Manual 800 Kva

Document No.: M02.
0210
Document Title: USER MANUAL
NHC20 / QST30G2
Issue:
F
Date:
01/02/2007
USER MANUAL
FOR
NHC20/QST30G2 Standard & Stackable
Document M02.0210
Document No.: M02.0210

NHC20 / QST30G2
Issue:
F
Date:
01/02/2007
TABLE OF CONTENTS
1.0
SAFETY
1.1. GENERAL INFORMATION.....................................................................................................1
1.2. ELECTRICAL POWER ...........................................................................................................1
1.3. MATERIALS............................................................................................................................1
1.4. OPERATIONAL PRECAUTIONS ...........................................................................................1
1.5. SAFETY LABELS ...................................................................................................................2
2.0
NOISE EMISSION
2.1. NOISE CONTROL PROHIBITED ACTS.................................................................................4
2.2. GENERATOR NOISE EMISSION CONTROL INFORMATION .............................................4
3.0
HANDLING
3.1. LIFTING / HANDLING.............................................................................................................5
3.2. STORAGE / TRANSPORT .....................................................................................................5
4.0
INSTALLATION
4.1. UNPACKING ...........................................................................................................................6
4.2. LOCATION OF THE PLANT...................................................................................................6
4.3. COMMISSIONING...................................................................................................................6
4.4. PRIOR TO STARTING ............................................................................................................6
4.5. ELECTRICAL CONNECTION.................................................................................................6
4.6. EARTHING ..............................................................................................................................6
4.7. REMOTE FUELLING ..............................................................................................................7
5.0
GENERAL DATA
5.1. GENERAL OPERATION.........................................................................................................8
5.2. DESIGN LOAD CAPACITY ....................................................................................................8
5.3. DESIGN TEMPERATURES ....................................................................................................8
5.4. CONTAINER & BASE FRAME...............................................................................................8
5.5. DIESEL ENGINE .....................................................................................................................9
5.6. ENGINE LUBRICATION SYSTEM .........................................................................................9
5.7. ENGINE COOLING SYSTEM .................................................................................................9
5.8. ENGINE FUEL SYSTEM.........................................................................................................9
5.9. EXHAUST SYSTEM..............................................................................................................10
5.10. ENGINE CONTROL SYSTEM ..............................................................................................10
5.11. GENERATOR........................................................................................................................10
5.12. MAIN CIRCUIT BREAKER ...................................................................................................10
6.0
OPERATING INSTRUCTIONS
6.1. OPERATING CONTROLS AND INSTRUMENTS ................................................................14
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6.2. PRIOR TO START ................................................................................................................23

6.3. STARTING ............................................................................................................................23
6.4. LOADING ..............................................................................................................................23
6.5. SHUT-DOWN ........................................................................................................................23
6.6. AUTO OPERATION (OPTIONAL) ........................................................................................23
7.0
MAINTENANCE
7.1. GENERAL .............................................................................................................................24
7.2. MAINTENANCE SCHEDULE ...............................................................................................25
7.3. DAILY MAINTENANCE ........................................................................................................26
7.4. WEEKLY MAINTENANCE....................................................................................................27
8.0
LUBRICATION
8.1. GENERAL INFORMATION...................................................................................................28
8.2. GENERATOR OIL CHANGE ................................................................................................28
8.3. OIL SPECIFICATION ............................................................................................................28
9.0
TROUBLE SHOOTING
9.1. INTRODUCTION ...................................................................................................................29
9.2. ACTION PLAN ......................................................................................................................29
9.3. TROUBLE SHOOTING CHART ...........................................................................................30
Note Appendix Sections C and F below for non CSA Approved units. See User
manual M020225 for relevant Appendix Sections C and F for 480V and 600V CSA
Approved units.
APPENDIX A:
Material Safety Data Sheets
APPENDIX B:
Operating Instruction Sheet
APPENDIX C:
Equipment Data Sheet
Document No.
Rev.
G080275 SHT. 1 to 3
APPENDIX D:
Installation Outline Drawings
Drawing No.
Rev.
A050001 SHT. 1 of 3
A050001 SHT. 2 of 3
A050001 SHT. 3 of 3
B
B
B
Standard
Standard
Standard
A050210 SHT 1 of 4
A050210 SHT 2 of 4
A050210 SHT 3 of 4
A050210 SHT 4 of 4
A
A
A
A
Stackable
Stackable
Stackable
Stackable
APPENDIX E:
Control Panel Layout
Drawing No.
Rev.
D210633 SHT. 1 of 1
A
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APPENDIX F:
Electrical Schematics
Drawing No.
Rev.
Title
D080771 SHT. 1 of 8
D080771 SHT. 2 of 8
D080831 SHT. 3 of 8
D080771 SHT. 4 of 8
D080771 SHT. 5 of 8
D080846 SHT. 6 of 8
D080846 SHT. 7 of 8
D080846 SHT. 8 of 8
C
C
C
I
D
A
B
B
Electrical Schematic for Main Circuit Diagram

Electrical Schematic for Generator Bus Bar Connections
Electrical Schematic for Circuit Breaker Control
Electrical Schematic for Cooling Fan(s) Schematic
Electrical Schematic for Change Over Panel
Electrical Schematic for Synchronising-Measuring-Load Control
Electrical Schematic for Engine ECM Interface
Electrical Schematic for Engine Safeties Wiring Diagram
APPENDIX G:
Earth Leakage Option ($Option382A)
APPENDIX H:
Livery Layout
Drawing No.
Rev.
D200090 SHT. 1 of 1
APPENDIX J:
Manufacturers Component Data
Document No.
Rev.
M040107 SHT. 1 of 1
APPENDIX K:
Container Certificate GB-LR 60515 07/04 (Standard)

Container Certificate BVCT 0681050/S (Stackable)
APPENDIX L:
DNV Spark Arrestor Certificate M-10408
APPENDIX M
Declaration of Conformity
APPENDIX N:
International Contact Information
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1.0
SAFETY
1.1.
GENERAL INFORMATION
Ensure that the operator reads and understands the decals and consults the manuals before
maintenance or operation.
Ensure that the Operation and Maintenance manual, and the manual holder, are not removed
permanently from the machine.
Ensure that maintenance personnel are adequately trained, competent and have read the
Maintenance Manuals.
Make sure that all protective covers are in place and that the container doors are closed during
operation.
The specification of this machine is such that the machine is not suitable for use in flammable gas
WARNING: NO ATTEMPT SHOULD BE MADE TO OPERATE IN SUCH
risk areas.
AREAS WITHOUT THE EXPRESS AUTHORITY FROM AGGREKO.
1.2.
1.3.
Installation of this generator must be in accordance with recognised electrical codes and any
local Health and Safety Codes.
ELECTRICAL POWER
Prior to installation of the generating set you should check that the electrical load to be applied is
within the rated output of the machine at the site ambient conditions.
Before carrying out any maintenance or repairs to the Engine/Alternator assembly disconnect the
starting battery and isolate the alternator from the switchboard.
Before carrying out any maintenance repair to the AC and DC circuits, isolate these from external
control panel and power supplies.
Ensure that the generator set and the load it is connected to be properly earthed.
The generating set should be connected to the load only by a qualified electrician and in
accordance with the applicable regulations.
MATERIALS
The following substances are used in the manufacture of this machine and may be hazardous to
health if used incorrectly:
Antifreeze
Engine Lubricating Oil
Preservative Grease
Rust Preventative
Diesel Fuel
Battery Electrolyte.
AVOID INGESTION, SKIN CONTACT AND INHALATION OF FUMES.
When handling fuel, lubricating oil, cooling fluid and battery electrolyte, wear appropriate personal
protection equipment.
For further information, consult Material Safety Data Sheet contained in this manual.
Avoid build-up of Engine Exhaust Fumes in confined spaces.
Avoid breathing Exhaust Fumes.
1.4.
OPERATIONAL PRECAUTIONS
Never operate unit without first observing all safety warnings and carefully reading the operation and
maintenance manual shipped from the factory with this machine.
IF IN DOUBT CONTACT AGGREKO.
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Never operate the engine of this machine inside a building without adequate ventilation. Avoid
breathing exhaust fumes when working on or near the machine. Do not alter or modify this machine.
A battery contains sulphuric acid and can give off gases, which are corrosive and potentially
explosive. Avoid contact with skin, eyes and clothing. In case of contact, flush area immediately with
water.
Exercise extreme caution when using booster battery. To jump battery, connect ends of one booster
cable to the positive (+) terminal of each battery. Connect one end of other cable to the negative (-)
terminal of the booster battery and other end to a ground connection away from dead battery (to
avoid a spark occurring near any explosive gases that may be present). After starting unit, always
disconnect cables in reverse order.
Never operate unit without first observing all safety warnings and carefully reading the operation
manual.
This machine may include such materials as oil, diesel fuel, antifreeze, brake fluid, oil/air filters and
batteries which may require proper disposal when performing maintenance and service tasks.
Contact local authorities for proper disposal of these materials.
This machine produces loud noise with the doors open. Extended exposure to loud noise can cause
hearing loss. Always wear hearing protection when doors are open.
Never inspect or service unit without first disconnecting battery cable(s) or using the battery isolator
switch to prevent accidental starting.
Do not remove the pressure cap from a HOT radiator. Allow radiator to cool down before removing
pressure cap.
Do not use petroleum products (solvents or fuels) under high pressure as this can penetrate the skin
and result in serious illness. Wear eye protection while cleaning unit with compressed air to prevent
debris from injuring eye(s).
Hot pressurized fluid can cause serious burns. Do not open radiator while hot.
Rotating fan blade can cause serious injury. Do not operate without guard in place.
Use care to avoid contacting hot surfaces (engine exhaust manifold and piping, etc.).
Never operate unit with guards, covers or screens removed. Keep hands, hair, clothing, tools, etc.
well away from moving parts.
1.5.
SAFETY LABELS
Look for these signs on machine, which point out potential hazards to the safety of you and others.
Read and understand thoroughly. Heed warnings and follow instructions.
DANGER
FIRE RISK
(Risk of electric shock)
DO NOT STAND IN FRONT

OF ALTERNATOR AIR
OUTLETS WHEN UNIT IS
RUNNING
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CAUTION
Hot
DISCONNECT STARTING
BATTERY AND ISOLATE
LOAD BEFORE WORKING
ON ENGINE /
ALTERNATOR ASSEMBLY
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2.0
NOISE EMISSION
2.1.
NOISE CONTROL PROHIBITED ACTS
WARNING
Tampering with noise control system prohibited
The following acts or misuse of the unit are prohibited:
1) The removal or rendering inoperative by any persons, other than for purposes of maintenance,
repair, or replacement, of any device or element of design incorporated into any new generator
for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is
in use
Or
2) The use of the generator after such device or element of design has been removed or rendered
inoperative by any person.
Among those acts included in the prohibition against tampering are these:
Removal or rendering inoperative any of the following:
a) The engine exhaust system or parts thereof.

b) The air intake system or parts thereof.
c) Enclosure or parts thereof.
Removal of any of the following:
a) Fan shroud
b) Vibration mounts
c) Sound absorption material
2.2.
Operation of the generator with any of the enclosure doors open.
GENERATOR NOISE EMISSION CONTROL INFORMATION

A. The removal or rendering inoperative, other than for the purpose of maintenance, repair, or
replacement of any noise control device or element of design incorporated into this generator in
compliance with the noise control act;
B. The use of this generator after such device or element of design has been removed or rendered
inoperative.
THIS GENERATOR HAS BEEN SPECIFICALLY DESIGNED WITH A SOUND ATTENUATING
ENCLOSURE. THE CONTAINER DOORS SHOULD REMAIN LOCKED SHUT UNDER NORMAL
OPERATING CONDITIONS. UNDER ANY OTHER CONDITIONS EXCESSIVE NOISE LEVELS
CAN BE PRODUCED AND PROLONGED EXPOSURE IS HAZARDOUS TO HEARING.
FOR SAFETY, EAR PROTECTION SHOULD ALWAYS BE

WORN WHEN WORKING IN THE VICINITY OF AN
OPERATING GENERATOR SET.
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3.0
HANDLING
3.1.
LIFTING / HANDLING
The generator set is enclosed in a standard size ISO 20ft container with integrated lifting forgings
on the corners.
All lifting and handling equipment must be adequately rated for applicable weights.
During all lifting and handling operations the following weights must be considered.
Complete Package Max. Fuel
17216 kgs
(37954 lbs)
Complete Package Without Fuel
16000 kgs
(35274 lbs)
The generator set is fitted with integral stepladders on the container front cargo doors & side.
Ensure that the correct lengths of strop / wire rope is used to ensure a level lift. Also ensure that
the included angle does not exceed 90.
CAUTION: THE GENERATOR SET SHOULD NOT BE DRAGGED.
3.2.
STORAGE / TRANSPORT
Carry out the following points before transporting the generator or preparing the generator for
storage.
Open the battery isolator switch.
Empty the fuel tank (in case of overseas transport).
Disconnect the battery terminals (in case of overseas transport).
Close all fuel valves.
Seal the remote fuel connection with a blind stop.
Ensure that the radiator cap is fitted securely and the exhaust rain cap is closed.
Close all doors.
All units are to be loaded flat onto transport and properly secured.
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4.0
INSTALLATION
4.1.
UNPACKING
Ensure that the correct marked lifting / tie down points are used whenever the machine is lifted or
transported.
4.2.
LOCATION OF THE PLANT

The generator can be installed on any solid, flat and level surface capable of supporting the full
operating load of the package. A dry, well-ventilated area where the atmosphere is as clean as
possible is recommended. Ensure that the machine is positioned securely and on a stable
foundation.
CAUTION: A minimum of 3 metres (9 ft) all round the generator is recommended. Hot air
will exit from the roof outlet. It is important that this hot air does not re-circulate to the
package inlet.
The generator must be allowed sufficient space all round and above, to enable the effective removal
of the cooling air which, in turn, will reduce the risk of recirculating the cooling air back through the
generator. Adequate clearance needs to be allowed around and above the machine to permit safe
access for specified maintenance tasks. Hard surfaces may reflect noise with an apparent increase
in the decibel level. It is recommended that provision be made for lifting heavy components during
major overhaul.
NOTE: When operating at elevated altitude please refer to engine manufacturers
guidelines for power deration.
4.3.
COMMISSIONING
Upon receipt of the unit, and prior to putting it into service, it is important to adhere strictly to the
instructions given below in section 4.4 PRIOR TO STARTING.
4.4.
4.5.
4.6.
Ensure all persons concerned are suitably competent with generator installations.
Ensure that the operator reads and understands the decals and consults the manuals before
maintenance or operation.
Ensure that the position of the emergency stop device is known and recognised by its markings.
Ensure that it is functioning correctly and that the method of operation is known.
PRIOR TO STARTING
Ensure that the unit is clean, free from debris and fluids. All connections, joints, seals must be
correctly fitted and tightened. All filters, louvers and air inlets are free and open.
Ensure that there is a safe working procedure which has been issued by supervisory personnel,
and that all persons concerned with the operation of the generator understand it.
Ensure that the safety procedure to be applied is based on the appropriate national and local
regulations.
Ensure that the safety procedure is followed at all times.
ELECTRICAL CONNECTION
A suitably trained electrician should carry out all electrical connections.
Ensure the generator main isolator is off and that the power cables are in good condition.
Ensure that the phases are correct after the cables have been connected.
Ensure all safety covers are back in place after electrical connection is complete.
EARTHING
An external earthing boss is fitted onto the container at each corner of the set. This allows a
dedicated earthing connection if required.
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NHC20 / QST30G2
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4.7.
REMOTE FUELLING
External fuel tank supply can be connected to the generator set.
One 1 Female Connector (supply)
One Female Connector (Return)
The fuel connections for external supply are located on the side of the container.
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5.0
GENERAL DATA
NOTE:
Each generator of this type is uniquely identified by a Plant Number and Serial Number
indicated on the identification plate affixed to the outside of the control panel. This information is
required when ordering spare parts. Major component serial numbers are contained within the
manual.
The technical data defining the generator and the limits on its operating environment are tabulated in
the Equipment Data Sheet. A copy of the Equipment Data Sheet has been included in the manual.
In order to assist in the operation and maintenance of the generator, a full set of electrical and
installation drawings has been included in the manual.
5.1.
GENERAL OPERATION
The generator is a diesel engine driven alternator with control electronics, mounted on a bedplate
with internal fuel tank. The standard package is composed of the following:
Alternator and engine assembly
Pressurised oil system
Automated control system
Instrumentation
Safety provisions
Engine cooler pack
Spark arrestor / Silencer
Internal fuel tank
The engine and alternator are integrally mounted. This assembly is isolated from the base by rubber
isolation mounts.
5.2.
DESIGN LOAD CAPACITY

The NHC20/QST30G2 (800kVA) generator set can be run up to a maximum of 812VA at prime
power rating 50Hz and 941 kVA at prime power rating 60Hz.
5.3.
DESIGN TEMPERATURES
The NHC20/QST30G2 (800kVA) generator set can operate through an ambient temperature range
of:
5.4.
-10C (14F) to 50C (122F)
CONTAINER & BASE FRAME

The overall dimensions for the generator set are 6060 X 2440 X 2600 mm.
The container is manufactured from welded steel and has access to the inside of the generator
through lockable doors. Access to the roof of the container can be gained by using the integral steps
on the end of the container.
The base frame has 120% capacity of the fuel tank to prevent fuel leaking out of the generator set in
the event of a fuel leakage inside the generator. A level switch is fitted inside the bund for spillage
indication. This will shut down the engine when activated.
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NHC20 / QST30G2
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5.5.
DIESEL ENGINE
The generator set uses a Cummins QST30G2 diesel engine, which is capable for either 50 Hz or 60
Hz. Details of the engine are outlined below.
Type:
Model:
RPM:
Nominal Engine Output @ 1500rpm:
Governor:
Starting System:
Fuel Consumption @ Continuous 1500rpm:
5.6.
Four Stroke, 12 Cylinder 50 V, Water Cooled,

Turbo charged, C/A Aftercooler
Cummins QST30G2
1500 / 1800
698kW @ Prime Power
Cummins Dominion
24V Battery System with Fitted Isolator
131 L/Hr @ 100% Prime Power
ENGINE LUBRICATION SYSTEM

The engine oil lubrication system includes pump, strainer and sump all fitted internally within the
engine block. Oil filtration is fitted to the side of the engine block for ease of access and
maintenance.
Sump Capacity:
133 Litres
The Lube oil specification is as per API/ASTM/SAE/CD (equivalent to series MIL-L-415993).

Recommended oils are Castrol Tection T 15W-40 (previously called RX Super Plus), Shell Rimula
15W 40.
The sump can be drained using the K1 pump via a Wallminster valve.
Refer to manufacturers data for all filter information.
5.7.
ENGINE COOLING SYSTEM

The engine cooling consists of a pump, thermostat, heater and radiator assembly.
Cooling fluid is fed from the radiator, through the pump, which is belt driven from the engine pulley.
The thermostat controls the flow to the radiator. The radiator assembly is mounted at the front of the
container in a separate compartment, with the fan mounted on the container roof.
Cooling air enters the generator through the container end louvers and noise attenuation baffles.
This air then passes into the container space then across the radiator assembly.
The cooling air exits through the roof of the package.
The radiator is factory filled with Shell anti-freeze and anti-corrosion coolant, in 50-50 water-coolant
concentration, providing protection to 32C. Please consult Aggreko if filling is required.
5.8.
ENGINE FUEL SYSTEM

The engine fuel system consists of an internal fuel tank, Racor filters (see Figure 5.2), fine fuel filter,
fuel pump, injection pump and nozzles.
Fuel can be taken from either an external or the internal fuel tank. Fuel is then pumped through the
Racor filters to the fine fuel filters and then passed to the injectors and then to the injection nozzles.
The internal fuel tank has a fuel capacity of 1288 Litres. A fuel level mechanical gauge is also fitted in
the internal tank. The fuel tank fill point is external. There are 4 cleaning ports on the fuel tank that
are all accessible through the container doors.
External fuel supply can be connected to the package using the quick release connections at the
side of the container. Internal supply and return fittings/valves must be re-configured to ensure that
the engine fuel is not drawn from the onboard supply.
The use of ASTM No. 2D fuel is recommended for optimum engine performance. At operating
temperatures below 0C, acceptable performance can be obtained using blends of No. 1 and No. 2D.
The use of lighter fuels can reduce economy. The viscosity of fuels must be kept above 1.3 cSt to
provide adequate lubrication.
Refer to manufacturers data for all filter information.
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NHC20 / QST30G2
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5.9.
EXHAUST SYSTEM
The exhaust system consists of the exhaust ducting, exhaust silencers complete with spark arrestor
and rain cap assembly. The exhaust gases exit the engine and are passed through the exhaust
ducting and exhaust, out the top of the container through the rain cap assembly. Insulation and heat
shields are fitted to the exhaust ducting to prevent user contact with high temperature surfaces.
Manufacturer:
Spark Arrestor:
Universal Silencers
DNV Certificate No M-9561
5.10. ENGINE CONTROL SYSTEM

An Electronic Cummins Dominion ECM controls the engine output.
A combined DIEF/GEMPAC system is used to monitor the safety circuits and set the operation mode
of the generator. See section 6.1.2 Safety Module for more detail.
5.11. GENERATOR
Manufacturer:
Voltage Range
Type:
HCI634H2
50Hz:
380-440 Volts
60Hz:
440-480 Volts
Excitation System:
Voltage Regulator
Newage Stamford
Rotating Field powered by Permanent Magnet

Pilot Exciter
within 1% from no load to full load MX321+PMG
5.12. MAIN CIRCUIT BREAKER

Manufacturer:
Type:
- 10 -
Schneider
NW25 Withdrawable Four Pole. Electronic
Overload Protection Micrologic 5.0A Motor
Operated. Lockable. Off Position

NHC20 / QST30G2
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Date:
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SPLITTER BOX
OIL FILTERS
DCA4
FUEL WATER SEPARATOR
OIL FILL DIPSTICK
LOAD TERMINAL
BATTERY ISOLATOR
FUEL FILTER
Figure 5.1 Right Bank Side 800 kVA Generator Part Locations
- 11 -
AUXILIARY SOCKETS ACB

CONTROL

NHC20 / QST30G2
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RACORS
CRANK CASE
BREATHER BOTTLE
K1 PUMP
ENGINE JB ECM
SOCKETS
ACB FACIA
Figure 5.2 Left Bank Side 800 kVA Generator Part Locations
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COOLANT DRAIN VALVE (RADIATOR COMPARTMENT)
FUEL COOLER (RADIATOR COMPARTMENT)
COOLANT DRAIN VALVE (RADIATOR

COMPARTMENT)
COOLANT LEVEL SIGHTGLASS (RADIATOR AIR INLET)
Figure 5.3 Additional 800 kVA Generator Part Locations
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6.0
OPERATING INSTRUCTIONS
6.1.
6.1.1.
OPERATING CONTROLS AND INSTRUMENTS
CONTROL PANEL
The operating controls and instruments are arranged on the control panel as shown in figure 6.1. A
description of each panel device is given in the key below.
12
11
13
10
Figure 6.1 Control Panel Exterior

1
Gempac Display
Volts Lower / Raise
11
Pressure Meter
Remote / Off / Local
Manual / Auto
12
Hours Run
Engine Start
CB Open
13
Temperature Meter
Engine Stop
CB Close
Speed Lower / Raise
10
Alarm Reset
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10
6
2
7
8
3
11
Figure 6.2 Control Panel Internals
1
2
3
Engine JB Socket
AVR Panel Aux.
Socket
Busbar Sensing
Socket
F14
GEMPAC
Terminals 1-82
Dominion ECM
10
Terminals 83-87
F12
11
Droop & Gain Pots.
F13
Key for figure 6.2
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6.1.2.
DEIF INTERFACE
Line 1 displays the mode of operation, as shown in Figure 6.3 below. If SETUP is selected, it is possible to
toggle through the display options for line 1 by repeatedly pressing the VIEW button. 7 options are
available:
Generator voltage L1 L2 L3 (Vac)
Bus voltage L1 L2 L3 (Vac)
Generator current (A)
Generator power factor and active power

(kW)
Generator apparent power (kVA) and

reactive power (kVAr)
Generator L1 frequency (Hz) and voltage

(Vac)
Figure 6.3 DEIF Interface
Bus L1 frequency (Hz) and voltage (Vac)
The default setting of line 2 is Generator L1 frequency and voltage, as shown above in figure 3. It is
possible to change the display option for line 2 using the up/down scroll keys, while in the SETUP menu. A
number of options are available, including:
F, P, Q, S, cos , angle between phases, V, I, frequency deviation, analogue inputs
The fourth line gives 4 options as shown in figure 3: SETUP, V1, V2, and V3. SETUP is used to enter the
SETUP page; position the cursor beneath SETUP (using the left/right scroll keys) and press SEL. V1, V2
and V3 are different display options. V2 and V3 are fixed (but can be configured in the utility software). V1
is selectable from 15 views using the up/down scroll keys (each view can be separately configured using the
utility software).
In addition to electrical parameters, the GEMPAC unit also displays engine parameters from the Cummins
ECM via the MODBUS connection. These are displayed in views contained within V1. The following engine
parameters are displayed:
-
Speed
Pressure Oil
Temperature Coolant
Fuel Rate
Fuel Rack Position - Left & Right
Temperature Intake Manifold - Left & Right
Pressure Intake Manifold Left & Right
Pressure Coolant
Temperature Oil
Fuel Supply
Fuel Temperature
Droop Adjust Potentiometer
Barometric Pressure
Engine Running Time
+/- 0.2V Speed Bias
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6.1.3.
ALARMS & SHUTDOWNS

When a warning or a shutdown is detected, the DEIF PPU display jumps to the alarm page and the fault is
displayed in clear text. This is shown in Figure 6.4. If one or more alarms have not been acknowledged,
the red LED at the top left-hand corner of the
display flashes. If all alarms have been
acknowledged but one or more are still
present, the red LED will be constantly lit. To
reset alarms, the alarm reset button on the
front panel should be used.
To jump to the alarm page at any time, press
the alarm INFO button. To scroll through the
alarms use the up/down scroll keys. It is
possible to jump directly to the first or last
alarm and to acknowledge an alarm by using
the left/right scroll keys and the select button.
Figure 6.4 Typical Alarm Page
Depending upon the fault condition detected, the GEMPAC unit will carry out one of 6 fail classes, and these
are listed below.
Fail Class 0 Warning
Fail Class 1 Engine Stop
Fail Class 2 Emergency Stop
Fail Class 3 Shutdown
Fail Class 4 Emergency Shutdown
Fail Class 5 Electrical Fault
The table below shows the function of each fail class.
Log Alarm
Display Alarm
Log Event
Deload
Open CB
CB Feedback
Timeout Cooling Delay
Engine Stop
Emergency Stop / Fuel Solenoid Close
Close Air Flaps
Trip CB
FC0
X
X
FC1
FC2
FC3
FC4
FC5
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
Cummins ECM generated fault codes

When the ECM detects a fault, one of two messages is displayed on the GEMPAC display:
-
Cummins Warning
Cummins Shutdown
ECM warning is classed as fail class 0 and will be displayed and logged by the GEMPAC unit. ECM
Shutdown is classed as fail class 2 and the generator set will shutdown. Note that this is in addition to any
action that the ECM will take, e.g. reduce the maximum power available or shut the engine down. For
action that the ECM will take, refer to the Cummins technical documentation on ECM fault codes. Once an
ECM alarm has been detected, it is possible to display the fault code and associated text.
To display the list of fault codes within the ECM, press and hold the INFO button for a minimum
of 2 seconds. Current ECM fault codes will then be displayed. Only the active (fault condition still
present) will be displayed.
The GEMPAC unit can display the following ECM fault codes.
- 17 -

NHC20 / QST30G2
Issue:
F
Date:
01/02/2007
Gempac Description
Afterc. w. inlet T exceed warn.
thresh.
Aftercooler w inlet temp shutd.
thresh.
Aftercooler w. inlet temp sen.
shorted h
Aftercooler w. link temp sen.
shorted l
Ambient air pressure sen.
shorted high
Ambient air pressure sen.
shorted low
Battery is dead. Eng. can't start
Blowby exceeded shutdown
threshold
Blowby pres. exceed. warning
threshold
Blowby pressure sen. shorted
high
Blowby pressure sen. shorted
low
Common shutd. relay driver
error
Common warning relay driver
error
Configuration error has been
detected.
Controller pow. down error
detected
Coolant level drop. below shutd.
thresh.
Coolant level drop. below warn.
thresh.
Coolant pres. drop. below shutd.
thresh.
Coolant pres. drop. below warn.
thresh.
Coolant press. sen signal low
Coolant press. sen. signal high
Coolant temp dropped below
warn. thresh.
Coolant temp. exceed shutdown
threshold
Coolant temperature exceeded
the warning
Coolant temperature sensor
shorted high
Cummins ECM Message

Aftercooler water inlet temp
exceeded the warning threshold
exceeded shutdown threshold
sensor signal is shorted high
Aftercooler water link temp
sensor signal is shorted low
AmbientAir pressure sensor
signal is shorted high
AmbientAir pressure sensor
signal is shorted low
Battery is dead. Engine will not
start
Blowby exceeded shutdown
threshold
Blowby pressure exceeded the
warning threshold
Blowby pressure sensor signal is
shorted high
Blowby pressure sensor signal is
shorted low
Common shutdown relay driver
detected an error.
Common warning relay driver
detected an error
Configuration error has been
detected.
Controller power down error has
been detected
Coolant level dropped below
shutdown threshold
Coolant level dropped below the
warning threshold
Coolant pressure dropped below
shutdown threshold
Coolant pressure dropped below
the warning threshold
Coolant pressure sensor signal
is shorted low
Coolant pressure sensor signal
is shorted high
Coolant temp dropped below the
warning threshold
Coolant temperature exceeded
shutdown threshold
Coolant temperature has
exceeded the warning
- 18 -
Fault
Code
Type
2113
Warning
2114
Shutdown
2111
Warning
2112
Warning
221
Warning
222
Warning
1443
Shutdown
556
Shutdown
555
Warning
719
Warning
729
Warning
1425
Warning
1426
Warning
1413
Shutdown
1417
Warning
235
Shutdown
197
Warning
228
Shutdown
233
Warning
232
Warning
231
Warning
152
Warning
151
Shutdown
146
Warning
144
Warning

NHC20 / QST30G2
Issue:
F
Date:
01/02/2007

shorted low
Droop adjust pot shorted high
Emergency Stop (ECM)
Eng. oil burn valve solenoid
shorted
Engine cool. l. data incorr. in l
and h
Engine failed start No action is
taken
Engine position sen. not
detected
Engine speed exceed. shutdown
threshold
Error det. in fuel rail act. sen. sig.
Error det. in timing rail act. sen.
sig.
Error fuel timing press. /actu. sig.
Error in fuel rail pressure sen.
sig.
Error internal ECM
E-stop path f. blown Eng. can't
start
Fail To shutdown
Fail to start relay driver, error

Droop adjust potentiometer
Engine oil burn valve solenoid
shorted low or high
Engine coolant level data
incorrect both low & high at
same time
Engine failed to start - No action
is taken by theECM
Engine position sensor signal is
not detected.
Engine speedExceeded
shutdown threshold
Error detected in the fuel rail
actuator sensor signal
Error detected in fuel timing
press. or timing actuator signals
Error detected in the timing rail
actuator sensor signal
Error detected in the fuel rail
pressure sensor signal
Error internal to the ECM
E-stop path fuse blown.Engine
will not start
Fail To shutdown
Fail to start relay driver detected
an error
145
Warning
1412
Warning
1433
1434
Shutdown
Shutdown
223
Warning
422
Warning
359
Warning
236
Shutdown
234
Shutdown
468
Warning
423
Warning
467
Warning
554
Warning
111
Shutdown
1437
Shutdown
1416
Warning
1479
Warning
1411
Warning
119
Warning
118
Warning
546
Warning
547
Warning
318
Warning
316
Warning
1423
Warning
171
Warning
174
Warning
514
Shutdown
fault code not known

Freq. adjust pot shorted high
Fuel p. deliv. pres. sen. shorted
low
Fuel p. deliv. pres.sen. shorted
high
Fuel pressure sensor shorted
high
Fuel pressure sensor shorted
low
Fuel pump act. not respon. to
ECM comm
Fuel pump actuator shorted high
Fuel pump drv det. an error
Fuel rack act. pos. sen. LB
incorr, data
Fuel rack act. pos. sen. LB
incorr. Data
Fuel rail actuator is responding
Frequency adjust potentiometer

Fuel pump delivery pressure
Fuel pump delivery pressure
Fuel pressure sensor signal is
shorted high
Fuel pressure sensor signal is
shorted low
Fuel pump actuator is not
responding to ECM commands
Fuel pump actuator signal is
shorted high
Fuel pump driver detected an
error
Fuel rack actuator position
sensor left bank incorrect data
Fuel rack actuator position
sensor left bank incorrect data
Fuel rail actuator is responding
- 19 -

NHC20 / QST30G2
Issue:
F
Date:
01/02/2007
Fuel rail actuator sensor shorted

high;
Fuel rail drv. det. an error
Fuel rail pressure sensor shorted
high
Fuel rail pressure sensor shorted
low
Fuel shutoff valve left bank
problem
Fuel shutoff valve no respond
ECM comm
Fuel shutoff valve right bank
problem
Fuel shutoff valve shorted low
Fuel supply pump P sen. shorted
high
Fuel supply pump P sen. shorted
low
Fuel temp exceeded shutdown
threshold
Fuel temp. exceeded warning
threshold
Fuel temp. sensor shorted high
Fuel temp. sensor shorted low
Gain adjust pot sig. shorted high
High curr. det. timing actuator 1
High current det. at fueling
actuator 2
High current det. fuel. actuator 1
High current det. timing actuator
2
High fuel supply P at fuel press.
sen.
High temp shutdown relay driver
error
High voltage det. for battery
Hot shutdown has occurred
Intake mani. air p sen. RB
shorted high
Intake mani. air p sen. RB
shorted low
Intake mani. air p sen. shorted
high
Intake mani. air p sen. shorted
low
Fuel rail actuator sensor signal is

shorted high
Fuel rail driver detected an error
Fuel rail pressure sensor signal
is shorted high
Fuel rail pressure sensor signal
is shorted low
Fuel shutoff valve left bank
problem
Fuel shutoff valve is not
Fuel shutoff valve right bank
problem
Fuel shutoff valve signal is
shorted low.
Fuel supply pump pressure
sensor shorted high
Fuel supply pump pressure
sensor shorted low
Fuel temp exceeded shutdown
threshold
Fuel temperature has exceeded
Fuel temperature sensor signal
is shorted high
Fuel temperature sensor signal
is shorted low
Gain adjust potentiometer signal
is shorted high
High current detected at fueling
actuator # 1
High current detected at fueling
actuator #2
High current detected at timing
actuator # 1
High current detected at timing
actuator #2
High fuel supply pressure
detected at the fuel press.
sensor
High temp shutdown relay driver
detected an error
High voltage detected for battery
Hot shutdownHas occurred
Intake manifold air pressure
sensor right bank signal is
shorted high
shorted low
- 20 -
455
Shutdown
1419
Warning
451
Warning
452
Warning
1211
Shutdown
259
Warning
1212
Shutdown
254
Shutdown
581
Warning
582
Warning
266
Shutdown
261
Warning
263
Warning
265
Warning
1418
Warning
379
Shutdown
397
Shutdown
395
Shutdown
399
Shutdown
449
Warning
1429
Warning
442
611
Warning
Warning
128
Warning
129
Warning
122
Warning
123
Warning

NHC20 / QST30G2
Issue:
F
Date:
01/02/2007
Intake mani. air T ex. shutd.

threshold
Intake mani. air T exceed. warn.
Thresh
Intake manifold air temp

exceeded shutdown threshold
Intake manifold air temp.
exceeded the warning threshold
Intake mani. air T sen. RB

shorted high
Intake mani. air T sen. RB
shorted low
Intake mani. air T sen. shorted
high
Intake mani. air T sen. shorted
low
Internal ECM error.
Low curr./open circ det. timing
act 2
Low curr./open circ. det. fuel. act
2
Low curr./open circ. det. fuel.
act.1
Low curr./open circ. det. timing
act 1
Low engine oil level (remote)
Low fuel supply pres fuel press.
sen.
Low oil pres. shutd. relay driver
error
Low voltage detected for battery
Mechani. misalign. betw.
cam/crankshaft
No sig. crankshaft engine pos.
sensor
No signal det. main/ backup
speed sen.
No signal from main and backup
speed sen
No speed signal from camshaft
pos. sen .
Oil level below shutdown
threshold
Oil level below warning threshold
Oil level exceeded shutdown
threshold
Oil level exceeded warning
threshold
Oil level sensor error
Oil level sensor shorted high
155
Shutdown
488
Warning
Intake manifold air temperature

shorted high
159
Warning

shorted low
161
Warning
153
Warning
154
Warning
343
Warning
396
Shutdown
398
Shutdown
378
Shutdown
394
Shutdown
219
Warning
482
Warning
1428
Warning
441
Warning
731
Warning
689
Warning
121
Warning
115
Shutdown
778
Warning
253
Shutdown
471
Warning
688
Shutdown
326
Warning
252
Warning
498
Warning

Internal ECM error.
Low current or open circuit
detected at fueling actuator # 2
detected at timing actuator # 2
detected at fueling actuator # 1
detected at timing actuator # 1
Low engine oilLevel (remote)
Low fuel supply pressure
detected at the fuel press.
sensor
Low oil pressure shutdown relay
driver detected an error
Low voltage detected for battery
Mechanical misalignment
between cam-shaft and
crankshaft
No signal detected from
crankshaft engine position
sensor
No signal detected from the main
or backup speed sensor
No signal from main & backup
speed sensor
No speed signal detected from
camshaft position sensor
Oil level dropped below
shutdown threshold
Oil level dropped below the
warning threshold
Oil level exceeded shutdown
threshold
Oil level has exceeded the
warning threshold
Oil level sensor error
Oil level sensor signal is shorted
high
- 21 -

NHC20 / QST30G2
Issue:
F
Date:
01/02/2007
Oil level sensor shorted low

Oil pres. below shutdown
threshold
Oil pres. below warning thresh.
Oil pres. sensor shorted high
Oil pres. sensor shorted low
Oil temp. exceeded shutdown
threshold
Oil temp. exceeded warning
threshold
Oil temp. sensor shorted high
Oil temp. sensor shorted low
Overspeed shutdown relay
driver error
Pre-high engine temp warn.
relay drv err
Pre-low oil p. warn. relay drv
error
Rack actuator pos. sen. LB
shorted high
Rack actuator pos. sen. LB
shorted low
Rack pos. sen. right bank
shorted high
Rack pos. sen. right bank
shorted low
Rack position sen. right bank
shorted h
Rack position sen. right bank
shorted l
Rack position sensor left bank
shorted h
shorted l
Relay high side drv detected an
error
The ECM watchdog has failed
Timing rail act. sen sig. shorted
high
Timing rail actuator not resp.
ECM comm.
Timing rail actuator sensor
shorted high
shorted low
Oil level sensor signal is shorted

low
Oil pressure dropped below
shutdown threshold
Oil pressure has dropped below
Oil pressure sensor signal is
shorted high
Oil pressure sensor signal is
shorted low
Oil temperature exceeded
shutdown threshold
Oil temperature has exceeded
Oil temperature sensor signal is
shorted high
Oil temperature sensor signal is
shorted low
Overspeed shutdown relay driver
detected an error
Pre-high engine temp warning
relay driver detected an error
Pre-low oil pressure warning
relay driver detected an error
Rack actuator position sensor
left bank signal is shorted high
Rack actuator position sensor
left bank signal is shorted low
Rack position sensor right bank
Relay high side driver detected
an error
The ECM watchdog has failed
shorted high
Timing rail actuator not
Timing rail actuator sensor signal
is shorted high
shorted low
- 22 -
499
Warning
415
Shutdown
143
Warning
135
Warning
141
Warning
214
Shutdown
421
Warning
212
Warning
213
Warning
1427
Warning
1432
Warning
1431
Warning
168
Warning
169
Warning
179
Warning
181
Warning
183
Warning
182
Warning
166
Warning
167
Warning
1424
Warning
1473
Shutdown
116
Shutdown
112
Shutdown
113
Warning
117
Shutdown

NHC20 / QST30G2
Issue:
F
Date:
01/02/2007
Timing rail driver 1 detected an

error
Timing rail driver 2 detected an
error
Warn. Engine cold potent. start
probl.
Warning Fail to crank
Warning HPI-PT fuel system drv
error
6.2.
Timing rail driver #1 detected an

error
Timing rail driver #2 detected an
error
Warning Engine cold - potential
starting problem
Warning Fail to crank
Warning HPI-PT fuel system
drivers detected an error
1422
Warning
1421
Warning
1435
Warning
1438
Warning
1436
Warning
PRIOR TO START
Execute Daily Maintenance see section 7.1.
6.3.
STARTING
1) Close the battery isolator switch.
2) Put Remote-Off-Local key switch to LOCAL.
3) Put Manual-Auto key switch in MANUAL position (Counter-clockwise).
4) Press the ENGINE START button and hold until the motor starts running.
5) Check voltmeter, Hz meter, oil pressure and coolant temperature.
6) Check the frequency and voltage on the control panel and adjust if necessary with the SPEED or
VOLTS LOWER/RAISE switch.
7) Walk around the engine and check for any leakages.
6.4.
LOADING
1) Allow the engine to warm-up prior to applying load.
2) Press CB CLOSE button; signal lamp should light, indicating that the main circuit breaker is
closed.
6.5.
SHUT-DOWN
1) Remove load from the generator.
2) Open the circuit breaker by pushing the CB OPEN button.
3) Stop the engine by pressing the ENGINE STOP button. The engine will continue to run for a
cooldown period before stopping.
CAUTION: - Always open the battery isolator switch to avoid unauthorised starting
during transport and maintenance.
6.6.
AUTO OPERATION (OPTIONAL)

1) Close the battery isolator switch.
2) Put Remote-Off-Local key switch to LOCAL.
3) Put Manual-Auto key switch in AUTO position (Clockwise).
4) Press the ENGINE START button and hold until the motor starts running.
5) When engine runs up to speed the circuit breaker will automatically close. If voltage is detected
on the bus bars, the generator will automatically synchronise to the bus voltage.
6) The generator will now regulate to the mode of operation selected.
7) A test run should be carried at least once a week.
Refer to separate manual for operation of remote option.
- 23 -

NHC20 / QST30G2
Issue:
F
Date:
01/02/2007
7.0
MAINTENANCE
7.1.
GENERAL
In addition to periodic inspections, many of the components in these units require periodic servicing
to provide maximum output and performance. Servicing may consist of pre-operation and postoperation procedures to be performed by the operating or maintenance personnel. The primary
function of preventive maintenance is to prevent failure, and consequently, the need for repair.
Preventive maintenance is the easiest and the least expensive type of maintenance. Maintaining
your unit and keeping it clean at all times will facilitate servicing.
Ensure that maintenance personnel are adequately trained, competent and have read the
Maintenance Manuals.
Prior to attempting any maintenance work, be aware of the following:
Any unauthorized modification or failure to maintain this equipment may make it unsafe and out
of factory warranty.
Use extreme care to avoid contacting hot surfaces (engine exhaust manifold and piping, etc.).
Never operate this machine with any guards removed.
Imperial and Metric hardware was used in the design and assembly of this unit. Consult the parts
manual for clarification of usage.
The machine cannot be started accidentally or otherwise, by posting warning signs and/or fitting
appropriate antistart devices.
All residual electrical power sources (mains and battery) are isolated.
Prior to opening or removing panels or covers to work inside a machine, ensure that:
Anyone entering the machine is aware of the reduced level of protection and the additional
hazards, including hot surfaces and intermittently moving parts.
The machine cannot be started accidentally or otherwise, by posting warning signs and/or fitting
appropriate antistart devices.
Prior to attempting any maintenance work on a running machine, ensure that:
The work carried out is limited to only those tasks which require the machine to run.
The work carried out with safety protection devices disabled or removed is limited to only those
tasks which require the machine to be running with safety protection devices disabled or
removed.
All hazards present are known (e.g. pressurised components, electrically live components,
removed panels, covers and guards, extreme temperatures, inflow and outflow of air,
intermittently moving parts, safety valve discharge etc.).
Appropriate personal protective equipment is worn.
Loose clothing, jewellery, long hair etc. is made safe.
Warning signs indicating that Maintenance Work is in Progress are posted in a position that can
be clearly seen.
Upon completion of maintenance tasks and prior to returning the machine into service, ensure that:
The machine is suitably tested.
All guards and safety protection devices are refitted.
All panels are replaced, container and doors closed.
Hazardous materials are effectively contained and disposed of.
To assist with ordering spare parts and other service activities, a short form list of Component
Manufacturers data has been included in this manual.
Prior to engine starting, check the oil and coolant levels.
Carry out a visual check of the following:
Leaks.
- 24 -

NHC20 / QST30G2
Issue:
F
Date:
01/02/2007
Loose or damage parts.
Worn or damaged belts, change in engine appearance.
Refer to the Maintenance Schedule for quick reference.
Report unusual noise/vibration and/or exhaust smoke and ensure the generator set is kept clean,
both inside and out.
7.2.
7.2.1.
MAINTENANCE SCHEDULE
INSPECTION CRITERIA
Daily
Engine Oil Level
Fuel Tank (Fill at end of

day)
Gauges / Lamps
Air Filter
Fuel / Water Separator

Drain
Battery Connections /
Electrolyte
Weekly
Radiator Coolant Level
Fan / Alternator Belts
Monthly
Hoses (oil, air, intake, etc.)
Automatic Shutdown
System Visual
3 Months /
400 Hrs
Fasteners / Guards
6 Months /
800 Hrs
12 Months
/ 1200 hrs
Engine Coolant Test
Shutdown Switch Settings

Test
C=check (adjust if necessary)

Refer to manufacturers operating and maintenance instructions for additional information and all
other maintenance.
7.2.2.
SERVICE CRITERIA
Daily
Weekly
Monthly
3 Months /
400 Hrs*
Engine Oil & Filters
Air Filter Element
Fuel / Water Separator

Element
Fine Fuel Element
Engine Coolant
6 Months /
800 Hrs
12 Months
/ 1200 hrs
R=replace
Refer to manufacturers operating and maintenance instructions for additional information and all
other maintenance.
* This figure should be in line with current service best practise.
- 25 -

NHC20 / QST30G2
Issue:
F
Date:
01/02/2007
7.3.
7.3.1.
DAILY MAINTENANCE
CHECK THE ENGINE OIL LEVEL:

1) Stop the engine and wait 5 minutes to allow the oil to drain to the oil pan.
2) Remove the dipstick and check the oil level.
3) Replenish if necessary using a recommended grade of engine oil (see section 8).
CAUTION: Never operate the engine with the oil level below the L mark or above the H
mark. See FIG. 7.1 below.
Figure 7.1 - Engine Oil Level Check
7.3.2.
CHECK THE FUEL TANK LEVEL.

Check the fuel level gauge on the control panel.
Replenish as necessary using clean, good quality, diesel/Derv/Gas Oil that conforms to ISO or
equivalent. Always ensure that the filler cap is replaced after replenishment.
7.3.3.
CHECK THAT ALL METERS AND GAUGES FUNCTION CORRECTLY.

Start the generator and inspect the following items:
7.3.4.
Oil pressure gauge is between 60 & 70psi.
After 5 minutes check that the cooling water temperature gauge reads between 85 & 95C.
The voltage and frequency gauges are within specification.
Fuel gauge indicates the tank is not empty.
Engine hours display increases after 10 minutes.
The DEIF Interface has no alarm indicators on.
CHECK THE AIR FILTER.

NOTE: In dusty conditions clean the primary filters regularly.
Check the air filter restriction indicator next to the air filter above the engine. If this has changed to
the restricted position, then the filter will need replaced.
- 26 -

NHC20 / QST30G2
Issue:
F
Date:
01/02/2007
7.3.5.
CHECK THE BATTERY.

Check that the battery connections are properly installed and that the electrolyte level in each cell
covers the top plates. If necessary, top up with clean distilled water.
7.3.6.
CHECK FOR LEAKS.

There are several fluids used inside the generator, e.g. diesel, oil, coolant. Look for signs of leakage
all around the engine.
Any source of leak should be checked and fixed. Clean up any fluid lying inside the generator and
dispose of according to the appropriate local regulations.
Recurring leaks should be reported to AGGREKO.
7.4.
7.4.1.
WEEKLY MAINTENANCE
CHECK THE WATER/ANTIFREEZE LEVEL.

Stop the engine and wait for the temperature to cool before checking the coolant level.
Remove the pressure cap slowly to relieve the pressure of the cooling system. Failure to do so could
result in personal injury from heated coolant spray (See Figure 7.2).
Check the coolant level. Replenish with the correct coolant fluid as necessary (see section 8).
Figure 7.2 - Coolant Level Check
7.4.2.
CARRY OUT A VISUAL CHECK OF THE DRIVE BELTS.

The cooling pump, alternator and radiator fan are driven by a single belt arrangement from the
engine pulley. Check the belts for signs of wear. Check the belt tension.
NOTE: Do not remove guards.
- 27 -

NHC20 / QST30G2
Issue:
F
Date:
01/02/2007
8.0
LUBRICATION
8.1.
GENERAL INFORMATION
Lubrication is an essential part of preventive maintenance, affecting to a great extent the useful life of
the unit. Different lubricants are needed and some components in the unit require more frequent
lubrication than others. Therefore, it is important that the instructions regarding types of lubricants
and the frequency of their application be explicitly followed. Periodic lubrication of the moving parts
reduces to a minimum the possibility of mechanical failures.
The Preventive Maintenance Schedule shows those items requiring regular service and the interval
in which they should be performed. A regular service program should be developed to include all
items and fluids. These intervals are based on average operating conditions. In the event of
extremely severe (hot, cold, dusty or wet) operating conditions, more frequent lubrication than
specified may be necessary. Details concerning lubrication of the running gear are in Maintenance
Section.
8.2.
GENERATOR OIL CHANGE

These units are normally furnished with an initial supply of oil sufficient to allow operation of the unit
for approximately 3 months or 400 hours, although this should be in line with the current service best
practise. The unit will however need to be topped up with oil during this period. If a unit has been
completely drained of all oil, it must be refilled with new oil before it is placed in operation. Refer to
specifications in Lubrication Table.
NOTICE: Some oil types are incompatible when mixed and result in the formation of varnishes,
shellacs, or lacquers that may be insoluble. Such deposits can cause serious problems including
clogging of the filters. Where possible, do NOT mix oils of different types and avoid mixing different
brands. A type or brand change is best made at the time of a complete oil drain and refill.
If the unit has been operated for the time/ hours mentioned above, it should be completely drained of
oil. If the unit has been operated under adverse conditions, or after long periods in storage, an earlier
change period may be necessary as oil deteriorates with time as well as by operating conditions.
An oil change is good insurance against the accumulation of dirt, sludge, or oxidized oil products.
Completely drain the reservoir, piping, and Purafiner system. If the oil is drained immediately after
the unit has been run for some time, most of the sediment will be in suspension and, therefore, will
drain more readily. However, the fluid will be hot and care must be taken to avoid contact with the
skin or eyes.
After the unit has been completely drained of all old fluid, close the drain valve. Add oil in the
specified quantity at the filler plug. Tighten the filler plug and run the machine to circulate the oil.
Check the oil level when unit is warm and not running. If not near the middle of the dipstick, stop the
unit and make corrections. DO NOT OVERFILL.
8.3.
OIL SPECIFICATION
The oil required for this engine is:
Manufacturer:
Product Name:
Castrol
Tection T 15W-40 (Formerly RX Super Plus)
Relative Density @ 25C
0.89 g/cm
Viscosity @ 40C
110 mm/s
Viscosity @ 100C
14.5 mm/s
Viscosity Index
CCS 20C
Total Base Number (TBN)
135
6450 mPA.s
11.6 mgKOH/g
Flash Point (COC)
228 C
Pour Point
-36 C
Sulphated Ash
- 28 -
1.5 %m

NHC20 / QST30G2
Issue:
F
Date:
01/02/2007
9.0
TROUBLE SHOOTING
9.1.
INTRODUCTION
Trouble shooting for a generator set is an organized study of a particular problem or series of
problems and a planned method of procedure for investigation and correction. The trouble-shooting
chart that follows in Section 9.3 includes some of the problems that an operator may encounter
during the operation of a generator set.
The chart does not attempt to list all of the troubles that may occur, nor does it attempt to give all of
the answers for correction of the problems. The chart does give those problems that are most
probable to occur. To use the trouble shooting chart:
1) Find the problem being experienced in the Symptom column on the far left.
2) Proceed to work through the possible causes in the next column, instigating the appropriate
corrective action where required from the next column.
9.2.
ACTION PLAN
A. Think Before Acting: Study the problem thoroughly and ask yourself these questions:
1) What were the warning signals that preceded the trouble?
2) Has a similar trouble occurred before?
3) What previous maintenance work has been done?
If the generator will still operate, is it safe to continue operating it to make further checks?
B. Do The Simplest Things First: Most problems are simple and easily corrected. Always check
the easiest and most obvious things first, following this simple rule will save time and trouble.
Note: For trouble shooting electrical problems, refer to the Wiring Diagram Schematic found
in Appendix E.
C. Double Check Before Disassembly: The source of most generator troubles can be traced not
to one component alone, but to the relationship of one component with another. Too often, a
generator can be partially disassembled in search of the cause of a certain trouble and all
evidence is destroyed during disassembly. Check again to be sure an easy solution to the
problem has not been overlooked.
D. Find And Correct Basic Cause: After a mechanical failure has been corrected, be sure to locate
and correct the cause of the trouble so the same failure will not be repeated. A complaint of
"premature breakdown" may be corrected by repairing any improper wiring connections, but
something caused the defective wiring. The cause may be excessive vibration.
- 29 -

NHC20 / QST30G2
Issue:
F
Date:
01/02/2007
9.3.
TROUBLE SHOOTING CHART

SYMPTOM
ENGINE DOES NOT CRANK

WITH 24V ELECTRIC MOTOR
ENGINE CRANKS BUT DOES

NOT START
ENGINE STARTS UP BUT

STOPS AFTERWARDS
ENGINE OVERSPEEDS
ENGINE SPEED NOT

STABLE
ENGINE SHOWS EXCESS

SMOKE AND / OR LACK OF
POWER
POSSIBLE CAUSE
CORRECTIVE ACTION
Battery isolator switch not

closed.
Close battery isolator switch.
Batteries flat or bad. Read

value on battery voltage meter
(must be 24V or more).
Replace or charge batteries.
Mini circuit breaker of 10A in

terminal box is open.
Reset.
Start relay at cranking motor

defective.
Measure the voltage over the

start relay.
Fuel tank empty.
Fill up fuel tank.
Air in the fuel system.
Check system for leaks. Bleed

the fuel system.
Dirty fuel filters.
Replace fuel filters.
Check voltage (24V) over fuel

shut-off valve during crank.
Call for AGGREKO support.
Optional air shutdown valve

closed.
Open air shutdown valve.
Overspeed protection is
activated.
Put key back to 0 and try to

start the engine again.

the fuel system.
Dirty fuel filters.
Overspeed during acceleration.
Decrease frequency setting.
Shutdown after 6 seconds.
Check safeties:
Oil pressure Water
temperature Water pressure
Oil temperature (option)
Frequency too high.
Adjust frequency to the correct

level.
Connection between governor

and fuel pump interrupted.
Repair connection.

the fuel system.
Engine not yet at operating

temperature.
Wait until engine has reached

the normal operating
temperature of 80-90C.
Dirty fuel filters.
Wear in ball eyes, linkage

governor / fuel pump.
Replace ball eyes.
Dirty air filters.
Replace air filters.
Dirty fuel filters.

the fuel system.
Overload.
Check load.
- 30 -

NHC20 / QST30G2
Issue:
F
Date:
01/02/2007
SYMPTOM
ALTERNATOR DOESNT
GENERATE VOLTAGE
ALTERNATOR VOLTAGE
TOO HIGH / LOW
ALTERNATOR VOLTAGE
NOT STABLE
MAIN CIRCUIT BREAKER

WILL NOT CLOSE
MAIN CIRCUIT BREAKER

CLOSES BUT TRIPS AGAIN
POSSIBLE CAUSE
CORRECTIVE ACTION
Voltmeter defective.
Measure voltage at outlet

terminals of alternator. If voltage
measured replace voltmeter.
Voltage regulator defective.
Replace voltage regulator,

the fuel system.
Speed frequency too high /

low.
Check frequency meter and

adjust if required.
Incorrect voltage setting.
Adjust voltage regulator.
No identifiable cause.
Consult AGGREKO.
Engine speed not stable.
Check stability of engine speed.
Incorrect stability adjustment.
Adjust stability on the voltage

regulator.
Circuit breaker control switch

(Figure 6.1) set remote control.
Select local position.
Circuit breaker tripped.
Reset circuit breaker.
Circuit breaker not charged,

motor mechanism broken.
Charge motor mechanism

manually, inform AGGREKO.
Lamp CIRCUIT BREAKER

CLOSED defective.
Replace lamp.
Switch on overload or short

circuit.
Remove load.
- 31 -
APPENDIX A

NHC20 / QST30G2
Issue:
F
Date:
01/02/2007
MATERIAL SAFETY DATA SHEETS
Appendix A - i

NHC20 / QST30G2
Issue:
F
Date:
01/02/2007
CASTROL TECTION T 15W-40
Appendix A - ii

NHC20 / QST30G2
Issue:
F
Date:
01/02/2007
Appendix A - iii

NHC20 / QST30G2
Issue:
F
Date:
01/02/2007
Appendix A - iv

NHC20 / QST30G2
Issue:
F
Date:
01/02/2007
Appendix A - v

NHC20 / QST30G2
Issue:
F
Date:
01/02/2007
LEAD ACID BATTERIES
HEALTH & SAFETY

LEAD ACID BATTERIES
####################################
The handling and proper use of lead-acid batteries is not hazardous provided sensible precautions are observed and
that Operatives having been trained in their use are adequately supervised.
The purpose of this letter is threefold:[ i] to indicate potential hazards that may arise.
[ ii] to outline the precautions to be taken to minimise such hazards.
[iii] to indicate action to be taken in the event of an accident.
[S.G. 1.260 - 1.300]
1. SULPHURIC ACID
Batteries contain sulphuric acid which may leak for a variety of reasons and may be given off as droplets and/or
spray during recharging.
[The Hazards]
Sulphuric Acid is a poisonous and corrosive clear liquid which can burn/irritate skin and eyes and could burn clothing.
[Precautions]
Always handle batteries with care
Always store upright
Never over-fill with acid
Always charge in a well ventilated area. Maximum voltage 15v per each 12v Battery.
Use eye protection and protective clothing if there is any risk of acid splashing.
[Emergency Action]
Skin Contact:
Immediately wash the affected area with copious amounts of
clean water. Remove any contaminated clothing.
Eye Contact
Immediately irrigate eyes for at least 10 minutes with clean

water.
Swallowing
Make the victim drink volumes of water, milk or milk of
magnesia.
DO NOT GIVE EMETIC
In all cases seek medical attention. Speed of action is vital.
[Spillages]
Small spillages can be swilled away with volumes of water.
[Disposal]
See Section 5.
2. ELECTRICAL ENERGY
[The Hazards]
The accidental connection of battery terminals by conductive objects, e.g. metal tools or metal personal jewellery etc.,
may generate sufficient heat to cause burns, create arcing or cause molten metal to splash.
Appendix A - vi

NHC20 / QST30G2
Issue:
F
Date:
01/02/2007
[PAGE TWO].
[Precautions]
Always ensure correct installation. The positive cable must be attached to the terminal marked [+] and the negative
to the terminal marked [-]. Cables and terminals should be kept clean and securely fitted.
Before using metallic tools on a battery remove metallic objects from hands and wrists.
Before working on a vehicle electrical system disconnect the Battery, disconnecting the earth strap first and
reconnecting last. Do not place tools on top of batteries.
[Emergency Action]
Burns:
Electric Shock:
Apply sterile bandage.

Approach victim with care. Switch off or otherwise break
current. If not possible, detach victim from contact by means
of insulating material [wood, rubber or plastic hosepipe, folded
newspaper etc]
Do not touch with bare hands.
In each case seek medical advice. Speed of action is vital.
3. EMISSION OF GASES
A mixture of oxygen and hydrogen is emitted during charging and may be emitted if a battery is moved or shaken.
[The Hazards]
An explosive atmosphere exists if the concentration of hydrogen exceeds 4%.
[Precautions]
Always charge in a well ventilated environment.
No naked flames
NO SMOKING
Be certain that current is switched off before making breaking connection. Always remove earth strap first and reconnect last.
[Emergency Action]
Explosion:
Seek medical advice remembering that acid may have been sprayed.
4. WEIGHT
In general terms batteries are heavy and awkward to handle. Care should be taken and correct lifting techniques
employed.
5. DISPOSAL
Batteries, Battery Acid, Lead and Lead compounds must be disposed of in accordance with:
[a] The deposit of Poisonous Waste Act 1972
[b] The Control of Pollution Act 1974
[c] Consumer Protection Act 1987
If in doubt, consult the Environmental Department of your Local Authority.
For further information refer to:BRITISH STANDARD BS 6604; 1985
SAFE OPERATION OF STARTER BATTERIES.
Appendix A - vii

NHC20 / QST30G2
Issue:
F
Date:
01/02/2007
SUPERCOLDMASTER ANTIFREEZE
Appendix A - viii

NHC20 / QST30G2
Issue:
F
Date:
01/02/2007
Appendix A - ix

NHC20 / QST30G2
Issue:
F
Date:
01/02/2007
Appendix A - x
APPENDIX B

NHC20 / QST30G2
Issue:
F
Date:
01/02/2007
OPERATING INSTRUCTION SHEET
Appendix B - i

NHC20 / QST30G2
Issue:
F
Date:
01/02/2007
Appendix B - ii
APPENDIX C

NHC20 / QST30G2
Issue:
F
Date:
01/02/2007
EQUIPMENT DATA SHEET
Appendix C - i

NHC20 / QST30G2
Issue:
F
Date:
01/02/2007

Manufacturing
Birch Road
Dumbarton, G82 2RF
Tel: 0044 (0)1389 742214
Fax: 0044 (0)1389 742554
Diesel Generating Set

50Hz
800kVA
60Hz
800kW
Ref
No.
Rev.
Date
G080275
B
01/02/2007
Page
1 of 3
Model
NHC20/QST30G2 STD & Stackable (AI)
Part Number
Ref
602094, 602109 (Stackable)
Specification
Ref
G32.0016
Installation Drawing
Ref
A05.0001, A050210 (Stackable)
Maximum Ambient
C (F)
50 (122)
50 (122)
Electrical Output
Hz
50
60
- Continuous Power (COP)
kW (kVA)
500 (625)
604 (755)
- Prime Power
kW (kVA)
650 (812)
755 (944)
70
70
- Fuel Stop Power/Standby
kW (kVA)
720 (900)
835 (1044)
Single Step load application
56
56
- Three phase
kW (kVA)
664 (830)
770 (963)
- Single phase
kW (kVA)
ISO 8528-1
(PRP)
- Permissible average of PRP

ISO3046/1
Alternator
Class F Temp. Rise (105C)
Ends Out
Make & Type
Cummins Generator
Technologies
AVR
MX321
Regulation
8
HCI634H2
0.5
Circuit Breaker
Make & Type
Schneider NW25
Number of poles
Rating
Amps
Trip Unit Type
2500
Micrologic 5.0
Overload Protection Range
Amps
1000 2500 (adjustable by selector)
Short Circuit Protection Range
Amps
1000 25000 (adjustable by selector)
Technical Department Dumbarton Approved by
Appendix C - ii

NHC20 / QST30G2
Issue:
F
Date:
01/02/2007

Manufacturing
Birch Road
Dumbarton, G82 2RF
Tel: 0044 (0)1389 742214
Fax: 0044 (0)1389 742554
9

50Hz
800kVA
60Hz
800kW
12
13
2 of 3
Busbar M12
lit/hr(US gal/hr)
186 (49.2)
227 (60.0)
100% Prime Power
"
"
167 (44.2)
201 (53.0)
75%
"
"
128 (33.8)
150 (39.7)
50%
"
"
86 (22.7)
102 (26.9)
Running Hours
100% Prime Power
Hours
7.7
6.4
75%
"
10.0
8.6
50%
"
15.0
12.6
Measurement Method
TA-Luft
EPA-MOH/CARB
Specific Load
100% prime 2%
ISO8178D2
NOx Oxides of Nitrogen
4000mg/nm
9.20g/kW.h
PM - Particulate Matter
130mg/hm
0.54g/kW.h
CO - Carbon Monoxide
650mg/hm
11.40g/kW.h
HC - Unburnt Hydrocarbons
1.30g/kW.h
Exhaust Emissions
Exhaust Silencer
Make & Type
14
Page
Fuel Consumption
Standby/Fuel Stop
11
G080275
B
01/02/2007
Load Terminals
Type
10
No.
Rev.
Date
Universal Silencers
Certificate
No
M-9561
Permissible back pressure
mm (ins) Hg
13 (0.5)
Sound Power EEC
dBA (Lw)
104
Sound Pressure at 1 metre
dBA
82
85
Sound Pressure at 7 metre
dBA
72
76
13 (0.5)
Noise
Appendix C - iii

NHC20 / QST30G2
Issue:
F
Date:
01/02/2007

Manufacturing
Birch Road
Dumbarton, G82 2RF
Tel: 0044 (0)1389 742214
Fax: 0044 (0)1389 742554
15

50Hz
800kVA
60Hz
800kW
17
18
Page
3 of 3
Make & Type
QST30G2 NR1 CPL 2968
Cylinders & Form
V12 50
Aspiration
Turbocharged & Aftercooled
Fuel Pump
Bosch P7100 Direct Injection
Governor Type
Electronic
Cummins Dominion
Steady State frequency
0.25
Battery Voltage
Volts
24
- Length
Metres (feet)
6.06 (200)
- Width
Metres (feet)
2.44 (80)
- Height
Metres (feet)
2.60 (86)
- Without fuel
Kg (lbs)
16000 (35274)
- With fuel
Kg (lbs)
17216 (37954)
Litres (US gall)
1431 (378.1)
Overall Dimensions
Weight
Capacities
- Fuel
- Lub oil
gross
usable
1288 (340.3)
total
154 (40.7)
pan
133-114 (35-30)
- Coolant
19
G080275
B
01/02/2007
Engine
Make & Model
16
No.
Rev.
Date
383 (101.2)
External fuel supply

- maximum above base
Metres (feet)
2.40 (710)
- maximum below base
Metres (feet)
1.50 (411)
Appendix C - iiii
APPENDIX D

NHC20 / QST30G2
Issue:
F
Date:
01/02/2007
INSTALLATION OUTLINE DRAWING
Appendix D - i

NHC20 / QST30G2
Issue:
F
Date:
01/02/2007
Appendix D - ii

NHC20 / QST30G2
Issue:
F
Date:
01/02/2007
Appendix D - iii

NHC20 / QST30G2
Issue:
F
Date:
01/02/2007
Appendix D - iv

NHC20 / QST30G2
Issue:
F
Date:
01/02/2007
Appendix D - v

NHC20 / QST30G2
Issue:
F
Date:
01/02/2007
Appendix D - vi

NHC20 / QST30G2
Issue:
F
Date:
01/02/2007
Appendix D - vii

NHC20 / QST30G2
Issue:
F
Date:
01/02/2007
Appendix D - viii
APPENDIX E

NHC20 / QST30G2
Issue:
F
Date:
01/02/2007
CONTROL PANEL LAYOUT
Appendix E - i

NHC20 / QST30G2
Issue:
F
Date:
01/02/2007
Appendix E - ii
APPENDIX F

NHC20 / QST30G2
Issue:
F
Date:
01/02/2007
ELECTRICAL SCHEMATICS
Appendix F - i

NHC20 / QST30G2
Issue:
F
Date:
01/02/2007
Appendix F - ii

NHC20 / QST30G2
Issue:
F
Date:
01/02/2007
Appendix F - iii

NHC20 / QST30G2
Issue:
F
Date:
01/02/2007
Appendix F - iv

NHC20 / QST30G2
Issue:
F
Date:
01/02/2007
Appendix F - v

NHC20 / QST30G2
Issue:
F
Date:
01/02/2007
Appendix F - vi

NHC20 / QST30G2
Issue:
F
Date:
01/02/2007
Appendix F - vii

NHC20 / QST30G2
Issue:
F
Date:
01/02/2007
Appendix F - viii

NHC20 / QST30G2
Issue:
F
Date:
01/02/2007
Appendix F - ix
APPENDIX G

NHC20 / QST30G2
Issue:
F
Date:
01/02/2007
EARTH LEAKAGE OPTION ($OPTION 382A)
Appendix G - i

NHC20 / QST30G2
Issue:
F
Date:
01/02/2007
Note:
For units fitted with Earth Leakage Option ($Option382A) all schematics include the necessary
wiring changes.
Please see photographs below for location of hardware.
Earth Leakage Relay
Earth Leakage Reset Off / On Keyswitch
Appendix G - ii
APPENDIX H

NHC20 / QST30G2
Issue:
F
Date:
01/02/2007
LIVERY LAYOUT
Appendix H- i

NHC20 / QST30G2
Issue:
F
Date:
01/02/2007
Appendix H- ii
APPENDIX J

NHC20 / QST30G2
Issue:
F
Date:
01/02/2007
MANUFACTURERS COMPONENT DATA
Appendix J- i

NHC20 / QST30G2
Issue:
F
Date:
01/02/2007
Document No.:
M040107
Rev:
Title:
NHC20/QST30G2 Spares List & Manufacturers Data
DESCRIPTION
Date:
QTY
Radiator
Radiator fan
Engine space fan
04/05/06
SUPPLIER /
MANUFACTURER
Covrad
Woods of
Colchester
Woods of
Colchester
SUPPLIER PART
No.
CRDA0925-E1
60 JEL 2/3
DFNV160LKEP
AGGREKO PART
No.
067035SS
BZ531211
053196SS-01
053165SS-03
Coupling, 3.86RB, sae18 SI470

round
Engine Control Module
Battery 180Ah, 12V
Charging belt
Starter motor
Battery charging alternator
Reynold Hitec
3580322B
051514SS
1
4
2
1
1
Cummins
DB Wilson
Cummins
Cummins
Cummins
N/A
339002A
N/A
N/A
N/A
Circuit breaker NW25, 4Pole
Schneider
Current transformer 2000/5A

Generator Control Module
Nicad battery
Container Air Inlet Filter
Lube oil filter element
3
1
2
8
4
Combustion air filter element

Secondary fuel filter element (eng)
2
1
Water filter element
Primary fuel filter element (eng)
Control Panel cooling Fan
Celsa
Deif
R.S. Components
Baldwin
Cummins
Baldwin
Baldwin
Cummins
Baldwin
Cummins
Baldwin
Cummins
Baldwin
Eldon
4067777 Dominion
324
3094909
4081237
3016627
See Technical
Description
IRP
Multiline 2 - 010429
180-358
PA3873
3101869
BD7154
RS3982
4010476
BF7760
3100308
BW5075
4095189
BF7764
EF10A
Primary fuel filter element (container)
Racor
1000F 2020SM
Baldwin
PF7890-30
Appendix J- ii
293434SS
273039A
275158A
339011A
055685A
N/A
055674A
N/A
N/A
317118A
100 Micron
Washable
30 Micron Paper
APPENDIX K

NHC20 / QST30G2
Issue:
F
Date:
01/02/2007
CONTAINER CERTIFICATE
Appendix K- i

NHC20 / QST30G2
Issue:
F
Date:
01/02/2007
Appendix K- ii

NHC20 / QST30G2
Issue:
F
Date:
01/02/2007
Appendix K- iii
APPENDIX L

NHC20 / QST30G2
Issue:
F
Date:
01/02/2007
DNV SPARK ARRESTOR CERTIFICATE
Appendix L- i

NHC20 / QST30G2
Issue:
F
Date:
01/02/2007
Appendix L- ii

NHC20 / QST30G2
Issue:
F
Date:
01/02/2007
Appendix L- iii
APPENDIX M

NHC20 / QST30G2
Issue:
F
Date:
01/02/2007
DECLARATION OF CONFORMITY
Appendix M i

NHC20 / QST30G2
Issue:
F
Date:
01/02/2007
Appendix M ii

NHC20 / QST30G2
Issue:
F
Date:
01/02/2007
Appendix M iii
APPENDIX N

NHC20 / QST30G2
Issue:
F
Date:
01/02/2007
INTERNATIONAL CONTACT INFORMATION
Appendix N i

NHC20 / QST30G2
Issue:
F
Date:
01/02/2007
In case of emergencies please contact the nearest service department of AGGREKO. They can be reached 24 hours
a day and are operational at any place in the world.
GREAT BRITAIN
FRANCE
BELGIUM
Aggreko Generators Ltd.
Aggreko S.a.r.l.
Aggreko N.V.
Overburn Avenue
1 Chemin de lAncien Parc
Smallandlaan 7
DUMBARTON
91220 Bretigny Sur Orge
2660 Hoboken
G82 2RL
France
Belgium
Tel: (+44) 1389 767821
Tel: +33 (0)825 008007
Tel: (+32) 03 825 02 71
Fax: (+44) 1389 761577
Fax: +33 (0)1 69 737119
Fax: (+32) 03 825 11 81
NETHERLANDS
NORWAY
SPAIN
Aggreko International (Ned)
Aggreko Norway A.S.
Aggreko Iberia S.A.
B.V.
Sorlandsveien 318
Avda. Torre Mateu, 35-37
Ketelweg 77
Postboks 543
Polg. Industrial Can Salvatella
3356 LD Papendrecht
EGERSUND
08210 Barbera del Valles
EUROPE
Netherlands
N-4379
BARCELONA
Tel: (+31) 078 64 41 441
Norway
Tel: (+34) 93 747 93 90
Fax: (+31) 078 642 80 83
Tel: (+47) 810 00 333
Fax: (+34) 93 729 02 83
Fax: (+47) 051 46 45 90
GERMANY
GERMANY
ITALY
Frankfurt
Mulheim
Aggreko Italia srl
(Central Europe South East) (Central Europe North)
Via Copernico, 60
Aggreko Deutschland GmbH Aggreko Deutschland GmbH
20090 Trezzano sul Naviglio
Darmstadter Strae 66-68
Ruhrorter Strae 112
(Milano)
64572 Bttelborn
45478 Mlheim/Ruhr
Italy
Germany
Germany
Tel: +39 02 4846 3024
Tel: +49 (0)61 52 93 93 0
Tel: +49 (0)208 58 09 70
Fax: +39 02 4451 243
Fax: +49 (0)61 52 93 93 99
Fax: +49 (0)208 58 09 798
CANADA
U.S.A.
Aggreko Inc.
Aggreko LLC
300 Clarence Street
4607 W Admiral Doyle Drive
NORTH
Brampton,
PO Box 10004
AMERICA
ONTARIO
NEW IBERIA, LA 70562-0004
L6W 1T5
Tel: (+1) 337 365 5479
Tel: (+1) 905 459 3321
Fax: (+1) 337 367 0870
Fax: (+1) 905 459 3392
REPUBLIC OF
SINGAPORE
Aggreko Singapore Pte Ltd
10 Pioneer Sector 1
ASIA
SINGAPORE
62844
Tel: (+65) 6862 1501
Fax: (+65) 6862 0182
UNITED ARAB EMIRATES
MIDDLE
EAST
AUSTRALIA /
PACIFIC
Aggreko Inc.
PO Box 17576
Jebel Ali
DUBAI
Tel: (+971) 04 834059
Fax: (+971) 04 834145
AUSTRALIA/PACIFIC
Aggreko Generator Rentals
Pty Ltd
101 Woodlands Drive
Braeside Victoria
3195
MELBOURNE
Tel: (+61) 03 586 5050
Fax: (+61) 03 586 50514
Appendix N ii

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Document No.: M02.

Document No.: M02.0210

Document No.: M02.0210

6.2. PRIOR TO START ................................................................................................................23

Material Safety Data Sheets

Operating Instruction Sheet

Equipment Data Sheet

Installation Outline Drawings

Control Panel Layout

Document No.: M02.0210

Electrical Schematic for Main Circuit Diagram

Earth Leakage Option ($Option382A)

Manufacturers Component Data

Container Certificate GB-LR 60515 07/04 (Standard)

DNV Spark Arrestor Certificate M-10408

International Contact Information

Document No.: M02.0210

Engine Lubricating Oil

Document No.: M02.0210

(Risk of electric shock)

DO NOT STAND IN FRONT

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Document No.: M02.0210

NOISE CONTROL PROHIBITED ACTS

Removal or rendering inoperative any of the following:

a) The engine exhaust system or parts thereof.

Removal of any of the following:

Operation of the generator with any of the enclosure doors open.

GENERATOR NOISE EMISSION CONTROL INFORMATION

FOR SAFETY, EAR PROTECTION SHOULD ALWAYS BE

Document No.: M02.0210

Complete Package Without Fuel

Open the battery isolator switch.

Empty the fuel tank (in case of overseas transport).

Disconnect the battery terminals (in case of overseas transport).

Close all fuel valves.

Seal the remote fuel connection with a blind stop.

Close all doors.

Document No.: M02.0210

LOCATION OF THE PLANT

Ensure that the safety procedure is followed at all times.

A suitably trained electrician should carry out all electrical connections.

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One 1 Female Connector (supply)

One Female Connector (Return)

Document No.: M02.0210

Alternator and engine assembly

Pressurised oil system

Automated control system

Engine cooler pack

Spark arrestor / Silencer

Internal fuel tank

DESIGN LOAD CAPACITY

-10C (14F) to 50C (122F)

CONTAINER & BASE FRAME

Document No.: M02.0210

Four Stroke, 12 Cylinder 50 V, Water Cooled,

ENGINE LUBRICATION SYSTEM

The Lube oil specification is as per API/ASTM/SAE/CD (equivalent to series MIL-L-415993).

ENGINE COOLING SYSTEM

ENGINE FUEL SYSTEM

Document No.: M02.0210

5.10. ENGINE CONTROL SYSTEM

Rotating Field powered by Permanent Magnet