diesel engine cranks but does not start:
 The diesel engine may be out of fuel. Purge the air from the fuel passages and
refuel the diesel engine to start the engine.
 The fuel system of the diesel engine may have a blockage or air in it. Clean
the diesel fuel system. After having unblocked the fuel lines, bleed the air from
the fuel passages.
terminal.
d- The diesel engine is running but the generator fails to supply the load:
 The alternator voltage may be out of the rated values. Check the alternator
voltage and verify that it is 400 V between phases and 231 V between phase-
neutral.
 The alternator contactor coil may be burnt out. If the contactor fails to draw
even though there is 220V AC voltage at the contactor coil terminals, the coil
may be burnt out. Replace with a new one.
In cases where some of these predictable faults cannot be corrected using the recommended
remedies, or if other faults or malfunctions arise, please contact the authorized service
center.

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Fuel and Fuel Tank
Diesel Injector Diesel Engine
Daily Tank
Generator Power Maximum Fuel Maximum Vertical Maximum Recommended

Stand-By (kVA) Pipe Length Height Number of Pipe Pipe Diameter
Fittings (inch)
0-800 6 0.9 6 1’’
800-1500 6 0.9 6 1 ½’’
1500-2200 6 0.9 6 2’’
Table of Recommended Pipe Diameters for Fuel Installations

Fuel Tank Height
In the case where the height of the fuel tank is more than 2m above the center of the
crankshaft, check valves are required. If the maximum fuel level does not exceed 2m above
the center of the crankshaft, the minimum fuel level should be at least 15 cm above the fuel
injection pump. If the fuel level exceeds 2m, the engine may be damaged. The fuel pump
inlet will not be able to maintain proper fuel pressure if the fuel level is lower than 15cm. That
is, the tank fuel level should not be above the injectors and not more than 180 cm below the
fuel pump.

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Check Valve
Fuel
Tank
Typical fuel diagram with the fuel tank located downstream of the engine
If fuel tank is raised to a height of about 1.5m above the injectors, 2 check valves are
additionally installed to protect the engine from hydraulic lockout as shown in the following
figure. These valves have a protection capacity from 0 to 1.5m height. If the fuel tank is to be
above 1.5m, a flotation tank is required.

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Check Valve
Main
Fuel
Tank
Fuel tank and check valve connection positioned approximately 1500mm above the fuel
return
Main
Fuel
Tank
Valve
Filter
Daily Fuel Tank
Flotation tank used with elevated fuel tank

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8. Quality Standards

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9. Warranty Conditions / User's Obligations
1) The warranty period starts upon delivery (commissioning and start-up) of the
genset and is 2 years or 1000 hours. The warranty period starts to run
automatically for generators that are not commissioned within 6 months as of the
invoice date.
2) The generator group, including all parts thereof, is covered by our Company's
warranty.
3) In case of failure of the genset within the warranty period, the time spent in repair
shall be added to the warranty period. The maximum repair time for the group is
20 working days. This period starts to run from the date of notification of the failure
related to the generator group to the Alimar's regional or authorized service center
or, in the absence thereof, to the respective distributor, dealer or representative
office. The consumer may report the failure by phone, fax, e-mail and similar
means. However, in cases of discrepancies, the burden of proof lies with the
consumer. In cases where the generator failure is not resolved within 10 working
days, Alimar shall be obliged to allocate another generator with similar features for
the use of the consumer until the generator is repaired.
4) If the generator malfunctions during the warranty period due to defects in material
and workmanship or assembly, the generator shall be repaired without any charge
under the name of labor, part costs or any other name.
5) In the event that the product is found to be defective, the consumer may exercise
one of the following rights under Article 11 of the Law No. 6502 on the Protection
of Consumers:
a) Rescinding the contract,
b) Asking for a discount on the sale price,
c) Asking for free repair,
d) Requesting the replacement of the sold product with a defect-free
equivalent.
6) If, in case the consumer exercises the right to free repair, the generator:
 Malfunctions once again within the Warranty period,
 Cannot be repaired within the maximum time required for its repair,
 Is found to be unrepairable according to the report issued by the authorized
service center, dealer, manufacturer or importer;
The consumer may ask the seller to return the generator set free of charge, to
reduce the price in proportion to the defect or, if possible, to replace the
generator set with a defect-free equivalent. The seller cannot decline the
consumer's request. The seller, manufacturer and importer shall be jointly and
severally liable for the fulfillment of such request.
7) The consumer shall be entitled to resort to the Consumer Arbitration Committee or
the Consumer Court in the place where the consumer has his/her place of
residence or where the purchase took place in case of disputes arising out of the
exercise of his/her rights under the warranty.

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8) The consumer may apply to the General Directorate of Consumer Protection and
Market Surveillance of the Ministry of Customs and Trade if the seller fails to
provide this Warranty Certificate.
9) All maintenance services, inspections, spare parts and other services outside the
scope of the warranty are subject to a charge.
Out-of-Warranty Conditions:
1. The purchased generator group shall be commissioned by Alimar Generator's
authorized service centers, the user shall not commission the generator group
himself/herself or have it commissioned by another service center. Otherwise, the
generator group falls outside the scope of warranty. Such commissioning shall be
valid only for the place where the operation is performed, and if the generator is to
be used in a new place, the generator shall be commissioned again by Alimar
Generator's authorized service centers. The second commissioning procedure
shall be at the user's expense.
2. The user shall be obliged to have the periodic maintenance of the generator group
carried out by Alimar Generator's authorized service centers on a regular and
timely basis and in return for a fee. If any of these maintenance operations are
neglected, the warranty will be void.
3. In case of malfunctions caused by the use of materials not approved by Alimar
Generator, malfunctions caused by negligence, improper use, use at inappropriate
power, improper positioning, storage under improper conditions and repair,
maintenance or interventions made by unauthorized service centers and persons,
the generator shall fall outside the scope of the warranty.
4. The damages and malfunctions caused by natural disasters, earthquakes,
blizzards, landslides, fires, torrents, floods or mains electricity shall not be covered
by the warranty.
5. The failures arising from the use of the generator group contrary to the
instructions for use shall not be covered by the warranty.
6. The warranty shall be void if the labels of the genset are removed or altered.

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10. Customer Service
If you wish to contribute to our product and service quality, please e-mail your suggestions to
[email protected] and report maintenance and malfunction-related issues to
[email protected] or contact us at 444 54 59.

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CERTIFICATE OF WARRANTY
MANUFACTURER, IMPORTER COMPANY
CENTER CONTACT INFORMATION Factory Contact Information

Kazım Karabekir Caddesi Örnek Han No. 27/15-2 Organize Sanayi Bölgesi 1. Cadde No. 18
İskitler Altındağ/ANKARA Altıeylül/BALIKESİR
Phone Fax Phone Fax
0312 384 15 80 0312 342 17 51 0266 290 80 10 0266 246 54 68
WEB www.alimar.com.tr e-mail [email protected]
Manufacturer, Importer, Authoritative Approval /

Date, Stamp, Signature
PRODUCT SELLER
Type Title
Generator
Brand
ALIMAR GENERATOR
Serial No.
Brand
Address
Engine
Model
-
Serial
No.
Brand
Phone & Fax
Alternator
Model
Serial Invoice Date Invoice No.

No.
Delivery Date
Authorized Approval
Delivery Location Date, Stamp, Signature
Max. Time To Repair 20 Work Days (Within the

Turkey’s Boundaries)
Warranty Time 2 Years

-

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ALİMAR
Ankara Center
Uzay Çağı Caddesi No:2 Ostim-Yenimahalle / Ankara - TURKEY
Phone: (+90 312) 354 59 48 (Pbx)
Fax: (+90 312) 354 50 45
E-mail: [email protected]
Factory
Organize Sanayi Bölgesi 1. Cadde No:18 Altıeylül / Balıkesir - TURKEY
Phone: (+90 266) 246 54 78
Fax: (+90 266) 246 54 68
www.alimar.com.tr

7

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ALIMAR GENERATOR

ALIMAR GENERATOR OPERATING MANUAL 2

ALIMAR GENERATOR OPERATING MANUAL 3

 "Danger" and "Warning" labels on the

ALIMAR GENERATOR OPERATING MANUAL 4

ALIMAR GENERATOR OPERATING MANUAL 5

2. Safety and Health

! Please read the operating manual carefully.

! Never start the generator if there is an unsafe condition.

 If you identify an unsafe condition related to the generator malfunction, please

! Avoid standing or leaning on parts that cannot support your weight.

! Do not operate the genset in a wet or humid environment.

! Battery electrolyte contains acid.

ALIMAR GENERATOR OPERATING MANUAL 6

! Prolonged exposure to more than 85 dB of noise can lead to hearing loss.

! Ensure that the generator's electrical wiring is connected by trained and

! Check the circuit breaker before starting the generator.

! Protect your body and garments from Moving Parts.

ALIMAR GENERATOR OPERATING MANUAL 7

! Fire and Explosion Hazard

ALIMAR GENERATOR OPERATING MANUAL 8

 Refuel the generator where you see the refueling label.

ALIMAR GENERATOR OPERATING MANUAL 9

ALIMAR GENERATOR OPERATING MANUAL 1

1 Diesel Engine 9 Exhaust Pipe Outlet

ALIMAR GENERATOR OPERATING MANUAL 1

ALIMAR GENERATOR OPERATING MANUAL 1

4. Storage, Lifting, Installation, Assembly

 Store the engine in a dry area with a constant temperature.

ALIMAR GENERATOR OPERATING MANUAL 1

Engine start-up following short-term storage

 Remove the tapes and warning labels on the engine.

 Run the engine until the engine coolant reaches 70°C.

ALIMAR GENERATOR OPERATING MANUAL 1

 Store the engine in a dry place with a constant temperature.

 Remove all the tapes and warning labels on the engine.

 Drain and flush the water system.

 Check the fan belt.

ALIMAR GENERATOR OPERATING MANUAL 1

 Uninterrupted and continuous,

ALIMAR GENERATOR OPERATING MANUAL 1

In the project design of the grounding system

 First, the location of the grounding system is determined.

ALIMAR GENERATOR OPERATING MANUAL 1

 Make sure that the application is on a flat surface.

ALIMAR GENERATOR OPERATING MANUAL 1

Battery state of charge Electrolyte density Voltage

50% 1.20 12.24

25% 1.17 12.06

Battery state of charge Electrolyte density Voltage

ALIMAR GENERATOR OPERATING MANUAL 1

75% 1.24gr/cm -45

25% 1.17gr/cm -15

DISCHARGE 1.14gr/cm -7,2

Replacing the Battery

 Turn the engine OFF. Remove all electrical charges.

NYY-Cable Section (mm²)

100 144.3 3x50+25

150 216.45 3x95+50

200 288.6 3x120+70