Mase PD 10 R User manual

PD 10 R
PD 10.4 R
Rev.2 A.A. 30-07-07 Cod. 41954
IMANUALE DI USO E MANUTENZIONE
GB USE AND MAINTENANCE MANUAL
DGEBRAUCHSANWEISUNG UND WARTUNGSVORSCHRIFTEN
FMANUEL D’UTILISATION ET D’ENTRETIEN
EMANUAL DE USO Y MANTENIMIENTO
FIN KÄYTTÖ- JA HUOLTO-OPAS

2
PD 10 R • PD 10.4 R
FACSIMILE
DICHIARAZIONE CE DI CONFORMITÀ
EC DECLARATION OF CONFORMITY
Fabbricante/Manufacturer: mase GENERATORS S.p.A.
Indirizzo /Address : Via Tortona 345, Pievesestina (FC)
Il sottoscritto Luigi Foresti in qualità di direttore tecnico della mase GENERATORS S.p.A., dichiara sotto la
propria responsabilità che il gruppo elettrogeno modello .................... :
The undersigned Luigi Foresti as maseGENERATORS S.p.A. technical manager declares, under his sole
responsability, that the generator model................:
Codice / Code Descrizione / Model Matricola / Serial N.
è conforme alle disposizioni delle Direttive di seguito elencate:
98/37 CE (come emendata delle Direttive 98/79 CE)
73/23 CEE modificata da CEE 93/68.
89/336 CEE direttiva sulla compatibilità elettromagnetica
corresponds to the requirements of the following EEC Directives:
98/37/EEC (as amended by the Directive 98/79/EEC )
73/23/EEC as amended by 93/68/EEC.
89/336 EEC directive on the electromagnetic compatibility
NR.000000
mase GENERATORS S.p.A.
Tel. [phone]
Fax [phone]
mase GENERATORS S.p.A. Sede legale ed Amm.: 47023 CESENA (FC) ITALY - Via Tortona, 345 - C.F./P.I. 00687150409 Cap. Soc. milioni 2000
di cui 949 versati - Registro Società Tribunale Forlì n. 6818 - CCIAA Forlì n.164063 - c.c.p. n. 11541471 - EXPORT FO n. 006368
Cesena, / /
Direttore Tecnico
Technical Director
Fig.1

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PD 10 R  PD 10.4 R
Fig.2
H
M
L
G
3
4
5
6
7
8
1
2
9
10
SERIAL No.
I
A
E
C
B
D
F

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PD 10 R  PD 10.4 R
Fig.5
Fig.3
Fig.4
1
3
2
2
1
2
4
1

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PD 10 R  PD 10.4 R
Fig.8
Fig.7Fig.6
2
1
3
Fig.9
1
109 4 5
11
2
3
6 7 8
12
1
109 4 5
11
2
3
6 7 8

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PD 10 R  PD 10.4 R
Fig.10
PD 10 R
A
BPO
A B
C.B.
B
21
20
24
6
18
14
11
10 15
16
19
17
7
9
12
4
2
3
22
123
5
16
6
4
12
12

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PD 10 R  PD 10.4 R
PD 10.4 R
Fig.11
A
BPO
A B
C.B.
B
4
15
9
23
24 24 99
12 10
7
2
13
3
14
8
23 6
19
18
1
20
1
16
21
11 11
22
17

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PD 10 R  PD 10.4 R

9
PD 10 R • PD 10.4 R
INDICE ..............................................................................................................................................................10
INDEX ...............................................................................................................................................................22
INHALTSVERZEICHNIS ...................................................................................................................................34
TABLE DES MATIÈRES ...................................................................................................................................46
INDICE ..............................................................................................................................................................58
SISÄLLYSLUETTELO ......................................................................................................................................70

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GB PD 10 R  PD 10.4 R
INDEX
1 GENERAL INFORMATION .......................................................................................................................23
1.1 Purpose and field of application of the manual ..................................................................................23
1.2 Symbols ...........................................................................................................................................23
1.3 Reference documents .......................................................................................................................24
1.4 Facsimile of CE declaration of conformity .........................................................................................24
1.5 Reference regulations and legislative provisions ................................................................................24
1.6 Marking.............................................................................................................................................24
1.7 Machine identification .......................................................................................................................24
1.8 enerator composition .....................................................................................................................25
1.9 Instrument panel ...............................................................................................................................25
2 TECHNICAL CHARACTERISTICS ...........................................................................................................26
2.1 eneral characteristics .....................................................................................................................26
2.2 eneral characteristics table ............................................................................................................26
3 SAFETY REGULATIONS ..........................................................................................................................27
3.1 eneral precautions ..........................................................................................................................27
3.2 Prescriptions for safety during installation and setup ........................................................................27
3.3 Connection to earth...........................................................................................................................27
4 USING THE GENERATOR ........................................................................................................................28
4.1 Positioning the generator ..................................................................................................................28
4.2 Preliminary checks ...........................................................................................................................28
4.3 Refuelling ..........................................................................................................................................28
4.4 Battery..............................................................................................................................................28
4.5 Starting .............................................................................................................................................29
4.6 Using the generator ...........................................................................................................................29
4.7 Stopping ...........................................................................................................................................29
4.8 Connection to automatic panel/remote control (optional) ..................................................................29
5 PROTECTIONS ........................................................................................................................................30
6 MAINTENANCE ........................................................................................................................................30
6.1 Preamble ..........................................................................................................................................30
6.2 Ordinary engine maintenance ...........................................................................................................30
6.3 Engine oil change .............................................................................................................................30
6.4 Oil filter .............................................................................................................................................31
6.5 Air filter .............................................................................................................................................31
6.6 Fuel filter ...........................................................................................................................................31
6.7 Battery check ...................................................................................................................................31
6.8 Troubleshooting ................................................................................................................................31
6.9 Scheduled maintenance table ...........................................................................................................32
7 TRANSPORT AND HANDLING ................................................................................................................32
7.1 Lifting ................................................................................................................................................32
7.2 Trailer (optional) ................................................................................................................................32
8 STORAGE ................................................................................................................................................32
9 SCRAPPING ............................................................................................................................................32
10 WIRING DIAGRAMS ..............................................................................................................................33
10.1 Wiring diagram PD 10 R .................................................................................................................33
10.2 Wiring diagram PD 10.4 R ..............................................................................................................33

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GB
PD 10 R  PD 10.4 R
1 GENERAL INFORMATION
FAILURE TO RESPECT THE SPECIFICATIONS CONTAINED IN THIS USE AND MAINTENANCE
MANUAL WILL RESULT IN FORFEITURE OF THE UARANTEE ON THE PRODUCT
Carefully consult this manual before proceeding with any operation on the generator.
1.1 Purpose and fie d of app ication of the manua
Thank you for choosing a mase product.
This manual has been drawn up by the manufacturer with the purpose of providing essential information and
instructions for proper use and maintenance in conditions of safety and constitutes an integral part of the generator
equipment. The manual must be kept safely, protected from any agent which might damage it, for the entire life of
the generator and must accompany the generator if transferred to another user or owner.
The information contained in the manual is addressed to all those persons involved in the operating life cycle of the
generator, and is necessary to inform both those who effectively carry out the different operations and those who
co-ordinate the activities, arrange the necessary logistics and regulate access to the place where the generator will
be installed and operated.
The manual defines the purpose for which the generator was constructed and contains all the information necessary
to guarantee safe and proper use.
Constant observance of the instructions contained in this manual guarantees the safety of the operator, operating
economy and a longer life of the generator.
It is warmly recommended to carefully read the contents of this manual and the reference documents; only thus
can regular functioning and reliability of the generator be guaranteed over time, and protection against damage to
persons or things.
The drawings are provided by way of example. Even if the generator in your possession differs considerably from
the illustrations contained in this manual, the safety of the generator and the information provided are nevertheless
guaranteed.
To facilitate consultation, it has been divided into sections identifying the main concepts;
for a quick look at the topics, consult the index.
Note: the information contained in this publication is correct at the time of printing. The manufacturer in his pursuit
of a policy of constant development and upgrading of the product reserves the right to make modifications without
prior notice.
1.2 Symbo s
Those parts of the text not to be ignored are highlighted in bold type preceded by a symbol, as illustrated and
defined below.
Indicates that particular attention must be paid in order to prevent running into serious danger
which could lead to death or possible hazards to the health of personnel.
A condition which may occur during the lifetime of a product, system or plant considered at risk
regarding damage to persons, property, the environment or economic loss.
Indicates that particular attention must be paid in order to prevent serious consequences which
could result in damage to tangible goods, such as the resources or the product.
Instructions of particular importance.

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GB PD 10 R  PD 10.4 R
1.3 Reference documents
The instructions for use provided with each generator
are made up of a collection of documents of which this
manual represents the eneral Part. Normally, the
following documents are provided:
a - CE declaration of conformity.
b - Instruction manual for use of the generators
(this manual)
c - Engine use and maintenance manual
d - Alternator use and maintenance manual.
e - Any other manuals for the optional accessories
issued by the respective manufacturers.
f - mase conditions of warranty
g - Warranty card (to be filled in and sent to mase)
h - List of mase Service Centres
1.4 Facsimi e of CE dec aration of conformity
The generators constructed by mase, intended for
countries in the European Community, are in conformity
with the applicable EEC Directives (see 1.5) and are
furnished with an EC declaration of conformity (Fig. 1).
1.5 Reference regu ations and egis ative
provisions
All the mase diesel generators are designed and
manufactured in compliance with the legislation in force.
The generator and its components are constructed in
accordance with the following applicable regulations and
directives:
EN 292-1/2 : Machine safety regulations. eneral
design principles.
EN 294 : Machine safety regulations.
Safety distances to prevent contact of dangerous parts
with the upper limbs.
ISO 3046 : Alternate internal-combustion engines.
IEC 34-1 : Rotary electric machines.
ISO 8528 -1 : Alternate current generators driven by
alternate internal-combustion engines.
EN 60204 -1(CEI 44-5) :
- Machine safety.
- Electrical equipment of machines.
EN 60439 -1 (CEI 17-13/1) : Assembled protection and
manoeuvring equipment for low voltage (low-voltage
panels).
EN 50081-1/2 (Electromagnetic compatibility) : eneral
regulation on emission.
- Part 1- Residential, commercial and light-industry
environments.
- Part 2 - Industrial environment.
EN 50082-1/2 (Electromagnetic compatibility) : eneral
regulation on immunity.
- Part 1 - Residential, commercial and light-industry
environments.
- Part 2 - Industrial environment.
89/392/EEC and subsequent amendments contained
in the Directives 91/368/CEE, 93/44/CEE and 93/68/
CEE : Essential machine requirements for safety and
health protection (Machine directive).
73/23/EEC and subsequent amendments contained in
the Directive 93/68/EEC : uarantee of safety of
electrical material intended for use within certain voltage
limits (Low Voltage directives).
1.6 Marking
The generator identification plate carries all the
identification data in conformity with ISO 8528 and in
accordance with the provisions for CE marking for those
cases where required. Below is a facsimile of the
identification plate fixed on the control panel of each
generator (Fig.2).
1.7 Machine identification
See Fig.2
1 - Manufacturer
2 - Machine code
3 - Year of construction
4 - Power factor
5 - Declared frequency
6 - Continuous power
7 - Rated voltage
8 - Rated current
9 - Weight
10 - Serial number
The machine code number, the serial number
and the year of construction must always be
indicated when contacting the manufacturer for
information, order of spare parts, etc..

25
GB
PD 10 R  PD 10.4 R
1.8 Generator composition
See Fig.2
The generators are essentially composed of the
following components:
A - Load-bearing chassis
B - Lifting hook
C - Instrument panel and outlets
D - Vibration-damper
E - Earth connection terminal
F - Exhaust
- Tank
H - Air filter
I - Engine
L - Alternator
M - Battery compartment
1.9 Instrument pane
Each generator is fitted with an instrument panel for
the controls with the following components:
PD 10 R - See Fig .8
1 - Ignition key
2 - Hour counter
3 - Remote control connector
4 - Voltmeter 300V
5 - Differential magnetothermal switch, 2P
6 - Single-phase outlet, EEC 32A 230V 2P+ ND
7 - Single-phase outlet, EEC 16A 230V 2P+ ND
8 - Single-phase outlet, EEC 16A 230V 2P+ ND
9 - Red low oil pressure warning light
10 - Red battery charger warning light
11 - Fusible
12 - Magnetothermal switch 1P
PD 10.4 R - See Fig.9
1 - Ignition key
2 - Hour counter
3 - Remote control connector
4 - Voltmeter 500V fs
5 - Magnetothermal Differential switch 4P
6 - Three-phase outlet, EEC 16A 400V 3P+N+ ND
7 - Single-phase outlet, EEC 16A 230V 2P+ ND
8 - Single-phase outlet, EEC 16A 230V 2P+ ND
9 - Red low oil pressure warning light
10 - Red battery charger warning light
11 - Fusible

26
GB PD 10 R  PD 10.4 R
2 TECHNICAL CHARACTERISTICS
2.1 Genera characteristics
The generators of the PD series have been designed to assure professional users maximum efficiency and reliability
for any type of work. All the models have been developed for heavy duty, using highly reliable 3000 rpm air-cooled
diesel engines and are fitted with low oil pressure protection.
The alternators are type 2-pole, synchronous, self-energized, self-regulating and have a capacitor (single-phase
versions) or compound (three-phase versions) for energizing; All the generators are protected by a powder-coated
plate inside which also the battery compartment is housed.
A magnetothermal differential switch is positioned on the instrument panel to safeguard the operators and protect
the alternator from damage caused by short-circuit or overload.
2.2 Genera characteristics tab e
02'(/ 3'5 3'5
*(1(5$/&+$5$&7(5,67,&6
L
DIMENSIONS W
H
WEIGHT
SOUND POWER (at 7 metres)
TANK CAPACITY
AUTONOMY AT 3/4 LOAD
*(1(5$725
TYPE
MAX. POWER AC 7500 W 3300 W
CONTINUOUS POWER AC 6700 W 3000 W
POWER FACTOR
MAXIMUM POWER AC \ 10000 VA
CONTINUOUS POWER AC \ 9000 VA
POWER FACTOR \ 0,8
FREQUENCY
EXCITATION CAPACITOR COMPOUND
(1*,1(
TYPE
MANUFACTURER
MODEL
COOLING
CAPACITY
NO. OF CYLINDERS
MAX. POWER
RPM
FUEL
OIL SUMP CAPACITY
STARTING
AIR
MD 150
654 cc
12.6 HP
ELECTRIC
2
DIESEL FUEL
3000
1.8 l
50 Hz
RUGGERINI
SYNCHRONOUS, TWO-POLE, SELF-
ENERGISED, SELF-REGULATING.
1
FOUR-STROKE DIRECT INJECTION
7+5((3+$6(9
100 Lwa
6 l
3 h
6,1*/(3+$6(9
950 mm
490 mm
650 mm
150 kg

27
GB
PD 10 R  PD 10.4 R
3 SAFETY REGULATIONS
3.1 Genera precautions
Before starting the generator and before starting any
lubrication or maintenance operation, it is indispensable
for the staff responsible to read and understand all the
WARNIN S and all the CAUTION and DAN ER
indications listed in this manual and in the
supplementary documentation furnished.
Nevertheless, the manufacturer cannot foresee all the
possible circumstances which may lead to potential risks
in the effective conditions of use of the generator.
Any operations and/or procedures for maintenance not
expressly recommended or indicated in the user
manuals must always be notified to and approved by
the Manufacturer.
In the event that a procedure not specifically
recommended needs to be applied, the user is
responsible for assuring that such procedure is safe
and does not cause harm to persons or things.
The manufacturer declines all responsibility for damage
to persons or things deriving from inobservance of the
safety regulations.
Carefully examine the safety warning plates on the
machine and respect the relevant instructions.
- Do not permit incompetent persons or without
adequate training to use the generator.
- Do not permit children or animals to approach the
generator when it is in operation.
- Do not access the generator with wet hands, since it
is a potential source of electric shock if improperly used.
- Any inspections of the generator must be carried out
with the engine off. Inspections with the engine on are
to be carried out by specialised personnel only.
Before carrying o t inspection or maintenance
operations on the generator connected to the
a tomatic starting panel, the RESET f nction m st
be set, or it m st be disconnected by detaching the
power connector.
- Exhaust gas contains carbon monoxide and other
noxious residues. Never operate the generator in
inadequately ventilated places.
- Do not operate the generator near places with a danger
of explosion or fire.
- Refuelling must be carried out exclusively with the
engine off.
- The generator must be connected to earth using a
copper wire of suitable cross-section.
- Do not allow access to persons wearing a
pacemaker beca se of possible electromagnetic
interference with the device.
- In the event of fire, se a homologated fire
exting isher and never se water.
When sing the generator always bear in mind that
in wet or very h mid places and in confined
cond ction spaces it is obligatory to comply with
articles 313 and 318 of Presidential Decree No. 547
27/04/55, as well as Chap. 11 Section IV of the CEI
64-8 reg lation.
3.2 Prescriptions for safety during insta ation
and setup
- The personnel in charge of installation and starting
of the generator m st always wear a protective
helmet; wear safety shoes and overalls.
- Immediately change wet overalls.
- Use protective gloves.
- Do not leave disassembled parts, tools or anything
else not forming part of the system on or near the
engine.
- Never leave inflammable liq ids or cloths soaked
in inflammable liq ids in proximity of the generator,
near electric eq ipment (incl ding lamps) or parts
of the electrical system.
- Take the necessary preca tions to prevent the
danger of electroc tion.
- Check that the earthing system has been installed
and constr cted in accordance with reg lations.
3.3 Connection to earth
For the safety of the users, the earth connection of the
generator must always be carried out paying particular
attention to the cable cross-section used.
For the connection of the earth cable use the dedicated
terminal on the front panel (see Fig. 2, Ref. E). For the
earth connection follow the indications in the table to
select the cable cross-section to use depending on the
generator power.
The manufacturer is not responsible for any
damage caused by failure to earth the system.
Power kVA 1÷10 10÷20 20÷40 40÷60 60÷80
Cross-section mm² 610253550

28
GB PD 10 R  PD 10.4 R
4 USING THE GENERATOR
4.1 Positioning the generator
The generators of the PD series must be positioned
horizontally, i.e. placed on a flat surface or made to sit
horizontally by placing shims under the support feet.
The engine f nctions properly if it does not exceed
a maxim m inclination of 20°, both on the
longit dinal and the transversal axis. Sho ld the
engine be operated in conditions at a greater
inclination, there is a risk of ins fficient l brication
or s ction of engine oil from the air filter.
4.2 Pre iminary checks
Before beginning with any starting procedure, it is
extremely important to become familiar with the
generator and its controls. Furthermore, a visual
inspection must be carried out on the machine and the
installation.
Any source of potential or real danger must be
eliminated before proceeding.
Identify the position of the emergency stop buttons,
switches and other emergency systems on the
generator.
Learn the special emergency procedures relative to the
installation in question.
Identify the position of the fire extinguisher or other
protection and emergency devices and learn their
functioning.
Identify any sources of danger such as fuel, engine oil
or acid solution leaks, condensate in the drip caps, high
voltage, high pressure.
Ensure that the generator is clean and that the
surrounding areas are clean and free of obstacles.
Check that there are no obstructions in the inlets and
ventilation ducts.
Check that the exhaust pipe is not oriented against
obstacles, or make sure that these are at least two
metres away.
Check that the earth connection has been carried out
properly.
At first starting of the generator, after having done any
type of maintenance work, it is always good practice to
check:
- the oil level by means of the dipstick (Fig. 3, Ref. 1 );
- that all the electrical utilities are off so that the generator
is not started on load;
- that the fuel pipes are undamaged and properly
connected;
- that there are no electrical connections in a bad state.
4.3 Refue ing
Refuelling must be carried out with extreme care, ensuring
that fuel does not overflow from the engine tank and
respecting the maximum level.
When refuelling has been completed, carefully close
the fillercap (Fig. 2 Ref. ).
- F el is toxic and inflammable and m st therefore
be kept in special airtight containers and stored in
inaccessible places.
- Ref elling m st always be carried o t with the
engine off.
- Do not smoke and do not se open flames d ring
ref elling.
- Ref el in well-ventilated places.
- Avoid contact of f el with the skin and do not
inhale the f mes.
4.4 Battery
Position a 12V battery in the battery compartment (Fig.2,
Ref.M) with a capacity of 50 A/h and dimensions of
207x175x190 to be used for starting.
The compartment is accessed by removing the plate
(Fig.2, Ref.M) after having removed the retaining screws
(Fig.6, Ref.3).
The battery must be charged before using it to switch on
the generator, since the battery charger with which the
generator is equipped is able to maintain the charge
constant, but not to charge it fully.
Connect the terminals (Fig.6, Ref.1) to the battery taking
care to respect the right polarity.
Spread some Vaseline grease on the positive (+) and
negative (-) terminals to protect them from corrosion.
Lock the battery with the special bracket (Fig.6, Ref.2).
- Before proceeding with charging the battery
remove the cover from each cell.
- Recharge the battery in a well ventilated place.
- Interr pt charging if the electrolyte temperat re
exceeds 45°C (130°F).
- Do not disconnect the battery when the generator
is r nning; the battery charger alternator and the
electronic eq ipment may irreparably be damaged.
- Respect + / - polarity when connecting; failing this
will ca se a short-circ it when starting, which will
irremediably damage the electronic eq ipment.
- Dispose of the acid can in an appropriate manner.
- Battery fl id is a corrosive acid, extremely harmf l
to the skin. Always wear protective gloves and be
extremely caref l to avoid spillage when po ring
the acid.
- In the event of contact, wash the affected part
thoro ghly with r nning water and cons lt a
physician, in partic lar when the eyes are involved.

29
GB
PD 10 R  PD 10.4 R
- The batteries develop hydrogen, a highly explosive
gas. It is recommended not to smoke nor ca se
sparks in the vicinity, in partic lar d ring charging.
- Do not ca se short-circ its by placing keys or
tools on the batteries or on the cable fittings.
4.5 Starting
Before starting the generator check that all the utilities
are off to prevent putting the still cold engine under
stress.
Proceed with starting by turning the ignition key
clockwise to the START position (Fig. 8,9, Ref. 1).
Do not hold the start key on for more than 10
seconds and let at least 15 seconds elapse before
attempting to start again.
Do not t rn the key to the START position when the
engine has started. This operation wo ld damage
the starter motor.
To prevent damage to the self-winding cord of the
engine, never release it abr ptly after having p lled
it o t f lly, b t g ide it ntil complete rewinding.
The generator engine has been calibrated, in idle,
to 3150 rpm eq al to 52.5 Hz, as the engine stabilises
at abo t 3000 rpm eq al to 50Hz with a load. For
this reason, the accelerator lever (Fig.3, Ref.4) m st
never shift for any reason, since the o tp t voltage,
freq ency and power val es of the generator wo ld
be compromised.
4.6 Using the generator
Before powering any utility, leave the engine to run without
applied load for at least five minutes so that it gradually
reaches the operating temperature. This will guarantee
longer life of the engine and eliminate the risk of seizures.
Each generator is equipped with the following outlets:
PD 10 R
- a single-phase outlet, EEC 32A 230V 2P+ ND
- a single-phase outlet, EEC 16A 230V 2P+ ND
PD 10.4 R
- a three-phase outlet, EEC 32A 400V 3P+N+ ND
- two single-phase outlet, EEC 16A 230V 2P+ ND
The available power is as indicated on the adhesive label
carrying the technical characteristics (Fig.2).
The s m of absorption of all the tilities connected
to the generator m st never exceed the contin o s
power val e of the generator.
4.7 Stopping
The generator is stopped by turning the ignition key
completely anticlockwise (Fig. 8, 9 Ref. 1) from the ON
to the STOP position.
Before stopping it, it is recommended to run it for a few
minutes without applied load so that the internal
temperatures of the engine and alternator are gradually
reduced.
4.8 Connection to automatic pane /remote
contro (optiona )
The generators of the PD series are fitted for connection
to an automatic control panel able to automatically start
the generator and switch the line in case of a power
failure and invert the operation when the power is
restored.
The automatic panel moreover maintains the generator
starter battery charged even when it is off.
The automatic panel is connected to the generator by
means of a 10-pin connector on the instrument panel
(Fig. 8, 9 Ref. 3) and a power plug to be inserted in the
outlet on the instrument panel.
The automatic panel arrangement can also be used for
connection to a remote control start, which consists of
a box with the start/stop key of the generator connected
to the connector with a cable of standard 50 m length.
When the a tomatic panel or the remote control is
connected to the generator, the ignition key on the
instr ment panel m st remain in the STOP position.
Set the RESET f nction when carrying o t
maintenance or repair operations on the generator
to prevent it from starting in the event of a power
fail re.
Before setting the AUTOMATIC f nction, the
selector m st be positioned on the RESET
f nction to reset the protections.

30
GB PD 10 R  PD 10.4 R
5 PROTECTIONS
The generators of the PD series are fitted with a series
of protections which protect them from improper use and
faults which may compromise integrity of the generator
and operators.
- Low oil pressure protection
Trips turning off the generator when the pressure in the
lubrication circuit is insufficient; when it trips, no warning
light comes on; therefore, if the generator stops, always
check the oil level to ensure that this is not the cause of
the generator stopping.
enerally, it suffices to fill up with oil in order to restart
the generator.
The low oil press re protection does not give an
indication of the oil level. The oil level m st
periodically be checked in order to prevent damage
to the engine.
- Protection against short-circuit and overload
For protection against short-circuits and overloads, the
generators have been fitted, depending on the various
versions, with magnetothermal differential /
magnetothermal / differential switches which trip, cutting
the power, if there is an overload condition on the
alternator, or a short-circuit or current leakage to earth.
Before restoring the power by returning the switch lever
to the ON position, remove the cause of the fault.
6 MAINTENANCE
6.1 Preamb e
Any maintenance operation on the generator m st
be carried o t with the engine off and leaving it to
cool down s fficiently, and m st only be carried o t
by a thorised and s itably trained personnel.
It is recommended to scrupulously follow the instructions
in the manual provided by the engine manufacturer with
each generator.
It is important to regularly inspect and carry out
maintenance on the generator. The frequency of
maintenance should be decided on the basis of the
number of hours of operation.
6.2 Ordinary engine maintenance
The periodic maintenance operations to be carried out
on the engine are indicated in the table at point 6.9. For
more detailed information consult the manual provided
by the engine manufacturer with each generator.
- Check the oil level with the dipstick. (Fig.3 Ref.1).
The oil level m st always be between the MAX and
MIN notches on the dipstick.
- When checking the oil level, ens re that the
generator is positioned horizontally.
6.3 Engine oi change
Use diesel engine oil 15 W 40
Top-up and fill through the hole indicated in Fig. 3 Ref. 3
.
For detailed information in this connection, consult the
engine use and maintenance manual which
accompanies the machine.
It is recommended to drain the oil when it is still
sufficiently warm to flow easily.
Always check correct viscosity of the engine oil in
relation to the range of ambient temperat res in
which the generator operates as indicated in the
table in Fig.7.
Dispose of the sed oil in an appropriate manner,
since it is a poll ting prod ct.
Take the sed engine oil to special collection
centres for disposal.
- Protect hands from contact with oil by wearing
gloves.
In the event of accidental contact with engine oil,
thoro ghly wash the affected part with soap and
water.
- D ring oil top- p and ref elling, respect the
maxim m level indication. An excessive q antity
of engine oil may ca se damage to the engine.

31
GB
PD 10 R  PD 10.4 R
6.4 Oi fi ter
Clean the oil filter (Fig.3, Ref.4) every 200 hours of
operation or every 6 months.
Replace it every 400 hours of operation or every 12
months.
The oil filter is accessed by removing the filter cap (Fig.3,
Ref.4.)
6.5 Air fi ter
For proper functioning and a long life of the engine it is
important to periodically clean and replace the air filter.
An inefficient filter may cause loss of engine power and
excessive smoke at the exhaust.
To replace the air filter (Fig. 4, Ref. 1), carry out the
following operations:
- to unhook the levers to rubber band(Fig. 4, Ref. 2)
- Remove the filter, extracting it from its housing and
clean or replace it;
- The paper element is cleaned with a blast of dry air,
from the inside to the outside, with a pressure not
exceeding 2 bar. Should it be very dirty or have holes,
replace it.
- Remount the cover and fix it with the external butterfly
screw.
Replace the air filter for the first time after 50 ho rs
of operation, then every 200 ho rs of operation.
Red ce the intervals if the generator operates in
partic larly d sty environments.
Never t rn on the engine witho t the air filter, since
this wo ld ca se serio s damage to the engine.
6.6 Fue fi ter
For the engine to deliver full power the filter must be
clean.
Clean the fuel filter (Fig.3, Ref.1) every 200 hours of
operation (or every 3 months) and replace it every 400
hours (or every 6 months).
Follow the instructions described in the use and
maintenance manual of the engine to properly clean
and replace the fuel filter.
Wash the f el filter with diesel f el.
6.7 Battery check
Periodically check the electrolyte level in the battery and
cleanliness and integrity of the connection cables to the
positive and negative terminals.
Normally, the acid level must be within the level lines
shown on the battery body.
When the MIN level is reached, top up the cells taking
care not to exceed the MAX level indicated on the battery
case.
If necessary, top p with distilled water.
6.8 Troub eshooting
The starter motor t rns b t the main engine does
not start
- Check that there is fuel in the tank (fill up)
- Check that the stop electromagnet valve is powered.
(consult Service Centre)
The generator switches off d ring the operating
period
- Check if the low oil level protection has been activated.
(Top up if necessary)
- Check that the stop electromagnet valve is powered.
(consult an authorised Service Centre )
- Check if there is fuel in the tank (fill up)
There is high smoke emission from the exha st.
- Check that the oil level does not exceed the MAX notch.
(Fill up)
- Check the state of the air filter. (clean or replace)
- Check the calibration of the injector (consult Service
Centre)
The alternator voltage is too low.
- Check the engine rpm without applied loads, both 3150
(consult Service Centre)
- Check the state of the air filter. (replace)
- Check the calibration of the injector (consult Service
Centre)
Starter battery flat.
- Check the electrolyte level in the battery. (fill up)
- Check the battery charging device. (replace)
- Check integrity of the battery
The engine r ns irreg larly
- Check the fuel filter. (clean or replace)
- Check the calibration of the injector (consult an
authorised Service Centre)
The generator does not deliver power to the o tlets
b t the voltmeter indicates that voltage is present.
- Check that the magnetothermal differential switch is
in the ON position.
The generator does not deliver power to the o tlets
and the voltmeter does not indicate that voltage is
present.
- Likely alternator fault. (consult Service Centre)

32
GB PD 10 R  PD 10.4 R
6.9 Schedu ed maintenance tab e
8 STORAGE
Before storing the generator for a long period of
inactivity, the following operations must be carried out
to safeguard the integrity of the generator:
- Completely empty out the fuel tank.
- Change the engine oil.
- Clean the air filter.
- Disconnect the battery from the terminals.
- Introduce a few drops of engine oil, about 2 cm3,
through the cap on the equalizer cover and manually
turn the engine shaft a few times.
- Clean the outside of the generator, removing all dust
and impurities.
- Cover the generator with a nylon sheet and store in a
dry and ventilated place.
When reused, again change the engine oil, fill up with
fuel, check the battery charge, and if necessary, charge
it before use.
9 SCRAPPING
At the end of its lifetime the generator must be taken to
official scrapyards.
Do not dispose of the generator at ho sehold ref se
disposal sites, as many of its parts are poll ting.
OPERATION HOURS
Oil level check 10
Battery fluid check 50
Air filter cleaning 200
Fuel filter cleaning 200
Oil sump replacement 200
Oil filter replacement 400
Air filter replacement 400
Fuel filter replacement 400
Equaliser play adjustment 400
Calibration and cleaning of the injector 400
7 TRANSPORT AND HANDLING
7.1 Lifting
All the versions are fitted with a lifting hook to be used
for handling (Fig.2 Ref. B).
Hook the machine carefully and lift it slowly without
sudden movements.
- Hooking the generator at points different from that
indicated may ca se damage to the generator or
be dangero s to the operators.
- D ring lifting all personnel m st keep a safe
distance and the operators m st wear protective
helmets.
7.2 Trai er (optiona )
A trailer complete with wheels and handles is available
to move the PD series generators.
It is a component kit which can also be assembled after
purchasing the generator, and is normally used by those
who need to frequently move the generator.