INSTRUCTION

MANUAL

MODELS:

DJ 30 DJS 30
DJ 40 DJS 40
DJ 60 DJS 60
DJ 80 DJS 80
DJ 100 DJS 100
DJ 180 DJS 180
 Generators sets GESAN

Thank you for buying a GESAN generator set.

This manual has been written to assist you in maintaining and operating your generator set
correctly. Please read it carefully before putting the machine into operation so as to become familiar
with the precautions to be taken during use and be able to perform maintenance in ideal conditions.

Please keep this manual at hand for consultation at all times and ensure it is included with the
machine should it be re-sold.

GRUPOS ELECTROGENOS GESAN, S.A. is constantly striving to improve its products, and
regularly introduces changes to the equipment it supplies. For this reason the characteristics and
information contained in this manual may be modified without prior notice and without incurring any
obligation.

If any problems or queries arise, please contact your distributor.

John Deere
 Generators sets GESAN

INDEX:

• SAFETY PRECAUTIONS

• GENERAL DESCRIPTION

• WIRING SYSTEM

• CONTROL CARDS

• LABELS

• BEFORE OPERATION

• OPERATION

• HANDLING AND STORAGE

• MAINTENANCE

• WIRING DIAGRAMS

• TROUBLESHOOTING

• ADVICE ON INSTALLING GENERATOR SETS IN CONFINED SPACES

John Deere
 Generators sets GESAN

SAFETY INSTRUCTIONS
Please read carefully the following warnings for your own safety and the safety of others :

1. Make sure that the control panel is well lit if you run your generator set in poor lighting
conditions.

2. Make sure that you know how to stop the generator set in case of emergency and familiarize
yourself with its controls and power outlets.

Do not permit operation by someone unfamiliar with the generator set.

Do not let children operate the generator set without the help of an adult.
Children and pets must be kept at a safe distance from the engine, in order to avoid burns or
injury.

3. Carry out all necessary checks before starting the generator set in order to avoid accidents or
damage to the equipment.

4. Earth the generator set as well as the load properly.

5. Do not operate the generator set without when it is raining or where there is snow. YOU
MAY BE ELECTROCUTED.

Do not get the generator set wet, or operate it with wet hands.

6. Do not connect the generator set to the mains. Connection should be carried out by a qualified
electrician in accordance with applicable standards and regulations.

A poorly made connection may cause current returns which could lead to the electrocution of
anybody working on the mains.

7.- The engine exhaust emits sufficient heat to set some substances on fire:

Ensure that the generator set operates at a safe distance from buildings and other equipment (at
least one metre).

Keep all inflammable substances away from the generator set.

Do not touch the engine or the exhaust pipe while the generator set is running. They can cause
serious burns.

Wait until the engine has cooled down before carrying out maintenance or storing it.

8. The fuel used is highly inflammable and volatile :

Ensure that the engine is not running when filling the fuel tank and that the premises are
sufficiently ventilated.

Do not get near flames or sparks while filling the fuel tank.

DO NOT SMOKE near the generator set.

Keep the generator set on a firm, level surface, otherwise fuel may spill and catch light.

John Deere
 Generators sets GESAN

Do not over-fill the fuel tank. After filling, ensure the fuel cap is properly closed.

Do not spill fuel when filling the tank. Fuel vapour or spilled fuel may catch light. If fuel is spilled,
ensure the area is dry before starting the engine.

9. Exhaust fumes from the engine are poisonous:

Do not operate the generator set in a closed environment.

If operating the set in an enclosed space, provide adequate ventilation and direct the exhaust
fumes out of the area.

10. If the generator set operates in a place where damp and dust are unavoidable, it must be dried
and cleaned regularly.

11. At the slightest abnormality, stop and disconnect the set. Locate and correct the fault before
starting up again.

12. Regularly inspect all electrical cables. If damaged cables or hazardous connections are
found, stop the unit immediately and replace or correct the faulty cables before starting up again.

13. Handle batteries with care. Batteries give off explosive gases; keep sparks, flames and
cigarettes well away. Provide adequate ventilation when charging or using batteries in enclosed
space.

Batteries contain sulphuric acid (electrolyte). Contact with the skin or eyes can cause severe
burning. Wear protective clothing and a protective mask.

- If electrolyte comes into contact with skin, wash with water.

- If electrolyte comes into contact with eyes, wash eyes with water for at least 15 minutes
and seek medical assistance immediately.

Electrolyte is poisonous. If you swallow it, drink large amounts of water or milk, and follow with milk
of magnesia or vegetable oil and seek medical assistance.

Use only distilled water in batteries. Tap water will shorten battery life. If the battery is filled above
the maximum level the electrolyte will overflow causing corrosion of the engine or adjacent parts.
Clean away electrolyte which has been spilled.

14. Used oil can cause skin cancer in cases of prolonged and frequent contact. Although this is
unlikely, washing your hands after contact with used motor oil is recommended.

KEEP OUT OF THE REACH OF CHIDREN.

Please refer also to the engine and alternator user’s manual.

For further information or enquiries please contact :

GRUPOS ELECTROGENOS GESAN S.A.

Polígono Malpica- Alfindén, c/ Encina, nº 8
50171 La Puebla de Alfindén (Zaragoza)
SPAIN
Phone +34 976 107 332 Fax +34 976 107 366

John Deere
 Generators sets GESAN

GENERAL DESCRIPTION
The generator set consists of an engine and alternator mounted on a fabricated steel profile
baseframe which is painted with a phosphate primer and top coat.

The alternator is directly coupled to the engine to SAE standards. The rotor is fixed to the flywheel
using steel discs for flexibility. This assembly ensures vibration free running.

The assembly is fixed to the baseframe using anti-vibration dampeners.

Each model exists in various versions:

VERSIONS

STATIONARY WITHOUT CANOPY

1- ENGINE
2- ALTERNATOR
3- CONTROL PANEL
4- SKID BASE

John Deere
 Generators sets GESAN

STATIONARY SOUNDPROOFED
This set features a SOUNDPROOFED METAL CANOPY lined with sound attenuating materials,
which, in combination with the exhaust silencer, attains a noise level compliant with directives
79/113/CEE and 84/536/CEE.

MOBILE SOUNDPROOFED
Generator set mounted on baseframe with independent trailer. Features metal canopy housing the
control panel.

The trailer consists of: speed wheels with pneumatic tyres, DIN towing eye, axle with rubber
suspension, over-run brake and stabiliser leg. Jockey wheel supplied on request.

John Deere
 Generators sets GESAN

WIRING SYSTEM

CONTROL PANELS
Control panels are supplied in IP 54 protected metal cabinets and mounted on the baseframe with
anti-vibration dampeners.

DJ: DJS:
DJ 30 y DJ 40: DJS 30, DJS, 40, DJS 60
DJS 80, DJS 100 y DJS 180:
• Frequency meter
• Switch volt meter • Frequency meter
• Ammeter • Switch volt meter
• Ammeter • Switch ammeter
• Ammeter • Hours run meter
• GPM-2 Control card • ELCB
• Lamp • Lamp
• Hours run meter • GPM-2 Control card
• Fuel level guage • Water temperature guage
• Water temperature guage • Fuel level guage
• Circuit breaker • Water temperature guage
• Battery charge guage

DJ 60, DJ 80, DJ 100 y DJ 180:

• Frequency meter
• Switch volt meter
• Ammeter
• Ammeter
• Ammeter
• GPM-2 Control card
• Lamp
• Hours run meter
• Fuel level guage
• Water temperature guage
• Battery charge guage
• Circuit breaker

John Deere
 Generators sets GESAN

AUTOMATIC MANIS FAILURE PANELS

Mounted in IP 54 protected metal cabinets and supplied loose for wall mounting. Include
measuring, control and load transfer systems.

DJ 30 Y DJS 30:

• Ammeter
• Frequency meter
• Volt meter
• Hours run meter
• Switch volt meter
• Lamp
• Emergency stop button
• Battery volt meter
• GECO Control card
• Circuit breaker

DJ 40, DJ 60, DJ 80, DJ 100,

DJS 40, DJS 60, DJS 80,
DJS 100 y DJS 180:

• Ammeter
• Ammeter
• Ammeter
• Frequency meter
• Volt meter
• Hours run meter
• Switch volt meter
• Hearter lamp
• Emergency stop button
• Battery volt meter
• Overcurrent protection
• GECO Control card

John Deere
 Generators sets GESAN

CONTROL CARD GPM-2

GPM-2 is a programmable engine protecting card, designed to control and monitor generator
sets, engines, air compressors, etc. and can be used either with 12 VDC or 24 VDC batteries.

OPERATION
GPM-2 can be used in two operating modes depending on the position of the key: MANUAL
and AUTOMATIC.

When the start button is pressed the engine will start. The starting order cuts out when the
“LOW OIL PRESSURE” and “BATTERY CHARGE ALTERNATOR” lights go out, or when
frequency is higher than 20Hz.

When the key is switched to the “MAN” position, the “LOW OIL PRESSURE” and “BATTERY
CHARGE ALTERNATOR” lights will come on. If the start button is not pressed within 20
seconds, GPM-2 will shut down the system and the hooter will sound for 120 seconds.

When the key is switched to the “AUTO” position, and if terminals 1 and 2 are closed, the “LOW
OIL PRESSURE” and “BATTERY CHARGE ALTERNATOR” lights will come on and the
generator will start automatically. The “AUTO TEST” light will also come on. Up to 3 start-up
attempts are possible. If the generator fails to start on the third attempt the “FAIL TO START”
light will come on. When terminals 1 and 2 are opened the set idles for a set period and the
engine then shuts down. GPM-2 disconnects itself from the battery and returns to standby
mode.

INDICATOR LIGHTS
AUTO TEST: Continuous green light / Remote operation
PRE-IGNITION: Continuous yellow light / Pre-ignition
STOP: Red
Flashing light: Signals idling for 60secs. after which GPM-2 will shut down the
system.
Continuous light: Stop order – 20 secs.

MAINTENANCE: Flashing yellow light

1st service: After 50 hours running time
2nd service: 150 hours after the first service (programmable)

John Deere
 Generators sets GESAN

ALARM SIGNALS

FAIL TO START
Flashing light: After three failed attempts, the hooter sounds. GPM-2 shuts down
the system.
Continuous light: Voltage failure or low frequency alarm signal. The hooter will sound
and GPM-2 will shut down the system.

BATTERY CHARGE FAILURE (BROKEN BELT) (20 second delay)

BAT

Continuous light: If the engine is not running (before starting), warning only.
Flashing light: Battery charge failure alarm signal. The hooter will sound and GPM-
2 will shut down the system.

LOW OIL PRESSURE (20 second delay.)

Continuous light: If the engine is not running (before starting), warning only.
Flashing light: Low oil pressure alarm signal. Hooter sounds and GPM-2 shuts
down the system.

HIGH TEMPERATURE / LOW WATER LEVEL

Continuous light: Low water level alarm signal. Hooter sounds and GPM-2 shuts
down the system.
Flashing light: High water temperature alarm signal. Hooter sounds and GPM-2
shuts down the system.

OVERLOAD

Flashing light: Overload alarm signal. Hooter sounds and GPM-2 shuts down the
system.

LOW FUEL LEVEL

Continuous light: Low fuel level alarm signal. Hooter sounds.

Flashing light: Low fuel level alarm signal. Hooter sounds and GPM-2 shuts down
the system.

M
EMERGENCY STOP/OVERSPEED

Flashing light: Emergency stop alarm signal. Hooter sounds and GPM-2 shuts
down the system.
Continuous light: Overspeed alarm signal. Hooter sounds and GPM-2 shuts down the
system.

OPTIONAL ALARM SIGNAL

Continuous light: “ “ alarm signal. Hooter sounds.

Flashing light: “ “ alarm signal. Hooter sounds and GPM-2 shuts down the
system.

John Deere
 Generators sets GESAN

SPECIFICATIONS:

INPUT:
12 and 24 VDC nominal: (max. 17.5 VDC and
35 VDC respectively) selected using

JUMPER SWITCH J4.

ALTERNATOR ENERGIZING:
2VDC. 24VDC. Non-energized selected using

JUMPER SWITCH J2.

START-UP CUT-OUT: Via “OIL PRESSURE”,

and “BATTERY CHARGE ALTERNATOR”,
signals or “Frequency” >20Hz.

OUPTUT SIGNALS
Contact, Start and Stop: + VDC (Battery
positive), 10 A. max.
Alarm (Hooter): - VDC (Battery
negative), 1 A. max.

STANDARD PRE-SET TIMES:

Duration required for alarm conditions: 1 sec.

Alarm signal start-up delay: 20 sec.
Pre-ignition duration: 10 sec.
Start order / Automatic pause: 10 sec.
Shutdown order duration: 20 sec.
Hooter output duration: 2 min.
Idling time 1 min.

STANDARD CONFIGURATION:

Battery voltage: 24V

Alternator energized: YES
Start-up attempts/pauses: 3
Start-up cut-out: O. Press., Batt. Ch. Alt. or Fr.>20Hz
Generator frequency: 50 Hz
Low frequency alarm delay: 30 s
Overspeed duration: 1/2 s.
Gen. Connect. delay: 10 s.

John Deere
 Generators sets GESAN

CONTROL CARD GECO

GECO is an AUTOMATIC CONTROLLER designed to start, control and monitor generator sets
in mains failure situations, and can be used with both 12 and 24 VDC batteries.

OPERATION A
U
TEST+SERV.-2

T TEST
O

AUTO

GECO can be switched to any one of six different operational modes: OFF/RESET
M
A SERV.-1/START
N

AUTOMATIC
SERV.-2/START

Vac

If mains is O.K. the mains light will be illuminated and the mains contactor will be
connected.
The mains contactor and load supplied lights will also be on.
SERV.-1

Vac Hz
If the mains fails and generator parameters are O.K., the generator lights
will come on.
Three seconds later the mains contactor will open and the generator contactor will close.

The SERV.-2 lights will illuminate.

Up to three 20 second starting attempts are possible, with a 10 second pause between each
attempt. If after three attempts the generator has not started, the “Fail to Start” light
will illuminate and the hooter will sound (2 min.).

The start-up signal will cut out when the controller recieves the engine running signal, either by
detecting generator frequency >20Hz or by receiving positive battery current through terminal 4.
When mains returns, after a 60 second delay, the load will be transferred back to mains and the
generator will idle for 2 minutes then shut down.

John Deere
 Generators sets GESAN

OVERRIDE MAINS (AUTOMATIC MODE): Light off. Current is supplied by

generator.
OVERRIDE GENERATOR (AUTOMATIC MODE): Light on. Generator will not
start on mains failure.

TEST
TEST

Works as TEST WITH LOAD, but the load is not transferred to the generator. If the mains
should fail while in this mode, the load will automatically be transferred to the generator. The
test finishes when the controller is switched to any other mode.

TEST WITH LOAD TEST+SERV.-2

Works as AUTOMATIC by simulating a mains failure and transferring the load to the generator.
When the controller is switched to any other position, and if mains is O.K., the load will be
returned to mains.

MANUAL
OFF/RESET SERV.-1/START SERV.-2/START

OFF/RESET
SERV.-1
Shuts down the generator and cancels all alarm signals (mains contactor closed). The
lamp lights up.

SERV 1 / START

The load is supplied by the mains (mains contactor closed) and the SERV.-1 lamp lights up.
The generator starts and runs manually. Alarm signals work automatically.

SERV 2/ START

Generator starts and runs manually (generator contactor closed). The lamp lights
SERV.-2
up.
Alarm signals work automatically.

STOP

Emergency stop. If not switched to OFF the mains contactor closes and the SERV.-1 lamp
lights up.

The hooter sounds and the lamp lights up.

ALARM SIGNALS:
FAIL TO START/EMERGENCY STOP/GENERATOR FAILfailure/running

The lamp lights up, the hooter sounds and GECO shuts down the system. Turn the switch to
the OFF position.

LOW OIL PRESSUREoil pressure

The lamp lights up, the hooter sounds and GECO shuts down the system. Turn the switch to
the OFF position.

John Deere
 Generators sets GESAN

HIGH WATER TEMPERATURE / WATER l

The lamp lights up, the hooter sounds and GECO shuts down the system. Turn the switch to
the OFF position.

OVERLOAD

The lamp lights up, the hooter sounds and GECO shuts down the system. Turn the switch to
the OFF position.

LOW FUEL LEVEL

The lamp lights up and the hooter sounds. Resets automatically when the fuel tank is refilled.

BATTERY CHARGER:
GECO features a 2 Amp automatic battery charger which is fed by an external transformer.

If battery voltage is O.K. the light will be on.

BAT

While the battery is being charged the light will be on continuously and when
the

floating voltage is reached the light will flash.

POTENTIOMETERS
Factory adjusted values

Potentiometer 1: Adjusts generator voltage monitor. 200-250 V.

Potentiometer 2: Adjusts generator frequency. 48-54 Hz.
Potentiometer 3: Adjusts min. mains voltage monitor. 200V.
Potentiometer 4: Adjusts battery charge voltage. 13.8(12VDC)/27.6(24VDC)

These potentiometers are adjusted at the factory to normal operating values.

SPECIFICATIONS

Mains failure-start delay: 3 sec.

Shutdown signal duration: 20 sec
Start-up impulse duration: 20 sec.
Generator alarm signal delay: 1 min
Pause between impulse duration: 10 sec
Running failure alarm signal delay: 3 sec
Generator contactor connection delay: 3 sec.
Max. battery charge current: 2 amp
Monitoring activation delay: 10 sec.
Max. hooter duration: 2 min.
Mains restored-transfer back delay: 1 min.
Number of start-up attempts: 3
Idling duration: 2 min.
Relay contacts rating: 8 amp

John Deere
 Generators sets GESAN

Flow chart for operation of an emergency automatic generator set

John Deere
 Generators sets GESAN

LABELS
On your generator you will find the following labels:

LABEL 1
(UNDEFINED HAZARD)

LABEL 2

LABEL 3
(EARTH)

LABEL 4
(ELECTRICAL HAZARD)

LABEL 5

For your safety and the safety of the others, please replace immediately all these labels in case
of loss or damage.

John Deere
 Generators sets GESAN

BEFORE OPERATION
(Please note that this section is valid for models DS170L, DS240L, DS240R and DS400L)

Before using the generator set, please take the following into consideration:

RECOMMENDED OIL:

The use of motor oil SAE 20W40 is recommended at all

temperatures.

It is however wise to select from the table of viscosity

applicable to the average temperature of the area where
the set is to be used.

FOR PERKINS ENGINES:

For models DP200, DP230, DP250, DP350, DP385, DP455 and DP500, only use one of the
following oils:

API CH-4 (Preferable)

API CG-H (Acceptable)

FOR VOLVO ENGINES:

THE FOLLOWING OILS ARE RECOMMENDED:

API (American Petroleum Institute) API (CD), CE, CF,CF-4, CG-4

CCMC (Committee of Common Market Automobile Constructors) CCMC D4, D5
ACEA (Association des Constructeurs Européen dÁutomobiles) ACEA E1, E2, E3
VDS (Volvo Drain Specification) VDS, VDS2

WARNING !!!

THE FOLLOWING OILS ARE RECOMMENDED:

This procedure should be carried out prior to each use in order to protect the unit from serious
damage.

John Deere
 Generators sets GESAN

a) Remove dipstick (see photo 1)

b) Check that oil level is at it’s maximum (See photo 2)

c) Replace dipstick.

d) If oil level is low, add recommended oil by removing

the cap on the engine body.

Foto 1⇒

⇐Foto 2

RECOMMENDED FUEL:

WHERE POSSIBLE USE MOTOR FUEL.

WARNING !!!

Using fuel with a high water content can lead to serious damage in the engine’s injection
system, thus affecting the performance of the generator set.

Do not allow dirt or water to enter into the fuel tank.

N.B. Problems arising out of using poor quality fuel will not be covered by warranty.

John Deere
 Generators sets GESAN

OPERATION
Once the engine is running, your GESAN generator set is ready to provide you with the energy
you require.

However, for your own safety and for the correct running of your generator set, please follow the
instructions set out below.

WARNING !!!

* Do not connect the generator set to the mains.

* Do not start the generator without checking that there is nothing connected to the output
sockets.

* Do not change the cable connections.

* Do not change the engine speed: The frequency and the voltage directly depend on the
rotation speed of the engine. This adjustment IS CARRIED OUT AT THE FACTORY.

MANIPULATING THE ACCELERATOR ON THE ENGINE ENTAILS THE LOSS OF THE

WARRANTY.

* Do not connect equipment using a voltage different from that supplied by the generator set.

* It is not advisable to use this generator set for equipment such as television sets, hi-fi
systems, computers, etc.

* If an electric welder is to be connected, please consult our engineers. Current peaks MAY
BURN OUT THE ALTERNATOR.

* Avoid overloads. The generator set is fitted with a circuit breaker. If the circuit breaker is set
off, ensure that the load is reduced before restarting the unit.

For problem-free operation remember that:

- The sum of the power ratings of the equipment connected to the generator set has to be
compatible with the characteristics shown at the end of this manual.

- Some apparatus (electric motors, air compressors, etc.) absorb power higher than their
nominal power rating when starting. Please consult your distributor in each case.

- Do not exceed the maximum current (Amps) values indicated for each output socket.

John Deere
 Generators sets GESAN

COMMISSIONING

INSTALLATION

a) Place the machine on a firm, flat surface.

b) If the machine is to work outdoors, protect it against rain. Make sure the machine is running
in an environment where there is minimal damp and dust. Check that the exhaust is not
pointing at people.

c) If the machine is to run in an enclosed space, install a pipe of sufficient diameter to

evacuate exhaust fumes outside, where they will not endanger people. Make sure that the
machine is ventilated sufficiently for the engine to run.

d) Allow enough space for supervision, servicing and maintenance. We recommend that at
least 1 metre is left free around the machine.

CONNECTIONS

Open the control panel and connect the apparatus to be used to the terminals, then lift the
circuit breaker.

The terminals can also be connected to an external distribution box, to which the apparatus is
then connected.

DURING OPERATION

Make sure that the maximum power consumption is within the values shown in this manual, in
order to avoid alternator breakdown.

Check the fuel level from time to time to prevent the fuel circuit from emptying.

STARTING UP

John Deere
 Generators sets GESAN

MANUAL STARTING WITH GPM2

1) Check that the installation that the generator is to be connected to is properly earthed.

2) Check the radiator water level and the oil level. Fill if necessary.

3) Check fuel level. If the level is too low the controller will not permit start-up.

4) Check that the circuit breaker below the control panel is disconnected (lever down) and
that the ignition key on the controller is in the 0 position.

5) Connect the load to the generator.

6) Connect the battery to the generator terminals, first the positive terminal, then the
negative terminal.

7) Turn the key to the MAN position. Check that the battery charge failure, low oil
pressure and choke lights are on.

8) When the choke light goes out, push the green start button.

9) Once the set is running, check that the frequency meter and voltmeter are showing the
correct values (for example 51 Hz, 380 V).

10) Connect the circuit breaker by raising the lever.

If the generator set is to start and stop remotely:

1) Open the control panel and connect terminals 19 and 20 to the signal which is to be
sent.

2) Follow the steps shown above, except (7), when the key must be turned to the AUTO
position.

If the generator set is soundproofed it will include an earth leakage relay.

1) Follow the 10 steps shown above and at step 3 check that the earth leakage relay is
pushed in before checking that the circuit breaker lever is down.

STOPPING THE ENGINE

MANUALLY

Switch off the circuit breaker (levers down) and turn the key to the "0" position

AUTOMATICALLY

If the bridge between terminals 19 and 20 is opened, first the generator contactor disconnects
and the engine stops one minute later.

It is important to leave the key in this position, otherwise the battery may discharge.

John Deere
 Generators sets GESAN

AUTOMATIC STARTING WITH GECO

These generator sets feature a set mounted terminal box and a control panel which may be
mounted on the set or separately if required. These generator sets may run both manually or
automatically.

2) Check that the switch on the control card is in the OFF position.

3) Following the wiring diagram supplied, wire up the terminal box to the control panel,
connecting both power cables and control cables.

4) Check that the circuit breaker inside the control panel is disconnected.

5) Check oil and radiator water levels. Fill if necessary.

6) Check fuel level.

7) Connect up the battery, first the positive terminal, then the negative terminal.

8) Connect the mains and check that the voltage indicator light is on.

9) Connect the circuit breaker or trip (lever up).

10) Turn the switch on the control card to the desired position:

STOPPING THE ENGINE

MANUALLY

Press button STOP of control card.

AUTOMATICALLY

If the bridge between terminals 1 and 2 is opened, first the generator contactor disconnects and
the engine stops one minute later.

John Deere
 Generators sets GESAN

HANDLING AND STORAGE

HANDLING
With the exception of stationary generator sets without canopy, your generator set is equipped
with a LIFTING ARCH for moving the set. We recommend you use this arch every time you
move the set, as shown below.

TRANSPORT

WARNING !!!

Before carrying the generator ensure that the battery is disconnected. Drain the fuel tank before
carrying the generator set.

John Deere
 Generators sets GESAN

LONG TERM STORAGE

When the generator set is withdrawn from service for a prolonged period please take the
following instructions into consideration:

a) Store the generator in a damp free and dust free environment.

b) If the generator set is not to be used for more than six months, drain the engine oil and
remove the oil filter. Replace when the set is to be used again.

c) Remove injectors and pour a small amount of oil in the cylinders through the cylinder orifices.

d) Crank the engine manually, if possible, to distribute the oil in the engine.

e) Disconnect the batteries.

Your generator set will thus be ready for starting whenever you need to operate it.

John Deere
 Generators sets GESAN

MAINTENANCE

The life span and performance of your GESAN generator set depend on regular maintenance.
It is therefore vital, to ensure long lasting service from your generator set, that you observe the
schedule provided and also consult the engine and alternator manuals.

WARNING !!!

*The engine and exhaust pipe reach very high temperatures and can cause serious burns or set
some inflammable substances on fire. Let the engine cool down for at least 15 mins. before
undertaking maintenance.

* The use of NON ORIGINAL or equivalent parts may damage your generator set

1. MAINTENANCE SCHEDULE

Daily checks.

In order to avoid problems and accidents it is important to maintain the machine in optimum
condition.

NOTE: These checks must be made when the machine is not running.

1.- Check parts which have caused problems in the past.

2.- Then check:

2.1- Water or oil leaking

2.2- Engine oil level and condition.
2.3- Fuel level.
2.4- Coolant level.
2.5- Dust on the air filter cover
2.6- Broken parts. Nuts and bolts missing

3.- When you turn the ignition key:

3.1- Correct functioning of measuring and indicating devices; these parts should be
kept clean.
3.2- Correct funcioning of fluorescent lamps.

4.- When you start up the set:

4.1 Colour of exhaust fumes.

4.2 Strange noises coming from engine.

John Deere
 Generators sets GESAN

Periodic checks.

Every… Check
50 hours Check fuel pipes and clamps
Replace air filter
Clean fuel filter
100 hours
Check battery water level
Check fan belt play
200 hours Check radiator hoses and clamps
300 hours Change oil filter cartridge
400 hours Change fuel filter cartridge
Clean water inside radiator
500 hours
Change fan belt
1 – 2 months Refill battery with distillled water
Year or 6 times Change oil filter element
the oil filter is
cleaned
800 hours Check valve gap
Change radiator coolant
2 years Replace radiator hoses and clamps
Replace fuel pipes and clamps

2. Specific Maintenance Instructions For Automatic Generator Sets

As well as the basic maintenance checks recommended in the Engine’s user manual, the
following steps should also be taken:

1. Every two weeks, leave the generator set running for 15 minutes. During this time,
check the voltage and frequency, as well as the engine components (the battery
voltmeter should read between 12.5 and 14 volts or between 25 and 27 volts depending
on the engine).

There are two ways to start up the generator set:

• Manually: As indicated in the instruction manual, use the switch on the control
panel to both start up and stop the engine.
• Automatically: When a short circuit occurs, the generator set starts up by
supplying an electrical current via the contactor. The control card detects said
current and if fitted with the necessary parameters, conmutation takes place,
thus shutting down the generator.

Before starting up water cooled generators, oil and water levels must be checked.

2. The water level in the battery should be checked every month. DO NOT FILL TO THE
TOP. Check also the battery voltmeter.

3. The oil in the carter, as well as the oil and fuel filetrs, should be changed once a year. It
is also advisable to check the fuel circuits.

John Deere
 Generators sets GESAN

ELECTRIC DIAGRAMS

ELECTRIC DIAGRAM MODELS DJ 30, DJ 40, DJ 60, DJ 80, DJ 100 AND DJ

180.

DIAGRAM Nº 1646

John Deere
 Generators sets GESAN

ELECTRIC DIAGRAM MODELS DJS 30, DJS 40, DJS 60, DJS 80, DJS 100
AND DJS 180.

DIAGRAM Nº 1755.I

John Deere
 Generators sets GESAN

ELECTRIC DIAGRAM AUTOMATIC MODELS DJ 30 AND DJS 30.

DIAGRAM Nº 1313

John Deere
 Generators sets GESAN

ELECTRIC DIAGRAM AUTOMATIC MODELS DJ 40, DJ 60, DJ 80, DJ 100,

DJ 180, DJS 40, DJS 60, DJS 80, DJS 100 Y DJS 180.

DIAGRAM Nº 1323

John Deere
 Generators sets GESAN

TROUBLESHOOTING
(Problems with the engine)
Problem Possible cause Solution
Engine does not start up 1. Valves 1. Remove and grind the valve base
2. Loose Cylinder Screws [Link]
[Link] ducts [Link] and clean
4. Blocked fuel filter 4. Replace
5. Air in fuel pipes 5. Ventilate
6. Check the nozzle and replace
[Link] injectors
where necessary
7. Blocked vent on tank 7. Clean
8. Check and replace where
8. Injection valve blocked
necessary
9. Pump 9. Check and replace damaged part
10. Battery discharged 10. Recharge
11. Cables connected incorrectly 11. Check wiring diagram and correct
12. Faulty start up switch 12. Replace
13. Faulty starter engine 13. Repair or replace
Engine starts up, then cuts out 1. Blocked air filter 1. Replace
2. Low ticking over 2. Change to 51.5 Hz
3. Blocked fuel filter 3. Replace
4. Air in fuel circuit 4. Release
5. Blocked vent on tank 5. Clean
6. Check and replace where
6. Hitched rack
necessary
1. Check recommended maximum
Engine does not accelerate 1. Overload
loads
2. Incorrect injection advance 2. Repair
3. Broken spring on regulator 3. Replace
4. Blocked fuel filter 4. Replace
5. Blocked vent on tank 5. Clean
6. Zip caught 6. Check and consult technician
7. Air in fuel circuit 7. Ventilate
Varying speed 1. Zip caught 2. Check and consult technician
2. High oil level 2. Check and adjust level
Black smoke 1. Air filter blocked 1. Replace
2. Check running hours and follow
2. Incomplete runninng in
indications to complete it
3. Check segments and cylinder
3. Worn down segments
sleeve
4. Worn down cylinders 4. Check and correct
5. High oil level 5. Check and correct
[Link] revolutions and bring them
The generator does not excite 1. Low engine speed
back to normal value
2. Condensor damaged 2. Change condensor
3 Defective winding 3. Check resistance on windings
4. Diodes broken 4. Check and replace
5. Loss of remanence 5. Apply 220V to condensor
High tension on empty 1. High speed 1. Check revolutions and adjust
Low tension on empty 1. Reduced speed 1. Check revolutions and adjust
[Link] Diodes 2. Check and replace
3. Damaged windings 3. Check resistance on windings
Correct tension on empty, but falls
1. Reduced speed with load 1. Check revolutions and adjust
with load
2. Check and intervene where
2. Load too high
necessary
3. Short circuit on diodes 3. Check and change
Tension unstable 1. Infrequent contacts 1. Check connections
2. Irregular rotation 2. Check uniformity f rotation
Noisy 1. Damaged bearings 1. Replace
2. Damaged coupling 2. Check and repair
High temperature on alternator 1. Opening on vents partially blocked 1. Remove and clean the
2. Possible overload 2. Check the load

John Deere
 Generators sets GESAN

(Problems with the alternator)

Problem Cause Solution
No current in the alternator 1. The circuit breaker or limiter arer 1. Screw in the circuit breaker
unscrewed
2. Failure to excite [Link] technician
[Link] speed on engine 3. Check engine speed
4. Damaged condensor 4. Change
5. Brush holder broken 5. Replace
6. Rectifying bridge 6. Replace
7. Damaged potentiometer 7. Replace
Tension too high without load 1. Capacity condensor too high [Link] capacity
Tension too low without load 1. Diodes or varistor damaged 1. Change
2. Faulty winding 2. Check and change
3. Capacity condensor too low 3. Check capacity
4. Potentiometro not set to maximum 4. Set to maximum
Correct tension on empty, but falls 1. Speed too low with load 1. Check the load
with load
2. Load too high 2. Check the load
3. Short circuit on diode 3. Check and change
Tension unstable 1. Poor contacts 1. Check
Noisy alternator 1. Faulty bearings [Link]
2. Faulty coupling 2. Check
Electrode is not melted correctly 1. Fault in excitation 1. Consult technician
2. Potentiometro poorly regulated 2. Regulate
No current in output terminals 1. Potentiometro damaged 1. Replace

John Deere
 Generators sets GESAN

ADVICE ON INSTALLING GENERATOR SETS

IN CONFINED SPACES
• Open generator sets, liquid cooled

Below is a typical set up of a generator set in a confined space:

1. Grill for air intake: Should be at least 1.4 times the size of the panel on the engine
radiator.
2. Conduct for exhaust fumes: Part of the tube should be flexible so that the engine does
not vibrate the silencer. Otherwise, there is a serious risk of fission occurring in the
exhaust.
3. Silencer: Should be secured to a fixed point.
4. Conduct for exhaust fumes to exterior: Fumes must exit from a point from which they
cannot reenter the room.
5. Grill for outlet of air from radiator: Should be at least 1.25 times the size of the radiator
panel. If the grating is very thick, take into consideration that the air flow will be
restricted and consequently the outlet surface area should be larger.
6. Joint for channeling cool air: To avoid the recirculation of warm air in the room, the cool
air must be channeled from the radiator to the outside grill, restricting recirculation.
7. (Optional) Fuel tank for one day’s work: All Gesan units come equipped with a fuel
tank. When using a supplementary fuel tank of a larger capacity, an intermediate from
which the engine fuel pump will aspirate. Please consult the current construction
restrictions for installing these tanks. The relevant construction law for this type of tank
is MI-IP-03.
8. (Optional) Auxilary fuel pump: For filling the intermediate tank between the large
capacity fuel tank on the generator set.
9. (Optional) Conduct for channeling fuel.

Points to take into consideration:

All our generator sets are fitted with a blowing radiator, this is the air current which flows
through the radiator and passing through the engine’s fan to the exterior. Therefore, it is not

John Deere
 Generators sets GESAN

convenient that the warm air outlet is situated in a wall open to strong winds from the outside,
as cooling will be made difficult.

A sufficient amount of space ahould be left around the generator set, so that any necessary
maintenance work may be carried out and so that the unit is kept sufficiently cooled. Placing
the generator set against a wall makes cool air circulation difficult.

It is important to place a joint for channeling air between the radiator and the outside. This way
we avoid warm air renetering the radiator and thus causing the generator to heat up.

The cool air inlet should be situated so that the unit is kept sufficiently cool. Having the outlet
and inlet of air opposite one another would be ideal as the air current would be equal.

The air inlet temperature should be less than 40ºC. The engine loses 2 % of it’s power for each
5ºC above 40ºC rises the temperature.

The silencer tends to get very hot, so keep it away from the engine. There are thermical
isolators available on the market which can be used on the exhaust pipes as well as on the
actual silencer. This way accidents caused by burns may be avoided. WARNING: Isolators
should not be fitted on turbo or engine block.

A piece of flexible tube should be fixed between engine outlet inductor and the silencer, to
absorb engine vibrations.

Avoid fitting long tubes for exhaust fumes, it is better to increase the diameter of the tube so as
to avoid excess counterpressure, overheating and power loss in the engine. If you have any
doubts, contact an authorized technician.

If using a large capacity fuel tank,an intermediate tank should be placed between vacuum tank
and generator set. The fuel pump on the engine will do for extracting the fuel from the
imtermediate tank. Before filling up with fuel, you should consult the laws in force and use fuel
tanks especially adapted to the MI-IP-03 legislation.

If strong ventilation is required, the ventilator should guaranteea minimum air flow calculated as
shown below:

Total irradiated heat to air

Necessary air current (m3/min.)= ------------------------------------+conumption of combustion air
Air Density*Λta* Cte.

• Total irradiated heat to air:( kW) Engine + Alternator. Information provided by

manufacturer
• Air density: Information depends on the temperature of the air, according to the
following table:

ºC 0 5 10 15 20 25 30 35 40 45 50 55
Kg/m3 1.30 1.27 1.25 1.22 1.20 1.19 1.17 1.16 1.14 1.12 1.09 1.08

• Λtª. Increase in the temperature in the room above room temperature

• Cte: Constant Value 0.0167
Air consumption necessary for combustion: (in m3/min). Consult manufacturer

John Deere