Use and Maintenance

of the Generating Set

Rev.2 of March 6, 2009

Bertoli s.r.l.
Via Tomasicchio 3/5
43013 Langhirano - Parma
Tel. 0521-861386 Fax: 0521-858265
Web: www.bertolisrl.it - E-Mail: info@bertolisrl.it

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 TABLE OF CONTENTS

1. GENERAL INFORMATION ....................................................................................................... 4

1.1 Purpose and field of application of the manual ................................................................ 4
1.2 Symbols........................................................................................................................... 4
1.3 Reference documents ..................................................................................................... 4
1.4 EC Declaration of Conformity .......................................................................................... 5
1.5 Applicable Standards and Legislative Provisions ............................................................ 5
1.6 Identification of the machine ............................................................................................ 6
1.7 Instrument panel.............................................................................................................. 7
1.8 Airborne noises and vibrations ........................................................................................ 7
1.9 Test, Warranty, and Liability ............................................................................................ 8
1.10 Ordering spare parts/Assistance ..................................................................................... 8

2. SAFETY REGULATIONS.......................................................................................................... 8
2.1 General precautions ........................................................................................................ 8
2.2 Safety provisions: installation and start-up ...................................................................... 9
2.3 Residual risks .................................................................................................................. 9
2.4 Safety symbols and labels ............................................................................................... 9
2.5 Personal protection equipment ...................................................................................... 11
2.6 Workstation ................................................................................................................... 11

3. CHARACTERISTICS OF THE GENERATOR......................................................................... 11

3.1 General characteristics.................................................................................................. 11
3.2 Control Panel................................................................................................................. 13

4. USE OF THE GENERATOR ................................................................................................... 15

4.1 Installation ..................................................................................................................... 15
4.1.1 Location ............................................................................................................... 15
4.1.2 Characteristics of installation facilities .................................................................... 15
4.1.3 Generating sets installation. ................................................................................... 18
4.1.4 Engine supply......................................................................................................... 18
4.1.5 Engine safety devices ............................................................................................ 19
4.1.6 Sets in metal enclosures. ....................................................................................... 19
4.1.7 Exhaust systems .................................................................................................... 19
4.1.8 Lubrication system ................................................................................................. 20
4.1.9 Electrical systems................................................................................................... 20
4.1.10 Portable extinguishers ............................................................................................ 20
4.2 Preliminary checks ........................................................................................................ 20
4.3 Deaeration of the fuel system ........................................................................................ 20
4.4 Start-up.......................................................................................................................... 21
4.5 Shut down ..................................................................................................................... 21

5. PROTECTIONS ....................................................................................................................... 21
5.1 Low oil pressure protection............................................................................................ 21
5.2 Engine high temperature protection............................................................................... 22
5.3 Fuel reserve protection.................................................................................................. 22
5.4 Short circuit and overload protection ............................................................................. 22

6. MAINTENANCE ...................................................................................................................... 22
6.1 Introduction.................................................................................................................... 22
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 6.2 Periodic engine maintenance ........................................................................................ 23
6.3 Engine oil and filter change ........................................................................................... 23
6.4 Cleaning the air filter...................................................................................................... 24
6.5 Replacing the fuel filter .................................................................................................. 24
6.6 Checking the coolant ..................................................................................................... 25
6.7 Checking the tension of the v-belts................................................................................ 25
6.8 Alternator maintenance ................................................................................................. 25
6.9 Battery maintenance...................................................................................................... 25
6.10 Storage.......................................................................................................................... 26
6.11 Inactive periods ............................................................................................................. 26
6.12 Table of scheduled operations....................................................................................... 26
6.13 Troubleshooting............................................................................................................. 27

7. TRANSPORT AND MOVING .................................................................................................. 27

7.1 Introduction.................................................................................................................... 27
7.2 General Warnings.......................................................................................................... 28
7.3 Lifting the machine ........................................................................................................ 28

8. DISCARDING OF THE MACHINE .......................................................................................... 28

8.1 Disposal......................................................................................................................... 28
8.2 Demolition materials ...................................................................................................... 28

9. WIRING DIAGRAM ................................................................................................................. 29

10. MANUALS FOR THE USE AND MAINTENANCE OF THE COMPONENTS ....................... 29

11. DECLARATIONS OF COMPONENT CONFORMITY ........................................................... 29

12. SPARE PARTS LIST............................................................................................................. 29

13. MAINTENANCE OPERATION REPORT .............................................................................. 30

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 1. GENERAL INFORMATION
Read this manual carefully before servicing the machine.

IF THE INDICATIONS PROVIDED IN THIS “USE AND MAINTENANCE MANUAL” ARE NOT DULY
APPLIED, THE PRODUCT WARRANTY IS TO BE CONSIDERED NULL AND VOID

1.1 Purpose and field of application of the manual

Thank you for choosing a Bertoli product.

This manual was drawn by the Manufacturer for the purpose of supplying the information and instructions necessary
for the correct and safe use and maintenance of this product and constitutes an integral part of the generating set
package. Keep this manual for as long as you own the product and protect it from deterioration. This manual must
remain with the generating set if ever transferred to a different site or to a new user or owner.

The information contained herein is intended for all persons involved in the operating life cycle and who have access to
the generating set, as well as to its actual installation; this implies all those individuals who will actually carry out
specific activities and those who will supervise them.

The manual defines the purpose for which the machine was constructed and contains all the information necessary to
guarantee its safe and correct use. Constant observance of the indications contained herein guarantees operator
safety, operating cost efficiency, and an increased life span of the machinery itself.

It is strongly advised that you read the contents of this manual and the reference documents carefully; this is the only
way to ensure the proper long-term functioning of the generating set, its reliability, and to prevent possible property
damage and personal injury. The drawings are supplied as way of example. Even if the equipment you possess differs
noticeably from the illustrations contained in this manual, the safety and information about it are still valid.

In order to facilitate the consultation of the manual, it has been subdivided into sections that identify the main concepts;
for quick reference of a specific topic, use the index provided.

Note: the information contained in this publication was correct at the time of printing. The Manufacturer, in keeping with
the product development and updating policy, reserves the right to make modifications without prior notice.

1.2 Symbols
Important sections of text that must not be neglected are highlighted in bold print and preceded by the
symbols illustrated and defined below.
(DANGER) Indicates that it is necessary to pay attention in order to prevent serious
consequences that may cause personal injury or death.
(CAUTION) A situation that may occur during the life span of the product, system, or
installation considered at risk with regards to personal injury, property or environmental damage, or
economic loss.
(WARNING) Indicates that it is necessary to pay attention in order to prevent serious
consequences that may cause damage to material goods, resources, or the product itself.
(NOTICE) Particularly important information.

1.3 Reference documents

The “Instructions for Use” supplied with each generating set consist of a collection of documents, including this manual
of general information. Normally, the following documents are supplied:

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a – Manufacturer’s EC Declaration of Conformity
b – Instruction manual for the use and maintenance of the generating sets (this manual).
c – Generating set installation manual.
d – Electrical wiring diagram of the command, control, and power panel.
e – Manual for the Use and Maintenance of the Motor.
f – Manual for Use and Maintenance issued by the Alternator Manufacturer.
g – Any other manuals for optional accessories issued by respective Manufacturers.
h – List of Bertoli Customer Assistance Centres.
i – Warranty Certificate
j – Warranty card

1.4 EC Declaration of Conformity

The generating sets manufactured by Bertoli for the European Community comply with the pertinent EEC Directive
(see 1.5) and include an "EC Declaration of Conformity".

1.5 Applicable Standards and Legislative Provisions

All the Bertoli diesel generating sets are designed and produced in compliance with current legislation. The generating
set and its components are produced in compliance with the following applicable Standards and Directives:
UNI EN ISO 12100-1/2: Safety of machinery. Basic terminology methodology.
UNI EN 12601: Reciprocating internal combustion engine driven generating sets
EN 294: Safety of machinery. Safety distances to prevent danger zones being reached by the upper limbs.
ISO 3046: Reciprocating internal combustion engines.
IEC 34-1: Rotating electrical machines.
ISO 8528 -1: Reciprocating internal combustion engine driven alternating current generating sets.
EN 60204 -1 (CEI 44-5):
-Safety of machinery.
-Electrical equipment of machines.
EN 60439 -1 (CEI 17-13/1): Low-voltage switchgear and control gear assemblies (LV panel).
EN 50081-1/2 (Electromagnetic Compatibility - EMC): Generic emissions standards
-Part 1 – standards issued on residential, commercial, and light industry environment
-Part 2 – industrial environments.
EN 50082-1/2 (Electromagnetic Compatibility - EMC): Generic immunity standards
-Part 1 – standards issued on residential, commercial, and light industry environment
-Part 2 – industrial environments.
2006/42/CE (recodification of Dir. 98/37/CE and subsequent modifications): Essential health and safety
requirements relating to the design and construction of machinery and safety components ("Machinery” directive).
2006/95/CEE and subsequent modifications contained in Directive 93/68/CEE: Electrical equipment designed for use
within certain voltage limits (“Low Voltage” directive).
Circ.M.Interno (Ministry of the Interior Circular) of August 31, 1978 n.31 (Text coordinated with Circular n° 12
of July 8, 2003) Safety standards for the installation of internal combustion engines coupled with electric generators or
processing machinery.

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 1.6 Identification of the machine
See Picture 2 ref. 1
1 – Manufacturer
2 – Machine model
3 – Year of construction
4 – Continuous power
5 – Rated voltage
6 – Serial number
7 – Declared frequency
8 – Rated current
9 – Machine operating speed
10 – Phases
The data that identifies the machine model, the serial number, and the year of construction must always be
communicated to the Manufacturer when requesting information, spare parts, etc.

Picture 2

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 1.7 Instrument panel

See Figures 3 and 4

Each generating set comes equipped with an instrument panel with the following commands and control units:
1 – Voltmeter
2 – Ammeter
3 – Frequency meter
4 – Hour counter
5 – Magnetothermal switch
6 – Protection fuses
7 – Motor protection module with relative warning lights
8 – Volumetric switch
9 – Utility outlets
Picture 4 – Motor protection module (key start panels)

1.8 Airborne noises and vibrations

The measurement of noise intensity relative to machine emissions was carried out according to current standards. The
measurement of acoustic pressure was carried out in correspondence to the workstation at 7 m from the surface of the
machine under normal operating conditions.
The measurements of noise intensity of the machine are reported in the test sheet attached to all the documentation.
The values reported are emission levels and not necessarily safe operating levels. Even though there is a correlation
between the emission and exposure levels, this cannot be used reliably to establish if further precautions are required
or not. Among the factors that influence the effective level of exposure of operators there are the characteristics of the
working environment, other sources of noise, like machine noise and other adjacent processes, and the length of time
an operator is exposed to the noise. Furthermore, the acceptable exposure levels may vary from country to country.
However, the information contained herein allows the user of the machinery to carry out a better evaluation of potential
danger and risk.
The measurement of vibrations was not carried out because it was evaluated as being considerably less than the risk
level due to the fact that the operator must stand near the generating set only for short periods of time (turning on,
turning off, and adjustment).

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 1.9 Test, Warranty, and Liability
Test
The equipment is shipped to the client after having passed the tests requested by the manufacturer according to
current legislation.
Warranty
The manufacturer agrees to guarantee the equipment described in this manual for a period of 12 months from the date
of delivery and agrees to repair or replace parts that are defective or malfunctioning within this time period provided that
the machine has been used correctly and according to the indications found in this "Use and maintenance manual".
The warranty becomes null and void if:
Personnel not authorized by BERTOLI have tampered with the equipment.
Non-original spare parts have been used.
The machine has not been maintained properly or has been used improperly.
The defective parts replaced under warranty were not returned to BERTOLI.
The warranty excludes parts of the equipment that are subject to wear.

Liability
BERTOLI is in no way liable for incorrect functioning or generic breakdowns caused by the inappropriate use of the
equipment or by servicing and/or tampering carried out by persons other than those authorized by BERTOLI.

1.10 Ordering spare parts/Assistance

Every request for spare parts or Assistance must be made by phoning the number below:
Bertoli – Technical Assistance/Customer Service Tel. 0521/861386 Fax. 0521/858265 e-mail info@bertolisrl.it
Always specify:

Machine model;
Serial number;
Code of the piece to be ordered;
Quantity required;
Shipping method;
Contact person.

2. SAFETY REGULATIONS

2.1 General precautions

Before starting up the generating set and before beginning any lubrication or maintenance operations, it is necessary
for the technician in charge to have read and understood all the WARNINGS and CAUTION and DANGER notices in
this manual and in further technical documentation supplied with the equipment. In any case, the Manufacturer cannot
foresee all the possible circumstances that may lead to potential risk under actual operating conditions and during use
of the generating set. The various operations and/or procedures for maintenance that are not explicitly recommended
or indicated in the user manuals must always be notified to the Manufacturer and approved by them. If a procedure that
has not been specifically recommended by the manufacturer should have to be carried out, it will be the responsibility
of the user to verify that it is safe and will not cause property damage or personal injury. The Manufacturer declines any
and all liability for property damage or personal injury if the safety regulations herein are not observed.
Examine the safety labels applied to the machine carefully and follow the indications they give.
-Do not allow the generating set to be used by unqualified personnel or those without adequate specific training.
-Do not allow children or animals near the generating set while in operation.
-Do not touch or access the generator with wet hands as it is a potential source of electric shock if used inappropriately.
-Any control on the generating set must be carried out when the engine is turned off; only specialized personnel must
carry out controls on the set while functioning.
-Do not breathe in the combustion fumes as they contain harmful substances.
-Use the generating set with the access doors closed.
- Never touch the engine or alternator body with your hands while the generating set is functioning or still hot.

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- When maintenance operations are carried out on the generating set, disconnect the negative terminal of the
start-up battery to avoid accidental starting.
-In case of fuel or oil leaks, carry out an accurate cleaning to prevent fire hazard.

- Access is not allowed to persons with pace-makers, due to possible electromagnetic interference on
cardiovascular devices.
-In case of fire, use an approved extinguisher. Never use water.
If a problem should arise or you need clarification, contact the BERTOLI SERVICE office.

2.2 Safety provisions: installation and start-up

- The personnel responsible for the installation and start-up of the generating set must always use protective
helmets; wear safety shoes, and overalls.
-Use safety gloves.
-Never leave unassembled parts, equipment, or other objects that are not part of the system on or near the
engine.
-Never leave flammable liquids or clothes containing flammable liquid near the generating set, near electrical
equipment (including lamps), or near parts of the electrical system.
-Take precautions to avoid the danger of electrocution.

2.3 Residual risks

The machine was designed and constructed with a view to guaranteeing operator safety. There are, however, some
residual risks linked to an inappropriate use of the machine by the operator; to this view, danger signs and symbols
are placed near and on some parts of the machine.

2.4 Safety symbols and labels

Some plates with the following symbols are applied to the machine to call attention to potential danger:

ELECTRICAL HAZARD

THIS SYMBOL INDICATES THE EXISTENCE OF A DANGER CAUSED BY ELECTRICAL ENERGY

WORKING ON ELECTRICAL EQUIPMENT WHILE CONNECTED TO POWER SUPPLY IS

PROHIBITED

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 DANGER OF MOVING PARTS

DANGER OF COOLANT LEAKAGE

DANGER OF HIGH TEMPERATURE

GENERAL DANGER

OIL CAP

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 OIL DIPSTICK

2.5 Personal protection equipment

The operator, before beginning work, must know the location and function of the commands and the characteristics of
the machine and must have read this entire manual as well as the manuals and documentation attached.
The employer must train personnel concerning their correct use and maintenance.
The operator must always observe the precautions indicated on the labels found on the
machine.

The P.P.E. that the operator must use includes work clothes, shoes with non-skid soles, and gloves during operation,
service and maintenance, and cleaning operations.

2.6 Workstation
The machine was designed to be used by only one operator. During the start-up, adjustment, and stopping of the
machine, the operator should remain next to the control panel. During normal functioning, the generating set does
not require the constant presence of the operator.

3. CHARACTERISTICS OF THE GENERATOR

3.1 General characteristics
Bertoli generating sets are designed to be installed in closed or open spaces. If there is a soundproof housing, opening
the door will allow easy access to the motor and the alternator for maintenance and control, allowing a reduction in the
sound level at the same time. The direct-injection diesel engine is extremely reliable and sturdy; the exhaust emissions
are in compliance with CARB standards. The alternator is a synchronous 4-pole, brushless type with electronic voltage
regulator (AVR) that guarantees stability within ± 5% of the nominal value. The high inrush capacity of the alternator
makes the generating set particularly suitable to power the electric motors of conditioners, desalinators, compressors,
etc. The generating set is equipped with a local control panel (Figure 3, ref. 4) where the commands and control
instruments are located.

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 Picture 3 – Key start panels

A3 for powers from 20 to 30 kVA

A4 for powers from 30 to 50 kVA

A5 for powers greater than 50 kVA

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 3.2 Control Panel
A control panel (Picture 3) for the commands and for starting and stopping operations is positioned on the generating
set. A motor protection module (Picture 4) controls the protection of the generating set by stopping the motor in case of
breakdown and signaling it by means of special warning lights.
1 – “OIL” warning light [ref. 1] if the red light is on, the engine oil pressure is insufficient.
2 – “BATT” warning light [ref. 2] if the red light is on, the alternator battery charger is not working.
3 – “HIGH TEMPERATURE” warning light [ref. 3] if the red light is on, the engine temperature is too high.
4 – “FUEL RESERVE” warning light (ref. 4) if the red light is on, the fuel tank is empty.
5 – “GENERAL ALARM” warning light (ref. 5) the red light stands as an alarm.
6 – STOP button [ref. 6] this red button can be used to turn the machine off.
7 – Start/stop key [ref. 6].

Picture n. 4

The manual control Panel also contains:

-a voltmeter [Picture 3, ref. 1] to indicate the voltage the set generates
-an ammeter [Picture 3, ref. 2] to indicate the current draw due to the charge
-a frequency meter [Picture3, ref. 3] to indicate the frequency of the voltage generated
-a magnetothermal switch [Picture 3, ref. 5] to interrupt the power supply in case of overloading or short circuit;
-an hour counter [Picture 3, ref.4];
-a overload cut-out [Picture 3, ref. 7] to turn off the generating set in case of breakdowns

Bertoli generating set may be equipped with 2 kind of Panels: Key Start [Picture 3] or automatic [Picture 5].
The key start version is equipped with an overload cut-out device to start, stop, and control the machine itself.
See [Picture 3] the various models of panels used depending on the power of the generating set.

The automatic version is equipped with an electronic controller managing the automatically switching between mains
and generator. See [Picture 5] for the various models of Automatic control panels.
For further information, please see the manual of the Automatic Panel, which is attached to
the panel.

When service is carried out on the generating set, disconnect the negative terminal of the
start-up battery to avoid accidental starting.

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 When service is carried out on the automatic generating set, disconnect the network to
avoid any accidental start-ups and damages to the electronic card.

Figure n. 5

QS panel for powers from 3 to 30 kVA

QM01 panel for powers from 50 to 100 kVA

QM02 panel for powers from 100 to 500 kVA

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 4. USE OF THE GENERATOR
4.1 Installation
Below are the provisions established by the Circ.M.Interno (Ministry of the Interior Circular) of August 31, 1978 n.31
(Text coordinated with Circular n° 12 of July 8, 2003) Safety standards for the installation of internal combustion
engines coupled with electric generators or processing equipment.

4.1.1 Location

The sets may be installed outdoors or in closed spaces that are either isolated or part of buildings.
If installed indoors, they may be installed in floors above ground.
Sets running on diesel fuel, fuel oil, or natural gas (with density less than 0.8 compared to air) may be installed on the
first underground floor.
LPG sets may be installed only on ground floor levels.
It is prohibited to install systems with power greater than 50 kW inside high buildings with the exception of systems
fuelled by the natural gas or methane installed on the highest terrace of the building.
When the building is used, entirely or partially, as a cinema, theatre, meeting room, school, church, hospital or similar
venues, it is prohibited to install natural gas or gasoline systems in adjacent rooms or underneath rooms used as public
meeting places or passages for groups of people.

4.1.2 Characteristics of installation facilities

Installation within the volume of a building.

The room must have the following characteristics:

a) Certification.
At least one wall or part of a wall (no less than 50%) must be face an open, outdoor space (road, courtyard, garden, or
cavity wall that is either open or covered with a grate facing an open-air space, embankments).
According to these regulations, an open-air space may also be an area in front of a wall with overhangs of a ratio
greater than 2 between the height of the station from ground level and the overhang.
If the open-air space consists of a courtyard closed on all sides, the walls of the courtyard must be at least 3.50 m from
each other and the surface area must not be less than the product of the height of the lowest wall (expressed in metres)
multiplied by 3.
If the wall faces a cavity wall, it must be used only as the boiler room; it must be at least 0.60 m wide and the grated
surface must have a net cross-section at least one and a half times the aeration surface of the room itself. When the
cavity wall faces the courtyard, the courtyard must comply with the conditions described in the previous paragraph.
If the wall borders an embankment, the rise between ground level and the ceiling must be at least 0.60 m, in order to
allow for an aeration opening.
This opening must face an open-air space and be at least 50 cm high.

b) Structure.
The horizontal and vertical structures must be fire resistant to at least 120'.

c) Dimensions.
The clear interior height of the ceiling from the floor must not be less than 2.50 m.
The distance, on at least three sides, between the walls and the generator overall dimension perimeter must not be
less than 0.60 m.

d) Access and communications. Access to the room may occur:

- directly from outside;
- by means of an aerated access room from the outside with an aeration opening of no less than 0.30 m² or by means
of an open air duct at a height of at least 10 m above the floor level with the ends at a distance of at least 1.50 m from
windows, doors, or other practicable openings;
- from standard cavity walls covered with a grate exclusively dedicated to the room;
- through smoke filters.
As for systems with a power less than 50 kW installed in buildings to be used collectively for public shows and special
purposes (like schools, hospitals, barracks, theatres, cinemas, libraries, department stores, hotels, etc.), access to the

15
room must occur directly from open-air spaces or from standard cavity walls covered with grates to be used exclusively
for this purpose.
The room must not have communication openings towards rooms destined for other uses.
For rooms where sets that run on liquid fuels are installed, the access opening must have a threshold at least 20 cm
high.

e) Doors. The doors of the room and of the access room must open outwards, be fireproof, and be equipped with
self-closing devices. Those that open onto indoor rooms must also be smoke-proof.

f) Ventilation. The aeration openings must have a surface area of at least 1/30 of the floor surface area of the room for
systems with power up to 400 kW and at least 1/20 of the floor surface area of the room for systems with power greater
than 400 kW with a minimum of:
a) 0.50 m² for systems with power up to 400 kW;
b) 0.75 m² for systems with power up to 800 kW;
c) 1.00 m² for systems with power up to 1,200 kW;

Indicative dimensions of the rooms for generating sets with water-cooled diesel fuel engines.

GENERATOR POWER LENGTH WIDTH HEIGHT MINIMUM AERATION

SURFACE AREA

16
Examples of installation rooms for generating sets

17
Aeration opening Metal door Footing Walls and ceiling REI 120 GE Panel
Emergency control GE/network switching Distances in meters Example of generating set
footing

Expanded polystyrene Reinforced concrete Sand Sand

Isolated rooms.
The rooms may have structures in non-combustible materials or in a Class 1 fire resistance class. In the latter case, the
room must not be less than 3 m from the nearest building. If the isolation is limited to three walls, the common wall must
have the characteristics of a firewall and a resistance of 120'.
The ventilation openings must not be less than those established in section 2.2.1 letter f).

Rooms located on terraces.

The rooms, if not adjacent to rooms to be used for other purposes, can also be constructed as specified in section
2.2.2.
The ventilation openings must not be less than those established in previous section 2.2.1 letter f).

Open-air installation.
Open-air installations must be located at a distance of no less than 3 m from combustible material storage.
The installations can be protected from atmospheric agents by a roof.

4.1.3 Generating sets installation.

Two or more sets may be installed either next to each other or on top of each other for a maximum of two layers
provided that the total maximum power is no higher than 1,200 KW.
The sets can be fuelled by different fuels.
The sets can be installed within an airtight enclosure or not. In this case, the distance from the walls and the ceiling are
to be measured from the surface of the enclosure.

4.1.4 Engine supply

Liquid fuels: Fuel system.

The supply to the built-in fuel tank must take place only by forced circulation.

Built-in fuel tank.

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a) Each engine must not have more than one built-in fuel tank, which must be firmly anchored to the frame and
protected against vibrations, impact, engine heat, and the exhaust pipe.
b) The fuel tanks must be in steel with welded joints or in other materials that guarantee the same performance
characteristics regarding fire prevention regulations (Circular 12/2003).
c) The fuel tank capacity must be proportionate to the engine power and in any case no greater than 50 litres for powers
up to 100 kW and 120 litres for higher powers. Sets located on ground floor level locations or outside on the ground
level that are fuelled by Category C fuels are allowed to use built-in fuel tanks with capacities no greater than 2,000
litres. In this case, a bund wall or basin with a volume at least equal to the tank capacity must be provided. (Circular
12/2003)
d) According to regulations, the supply of the built-in fuel tank must occur by means of a fixed piping system.
e) When the system is fuelled only by built-in tanks, the tank supply is allowed only with portable recipients if the engine
is not running and while taking maximum precautions.

Service tanks and storage tanks.

a) Built-in tanks can be filled directly from storage tanks and/or service tanks.
b) The installation of diesel fuel and fuel oil tanks is regulated by the Ministerial Circular n. 73 of July 29, 1971 (See).
c) The gasoline storage tanks cannot be located inside rooms or on terraces. The installation of these tanks is
regulated by the Ministerial Decree of July 31, 1934 (See).

Fuel flow control devices

a) The built-in fuel tanks must be equipped with an overflow drain into the service or storage tank. This tube must not
have valves or any other closures.
b) The tanks must be equipped with the following safety devices that intervene automatically when the fuel level of the
built-in fuel tank exceeds the maximum level allowed.
- Flow intercepting device;
- Fuel pump stopping device;
- Visual and audio alarm.

4.1.5 Engine safety devices

Each set is equipped with an automatic safety system and/or control with a view to the following objectives:
a) shut down of the engine/turbine for either exceeding operating temperature or for a drop in oil pressure or level;
b) interception of fuel flow due to the stopping of the motor/turbine or to a lack of electrical energy generated (Circular
12/2003).

Stopping of the engine causes the exclusion of the electrical power of the engine power supply circuits, except for
safety lighting where the set is installed, which must always be guaranteed. (Circular 12/2003)

4.1.6 Sets in metal enclosures.

The free space around the enclosure must be ventilated by means of a forced ventilation system with continuous
functioning or discontinuous functioning if activated by the signal of an EC-approved gas or fume detector installed
inside the enclosure itself.
As an alternative to the forced ventilation system, an EC-approved gas or fume detector may be installed inside the
enclosure. This detector will block the power supply and the electrical system and will signal the audio and optical
alarms in the presence of gas or fumes in concentrations greater than 50% of the lower flammability limit. (Circular
12/2003)
Any insulating material installed inside the metal enclosure must have characteristics no lower than those for Class 1
fire resistant materials.

4.1.7 Exhaust systems

Materials.
Engine exhaust systems must be made of sufficiently strong and airtight steel, while connection fittings may be made in
cast iron.

Installation lay-out.
The gas piping must be installed in such a way as to discharge directly, or through a chimney, outside. In order to
guarantee that hot gases and sparks will not cause damage, the ends of the exhaust tubes must be installed at least
1.50 m from windows, doors, or practicable openings or air intakes and at a height of no less than 3 m from the floor
level.

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Piping protection.
a) The piping inside the room must be protected with insulating materials to ensure that their external surface does not
reach a temperature of at least 100° C lower than the self-ignition temperature of the fuels used.
b) The piping must be adequately protected or shielded to prevent people from accidentally coming into contact with
them.
c) The insulating and protective materials must be non-combustible or combustible with Class 1 of fire resistance.

Connection to more than one engine.

The connection to one exhaust pipe of more than one exhaust collector of each engine in the same room is allowed
provided that there is a manual gate valve for each collector.

4.1.8 Lubrication system

The lubricating oil tanks must be airtight; oil fumes must be recycled in the engine or condensed in specific containers.
Any vent hole must be directly connected to the outdoors by means of a ventilation duct and the end of the duct must be
at least 1.50 meters from doors, windows, practicable openings, or air intakes.

4.1.9 Electrical systems

The electrical systems and devices must be installed in the relative rooms according to current standards as
established in Law n. 186 or March 1, 1968.
The circuit commands, excluding those built-in in the system, must be centralized on a panel to be situated as far a
possible from the sets and in an easily accessible position.
All circuits must be connected to a master switch to be installed outside of the rooms and in an easily accessible
position.

4.1.10 Portable extinguishers

For fire prevention, portable fire extinguishers approved for Class B and C fires containing no less than 6 kg of
extinguishing agent must be installed.
The number of extinguishers must be:
- One for installations of sets with power up to 400 kW;
- Two for powers up to 800 kW;
- Three for powers up to 1,200 kW.

4.2 Preliminary checks

Before beginning any start-up procedure, it is extremely important to familiarize yourself with the generating set and its
commands. A visual safety check of the machine and its installation must also be performed. Any source of real or
potential danger must be eliminated before continuing.
- Identify the position of the emergency stop buttons, switches, and other emergency system on the generating set.
- Be aware of the specific emergency procedures regarding the installation.
- Check the oil level with the dipstick.
- Check that all the anchoring of the set is properly tightened.
- Check that all the electrical devices have been disconnected to prevent accidental start-up of the unit.
- Check that the fuel lines are properly connected.
- Check that all the electrical connections have been carried out correctly and that there are no connections in poor
condition.

4.3 Deaeration of the fuel system

The presence of air bubbles inside the fuel supply system is the cause of irregular engine function or its failure to reach
the nominal rpm. The air may enter the fuel circuit through a slightly imperfect joint or seal (pipes, filters, tanks) or when
the fuel is at a minimum level in the tank. In order to eliminate air bubbles, first remove the cause that allowed them to
enter and perform the following operations below:
1 - Manually adjust the "C" fuel pump lever until all the air contained inside the fuel system is released.
2 – Repeat this operation if the engine still does not run smoothly.

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 For more detailed information, consult the manual provided by the engine manufacturer
and included with each generating set.

4.4 Start-up
Before starting the set, verify that the preliminary checks described in paragraph 4.1 have been carried out. Proceed
with the start-up by turning the key to the START position on the control panel [Picture 4, ref. 7] and release it only
when start-up has occurred, taking care not to exceed 15 seconds for each attempt and pausing for at least 30 seconds
between attempts. .

Repeated failed start-up attempts may cause the starter to overheat, causing potentially
serious engine problems. If start-up is difficult, do not insist, but call authorized personnel immediately.

4.5 Shut down

To shut down all machine movement, just push the relative general shut-off command (main isolating switch
represented in Picture 4, ref.6).
If it should become necessary to shut down dangerous machine movements, push the emergency stop button located
on the panel or on the outside if the set is soundproofed [Picture 2 ref. 2].

Before stopping the generating set, it is advisable to let it run for a few minutes without
drawing power supply in order to allow a gradual cooling of the engine and alternator.

5. PROTECTIONS
Generating sets are equipped with a series of protection devices that prevent them from improper use or faults that
may compromise the functioning. When the generating set is shut down by a protection device, a warning light will
appear on the motor protection module of the control panel to indicate the reason for the intervention [Picture 4].

5.1 Low oil pressure protection

This device shuts down the set when the engine oil pressure is insufficient; the "OIL" warning light will turn on to signal
it (Picture 4, ref. 1). It is generally sufficient to refill the oil tank to restart the set.

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 Picture 4

The low oil pressure protection does not indicate the level of motor oil in the pan. This level
must be checked daily.

5.2 Engine high temperature protection

This device shuts down the generating set if the engine temperature is too high. The tripping of the protection device is
signaled by the warning light [Picture 4, ref. 3]. The generating set must be started only after having identified the cause
of overheating.

5.3 Fuel reserve protection

This device shuts down the generating set when there is a low fuel level. The tripping of the protection device is
signaled by the warning light [Picture 4, ref. 4]. The generating set must be started only after having refuelled. It is
therefore recommended to seek and eliminate the cause of protection device tripping.

If one of the abovementioned protection devices is activated and the cause of activation
has been found and eliminated, it is then necessary to position the key on "0" to reset the control panel
(otherwise the signal will stay lit and inhibit engine start-up).

5.4 Short circuit and overload protection

The generating set is protected from short circuit and electrical overload. A magnetothermal switch [Picture 3, ref. 5]
interrupts the electrical power supply in case of a short circuit or when the electrical supply exceeds its nominal value.
Before re-establishing contact by lifting the lever of the magnetothermal switch, disconnect the utilities.

6. MAINTENANCE

6.1 Introduction

Any maintenance operation to the generating set must be carried out when the equipment is

22
shut down, after it cooled sufficiently, and must be executed by duly trained, authorized personnel.

It is strongly advised to carefully follow the indication provided in the attached Engine Manufacturer's manual provided
with each generating set. It is important to inspect and carry out maintenance on the generating set regularly and
service must be scheduled according to the number of hours of operation.

Before accessing the generating set, remove a terminal of the start-up battery in order to
avoid accidental start-up.

6.2 Periodic engine maintenance

Periodic servicing to be carried out on the engine is indicated in the TABLE “A” in paragraph 6.12. For more detailed
information, consult the manual provided by the engine manufacturer and included with each generating set.
Check the oil level on the graduated dipstick provided. The level must always be between
the MAX and MIN markings on the dipstick.

6.3 Engine oil and filter change

The engine casing capacity can be found in the engine manual. Filling and topping up of the engine oil must be done
through the specific hole commonly indicated by the label. The replacement of oil in the engine starts by removing the
cap on the oil pan or using the special oil extraction pump, which is present if the set is soundproofed. It is advisable to
empty oil while it is still sufficiently hot in order to allow easy flow.

- The first oil change must be carried out after 50 hours of operation of the generating set; the second and
following changes may be carried out after every 200 hours of operation.
-For more detailed information concerning engine lubrication, consult the engine use and maintenance
manual attached to the generating set.
-Do not pollute the environment by disposing of used oil or fuel inappropriately. Bring the used oil to
specialized Collection Centres for safe and proper disposal.
Do not bring the engine oil into contact with skin. During maintenance operations, use
protective gloves and glasses. In case of contact with the lubricating oil, wash the area immediately with soap
and water.

In order to replace the oil filter cartridge, unscrew it from its support by using the special tool that is normally available
for this purpose. Reposition the new cartridge, taking care to lubricate the rubber ring gasket. The first change should
be carried out after 50 hours of operation of the generating set, while the second and following changes should be
made after every 400 hours of operation. For further information, consult the engine use and maintenance manual.

Use only original spare parts in order to guarantee the long-life and proper running of the
engine.
When operations are completed, carefully clean all the parts of the generating set that have
been dirtied with oil or fuel.

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6.4 Cleaning the air filter
Generating sets are equipped with an air filter that prevents foreign bodies from entering the combustion chamber. In
order to maintain it, clean the filtering material with diesel fuel once a year to free it from impurities.

Do not dispose of the liquids used to wash the air filter in the environment. Bring them to the
specialized Collection Centres for safe and proper disposal.

6.5 Replacing the fuel filter

In order to guarantee the long life and correct functioning of the engine, it is extremely important to periodically replace
the fuel filter cartridge according to the times recommended by the engine manufacturer and included in the Table in
paragraph 6.12. This operation is carried out by following the steps below:
-Completely unscrew the support ring nut.
-Remove the old cartridge and position the new one.
-For assembly, repeat this operation backwards.
When the filter has been replaced, the fuel system must be deaerated as described in paragraph 4.2.

Do not bring the fuel into contact with skin. During maintenance operations, use protective
gloves and glasses. In case of contact with the fuel, wash the area immediately with soap and water.

When the operation has been completed, carefully clean all the traces of fuel and bring the
clothes used to the specialized Collection Centre for safe and proper disposal.

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6.6 Checking the coolant
It is necessary to periodically check the level of coolant in the closed cooling circuit. If the level is insufficient, add
coolant inside the radiator chamber, taking care not to exceed the maximum level index.

Never open the radiator cap when the engine is hot to avoid dangerous coolant leaking.

Do not pollute the environment by disposing of used coolant inappropriately. Bring the
used coolant to specialized Collection Centres for safe and proper disposal.

6.7 Checking the tension of the v-belts

The belt is used to transmit rotatory motion from the drive shaft pulley to the DC Alternator battery charger. Always
check the condition and tension of the belt. If the belt is not functioning properly, contact authorized personnel.

In order to avoid slipping, keep the belt clean from oil. Clean the belt with gasoline if it
seems dirty with oil.

Never put your hands near the v-belt or pulleys with the engine running.

6.8 Alternator maintenance

The alternator used in this model of generator is a synchronous, self-excited model. This model of alternator has no
collector or brushes and needs no particular maintenance. Periodic inspections and maintenance are limited to the
removal of any traces of humidity and oxidation that may damage it. For more detailed information, consult the manual
provided by the alternator manufacturer and included with each generating set.

6.9 Battery maintenance

For the start-up of all models of generating sets, an 80 A/h battery is recommended for environments above 0° C and
100 A/h for lower temperatures. Before installing a new battery, it is important to recharge it completely. Check the level
of electrolytes at least once a month and top up with distilled water if necessary. During long periods of disuse, it is
advisable to disconnect the battery and store it in a dry place with a temperature above 10° C and carry out a complete
recharging cycle once a month.

If the battery is left completely dead for long periods, it may be irreparably damaged.

25
The positive terminal of the battery must be protected with vaseline grease to prevent corrosion or oxidation from
building up.

To top up with sulphuric acid, a pre-prepared solution must be used.

Protective rubber gloves and glasses must be worn to prevent accidental contact of
sulphuric acid with the skin while topping up the battery, either with distilled water and/or with acid. In case of
accidental contact, wash the part involved with water and soap and contact a physician.

Before charging the battery, check the electrolyte level and top it up with distilled water if
necessary. This operation must be repeated following completion of the recharging cycle.

6.10 Storage
In case of extended storage, leave the machine sheltered from rain and wind and possibly in a dry place.
Take particular care to protect electrical components from rain and atmospheric agents.
The machine may suffer serious damage if, while awaiting installation, it is kept in an environment with critical
temperatures.
Do not expose the machine to temperatures lower than -10° C or higher than +60° C.

It is prohibited to place tools or other objects on the machine that have not been
specifically designed for this purpose.

6.11 Inactive periods

Start-up the generating set at least once a month.
If the generating set must remain unused for a long period of time, the following procedure must be followed:
-Change the engine oil.
-Change the oil filter cartridge (see par. 6.3).
-Change the fuel filter cartridge (see par. 6.5).
-Remove the injectors and fill each cylinder with 2 cc of engine oil and turn the motor manually a few times by holding
the pulley of the drive shaft.
-Disconnect the start-up battery and store it in a dry place (see par. 6.9)

6.12 Table of scheduled operations

Operations hours
Control oil level 50
Control coolant level 50
Control for liquid leakage 50
Belt tension adjustment 100
Check battery charge 100
Clean fuel filter 200
* Change motor oil 200
Control integrity of electrical connections 400
Replace fuel filter 400

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 * Replace oil filter 400
Control battery electrolyte level Monthly
Clean and deoxidate metal parts Annually
Clean air filter Annually

* First service after 50 hours, then follow maintenance intervals according to the
table.

Record service performed on the "MAINTENANCE LOG" form in Chapter 13.

6.13 Troubleshooting

The generating set shuts down when running.

- Check if a protection device has been activated and if the warning light is on. (Eliminate the cause and retry start-up)
- Check the level of fuel in the tank. (Adjust level if necessary)

The engine has very smoky exhaust

-Check that the level of oil in the pan is not above the MAX index. (Adjust level if necessary)
-Check that the Set is not overloaded.
-Check the calibration of the injectors. (Consult the Technical Assistance Centre)

The engine functions irregularly.

-Check fuel filters. (Replace)
-Carry out de-aeration inside the supply circuit. (See par. 4.2)

The alternator voltage is too low.

-Check the rpm: 1,560 rpm without utilities connected at 50Hz 1,860 rpm without utilities connected at 60Hz
-Correct the voltage value by adjusting the electronic regulator.

Dead start-up battery.

- Check the electrolyte level in the battery. (Adjust level if necessary)
- Check the functioning of the DC alternator.
- Check the condition of the battery.

The generating set doesn’t supply voltage.

- Check that the magnetothermal switch [Picture 3, ref. 5] is in the “ON” position. If this does not solve the problem,
contact an Authorized Technical Assistance Centre.

The starter turns but the engine does not start up.
- Check if there is fuel in the tank. (Refuel)
- Check if the stop switch is activated. (Consult the Technical Assistance Centre)
- Carry out de-aeration inside the supply circuit. (See par. 4.2)

The engine protection module does not turn on when the START button is pushed
-Check if the thermal protection switch [Picture 3, ref.5] is open. (Reset the contact by pushing the red button [Picture 4,
ref. 3]).
- Check the connection cables and terminals to the battery and the electrical connections. (Reconnect)
- Check the condition of the battery. (Recharge or replace)

7. TRANSPORT AND MOVING

7.1 Introduction
The purpose of the following chapter is to supply information about lifting and moving the machine.
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The information in this chapter is intended for TECHNICALLY QUALIFIED persons with sufficient knowledge to
correctly and safely operate crane trucks, overhead cranes, and other equipment that may be required.

7.2 General Warnings

- To prevent personal injury if the machine should fall, ensure that there are no people in the range of action of
lifting machines during their operation.
-Lifting, transport, and positioning activities and electrical connections must be carried out by technically
qualified persons who have been specifically trained in these fields.
-Before any movement, always check that the lifting equipment and relative tools (cables, hooks, etc…) are
appropriate to the load to be moved and check that the load itself is firmly secured.

7.3 Lifting the machine

THE WEIGHT OF THE MACHINE IS APPROX. 1300 KGS

In order to lift and move the machine, suitable means of transport capable of handling this weight must be used; the
use of hooks and other lifting equipment (cranes or other) with the necessary capacity is obligatory.

Check the stability of the element to be transported.

Picture n. 6

8. DISCARDING OF THE MACHINE

8.1 Disposal
The owner is responsible for following the correct and legal procedure for the disposal of consumable materials and
demolition materials in force in the country in question.
It must be remembered that any substance or object that the owner wishes to discard or has decided or is obliged to
discard is considered waste or refuse (L.D. n.22 of February, 5 1997).
According to the abovementioned decree, waste materials are classified according to their origins as urban waste and
special waste and, according to hazard characteristics into hazardous waste and non-hazardous waste.
Waste from the demolition of the machine is classifiable as special waste.
It is prohibited to mix different categories of hazardous waste or hazardous waste with
non-hazardous waste.

8.2 Demolition materials

The following are considered special, non-hazardous waste that may be recycled according to M.D. February 5, 1998:
• Iron, aluminium, stainless steel, copper materials
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 • Plastic materials
• Electronic cards
• Lubrication oil
INDICATIONS FOR SAFE AND APPROPRIATE WASTE DISPOSAL
Iron materials:
Recyclable material (secondary raw materials) to be delivered to a special collection center.
Plastic materials
Recycling allowed where possible
Disposal in a dump for waste materials similar to urban wastes.
Increase allowed in facilities equipped with post-combustion and dust control systems before emission into the
atmosphere.
Electrical system:
Disposal in a dump for waste materials similar to urban wastes.
Mineral oil:
If not usable in other equipment, delivery to special authorized collection centres (Mandatory Consortium for Used
Oils).
It is absolutely prohibited to dispose of oils in sewer systems or in any other place.

9. WIRING DIAGRAM

The wiring diagram is in the set documentation. Please consult this documentation before
modifying the panel itself.

10. MANUALS FOR THE USE AND MAINTENANCE OF THE COMPONENTS

The Manuals for the Use and Maintenance of the components are attached to the machine
documentation. Please consult these manuals for any problems that may arise.

11. DECLARATIONS OF COMPONENT CONFORMITY

Each component has a declaration of conformity included in the documentation supplied with the
set.

12. SPARE PARTS LIST

The spare parts list and code can be found in the relevant component manual. Before ordering a
spare part, please consult the component manual.

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 13. MAINTENANCE OPERATION REPORT

MAINTENANCE OPERATIONS PERFORMED

Date Breakdown description Maintenance description Result Operator’s Signature

30