Service Manual 311 Pagespdf Compress

SERVICE MANUAL
Aggreko International
Technical Services
Technical Services
P.O.Box 17576
Jebel Ali, Dubai
United Arab Emirates
Tel : +971 (0)4 8834059

Fax : +971 (0)4 8834145
Email: Technical.Records@aggreko.ae
: Product.Support@aggreko.ae
Website : www.aggreko.com
Service Manual
Generator
Service Manual Index

REV STATUS
Section 1. (A) Projects Operational Overview April 2008
(B) Depots Operational Overview April 2008
Section 2. Maintenance Procedures & Schedules April 2008
Section 3. Approved Service Consumables March 2007
Section 4. Work Instructions April 2008
Section 5. Forms April 2008
Section 6. Technical Documentation April 2008
Section 7. Transformer April 2008
Section 8. LoadBank March 2007
Section 9. Switchgear April 2008
Section 10. Temperature Control April 2008
Section 11. Useful Information March 2007
Section 12. Product Bulletins & Information April 2008
Section 13. Revision Status April 2008
All Procedural Changes Highlighted in Red

Aggreko International Technical Services Page No.3 April 2008
Blank Page Page No.4
Diesel Generator
Service Manual
Aggreko International Technical Services

Page No.5
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Diesel Generator
Service Manual
TABLE OF CONTENTS
Section 1 (A)- Projects Operational Overview
(B)- Depots Operational Overview
Section 2 - Maintenance Schedule and Procedures

Section 1(A)
PROJECT
Operational Overveiw
Revision April 2008
Prepared By Allan Methven
Reviewed By Ray McElhinney Approved By Jack Denz

Page No.9
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Section 1(A)
PROJECT
Operational Overveiw
Table of Contents
1. Purpose
2. Project / Operations Service Responsibilities
3. Equipment Responsibilities
4. Field Service Checks

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GENERAL
1 Purpose
The purpose of following operation & maintenance work instructions are to:
• Keep our customers satisfied and willing to rent Aggreko equipment every time
• Maximise the operational effectiveness of our equipment.
• Prolong and maximise the economic life of our equipment
Act as a professional quality conscious company at all times
2 Project/ Operations Service Responsibilities
Each Project is responsible for:
• Maintaining a full history (Service Reports, Component change notes, etc.) of all
equipment by Plant Number operating on the Project. Ensuring that all the equipment
is serviced according to the AIP established service procedures described in this
manual.
• Maintaining in good condition all the equipment and ancillaries as long as it is on

the Project. All faulty Damage / components found on equipment should be reported
back to AIP Technical Services. Should damage be due to local transport in the
country in which the project is to operate, the site manager will be responsible for
making and logging claim against the Transport Co., guidance may be sought from
Jebel Ali Central Operations Department.
• Ensuring all Service Reports / Component Change Note, etc. are sent to AIPP Head
Office Technical Records Department on a weekly basis.
• Maintaining a full set of technical data sheets, drawings, operation & maintenance
manuals, Service reports / Component Change Advice Note, etc. From time to time
AIP Technical Services will issue technical updates to the Projects, these must be
correctly filed as soon as possible and Site engineers must be made aware of all the
technical information available to them.
• Carrying out repairs on equipment within its own capabilities. All large repairs and
overhauls are not to be carried out on Site unless with prior agreement of AIP
Technical Services.
• Holding in secure store sufficient spare parts to ensure smooth day to day operation
of its equipment. Running the stores program and ensuring the site complies with the
stores procedure. There are no hard and fast stocking requirements as this depends
upon size of fleet, the availability of spare parts from local suppliers and the nature of
the Project.
• Ensuring clean containers are used for storing and transporting lubes, fuels and
coolant.

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• Ensuring fuel pumps, hoses and manifolds are maintained, leaks are contained and
rectified in as short a period as possible.
• Ensuring bulk oil storage tanks are fitted with moisture control filter on breather and
these should be well maintained.
• Ensuring oils / fuel in drums are stored; in a specified area; horizontally with openings
at 3 & 9 O’clock positions to prevent ingress of moisture.
• Ensuring usage of only 15W40 multigrade oils to at least the minimum specification
as per guideline in this manual.
3 Equipment Appearance
• Equipment will always be kept clean
• Equipment will always be kept well painted
• Equipment will carry all necessary decals & signboards
4 Field Service Checks
Receiving of Equipment at Project Site.
• Directly after the unloading of any Equipment at the Project Site a Damage report
must be completed (form attached in forms section), recording the condition of the
Equipment plus hours, fuel level, etc.
• If possible, after checking Oil and Water levels, the Generators should be started to
ensure that there are no obvious mechanical problems.
• All damage and shortages to the equipment must be noted on Damage Report, it
is very difficult to make a claim against Transport Company if we notice the damage
later, so the person receiving the equipment must take time to ensure that all our
equipment is well inspected as it comes on to the Project Site.
4. Commissioning
• ALL Commissioning sheets must be completed. The information contained in the
commissioning sheets is very important, particularly protection settings and ‘as built’
modifications as these can save time if a fault has to be investigated by AIP Technical
Services / Commissioning.
• Only after completing the Commissioning Sheets and making sure that the Site is
in a safe, good & fit condition can the equipment be handed over to Operations
Personnel.
• If any unit is not in a good and fit condition then an evaluation by the Site Manager/
Senior Commissioning engineer should be made determining what is wrong and if
possible, any remedial action that can to be taken on site.
For refurbished equipments from SRC, Jebel Ali, the Base Operations Manager, SRC
should be informed by completing feed back form.
For new equipments any damage must be reported on a New Fleet Acceptance

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Form and send to Technical Records Dept, Jebel Ali.
• A copy of the completed Commissioning documents will be issued to the sites within
the specified time scale laid down in commissioning manual.
• Commissioning Manual covers commissioning in more detail.
4.1 Decommissioning / Transfer To Jebel Ali or Another Project Checks
• Before transfer always check the fuel tank. It must not contain fuel.
• As a minimum before transfer always ensure that machine starts and check:
4.1.1 Engine oil pressure
4.1.2 Water temperature
4.1.3 DC charging circuit
4.1.4 AC voltage and Operating Hz is stable.
4.1.5 Hour meter is running, note the hours on the dispatch/delivery note
4.1.6 Fan & alternator belts for tightness
4.1.7 Water & Antifreeze level
4.1.8 Battery water level
4.1.9 Battery cables (apply grease/vasaline to cable ends)
4.1.10 Water hoses & connections for leaks
4.1.11 DC wiring (loose connections)
4.1.12 AC wiring
4.1.13 Exhaust connections
4.1.14 Engine / Generator mounts
4.1.15 Oil level
4.1.16 Racor bowl cleanliness
4.1.17 All necessary sea fastening has been carried out
4.1.18 Project Service Records be placed within the machine control pannel
Note:-
For more details on decommissioning, refer to the Commissioning Manual.

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Section 1(B)
DEPOT
Operational Overview
Revision April 2008
Reviewed By Garry McMahon Approved By Jack Denz

Page No.17
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Section 1(B)
DEPOT
Operational Overview
Table of Contents
1. Purpose
2. Depot Service Responsibilities
3. Equipment Appearance
4. Plant Files
5. Off Shore Rentals
6. In Depot Service Checks
7. Preventive Maintenance
8. Installation & Commissioning of Equipment

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GENERAL
1 Purpose
The purpose of the following service work instruction is to:
• Keep our customers satisfied and willing to rent Aggreko equipment when they
have a requirement.
• Maximise the operational effectiveness of our hire fleet
• Prolong and maximise the economic life of our equipment
• Act as a professional quality conscious company at all times
• Establish ourselves as the lowest breakdown call-out company
2 Depot Service Responsibilities
Each Depot is responsible for:
• Maintaining a full history of service records of all equipment by Plant Number

presently operating in the depot territory. Ensuring that all the equipment is regularly
serviced according to the Aggreko standard service procedures described in this
manual.
• Ensuring that all equipment and ancillaries are in a good condition. Any faults found
on transferred equipment are the responsibility of the dispatching depot. Should
damage be caused due to transportation, the depot that arranged transport will be
responsible for making and logging any claim against the Transport Company.
• Ensuring all original service records/files are handed over to the driver of the
transport company and then handed over to the receiving depot. HDC will record
this on the Delivery Note. The receiving depot will acknowledge receipt on the
Delivery Note and Service Records and send the acknowledgement back to the
dispatching depot.
• Ensuring that the details of all service reports are sent to Records Department at
Jebel Ali on a weekly basis through Service/CCAN log. This will enable all other
depots to have free access to request the complete up-to-date service history on
any transferred equipment.
• Component Change Advice Notes must be sent to the Technical Records

Department in Jebel Ali.
• Maintaining a full set of technical data sheets, drawings, operation &maintenance

manuals, Service report pads, Green Cards, etc.From time to time the Records
Department will issue technical updates to the depots and these must be correctly

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filed and depot engineers must be made aware of all the technical information
available to them.
• Carrying out repairs on equipment within its own capabilities. Large repairs and
overhauls are not to be carried out in Depots unless it is agreed with the General
Manager or Area Director.
• Holding in a secure store the sufficient amount of spare parts to ensure smooth
day to day operation of its fleet/equipment. There are set stocking requirements
as this depends upon size of the fleet, the availability of spare parts from local
suppliers and the nature of the Depots business. When transferring equipment
between depots spares and or filters that will no longer be used by the depot
dispatching the equipment should be sent with the equipment.
• Ensuring clean containers are used for storing and transporting lubes, fuels and
coolant.
• Ensuring bulk oil storage tanks are fitted with moisture control filter on the breather
and these are well maintained.
• Ensuring oil /fuel in drums are stored horizontally with openings at 3 &9 O’clock
positions to prevent ingress of moisture.
• For Brands of oil recommended by Aggreko, please see Appendix 1 of (Section

3 -Approved Service Consumables)
3 Equipment Appearance
• Equipment will always be kept clean
• Equipment will always be kept well painted
• Equipment will carry all necessary livery &signboards.
4 Plant Files
• Plant Files should be neat and tidy, contain service related information of the
plant e.g. Service Report, Component Change Advice Note, Depot Checklist.
They should be sectionalized with relevant sheets and filed in date order with the
most recent at the front.
• The Maintenance Record Sheet will record all services performed on particular
equipment. See sample attached i n the Forms section.
5 Off-Shore Rentals

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• A Generator Shipping Hire Service Report will be sent to the Customer along
with the equipment to enable them to record the servicing of Aggreko Equipment.
A sample of Service Report is attached in the forms section. Hire Desk Controller
will make reference to these forms in the Delivery Note.
• The Hire Desk Controller will liaise with the Customer’s base office to get the
completed Service Reports made available.
• A basic spares package will be dispatched with all off shore hires & highlighted
on the Delivery Note.
• The reconciliation of consumables supplied will be done with respect to the

Service Reports available.
• While there are variations depending upon region. Aggreko personnel may require
specialist training i.e. Basic Survival Course prior to leaving for off-shore.
• A controlled copy of the Aggreko Service Schedule must be issued with all offshore
hires. Laminated copies will be issued to all depots so these can be fitted to all
generator panels’ pre delivery for the clients’ reference.
• A controlled copy of the service procedure for the particular plant must also be
issued with all offshore hires, i.e. Canopies ‘A’ Service or Container ‘A’ Services.
This will allow the client to follow our service standards correctly and a reference
to follow.
• Where possible an engineer must be sent to the subject vessel/site to demonstrate

to the client how to operate the equipment and explain our service proocedure,
pointing out any key points. (Filters location, oil filling point etc).
6 In Depot Service checks
6.1 Booking in of Equipment after Hire
• Directly after the unloading of any Equipment at the end of a hire in the depot, a
Red Card relevant to the equipment must be completed recording the condition of
the Equipment (hours, fuel level, etc.).In the event equipment arrives after normal
office hours and/or weekends, the equipment should be red carded within the
next working day.
• Generators should be started; check Oil and Water levels to ensure that there are
no obvious mechanical problems.
• All damage to the equipment must be noted on the Red Card, it is very difficult
to make a claim against a customer if we notice the damage later. The person
receiving the equipment must take time to ensure that all our equipment is
inspected thoroughly when it comes into the Depot.
• The lower portion of the Red Card must be given to the Hire Desk Controller as
soon as possible in order to finalize the Service Contract with the customer.

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• After booking in, the Service Team Leader will assign a Service Engineer to inspect
and carry out the Depot Checklist. If possible, equipment-awaiting inspection (AI)
should be kept in a different area of the yard from the available (AV) for hire
equipment.
• Our target is that No equipment will be awaiting inspection for more than 3 working
days. If equipment cannot be made available within 3 working days, The Service
Department must attempt to identify the status of the equipment whether it is “AI”
(Awaiting Inspection)or “UR”(Under Repair).If the status of equipment changes
to “UR”from “AI”,the old Red Card must be replaced with a new Red Card and
the reason must be stated on the reverse of the card and then the lower portion
of the Red Card can be passed to the HDC (Hire Desk Controller)for Fleet Status
Purposes. Our sales people need to know if the equipment can be available at
short notice or if any repair work needs to be carried out prior to the next hire.
6.2 Aggreko Depot Checklist/Load test sheet /Green card
• In order to make our equipment available for hire we need to carry out a thorough
check on it. The Aggreko Depot Check List/Load test Sheet,(particular to the
equipment)is a reminder of all the items that must be checked. All actions
performed should be ringed in the “Service Category” boxes and items requiring
specific records should be entered wherever possible ,i.e. Load/Phase, L/O
Pressure PSI,ELCB reading, Water Temperature,DCA level, Battery Charging
Volts DC and Anti Freeze %.
• Items not applicable to be marked N/A.
• The remarks section should record details of breakdown, services or any factor
that could have a bearing upon the future hire of the hire or plant. Relevant “Fault
Code” should be ringed.
• Service Reports should be completed at the time of the service and not stockpiled
for completion later.
• Only after completing the check list and making sure that it is in a good &acceptable
condition can the equipment be “Green Carded” and become ready for hire.
• If the unit is not in a good condition then an evaluation must be carried out. The
problem must be identified and any remedial action required must be taken by the
Senior Engineer in the depot. The Hire Desk Controller needs to be informed so
that a change in the Fleet Status Report can be made from ‘AI’,to ’UR‘.A reason
must be given in case the costs can be charged to the customer together with
estimate of the repair time.
• The completed Depot Check sheet and the bottom tear off portion of the Green
Card must be handed in to the Hire Desk Controller as soon as possible to enable
the unit’s status of ‘AI’ to “AV”(Available for Hire)to be made.
• The upper two portions of the Green card are to be fixed in a visible place on the
equipment. The Pre Delivery Inspection (“PDI”) Portion is to be completed prior

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to equipment going on hire.
• Our aim in the Service Department is to maximise our fleet availability by

performing these thorough checks on our equipment efficiently & quickly. Delays
in completing paperwork, correctly and on time cause the Sales Department to
possibly turn down hires for available equipment.
• At the start of every week, check all the “AV” generators to ensure that they
start and there are no leaks. Record date and time of this action. The Service
Engineer must sign and record this action on the reverse of the green card. Run
“AV” generator sets every week at no load until the engine has reached stabilized
coolant temperatures (Engine Running Temperatures).
• Aggreko recommends that the engines must be exercised on a regular basis for
the following reasons:
• Demonstrate that most of the key engine and generator subsystems are
functioning.
• Maintain a coating of lubricating oil around the engine bearings.
• Maintain a coating of corrosion inhibitor throughout the cooling system.
• Typically, a generator set is exercised at No-Load for 30 minutes, or until the

engine has reached stabilized coolant temperatures. This No-Load exercising is
performed on Weekly intervals.
• Generator sets are often “exercised” by starting and operating at rated frequency
(Hz or RPM) with no load since non-critical load is not always available for testing.
However, repeated or extended testing without load can cause combustion-
related problems that have the potential to cause engine damage.
Operating the Engine at Low Load
Operating engines at no-load or loads less than 30%of the Standby Power Rating
for prolonged periods of time may result in:
• Wet Stacking –Wet stacking manifests itself in the accumulation of carbon

particles, unburned fuel, lube oil, condensed water and acids in the exhaust
system. This accumulation is due to incomplete combustion caused by low
combustion temperatures.
• Carboning -Is the result of carbon particles deposited on top of the piston rings
and in the injectors due to incomplete burning of fuel.
• Fuel Dilution of Lube Oil -Piston rings are designed for optimum sealing under
elevated combustion pressures. When these pressures are not achieved due to
the application of low loads, the fuel injected into the combustion chamber can
get past the piston rings causing a fuel dilution situation in the lubricating oil.
• Water Contamination of Lube Oil -If the lubricating oil does not attain the desirable
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operating temperature, condensation of water may form in the engine oil pan.
• Piston Detonation –Piston detonation damage is caused by excessive engine

idling or low load conditions that lead to localized burning of fuel above the top
ring when larger loads are required of the engine.
6.3 Before Rental /Transfer to another Depot Checks
• Before rental always check the fuel tank. It must contain clean fuel. The level
should be noted on the dispatch/delivery note.
• Before rental always check the following:
6.3.1 Engine oil pressure
6.3.2 Water temperature
6.3.3 DC charging circuit
6.3.4 AC voltage and Operating Hz is correct as per the Order sheet from the Hire
Desk Controller
6.3.5 Hour meter is running, note the hours on the dispatch/delivery note
6.3.6 Fan &alternator belts for tightness
6.3.7 Water &Antifreeze level
6.3.8 Battery water level
6.3.9 Battery cables (apply suitable grease/vasaline to cable ends)
6.3.10 Water hoses &connections for leaks
6.3.11 DC wiring (loose connections)
6.3.12 AC wiring
6.3.13 Exhaust connections
6.3.14 Engine /Generator mounts
6.3.15 Oil level
6.3.15 Racor bowl cleanliness
6.3.16 Complete pre-delivery inspection portion of Green Card &give to HDC for insertion
in Service File. In case of depot transfer PDI receipt shall be included in Plant File
and sent to receiving depot

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6.3.17 Ensure that “Safety Must Have Priority” Sticker is affixed prominently on the
equipment (not on outside of the canopy /container).Sample attached in the
Forms sub section of the Generator section.
6.3.18 It is important that plant is maintained to the highest standard and working practices
and that work is performed to the company standards with considerations of
avoiding contamination or spillages. All spillages to be reported to the QHSE
Manager at Jebel Ali using “Spill Report” form available in the EH&S Best
Operating Practices.
6.4 Load Test
6.4.1 Load test should be carried out whenever circumstances permit, upon the
judgment of a Service Engineer taking into consideration the plant history and
duty and/or application since the last test. As a minimum, plant should be load
tested at the “B”service.
The load should be increased as follows:
10 minutes –Warm Up
15 minutes –25%
15 minutes –50%
15 minutes –75%
10 minutes –100%
7. Preventative Maintenance Service Intervals for Generator Sets
• All generator sets are to be serviced as per the Service Schedule attached
in this manual. Tolerance of +10%on “A” service is acceptable.
• For certain models of engines service interval may be changed as per

Manufacturer’s Instructions and Technical Services Department directives i.e.
QSK engines as above.
• The service standards for “A” services are detailed on the following pages for
Containerized and Canopy sets, at the customers’ site and in the Depot.
• Note: If a generator returning to the depot from hire is within 100 hours of its next
“A” service, the “A” service must be carried out prior to making the set available for
hire. This 100 hour time frame can be extended upon application of the equipment
and location of hire. This decision can be taken by the Service Team Leader in
conjunction with the Sales Manager and/or Engineering Service Manager. The
reason will be recorded on the Service Report. Sending out a generator set to a
customer and 2 days later asking him to stop it so that we can service it does not
help with our goal of Customer Satisfaction.

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8. Installation &Commissioning
This Work Instruction covers installation and commissioning of Generators,

Load banks, Transformers &Temperature Control Equipment.
• The installation and connection of Aggreko equipment shall be carried out by

Aggreko qualified engineers only.
• An “Installation &Commissioning Report”(copy attached)must be completed

every time the customer’s equipment /switchgear is connected to by an Aggreko
engineers.
• The White copy of the report must be left on site or with the customers’
representative. The blue copy shall be retained with the equipment contract. It is
very important to complete this report and retain a copy as it will, in the event of
an accident, prove that Aggreko took all reasonable precautions in installing and
connecting to the customer’s equipment/switchgear.
• This instruction must be adhered to at all times.
8.1 Generators, Load bank, Transformers &Temperature Control

Equipment
8.1.1 Where installation and/or commissioning is agreed, details will be specified in the
Customer order, or in the Aggreko Sales Engineer’s Quotation.
8.1.2 If required, the Sales Engineer will visit the site during the pre- contract stage,
to assess the technical requirements (e.g.voltage,load and access to the site,
position, cable length, ventilation etc.).
8.1.3 The Service Engineer, either from the Sales Engineer feedback or during his
installation visit, will assess the location and ground condition for installing the
equipment. At times, if ground is not level, wooden sleepers are placed below the
equipment.
8.1.4 The equipment and accessories are transported to site and unloaded on the firm
ground, using crane equipment supplied by Aggreko or the hirer, as agreed in the
contract.
8.1.5 The set is placed in such a way that adequate air circulation and ventilation is
available for natural cooling.
8.2 Bulk Fuel Storage Tanks
8.2.1. If supplied, the storage tank will be installed adjacent to the generator, on level
ground (or supported by sleepers),and connected to the generator using snap
–on type of connections. Ensure that the fuel system is bled and that there is no

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risk of spillage. Fuel tanks should not be delivered to site or removed from site
with more than 10%fuel inside them.
8.3 Cabling
Note: This section of the Work Instruction covers electrical connection

of Generators, Transformers, Load banks and Temperature Control
equipment.
8.3.1 This instruction only covers the connection of the supply cables from the Aggreko
generating equipment to the customer’s equipment/switchgear or Aggreko
equipment. It does not cover any current carrying medium, either intended or not,
beyond the point of connection. This instruction also only covers the connection
of low voltage systems. High voltage systems are the responsibility of the AIP
Technical Services.
8.3.2 The cables connecting the Aggreko equipment to the customer’s equipment/
switchgear or Aggreko equipment must be checked that they are in good condition
and suitably rated for the intended current and any current likely to pass in the
event of a fault. The terminations must be in good condition and suitable for the
intended type of connection.
8.3.3 Where required, cables will be laid on appropriate cable management system.
Cables shall be secured using cable ties. Where more than one cable per phase
is used, the cables must be trefoiled.
8.3.4 Before connecting the supply cable to the Aggreko equipment or the customers
equipment /switchgear or Aggreko Equipment ensure that the Aggreko equipment
is switched off, isolated and that the necessary precautions have been taken
to prevent the Aggreko equipment from starting.(Circuit Breaker locked in open
position)
8.3.5 Before commencing, a 500V Insulation resistance tester (Megger )and “Installation
& Commissioning Report” are required.
8.3.6 Check with the customer or with the Aggreko equipment that the equipment will
not be damaged by insulation a resistance test.
8.3.7 At the main connection terminal of the customers’ equipment or Aggreko Equipment
with the main switch off/open, test the insulation resistance between each of the
phases and earth with the insulation resistance tester set at 500V and record the
values on the “Installation Report”
8.3.8 The value of the insulation should be not less than 0.5 Mega-ohms. If the value
is less than 0.5Mega-ohms the customer should be informed and the equipment/
switchgear should not be connected until such time that the resistance rises
above 0.5Mega-ohms.

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8.3.9 If you have a satisfactory reading of the insulation. It is safe to connect the cable.
Ensure that the connections are tight and no unnecessary undue strain is placed
upon the cable and that it is protected from mechanical damage.
8.3.10 If a wire armoured cable or cable gland is used it should be checked that it has
been properly installed and tightened.
8.3.11 Connect the other end of the cable to the Aggreko equipment output terminal
ensuring that the same phase sequence is used as connected at customer’s
equipment/switchgear.
8.3.12 An earth cable of the appropriate size in line with the main cable installed
shall be run from the earth point of the Aggreko equipment to a suitable earth
point on the customers equipment/switch gear. The star point of the Aggreko
equipment shall be connected to the frame of the Aggreko equipment unless
the application determines that it should not be (Marine)or it is requested not
to be by the customer in which case his should be recorded on the “Installation
&Commissioning Report”.
8.3.13 The star point of the Aggreko equipment and the main earth point of the customer’s
equipment/switchgear shall be checked for continuity.
8.3.14 After connection of Aggreko equipment supply cable and earth cable,
test the insulation resistance between each of the phases and earth with the
insulation resistance tester set at 500V and record the values on the “Installation
&Commissioning Report”.
8.3.15 The reading should be greater than 0.5 Mega-ohms. If the reading is below this
check installation again. Once you have a satisfactory reading record this on the
“Installation &Commissioning Report”.
8.3.16 It is now safe to turn on the Aggreko equipment. Before closing the Aggreko
equipment’s circuit breaker, ensure that the customer’s equipment/switchgear is
“OFF”. Close the Aggreko equipment’s circuit breaker and check the voltage,
frequency and phase rotation at the customer’s equipment/switchgear, in line
with the requirements in the contract. The Aggreko equipment is now deemed to
have been commissioned.
8.3.17 Ensure that the “Installation &Commissioning Report” is completed with the date,
plant no, hirer’s name, installation address and installation description and signed
by the customer’s representative and Aggreko engineer.
8.3.18 The customer can now switch “ON” their equipment/switchgear.
8.3.19 The Customer Feedback Survey will now be given to the hirer with a
request to complete the relevant details and return to Aggreko.

Section 2
Project and Depot
Maintenance Schedule and Procedures
Revision April 2008

Page No.31
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TABLE OF CONTENTS
Appendix 1. Maintenance Schedules
Appendix 2. Maintenance Procedures
i. “A” Service Standards for Container Generator Sets
ii. “A” Service Standards for Canopy Generator Sets
iii. “B” Service Standards for Container Generator Sets
iv. “B” Service Standards for Canopy Generator Sets

– Cummins, Scania
v. “B” Service Standards for Canopy Generator Sets

except – Cummins & Scania.

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1. Maintenance Schedule - 2008

“A” Service
Fuel Sulphur
Generator Type Interval Comments
(High is 0.5%+)
All Containers Includes KTA ,QST, MTU &
High or Low 400 Hours
(Without Puradyn) DC Series.
Unless On Site Oil Sampling
All Containers
High or Low 400 Hours indicates extension to 800
(With Puradyn)
Hours *
QSK 45 only High or Low 250 Hours QSK 45 Only
Unless oil sampling indicates an
All Canopies High or Low 400 Hours
extension *
“B” Service including top settings
Generator Type Interval
First “B” Service at 1,000 Hours, second at 5,000 Hours and then
KTA Only
every 5,000 hours onwards (1000,5000,10000,15000 etc)
These engines only require One “B” Service between 1000 and
QSK45 only
1500hr only.
First “B” Service at 2,000 Hours and then every 2,000 hours onwards
MTU & QST30
(4000, 6000, 8000, 10000 etc)
First “B” Service at 400 Hours and then every 2,000 hours onwards
Scania DC9, 12 & 16
(2400, 4400, 6400, 8400 etc.)
All Non Scania First “B” Service at 1,000 Hours, Second at 3,000 Hours and then
Canopies every 2,000 hours onwards (1000, 3000, 5000, 7000 etc.)
“Injector Change”
Generator Type Comments
All Containers Change only if Health Check indicates change is required
All Canopies Every 2,000 Hours or at the discretion of an authorized person
“Health Check”
Generator Type Comments
All 1250KVA First “Health Check” at 5,000 hours to establish base line and then
GENSETS every 5,000 hours onwards until 20,000hrs & then very 2000hrs.
Other than 1250KVA
At the discretion of Area Operations Managers or as required
Sets
Alternator Greasing
Alternator Type Interval Repack grease qty.
Newage - HC7 / PI7 /
Every 5000 hrs NDE- 75gms, DE - 89gms
PE7
Newage HC6 Every 5000 hrs NDE -53gms, DE - 66gms
Newage HC5 Every 5000 hrs NDE -29gms, DE - 41gms

Every 3000 hrs -60Hz,
Marathon - 743 NDE - 68gms
Every 4500hrs - 50Hz
* Any extension will be decided by the Technical Director

Service Manual
Generator
i. “A” SERVICE STANDARDS FOR CONTAINER GENERATOR

SETS
Review the previous Service Reports or if an operator is available check if there has
been any operational issues with the unit and address as required.
An Oil sample MUST be taken prior to the engine being stopped for service, in line
with Project / Depot requirements.
(See Work Instructions 1,2 of the Work Instruction section of this manual)
Isolate the batteries before commencing work.
Ensure set is isolated electrically and engine is up to operating temperature.
Change engine oil. Only drain cold if engine cannot be run up to the temperature for
some extreme reason.
Change the oil filters, main and bypass (Where applicable).

Remove and clean the Centrifugal oil cleaner and re-fit.(Scania engine only)
Change the fuel filters, Racor & Seconday as required. If necessary remove the Racor
bowls and clean.
Check the fuel tank for water and drain down as required.
Check / change air intake filters in rear door(s).
Check / change main engine air filter & safety element as required.
Check / change main alternator air intake filter (If appliable)
Check / change coolant filters at 3000hrs interval (If appliable)
Renew all Filter replacement date stickers onto each unit
Check the tension and condition of battery charging alternator drive belt, re-tension or
renew as required.
Check the tension and condition of Radiator cooling fan drive belt, re-tension or renew
as required (If applicable)
Check the condition of Radiator cooling fan drive bearings and lubriate in line with
manufacturer’s specification (If applicable)
Check the governor oil, lubricate fuel linkage and check condition of rose bearings (if
applicable).
Check the coolant system top tank level.
Check and Log the anti freeze protection level (50/50 mix).
Check and Log the DCA levels. (Cummins only) (0.8 Units per LTR)
Check and Log the Coolant PH Value. (Range 5.5 - 9.0)

Service Manual
Generator
DCA and Anti Freeze concentrated to be topped up as required.

(See Work Instruction 16 of the Work Instruction section of this manual)
On systems where the PH Value fails to meet the above limits the system should be
drained and refilled with pre mixed coolant.
(See Section 3 of this manual - “Approved Service Consumable” for the Coolant Spec)
Check the condition of radiator, all water hoses and hose clips, check cooling system for
leaks.
Check the radiator fan motor and engine space fan motor (if applicable).
Check all guards and safety notices, check fire extinguisher if fitted.
Check all batteries, battery isolator, electrolyte level, terminals and cables.
Check the Panel Mounted battery charging system for operation and log voltage.
Check all panel meters, switches and connection.
Check the operation of all shutdowns.
Check all earth studs, load cable terminals and terminal safety covers.
Check all door hinges, locks and seals, and fuel tank caps.
Check the rain cap whether it is operational? If not, replace it.
Carry out a visual check for fuel/oil/water leaks and rectify as necessary.
Check all AC and DC container lighting.
Check ELCB if fitted (Press Test).
Check the “tell tale” on all water pumps for leaks.
Check all safety stickers / labels on the set are correct.
Fill in a “LAST SERVICE” sticker and attach to the panel close to the hour meter. (Remove
old sticker)
Run set up and check pressures , temperatures and DC alternator function (Log
Voltage).
Steam clean the Generator inside & out where possible
Carefully dispose all waste material in line with the Aggreko BOP38 (Best Operating
Practice)
Complete Service Report and update the Electronic Service/CCAN Log.Both Report
Formats are in Section (5)-Forms.
A copy of the Service Report has to be sent to the Technical Records in Jebel Ali or email
to (Technical.Records@aggreko.ae)

Service Manual
Generator
DEPOTS :
In Field Servicing
Ensure customer signs COMPLETED Service Report (Depots only) and the
Customer is given a copy.
In Depot Servicing
Run generator on load test.
Complete a Depot Check list / Load Test Sheet (Format Attached). Distribute
completed Aggreko Depot Check list/Load test Sheet as Indicated on the bottom of
the sheet.
Attach a Green Card to the Machine.
Check whether “Safety Must Have Priority” sticker is in place. Sample of this sticker
is attached in this manual.

Service Manual
Generator
ii. “A” SERVICE STANDARDS FOR CANOPY GENERATOR SETS
Review the previous Service Reports or if an operator is available check if there has
been any operational issues with the unit and address as required.
Isolate the batteries before commencing work.
Ensure set is isolated electrically and engine is up to operating temperature.
Change engine oil. Only drain cold if engine cannot be run up to the temperature for
some extreme reason.
Change the oil filters, main and bypass (Where applicable).

Remove and clean the Centrifugal oil cleaner and re-fit. (Scania engine only)
Change the fuel filters, Racor & Seconday as required. If necessary remove the Racor
bowls and clean.
Check the fuel tank for water and drain down as required.
Check / change main engine air filter & safety element as required.
Check / change main alternator air intake filter (If appliable)
Check / change coolant filters at 3000hrs interval (If appliable)
Renew all Filter replacement date stickers onto each unit
Check the tension and condition of battery charging alternator drive belt, re-tension or
renew as required.
Check the tension and condition of Radiator cooling fan drive belt, re-tension or renew
as required (If applicable)
Check the condition of Radiator cooling fan drive bearings and lubriate in line with
manufacturer’s specification (If applicable)
Check the governor oil, lubricate fuel linkage and check condition of rose bearings (if
applicable).
Check the coolant system top tank level.
Check and Log the anti freeze protection level (50/50 mix).
Check and Log the DCA levels. (Cummins only) (0.8 Units per LTR)
Check and Log the Coolant PH Value. (Range 5.5 - 9.0)
DCA and Anti Freeze concentrated to be topped up as required.

On systems where the PH Value fails to meet the above limits the system should be
drained and refilled with pre mixed coolant.
(See Section 3 of this manual - “Approved Service Consumable” for the Coolant Spec)

Service Manual
Generator
Check the condition of radiator, all water hoses and hose clips, check cooling system for
leaks.
Check the radiator fan motor and engine space fan motor (If applicable).
Check all guards and safety notices, check fire extinguisher if fitted.
Check all batteries, battery isolator, electrolyte level, terminals and cables.
Check all panel meters, switches and connection.
Check the operation of all shutdowns.
Check all earth studs, load cable terminals and terminal safety covers.
Check all door hinges, locks and seals, and fuel tank caps.
Check the rain cap whether it is operational? If not, replace it.
Carry out a visual check for fuel/oil/water leaks and rectify as necessary.
Check all AC and DC canopy lighting (if appliable)
Check ELCB if fitted (Press Test).
Check the “tell tale” on all water pumps for leaks.
Check all safety stickers / labels on the set are correct.
Fill in a “LAST SERVICE” sticker and attach to the panel close to the hour meter.
(Remove old sticker)
Run set up and check pressures , temperatures and DC alternator function (Log
Voltage)
Carefully dispose all waste material in line with the Aggreko BOP38 (Best Operating
Practice)
A copy of the Service Report has to be sent to the Technical Records in Jebel Ali.
(Technical.Records@aggreko.ae)

Service Manual
Generator
DEPOTS :
In Field Servicing
Ensure customer signs COMPLETED Service Report (Depots only) and the
In Depot Servicing
Run generator on load test.
Complete a Depot Check list / Load Test Sheet (Format Attached).

Distribute completed Aggreko Depot Check list/Load test Sheet as Indicated on the
bottom of the sheet.
Attach a Green Card to the machine.
Check whether “Safety Must Have Priority” sticker is in place. Sample of this
sticker is attached in this manual.

Service Manual
Generator
iii. “B” SERVICE STANDARDS FOR CONTAINER GENERATOR

SETS
• Review the previous Service Reports or if an operator is available check

if there has been any operational issues with the unit and address as
required.
• An Oil sample MUST be taken prior to the engine being stopped for service,
in line with Project / Depot requirements.
(See Work Instructions 1,2 of the Work Instruction section of this manual)
• Isolate the batteries before commencing work.
• Ensure set is isolated electrically
• Only engineers who have been trained to do Valve & Injector adjustments on
Cummins & Scania engines should carry out these adjustments.
A service to be completed
All Valves and injectors adjustments must be carried out in line with Maintenance
Schedule
All adjustments must be made in line with engine manufacturers’ Operation and
Maintenance manual.
Inspect and Maintain the Circuit Breaker

*** See Note
Alternator NDE & DE bearings have to be Re-packed with Grease, (Where
applicable)
If the service schedule indicates that a Health Check is required, complete Health
Check
Fill in a “LAST ‘B’ SERVICE” sticker and attach to the panel close to the hour
meter. (Remove old sticker)
Carefully dispose all waste material in line with the Aggreko BOP38 (Best
Operating Practise)

Service Manual
Generator
A copy of the Service Report / CCAN has to be sent to the Technical Records in
Jebel Ali or Email to Technical.Records@aggreko.ae
DEPOTS :
In Field Servicing
Ensure customer signs COMPLETED Service Report and the

*** Note : On Depot application,In the Field Circuit Breaker maintenance has to
be carried out where possible, if this is not possible the maintence must be
sheduled in as and when the unit returns to the Depot.
In Depot Servicing
Remove soot plugs from silencer (if necessary fit extension tube to control
discharge)
Carry out a 1 hour load test on the set to ensure its performance and
complete the load test portion of the service report
Distribute completed Aggreko Depot Check list/Load test Sheet as Indicated
on the bottom of the sheet.
Check whether “Safety Must Have Priority” sticker is in place. Sample of

this sticker is attached in this manual.

Service Manual
Generator
iv. “B” SERVICE FOR CANOPY GENERATOR SETS (CUMMINS/

SCANIA)
• Review the previous Service Reports or if an operator is available check

if there has been any operational issues with the unit and address as
required.
• An Oil sample MUST be taken prior to the engine being stopped for service,
in line with Project / Depot requirements.
(See Work Instruction 1,2 of the Work Instruction section of this manual)
• Isolate the batteries before commencing work.
• Ensure set is isolated electrically
• Only engineers who have been trained to do Valve & Injector adjustments on
Cummins & Scania engines should carry out these adjustments.
A service to be completed
All Valves and injectors adjustments must be carried out in line with Maintenance
Schedule
All adjustments must be made in line with engine manufacturers’ Operation and
Maintenance manual.
Inspect and Maintain the Circuit Breaker

*** See Note
Alternator NDE & DE bearings have to be Re-packed with Grease, (Where
applicable)
Fill in a “LAST ‘B’ SERVICE” sticker and attach to the panel close to the hour
meter. (Remove old sticker)
Carefully dispose all waste material in line with the Aggreko BOP38 (Best
Operating Practise)
A copy of the Service Report / CCAN has to be sent to the Technical Records in
Jebel Ali or Email to Technical.Records@aggreko.ae

Service Manual
Generator
DEPOTS :
In Field Servicing
Ensure customer signs COMPLETED Service Report and the Customer is

given a copy.
*** Note : On Depot application,In the Field Circuit Breaker maintenance has
to be carried out where possible, if this is not possible the maintence must be
sheduled in as and when the unit returns to the Depot.
In Depot Servicing
Remove soot plugs from silencer (if necessary fit extension tube to control
discharge)
Carry out a 1 hour load test on the set to ensure its performance and
complete the load test portion of the service report

Distribute completed Aggreko Depot Check list/Load test Sheet as Indicated
on the bottom of the sheet.
Check whether “Safety Must Have Priority” sticker is in place. Sample of

this sticker is attached in this manual.

Diesel Generator
Section 3
Approved Service Consumables
Revision March 2007

Page No.47
Service Manual
Generator
Table of Contents
1. Grades of Engine Oil recommended by Aggreko
2. Fuel Specifications for Aggreko Fleet
3. Coolant Specification

Service Manual
Generator

Service Manual
Generator
1. Grades of Engine Oil recommended by Aggreko
The oil must be a multigrade product able to satisfy a viscosity range of 15W-40
and must meet the minimum specification of API - CH4 for QSK45 and QSK60
engines and API - CG4 for KTA50G3 engines. With the advance in oil technology
many suppliers are already into API-CHI specification. This is acceptable to
Aggreko as they may supply this grade as an alternative to CG4 and CH4.
Gas engine oil can only be as specified, no other grades are allowed
An alphabetic list of the acceptable brands meeting these criteria follows
but may differ in name from country to country:
If in doubt contact Technical Services in Jebel Ali
Brand Diesel engine oils API rating
ARAL MEGA TURBORAL 10W40 CH4

BP VANELLUS C6 GLOBAL CH4
DELO 400 GOLD
CALTEX CH4
MULTIGRADE
CASTROL RX SUPER 15W40 CH4
ENGEN DIESEL LUBE 600 SUPER CG4
ESSO XD-3 EXTRA CH4
FINA FINA KAPPA FIRST CH4
MOBIL DELVAC 1300 Super 15W40 CI4
SHELL RIMULA X 15W40 CH4
TEXACO URSA SUPER PLUS 15W40 CH4
TOTAL RUBIA TIR 7400 CH4
TOTAL RUBIA 4400 CG4
PREMIUM BLUE
VALVOLINE CH4
Part No.17718
Brand QSK60 Gas engine oils SAE grade
VALVOLINE Valvoline GEO 40 SAE40

Service Manual
Generator
2. Fuel Specifications for Aggreko Fleet
Aggreko diesel engines have been developed to take advantage of the high-
energy content and generally lower cost of No.2 diesel fuels.
Experience has shown that the diesel engines will operate satisfactorily on No.1
fuels or other fuels within the following specifications.
The following specifications apply with relevant ASTM test method.

Specification of Fuel Oil properties - ASTM D-975
Viscosity Centistokes 1.3 to 5.8 @ 40°C (104°F) (30 to 45

(ASTM D-445) SUS)
40 Minimum except in cold weather or in service

Cetane Number
with prolonged idle, a higher cetane number is
(ASTM D-613)
desirable.45 Minimum below 0°C (32°F)
Sulfur Content
Not to exceed 0.5 mass percent
(ASTM D-129 or 1552)
Water and Sediment (ASTM
Not to exceed .05 volume percent
D-1796)
Carbon Residue
Not to exceed 0.35 mass percent on 10 volume
(Ramsbottom ASTM D-524 or
percent residuum
D-189)
42° to 30° API gravity (0.816 to 0.876 g/cc at 15°C)
Specific Gravity (ASTM D-287)
at 60°F
6°C (10°F) below lowest ambient temperature at
Pour / Cloud Point (ASTM D-97)
which the fuel is expected to operate.
Active Sulfur - Copper Strip Cor-
Not to exceed No.2 rating after 3 hours at 50°C
rosion
(122°F)
(ASTM D-130)
Ash Not to exceed 0.02% by weight (0.05 mass percent

(ASTM D-482) with lubricating oil blending)
The distillation curve should be smooth and con-

tinuous. At least 90% of the fuel should evaporate
Distillation (ASTM D-86) at less than 360°C. (680°F) All of
the fuel should evaporate at less than 385°C
(725°F)
Lubricity SLBOCLE or HFRR 3100 grams or greater SLBOCLE, or 0.45 mm

ASTM D-6078 maximum:
Wear Scar Diameter (WSD) at 60°C [140°F] HFRR
10-01-07
Always submit Fuel Sample results to Technical Services Department Jebel

Ali at the start of a new project.

Service Manual
Generator
3. Coolant Specification for Aggreko Generators
The acceptable coolant for Aggreko Generators is a mix of 50%

water and 50% Glycol coolant concentrate. In some engines, such as
Cummins, there will be a need to add SCA’s (supplementary coolant
additives). Correct type and level of concentration will be found by
referring to the engine manufacturers service information.
Minimum Acceptable Cooling Water Characteristics for Use in

Engine Cooling Systems
PROPERTY LIMITS ASTM TEST METHOD
Chloride (Cl), gr/gal 2.4 (40) max D512b, D512d, D4327

(ppm)
Sulphate (SO4), gr/gal 5.9 (100) max D516b, D516d, D4327

(ppm)
Total Hardness, pr/gal 10 (170) max D1126b

(ppm)
Total Solids, gr/gal 20 (340) max D1888a

(ppm)
Ph 5.5-9 D1293
Glycol Coolant Specification
The glycol coolant concentrate (normally referred to as “anti-freeze”) must

meet either Ethylene Glycol ASTM D6210 / TMC RP 329 standard or Propylene
Glycol ASTM D6211 / RP 330 standard.
Proprietary products meeting these requirements are as follows and may

normally be ordered as concentrate or premixed:
- Shell Tri Guard (Premix) or Cool Guard (Concentrate)

- Castrol Antifreeze/Antiboil
- Fleetgaurd Complete (Cummins engines only) and is premixed.
- Valvoline HD Extended Life RTU (Pre-Mix)

Section 4
Work Instructions
Revision April 2008

Page No.55
Service Manual
Generator
Work Instructions
Table of Contents
1. Oil Sampling Procedure for Live Sampling on QSK 45/60 Engine
2. Oil Sampling Procedure for Live Sampling on KTA 50 G3 Engine
3. Purifiner Start up & Maintenance Procedure
4. Kittiwake TBN Setup & Test Procedure
5. Kittiwake Oil Viscosity Test Procedure
6. Wear Check Oil Sample Summary Sheet Details
7. Battery Filling, Charging & Maintenance Procedures.
8. On Site Health Check Procedure.
9. Alternator Bearing Re-Greasing procedure.
10. Alternator Bearing Installation information
11. Alternator Cleaning and Insulation Resistance Test procedure
12. Alternator Rebuild and Refurbishment procedure.
13. Circuit Breaker Maintenance Procedure.
14. Cummins New Engine Inspection Procedure
15. Engine Hot Shutdown Procedure
16. Coolant Test Procedure

Service Manual
Generator

Service Manual
Generator
1. Oil sampling procedure for live sampling on QSK 45/60 engine
This Procedure details the steps required to take a live oil sample from a running
QSK45 fitted with a live sampling valve and using Wearcheck sampling bottles.
If a sampling valve is not fitted, please notify TS (Technical Services) at Jebel Ali
Warning Gloves should be worn as all components will be hot!
You will require a clean Wearcheck oil sample bottle, a tray or bucket to catch
purge oil, a sampling probe part no2705034718, complete with clean clear tubing
attached, lint free wipe and dry working gloves.
Wipe the valve after dust cap is removed and before replacement.
• Ensure that the engine is running and

up to operating temperature.
• Locate the sample valve which is

located behind and between the right
hand oil filter and the main water
pump.
• Remove the dust cap and place

sample probe with tube onto the
valve.
• Purge valve and tube by positioning

a catch tray or bucket under the
tube and exerting slight downward
pressure onto the valve until a
stream of oil flows.
Tray • Remove the pressure after a few

seconds and discard the purged
oil.

Service Manual
Generator
• Leave probe in place. Remove the cap from sample bottle and any internal
seal.
• Position the bottle at end of tube.
• Push on the probe to start the flow of oil and fill the bottle. Release the pressure
before the bottle over flows
• Replace internal seal (if any) firmly and then fit the external cap.
• Remove probe and replace dust cap onto valve.
Complete all the required details on sample bottle label. (See Wearcheck sample
form in forms section)
The sample must be sent for analysis within 24Hrs. It is the sites responsibility to
ensure that samples are collected. If there is a problem having samples collected
please inform Project Manager to arrange other alternative.
Note: Do not use any other container and then decant into the Wearcheck bottle.
The sample must go straight into the Wearcheck bottle as mentioned above.

Service Manual
Generator
2. Oil sampling procedure for KTA 50 G3 engine
Procedure for Live Oil Sampling on KTA 50 G3 Engine
This Procedure details the steps required to take a live oil sample from a
running KTA 50G3 fitted with a live sampling valve.
If a sampling valve is not fitted, please notify TS (Technical Services) at Jebel
Ali
Warning Gloves should be worn as all components will be hot!
You will require a clean oil sample bottle, a tray or bucket to catch purge oil, a
sampling probe part no2705034718, complete with clean clear tubing attached,
lint free wipe and dry working gloves.
Wipe the valve after dust cap is removed and before replacement.
o Ensure that the engine is running

and up to operating temperature.
o Locate the sample valve which is

located on top of the filter head
assembly. (On some engines
the valve may be in a different
location)
o Remove the dust cap and place

sample probe with tube onto the
valve.
o Purge valve and tube by

positioning a catch tray or bucket
under the tube and exerting slight
downward pressure onto the
valve until a stream of oil flows.
o Remove the pressure after a few

seconds and discard the purged
oil.

Service Manual
Generator
o Leave probe in place. Remove the cap

from sample bottle and internal seal.
• Position the bottle at end of tube.
• Push on the probe to start the flow of oil

and fill the bottle. Release the pressure
before the bottle over flows.
• Replace internal seal (if any) firmly and

then fit the external cap.
• Remove probe and replace dust cap

onto valve.
• Complete all the required details on

sample bottle label.
Complete all the required details on sample bottle label.

(See Wearcheck sample form in forms section)
The sample must be sent for analysis within 24Hrs. It is the sites responsibility to
ensure that samples are collected. If there is a problem having samples collected
please inform Project Manager to arrange other alternative.
Note:
Do not use any other container and then decant into the Wearcheck bottle. The
sample must go straight into the Wearcheck bottle as mentioned above

Service Manual
Generator
3. Purifiner® “Start Up”

PURIFINER® filter should be installed at time of ‘A’ Service. The service sticker
should be completed to show next Filter change due in 800Hrs (Containers) & 400Hrs
(Canopies).
It is important to use high quality oil. Save a small amount of the new oil, which should be
sent to an oil laboratory for analysis? The report you get back will establish a base line
for later comparisons of the condition and additive level of your oil. It is also necessary
to take a sample of the old engine oil prior to change as this will indicate the condition of
the engine.
Remove the cap of the PURIFINER®, diffuser plate and remove the filter. Check to be
sure that the brass metering jet is installed in the bottom of the can. Replace the filter,
being sure that the “O” rings are in place on top and bottom of the filter. Place the
diffuser plate on top of the filter, being sure that the cut-out in the baffle plate aligns with
the return hose fitting on the side of the canister.
Insert the loose end of the pressure hose into the plastic cup and have someone start the
engine and let it run until you get a flow of oil. This will flush the oil line and assure you
that you have a pressurized oil flow. Turn off the engine.
Connect the pressure hose to the PURIFINER® and tighten securely.
Start the engine and visually check all fittings for oil leaks.
After 3-5 minutes of operation, carefully touch the head near the heater cap, it should be
hot to the touch. This assures you that the heater element is working properly.
Let the engine run for 20-40 minutes. The larger units, with their bigger filters will take
longer to fill. As soon as you are able to see oil flowing through the flow meter or sight
hose (it will be about full), shut the engine off, wait five minutes and check the oil level
and top up as necessary. The PURIFINER® installation is now complete.
Record the date and hours on CCAN of installation and return to Jebel Ali Records
Department.

Service Manual
Generator
Operation
Operation And
And Maintenance
Maintenance Requirements
Requirements (Purifi
(Purifi ner)
ner)
• PURIFINER® filters, which include built in time released additive replenishers,

have a gold coloured filter pad at the bottom of the filter canister; those without
have a red colored pad.
FILTER CHANGING PROCEDURES
Filter element change for TF 40/60/240P models
Loosen the four head nuts, swing down the bolts out of the slots in the head and
remove the head and diffuser plate. Be careful, the head and diffuser plate
will be hot.
Lift the filter out of the canister with the built-in handle. Ensure that both ‘O’
rings come out with the filter. Properly discard the used filter. The best method
to prevent oil spillage is to place the used filter in the bag the new filter is supplied
in.
Do not remove the oil that is in the bottom of the canister. Install the new filter
element into the PURIFINER® canister.
Remove the old gasket from the underside of the head plate, clean the plate
and fit a new head gasket dry.
Place the diffuser plate and head on top of the ‘O’ ring, being sure that you align
the slot in the side of the plate with the large return hose fitting on the side of the
PURIFINER® and that vent port on the lid is positioned 180 degree (opposite)
return. Swing up the four bolts into the slots in the head and tighten the head nuts
securely. This completes the filter element installation
START UP AFTER FILTER REPLACEMENT
Start the engine and let it run until you have a flow of oil in the sight hose.
Shut off the engine and wait five minutes. Check the oil level on the dipstick and
top up as necessary. This completes Filter Change procedure.

Service Manual
Generator
TROUBLESHOOTING THE PURADYN
The Puradyn has been engineered to be as simple and trouble-free as possible.

It is manufactured from the highest quality materials available and with superior
workmanship. If, however, your Puradyn is not functioning properly, check for the
following conditions, and correct as indicated:
Restricted oil flow:
• Shutoff valve closed – open valve

• Filter dirty and clogged – change filter
• Clogged strainer – clean strainer
• Clogged metering jet – clean metering jet
Oil coming out of vapour tube:
• Crank case breather restriction causing the oil level to backup within the filter
housing.
• Sharp bend, dip or trap in return hose – reroute hose
• Make sure that the oil return line is always dropping into a non-pressurised
location on the engine. For best results, the oil return should be located below
the oil level in the pan.
• Check that the return orifice into the sump is of sufficient diameter.
Top of the Puradyn not hot after five minutes of operation:
• Check fuse – if fuse is good, check power source and ground. If you have
power, the heating element is burned out and needs to be replaced.

Service Manual
Generator
4. Kittiwake TBN Setup

Service Manual
Generator

Service Manual
Generator
Kittiwake TBN Test Procedure

Service Manual
Generator

Service Manual
Generator
5. Kittiwake Oil Viscosity Test Procedure

Service Manual
Generator

Service Manual
Generator
6. Wear Check Oil Sample Summary Sheets Details

Service Manual
Generator

Service Manual
Generator
7. BATTERY FILLING & CHARGING PROCEDURE
Dry –Charged Batteries
1. Check the fresh battery for any physical damage before filling.
2. Ensure proper specific gravity (by using Hydrometer) of filling electrolyte.

The acid should have a specific gravity of 1.260 @ 20°C. Refer table below
for other
temperatures.
3. Fill the cells till the maximum line or up to the top mark (in case of opaque
batteries). Wait for 30 minutes; replenish the electrolyte if the level has
dropped below max line. Check for the open circuit voltage of the battery.
12.6 ± 0.15V
4. Put the battery on charge till the top of charge is reached which is indicated
by freely gassing cells.
In case of constant current charging set the current as recommended

below,
5 amps up to 75Ah type battery & 8 amps for batteries above 75 Ah till the
specific gravity reaches 1.260 @ 20° C
5. If for some reason the acid filled (wet) batteries require storage, then the
battery should be maintained and kept in a charged condition.
6. Dry charged batteries stored for long periods of time or stored improperly
would show difference in the initial activation.
To ensure good performance of the battery , follow point no 4 above
Temperature in ° C Specific Gravity

25 1.262
27 1.260
30 1.258
35 1.254
40 1.250
45 1.247
50 1.243
55 1.240
60 1.236
65 1.232
70 1.229

Service Manual
Generator
BATTERY MAINTAINING & CHARGING PROCEDURE
1. Ensure Open Circuit voltage of more than 12.6 ± 0.15 volts before fitment on the
generator
2. All wet batteries will loose charge if stored for long periods. This is known as self
discharge.
3. Prolonged storage of wet batteries without recharging may accelerate grid

corrosion resulting in loss of capacity and cranking power.
4. In order to ensure proper maintenance of wet batteries, check the voltage,

electrolyte level & specific gravity of the batteries regularly at weekly interval.
Top up the empty cell with DISTILLED WATER only. Never use Acid to top up
except in the initial filling.
5. Batteries having open circuit voltage < 12.40 volts should be charged with
constant potential chargers till the cells are freely gassing.
In case of constant current charging set the current as recommended below,
5amps up to 75Ah type battery & 8amps for batteries above 75Ah until the
specific gravity reaches 1.260 @ 20° C
6. The batteries should be stored in a cool & dry place. Large temperature
fluctuations can cause adverse voltage drops in dry batteries and would reduce
the life of the battery in the case of wet battery.
7. Ensure that Vents are firmly in position before fitment.
8. Smear terminals with Petroleum jelly (Vaseline) after fitment.

Check the belt tension of the alternator. Ensure that the alternator output at the
normal RPM is in the range of 14.2 ± 0.2 volts on a 12 volts system and 26.2
volts ± 0.2 volts on a 24 volts system.

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Generator
8. On Site Health Check Procedure
Service Standards for Health Check
• The result of these tests will highlight prime engine performance parameter
against Aggreko specifications.
• All tests to be conducted as per guidelines stated in the Engine Evaluation

Test Points and Engine Evaluation Test sheets.
• All tests results will be entered into the master fleet history database by
Records Department. After Evaluation by Product Support Manager /
Technical Director.
• Any out of specification issues are to be diagnosed by the engineer and

repaired accordingly.
• A copy of the Evaluation Test Sheets are to be kept on site with the unit’s
service history.
• Frequency of Health Check as per schedule.
• Health checks MUST be performed by suitably trained technician.
• Health Check Procedure
KTA 50 On Site Health Check Procedure
The reason for this assessment is to evaluate the running condition of

the engine to allow Technical Services Department to produce a predicted
engine rebuild plan.
Pre Evaluation Criteria
o Perform any “B” service that is due before carrying out the Health
Check.
• If a “B” service is not due an oil sample must be taken (Details to be

added to the test sheet) and a full “A” service carried out prior to the test
so that all readings are taken with new filters.
• After the service is complete, Cut open One oil filter for inspection,
(Comments to be added to the test sheet).
• The CAT pressure gauges and CAT blow-by gauge must be fitted for the
duration of the test.

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Generator
Set Up of the Test Gauges
o Fit the CAT Pressure Gauge set as follows:-
o Fit the CAT blow-by meter as shown in the

opposite figure
o The Standard hose (5ft) that comes in the CAT kit

must NOT be cut.
o If the engine is fitted with a crankcase breather

on each side engine one outlet MUST be blocked
off and the CAT unit fitted using the appropriate
adaptor.
o Oil pressure gauge connect to ¼” port shown

opposite. Use the bottom right hand gauge.
on the test kit
o Boost pressure after the Aftercoolers

must be connected to both left and right
connections on the test set and both ¼”
conn on the rear aftercoolers of both
banks.

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Generator
o The fuel Pump pressure gauge connection on the test kit should be connected to
the ¼” connection on the fuel pump outlet and to the Gauge indicated.
o The Air inlet restriction should be measured during this

evaluation, Using this kit it is only possible to measure
one side at a time as the Test kit has only one Vacuum
measuring point.

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Generator
Cooling system checks
Prior to the test commencing a coolant sample must be checked for anti freeze
concentrate, PH level and DCA additive level. (Details to be noted on the test
sheet)
The three measuring points for the coolant temperature readings should be clearly
marked with a marker pen so that the reading point is consistent throughout the
test. (See below)
Return from Rad L/bank and

R/bank discharge.
Exhaust Gas Temperature
The exhaust temperature should also be

measured during the evaluation, Whether
you are using a “K” type surface probe or an
Infrared temperature Gun the readings again
have to be taken at a consistent position, on
each turbo out let there is a Stainless steel
pocket fitted in the exhaust pipe work access
to the pipe work can be made to one side if
this boss. (See Figure)
Oil temperature
The oil temperature has also to be measured

during the evaluation; this must be measure
on the surface of the oil pan adaptor using
a “K” type surface probe or an Infrared
temperature Gun the readings again have to
be taken at a consistent position. (See figure
for the position)

Service Manual
Generator
The Test
400kw
• Run the engine for a period of 1hr at 400kw, checking over the machine for
any oil, coolant, exhaust and fuel leaks.
• These must be noted on the test sheet.
• Once all temperatures are stable, all pressures and temperature readings
should be noted on the test sheet provided.
• The blow-by reading can be taken as follows:-
The operation of the unit is simple; Turn on using the ON button, Push the
FT³/HR button after the engine has competed its 1hr run the reading from the
LCD display must be logged on the test sheet provided.
850kw
• After all information has been logged the machine load should be increased
to 850kw and allowed to run until all temperatures are stable a period of one
hour should be sufficient.
• Another set of readings as taken at the previous load step should then be
taken and added to the test sheet provided.
During the Health Check both parts of the Test Record Sheet
MUST be completed
(See the Forms section for an example)

Service Manual
Generator
9. Alternator Bearing Re-Greasing.
On all new and refurbished alternators there is a Newage sticker relating to

bearing re-greasing. The sticker shows the interval as 4,000 to 4,500 hours and
the Service Sheet shows greasing to be done at:
5,000 hour B service (For Diesel Products)
4,500 hour B Service (For Gas Products)
Ignore the sticker and grease at the B service interval as record keeping will be
easier and 500 extra hours for Diesel Products will not cause a problem.
Preparation:
• Before starting the machine remove the PMG cover,
• This will allow grease expelled from the Non Drive End Bearing carrier (Picture1)
to be contained.
• Grease expelled from the Drive End Bearing carrier (Picture 2) will be expelled
behind the Drive coupling.

Service Manual
Generator
• Access to this area can be gained

through the two inspection cover
(Picture 3) on the Drive Housing.
• This area must only be opened after

the greasing is complete for cleaning
purposes.
• Greasing should be done with the engine running.
• To do this as safely as possible the excitation should be switched off and the circuit
breaker opened.
Greasing “on the run” will help prevent any “hydraulic” shifting of the bearing
assembly that is possible with static greasing, similarly over greasing may cause
“hydraulic” shifting which will lead to premature bearing failure.
Procedure:
• Only Kluber Asonic GHY 72 Grease has to be used for Newage Alternators
• Kluber Asonic GHY 72 is available in 400 gram cartridges from Jebel Ali stores
(Aggreko Part Number GHY72) as are the required Grease Guns (Aggreko Part
Number 12632).
• A dedicated grease gun to hold the cartridge is needed as we do NOT want to use
re-fillable grease guns due to the chance of dirt entry when filling.
• Quantity of grease for 1250 alternators is 89 grams for the DE bearing and 75
grams for the NDE bearing (check the sticker for other sizes).
• This is roughly equivalent to 67 strokes of the grease gun for the DE bearing and
56 strokes for the NDE. (1 stroke = 1.35 grams)

Service Manual
Generator
• This should be pumped in slowly to allow the grease gun to recharge between each
stroke.
• Grease Meters to measure the quantity of grease being re-packed into each bearing
are also available from Jebel Ali Store (Aggreko Part Number 411100) see next
page for details.
• Once the Generator has been stopped complete the next task!
• Clean up any old grease that may be ejected from the bearing carrier’s and refit the
PMG cover and inspection covers on the drive housing.
If any of the below SKF / Samoa Grease meters (Part Number 411100) are
available on site please use this instead of counting the numbers of strokes of the
grease gun mentioned in the above procedure:

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Generator
10. Alternator Bearing Installation information
Please use the following information when Removing, Replacing and Maintenance
of the Drive and Non-Drive End Bearings used in the above Main Alternators:
Special attention MUST be paid to the “Initial Lubricating Details” in

Table 1.
BEARING REPLACEMENT
Environment
Every effort must be made to establish a clean area around the generator when
removing and replacing bearings. Contamination is a major cause of bearing
failures.
Equipment
Suitable cleaning solvent.

Bearing puller – two or three leg.
Thin protective gloves.
Lint free cleaning cloth.
Induction heater.
Preparation
Remove PMG if fitted.

Remove the lubrication pipe-work if fitted.
Position the rotor so that the full pole face of the main rotor is at the bottom of the
stator bore.
Remove the end bracket.
NOTES:
It is not necessary to remove the rotor.

Ensure that the bearing contact surfaces show no sign of wear or corrosion prior
to fitting the bearing.
Never refit used bearings, wave washers or ‘O’ rings.
Never refit used bearings, grease flingers, wave washer or ‘O’ rings.
Only the outer race should be used to transmit load during assembly
(NEVER use the inner race)

Service Manual
Generator
REMOVAL OF REGREASABLE BEARINGS
The bearings are a press fit on the shaft and can be removed with standard tooling.
i.e. 2 or 3 legged manual or hydraulic bearing pullers.
To remove bearings proceed as follows:
1) Remove 4 screws holding bearing cap.
2) Remove cap.
3) Non drive end – remove wave washer and Circlip (single bearing only)
4) Remove bearing cartridge housing complete with bearing (and grease flinger if
fitted)
5) Remove bearing from cartridge.
6) Discard the old bearing ‘O’ rings and wave washer where fitted.
The bearing cap(s) and cartridges(s) must be thoroughly flushed out with clean solvent
and checked for wear or damage before re-assembly. Damaged components should
be replaced before refitting the bearing.
Bearing preparation
1) Remove the bearing from its packaging.
2) Wipe off the preservative oil from the surface of the inner and outer rings – using
lint free cloth only.
3) Place the bearing on the clean assembly surface
Bearing Assembly (Lubrication) Table 1.
INITIAL LUBRICATION DETAILS

REGREASEABLE BEARINGS
GREASE QUANTITY
FRAME BEARING BEARINGS CARTRIDGE CAP
POSITION CM2 GRAMS CM2 GRAMS CM2 GRAMS
5 Non-Drive End 65 58 33 29 33 29
5 Drive End 92 82 46 41 46 41
6 Non-Drive End 121 111 63 56 63 56
6 Drive End 156 139 78 69 78 69
7 Non-Drive End 174 154 87 77 87 77
7 Drive End 208 185 104 92 104 92
Lubricant : KLUBER ASONIC GHY 72 (Aggreko Part Number – GHY72)

Service Manual
Generator
Cartridge:
1) Apply the specified cartridge grease fill quantity to the back face of the bearing
housing I.E. HC7 / PI-E7 – NDE 77 grams.
HC7 / PI-E7 – DE 92 grams.
2) Apply a small amount of grease to the grooved sealing surface in the cartridge.
3) Apply anti-fretting lubricant (MP14002 – Kluber Altemp Q NB 50) to the bearing

housing circumference. Apply paste in a thin coherent layer by use of a lint free
cloth (DO NOT rub in) (use clean protective gloves)
4) Non-drive end-fit new ‘O’ Rings into the ‘O’ Ring grooves in the bearing housing
circumference.
Bearing:
1) Apply HALF the specified bearing grease fill quantity (see table 1) to the upper
face of the bearing.
I.E. HC7 / PI-E7 – NDE 154 ÷ 2 = 77 grams
HC7 / PI-E7 – DE 185 ÷ 2 = 92.5 grams.
2) Thumb the applied grease into the bearing, ensuring good penetration into the
raceways / balls (use clean protective gloves)
3) Turn the bearing over on the assembly surface and apply the remaining HALF
of the specified bearing grease fill quantity (see table 1) to the upper face of the
bearing.
I.E. HC7 / PI-E7 – NDE 154 ÷ 2 = 77 grams
HC7 / PI-E7 – DE 185 ÷ 2 = 92.5 grams.
4) Thumb the applied grease into the bearing, ensuring good penetration into the
raceways / balls (use clean protective gloves)
Assemble Bearing into Cartridge
1) Heat the bearing cartridge to 25ºC above ambient with an induction heater (Do not
exceed 100ºC)
2) With greased face of the bearing facing the cartridge bore, assemble the bearing
into the bearing housing. Ensure the bearing outer race contacts the location
shoulder.

Service Manual
Generator
Assemble Bearing onto the Shaft
Bearing Cartridge:
1) Heat the Bearing and Cartridge assembly to 80ºC above ambient with an induction
heater. (use induction heater, no other heat source is suitable)
2) Slide the Bearing and Cartridge assembly over the shaft, pushing it firmly against
the bearing seating shoulder.
3) Rotate the assembly (including inner race) 45º in either direction, to provide correct
alignment. The bearing must be held firmly in place until it is cool enough to
positively self locate.
Note: Ensure cartridge is at ambient temp, before assembling bracket.
Cap / Flinger:
1) Apply the specified cap grease fill quantity to the inside face of the Cap.
I.E. HC7 / PI-E7 – NDE 77 grams
HC7 / PI-E7 – DE 92 grams.
2) Fill the grease exhaust slot with grease.
3) Apply a small amount of grease to the grooved sealing surface in the cap.
4) Fit Circlip. (Single bearing only)
5) Heat flinger to 120ºC and place on shaft up to the bearing inner race. Hold firmly
until positively located.
6) Place wave washer in cap, fit cap to bearing cartridge.
Re-lubrication pipe:
1) Fill pipe and grease nipple with grease.
2) Fit pipe work to machine.
Once the Alternator has been completely re-assembled see the below procedure
which is within the “Useful Information Section” of this manual for the information
required when refitting the Drive coupling;

Service Manual
Generator
Maintenance
The following chart shows the required re-greasing interval and quantity of grease
required for both models of Alternator:
RELUBRICATION DETAILS FOR REGREASABLE BEARINGS
BEARING
GREASE QUANTITY
HC / HCK POSITION
CM3 Grams
5 Non-Drive End 33 29 4,500 Hrs
5 Drive End 45 41 4,500 Hrs
6 Drive End 75 66 4,500 Hrs
7 Drive End 100 89 4,500 Hrs
The re-greasing of the Alternator bearings must be

carried out in line with the below procedure:
Appendix 1:
If any of the below SKF / Samoa Grease meters (Part Number 411100) are available
on site please use this instead of counting the numbers of strokes of the grease gun
mentioned in the above procedure:

Service Manual
Generator
11. AC Alternator Cleaning and Insulation Resistance Test Procedure
Object
The object of this instruction is to enhance the current maintenance and cleaning
process, in order to improve the reliability of the AC Generator
Scope
This instruction is a supplement to existing maintenance & cleaning methods and

applies to all AC generators.
Responsibility
Persons operating on the above machines must do so in accordance with this

instruction. This must be carried out to ensure safe and reliable operation of the
AC generator. It is the individual’s responsibility to keep equipment and localised
work area tidy at all times, in order to be compliant with company health and
safety procedures.
Procedure
Before cleaning commences on the AC Generator, refer to the Manufacturers

service and Maintenance Manual for any special requirements.
The unit must be visually inspected to remove any debris within the fan cowl.
During the washing process, a hot pressure jet should be used with NO ADDED
DETERGENT, ensuring debris is forced out of the winding.
On completion, the machine must be dried out thoroughly to remove any standing
water. Excess water left in the machine will create a high dew point, reducing the
Insulation Resistance (IR) value of the AC generator.

Service Manual
Generator
INSULATION RESISTANCE TEST
The following is pre- commissioning procedure for canopy generators fitted

with the P2002 & 522 engine protection modules.
If the generator has been standing for any length of time or transported in a
wet condition it is important to ensure that the alternator winding resistance
is above 1MΩ before running.
Carry out the following checks:
• Disconnect all the wires from AVR.
• With alternators fitted with Aggreko link board remove the links connecting
the winding ends to the neutral. As shown in Fig 1
• Switch off all AC MCB’s in panel.
• Connect a Mega-ohm meter set to 500V (Megger) to U1 – V1, V1- W1, W1-
U1 in turn & then each to earth (generator frame) Maintain voltage for 1minute
and ensure resistance is greater than 1 MΩ. Note: On alternators pre 1990
the winding ends were marked in opposite direction hence the output ends
were U6, V6, W6 and the neutral U1, V1, W1. The link arrangement remained
as above.
• If reading is slightly below 1MΩ then it may be simply some surface moisture
that is giving this reading this can normally be rectified by running the
generator unexcited for about 10 minutes. After this the Mega-ohm test
should be carried out again to ensure the winding resistance is above 1MΩ.

Service Manual
Generator
• Generator sets fitted with the P2002 engine module have an alternator output
detection circuit which will cause the generator to stop once the protection hold
off time (15 sec) has elapsed. Therefore a 10 minute run is not possible without
manually bypassing fuel solenoid control.
Drying out procedure
In some case it is necessary to dry out the alternator to increase the insulation
resistance to an acceptable level.
This can be achieved by blowing hot air into alternator from a small electric
convection heater. This method normally takes 24hrs to get winding insulation
above 1 MΩ.
Another way is the Short Circuit method. For this you will need shorting links
capable of carrying full load of the alternator, a variable resistance of 80-100Ω
capable of carrying up to 2A and a clamp on ammeter.
• Ensure AVR is disconnected.
• The neutral links need to be in place as shown in diagram Fig 1.
• Connect the shorting links across output terminals U, V & W.
• Connect the resistor across a 12V battery and exciter. See Fig 2
• Start engine and ensure it is running at correct speed. Note: as the alternator
is unexcited at this stage the Hz meter will give incorrect reading, normally full
scale. Do not adjust speed down if it sounds like it is running normal.
• Slowly adjust resistor until approximately 80% of full load current is being
carried.
• Allow to run for 1 hour, stop engine, remove links and carry out insulation resistance
tests as above.
• If reading is above 1MΩ. Reconnect AVR and run up generator.
• Check all voltages are balanced between phases and neutral.
• If voltages are not balanced or insulation level does not come above 1MΩ refer
to Newage fault finding manual.

Service Manual
Generator
Pre-run check.
Check the following:
• Fan and battery charging alternator belts for tightness.
• Battery electrolyte level.
• Battery cables (apply petroleum jelly/ Vaseline to cable ends)
• AC/DC wiring (loose connections)
• Water & anti-freeze levels.
• Water hoses and connections for leaks.
• Oil level.
• Exhaust connections.
• Engine and alternator mounts.
• Racor bowl for cleanliness.

Service Manual
Generator
Set Voltage and frequency
Before starting the generator, determine the voltage and frequency it is to run at
and confirm with client.
Set Over-speed protection
• P2002 module, remove back cover. Select Hz (50/60) by moving DIL switch.
• 522 modules, Select Hz (50/60) by moving DIL switch on rear of module.
Set AVR
• Move link at bottom of AVR for 50/60Hz operation. On some generators a switch
is fitted for this and is inside panel.
• Turn volts pot on AVR to mid position.
Run Generator and adjust frequency to desired level. For engines fitted with
electronic governors the speed should be set using rated speed potentiometer
on governor controller. Fine adjustment can be made using remote pot if fitted. If
Generator is running on its own not in parallel the droop pot on controller should be
turned fully anti- clock wise. Generators with mechanical governors the frequency
should be set to 52Hz or 62Hz to allow for governor droop on load.
Shut down checks.
When it has been determined that the generator windings are ok and the engine
safe to run the shut downs should be checked prior to putting generator into
service.
• Start generator allow 1 min for engine safety l.e.d on module to light.
• Ensure it is safe to close circuit breaker and close.
• Disconnect wire from oil pressure switch and short to engine chassis. Circuit
breaker should trip, engine shut down and module L.O.P l.e.d lit.
• Repeat for High coolant temperature, where applicable.
• If an ELCB is fitted this should be tested using the test button.
The generator is now ready to be put into service, the Installation and commissioning
procedure should now be carried out.

Service Manual
Generator
12. ALTERNATOR REBUILD AND REFURBISHMENT PROCEDURE
The idea behind this is to offer guidance about a meaningful inspection and
rebuild of a generator. It is expected that the generator has been operating for
some considerable time, and for reasons of complete generating set overhaul an
opportunity arises to thoroughly assess its condition, and refurbish in line with the
prime mover manufacturers maintenance /overhaul program.
Whilst generators are identified as a low maintenance component part of a
generating set, they must not be considered to be a No maintenance item.
The only way an effective study of the generator condition can be established is
with it removed from the engine and the rotor withdrawn.
The facilities required for safely removing the generator from the engine and
conducting a generator overhaul program are those available in any reasonably
equipped workshop with lifting capabilities and experience of Electro-mechanical
assemblies. Such experience and equipment should extend to safe handling and
storage of component parts, specialist bearing and coupling ‘pullers’, adequate
pressure washing equipment, thermostatically controlled oven, electrical insulation
and impregnation materials, and adequate, and calibrated test equipment and
instruments.
The Generating Set manufacturer will have provided technical literature to support
the engineering package. Any maintenance and overhaul work must follow
correct safety procedures, be conducted by trained personnel, working within the
guidelines of the appropriate generator set component manufacturers technical
support literature.
General guidance regarding safe working practice, generator parts removal,

winding resistance values, circuit diagrams, and component test procedure can
be found in the Newage Installation, Service & Maintenance Manual.
It is good practice for the complete strip down to be followed in an ordered

manner and for written notes to be made of specific mechanical arrangements,
and electrical connections. It is often advisable that the electrical connections
be marked just for the purpose of easy identification during the final rebuild. It is
strongly recommended that even if the manufacturer’s original electrical drawings
are to be the reference documents, the machine connections be double-checked
against these drawings to confirm status and authenticity.
COMPONENT INSPECTION.
As the generator is removed from the engine the first visual checks can begin.
The removal of each securing bolt – foot, adaptor flange, and coupling, etc. -
should initiate an inspection for any signs of looseness, fretting, elongation of
holes, and damaged threads.
As component parts are pulled apart a visual check should be made for signs
of water ingress/ rust/ contamination onto surfaces that should have remained
untainted. Specifically the coupling / adaptor/ mounting regions are the most
important areas to concentrate this visual study.

Service Manual
Generator
PMG Removal…. if fitted.
Before the NDE –Bracket can be removed the PMG assembly must be removed. The
procedure is covered in the Newage Installation, Service & Maintenance Manual.
Remember that the rotor of the PMG is strongly magnetised, so care should be
taken when handling and this item should be stored in a clean plastic bag to stop
contamination by metal particles whilst the rotor is in storage.
End-Bracket Removal.
Whether a single or two bearing generator the DE Adaptor or End-Bracket should

be removed. The timing of the removal of a single bearing machine adaptor may
depend on fan type and the fans outside diameter relative to the adaptors dimensions
in the frame location flange region.
The NDE bracket should be removed, with appropriate care as instructed in the
Newage I, S & M. Manual with regard to bearing housing dismantling.
It is most important to adequately support the rotor weight when the end-bracket is
withdrawn from its frame location point.
Bearing Assembly.
The condition of the bearing assembly, especially in the region where the bearing
outer race is located, should be carefully inspected for signs of wear.
If a wear groove can be detected then the assembly should be replaced.
In the NDE housing the condition of the bearing outer race anti-creep rubber ‘O’ ring
should be established and replaced if any signs are found that it is no longer circular
in section, or has lost its original snug fit in its machined groove.
The bearings should be removed from the shaft, and the bearing location diameters
should be inspected for signs of wear marks, or fretting. Removed bearings no
matter what their age should not be refitted.
Rotor Removal.
With the generator removed from the engine and now securely supported the rotor
should be removed. The Newage Installation, Service & Maintenance Manual
will provide guidance about the procedure that should be followed to safely support
the rotor whilst sliding it out of the stator bore. With the rotor carefully removed
it should be stored in a well-supported manner in a position where no accidental
damage will occur.
Terminal Box and UC / BC machines sheet Metalwork
These covers should be removed to allow unrestricted access to all parts of the
machine. Any patterns of metal oxidization on this metalwork will provide guidance
of the amounts of moisture that has been present within the machine. It will also
offer useful guidance about areas within the generator that must be most carefully
inspected, and also guidance about the performance of the Engine & Generators
Housing /Canopy/Enclosure.

Service Manual
Generator
Stator Inspection.
The general condition of the stator winding can be established by a visual inspection.
Its appearance will offer guidance regarding the level and type of contamination on
the windings. Any obvious areas of stress should be examined before the evidence is
tampered with. To ensure that the windings are basically sound a Megger test should
be conducted to gauge the overall condition of the assembly. It may be that this test will
result in some very low measured values, but providing there is no ‘dead short’ it may
be that the dirty-damp condition of the winding is the cause, and this is a recoverable
situation. The winding resistance values should be measured and checked against
the values in the Installation, Service & Maintenance Manual.
Rotor Inspection.
A visual inspection will establish the basic condition of the main rotor windings, the coil
support mouldings and wedges, and any localised areas that have been stressed.
The exciter armature and the rotating diode assembly must also be carefully
inspected.
A Megger test for values of IR will establish the basic condition of the assembly.
The winding resistance values should be measured and checked against the values
in the Installation, Service & Maintenance Manual.
Exciter Field Inspection.
The condition of the field coils should be inspected. In particular the corners of the
coils should be inspected for Blue-green – verdigris - deposits that are the result of
this polarised winding operating in damp salient atmospheres.
The bore of the lamination pack should be inspected for any signs of rubbing, and if
any found the exciter armature lamination OD should be closely inspected for rubbing
marks. If there are clear indications that the these items have been in mechanical
contact then any signs, the result of frictional heat, should be looked for on the winding
insulation materials.
Fan Condition.
The fan should be inspected for any signs of stress. This may be cracks, and bent
blades. Any stress marks should be carefully considered with regard to assembly
integrity, and if in doubt the fan should be replaced.
Pressure Washing.
The most effective way to clean the stator, rotor winding, and exciter field assemblies
are to pressure wash them. This should be done with a hot pressure wash with no
added detergent. The problem with a detergent wash is that it may contain surface
tension reducing chemicals and wetting agent salts. These can leave a hygroscopic
residue on the surface of the windings, with the result that they may stop good adhesion
of a protective ‘overcoat’ which is the next part of the refurbishment exercise.
The washing action should be sympathetic to the construction of the winding out-hang,
but nevertheless must be thorough, and conducted in a manner that the particles of
dirt flow out of the windings rather than forced further in.

Service Manual
Generator
Drying Out Procedure.
The washed components must be thoroughly dried out in temperature-controlled oven.

The winding assembly should be slowly heated to 105ºC, and held at this temperature
for several hours to absolutely ensure that all the moisture is evaporated, rather than
boiled, from the winding assembly.
The Testing of Cleaned Wound Components.
Once removed from the oven the assembly should be allowed to cool to normal
ambient temperatures in a clean and dry workshop environment with typical 45% RH
values. The wound assembly is then ready to be Megger tested to establish the IR
values, which should be measured phase to phase, and phase to earth. A minimum
acceptable value is 2.0 Meg Ohms.
Insulation Overcoat.
With clean dry windings, that have an acceptable IR value, an overcoat of a suitable
electrical resin should be applied. A known compatible material is manufactured
by Sterling Varnish, identified as VA 42. An alternative is the Epoxylite 213RT that
is the Black Epoxy Overcoat the Newage use during original BC & UC machine
manufacture.
The choice of an ‘Overcoat’ material is quite involved, as compatibility with the

original impregnation material can be very difficult to achieve. The major problem
is with ensuring that the overcoat will adhere to the original impregnation. This is
especially so with the HC product which use an epoxy impregnate, designed not to
allow contaminants to collect and build-up on its surface, and so it is hard for just any
overcoat to stay adhered.
The ‘Overcoat’ can be applied by paintbrush, or by use of a Venturi spray gun powered
by a clean and dry source of pressurised air. The application of this material will offer
good protection to the now clean windings, but is only effective if great care is taken
to cover 100% of the winding surface.
There is no great benefit in applying the overcoat in a layer of great thickness. The
heat cycling of the windings during normal operation will simply cause the overcoat
to separate from the windings if the overcoat is too thick. On a rotor assembly a thick
coat will lift and under centrifugal force will peel off
To assist with any exercise in identifying a suitable Overcoat Material the following
information is provided about the original impregnation materials and process.

Service Manual
Generator
Materials.
All generators have a class ‘H’ insulation system, used with the following
impregnation methods:
Stator
HC; VPI epoxy….UC & BC; Trickle / polyester resin + epoxy / spray overcoat.
Rotor.
HC; Trickle / epoxy resin.

UC & BC; Roll-dip / polyester resin.
Exciter Stator [field].
Dip and Bake / polyester resin + epoxy / spray overcoat.
Exciter armature & PMG Stators.
Dip and Bake / polyester resin.
Rotating Diode Assembly.
Experience suggests that the connections of the diode assembly become corroded
after several years use, and the most prudent way to ensure reliable service is
ensured after this major overhaul is to remove the diodes, surge suppresser, and main
rotor field connections. Then clean the entire surface contact points on the rectifier
plates, before reassembling with new diodes and surge suppresser, and cleaned field
connections.
Stator Assembly.
The stator assembly can be rebuilt with cleaned and ideally repainted sheet metal work.
The terminal arrangement can be reassembled, with care being taken to ensure careful
routing of stator leads, clean connections, and if necessary new lead identification
markers. The wiring loom between terminals and AVR should be inspected, cleaned
and then reused if considered fully serviceable.
Rotor Assembly.
The rotor assembly should be fitted with new bearing[s], and before refitting the cir-
clip should be examined and confirmed serviceable. The fitting of bearings should be
done in a professional manner using appropriate method to heat the bearing, and then
fit the bearing with no force being applied across the rotating element, e.g. balls.

Service Manual
Generator
Rotor into Stator.
The re-fitting of any Drive End adaptor ring, complete adaptor should be carried out
if it is known that this component must be fitted before the rotor assembly is inserted.
The refitting of the rebuilt rotor into the stator bore requires care and consideration to
support the rotor weight during the insertion. A ‘Rotor bar’ must be used to guide the
exciter armature through the stator bore, and then the main rotor into the stator bore.
At all times taking care to ensure no damage occurs to any part of these carefully
rebuilt assemblies.
End Brackets.
These should be re-fitted in a workman like manner, and this should include a smear
of grease to all spigots and location faces, the use of new bolts, washers, or lock nuts
as required. The end bracket and its located assembly must be adequately supported
during the initial alignment, squarely aligned with the bearing, or the bearing cartridge,
and no undue or uneven force applied. As the end bracket is re-located onto the
generator frame assembly the weight of the end bracket and rotor should be supported
by suitable lifting equipment to ensure the frame / end bracket location spigots are not
damaged.
Terminal Box.
The terminal arrangement should be reassembled with due consideration of the

condition of the insulating material by inspecting for cracks, and ingrained grime
that would encourage surface tracking. New parts should always be used when the
condition of any component part is considered questionable. It is essential that great
care is taken with the accuracy of the re-connection of the wiring loom for the AVR,
and any fitted electrical / electronic accessory.
The main stator leads should be positioned and incorporated in the terminal arrangement
in such a way that ensures that the leads are not in danger of mechanical damage.
The electrical connection between the stator leads, to Customers cables must be
achieved by best possible surface-to-surface electrical contact with good and clean
contact areas. The assembly of the terminal box sheet metal work should be undertaken
with due consideration to the environment in which the generator is to operate, based
on the condition of the generator when it was first removed for overhaul. If it came in
rusty, and showing signs of water ingress then the final re-assembly of the t/box might
well benefit from the incorporation of RTV silicon sealant at the joint faces.
Typically Expected Insulation Resistance [IR] Values.
The following is offered as general information about IR values and is aimed at

providing guidance about the typical IR values for generators from New through to the
point of Refurbishment as discussed and outlined above.

Service Manual
Generator
New Machines:
The generators Insulation Resistance, along with many other critical factors, will have
been measured during the Newage Factory processes of manufacture, assembly and
test. The generator will have been transported with a packaging appropriate for the
journey to the Generating Set assembler’s works, where it is expected it will be stored
within a weather protective building. However, absolute insurance that the generator will
arrive at the Generator set builder’s production line with IR values still at the factory test
levels of above 100 Mega-Ohms cannot be guaranteed.
At Gen’Set Manufacturers Works.

The generator should arrive at the Generator set assemblers works in a clean dry condition.
If held in appropriate storage conditions the generator IR value should be typically 25
Mega-Ohms. If the unused / new generators IR values fall below 10 Mega-Ohm then
a drying out procedure should be implemented by one of the processes outlined below
before being dispatched to the Customers site and some investigation undertaken into
the storage conditions the generator had been subjected to.
Generators in Service.
Whilst it is known that a generator will give reliable service with an IR value of just 1
Mega-Ohm, but for a relatively new generator to be this low it must have been subjected
to inappropriate operating or storage conditions.
Any temporarily reduced IR values can be restored to expected values by following the
below explained drying out procedures. Then further operation on load will complete a
thorough heating of the winding assemblies, which will completely dry-off the IR reducing
moisture.
The following is offered as helpful guidance, but should be read in

conjunction with the
Generators - Installation, Service & Maintenance Manual.
Insulation Resistance Values.

The IR value when measured on a new wound component will have values above
100MegOhm.
When in service various mechanisms will contribute to factors that will affect the IR value,
and site measurements of just a few Mega-Ohms become more typical. Major factors,
which affect and reduce the IR value, start with the winding out hang. Surface moisture,
often present in conjunction with surface contamination, is both the result of prevailing
site conditions. Either will seriously reduce measured IR values, and if the root cause that
allows this contaminant to be present is not addressed then the expected life span will
be considerably reduced. The Newage manual - Installation, Service & Maintenance
Manual - issued with every generator, in Section 7 –Service and Maintenance - offers
guidance about measuring the IR value and expected typical values. If the IR measurement
is considered to be low, and further guidance and understanding about the risk of operation
of the generators insulation system is required, then the next test would be a Polarisation
Index - PI Test.

Service Manual
Generator
Maintaining Acceptable IR Values.
Basically, keep the wound component clean and dry, and good values of IR
are assured. But achieving the ‘clean and dry’ has to be engineered into the
original Generating Set design, and then maintained by an effective On Site ‘Care
regime’. Considerations at the Engineering stage must include a way to combat
moisture and contaminants carried airborne with the cooling air especially when
the Gen’Set is operating in Rain, Fog, or Sea Mist etc. Then also carefully consider
the microclimate conditions that occur inside a typical Gen’Set canopy, especially
just after the hot unit is taken out of surface and is stopped. Within the canopy the
cooling down of the Generator set promotes high humidity levels, which result in
surfaces become wet, and this includes the generator windings. It is necessary to
find a way to combat this, and basically it requires engineered natural convection
of airflow through the canopy, to counteract the dew point situation and so keep
the levels of Relative Humidity – RH - low.
Ways to Maintain High IR Values.
Anti-Con Heater
Fit the generator with an anti-condensation heater, and ensure that this is
automatically switched on when the Gen’Set is at rest. This will maintain a high
value of IR for windings that are already in a clean and dry condition.
Gen’Set Canopy Space Heater
Of a power rating capable of maintaining low RH values within the generator set
enclosure at the site environmental conditions.
Regular Use as part of Planned Maintenance
Planned routine operation of the generator set at a rating that elevates the stator
temperature to some 110ºC T-total for a period of say one hour will drive out
any moisture that might otherwise begin a degradation process to the Insulation
system.
Ways to Increase IR Values.
Consider a known good condition generator that has not been run for some time
but during which it has been standing in conditions of high RH. It is possible that
simply running the generator set unexcited for a period of say 10 minutes will
sufficiently dry the surface of the windings and so raise the IR sufficiently – to >
1megOhm – and so allow the unit to be put into service.
If the above unexcited ‘blow-drying’ does not raise the IR value sufficiently then
consider separately exciting the generator with its output terminals connected by
appropriately rated short circuit links. By sep-exciting at a level such that some
80% of rated current flows through the short circuit link the generator stator inding
will start to heat up. This will drive off the embedded moisture, during a run period

Service Manual
Generator
dependant upon the size of the generator but consider:
1 hour for a BC16/18,

2 hours for a UC22/27
hours for an HC4, 5, 6&7
If the IR value remains below 1megOhm, even after the above drying methods have
been properly conducted, then a Polarisation Index test [PI] should be carried out.
This will offer some guidance about the characteristics and so reason for the ‘leakage
current’ that is causing the low IR. If surface contamination is the cause, therefore
promoting surface tracking, then the generator must be removed from the engine and
stripped down to enable the stator winding to be thoroughly but carefully pressure
washed, then baked in an oven to completely dry out. If now the value of IR is acceptable,
then the stator should be treated with an over coating resin that is compatible with the
original factory impregnation, before the generator is reassembled onto the engine.
USEFUL DATA FOR NEWAGE GENERATORS.
Approximate Machine Weight.

The following is offered for guidance for lifting of complete machines.
BC 164 machines…………….. 80 < 120kgs

BC 184………………………… 130 < 180kgs
UC 224………………………… 270 < 420kgs
UC 274………………………… 400 < 675kgs
HC 4……………………………850 < 1200kgs
HC 5………………………… 1265 < 1780kgs
HC 6………………………… 1960 < 2650kgs
HC 7…………………………. 2750 < 3950kgs
FRAME 8…………………… 5750 < 8300kgs.
Insulation Levels.
Always make first Megger test at 500V. Minimum acceptable value for a winding IR
reading is: 1.0 mega-ohm. Typical PI ratio: 2.5
Winding Resistances.
Stator resistances are always very low. Typically 1.5 ohm L-N for a BC, the resistance
reducing as the generator size increases, to 0.001 ohm L-N on HC 7.
Main Rotor resistance varies from 0.5 ohm on BC, but more typically 1.5 ohms on the
rest of range. Exciter Field windings are typically 20 ohms [unless series 5 then 140
ohms].
Exciter armature; very low 0.2 ohm phase to phase.
PMG stator; typically 5.0 ohms phase to phase.

Service Manual
Generator
Bearings;
Should never be re-used if removed.

Type used: Deep Groove Ball Bearing.
Most bearings used are double shield, considered ‘sealed for life’, as supplied by
the bearing manufacturer.
Older machines were supplied with open bearings, but these were housed within
a Newage sealed cartridge arrangement.
Bearing Grease information for machines employing the Newage cartridge
scheme.
HC Alternators < 1998 used lithium based Mobilux EP2 or Shell Alvania R3.
HC Alternators 1998 onwards and all CG Alternators use Kluber Asonic GHY
72.
IT IS MOST IMPORTANT THAT THE TWO TYPES OF GREASE ARE NOT

MIXED. ALWAYS CONTACT THE FACTORY WITH THE GENERATORS SERIAL
NUMBER FOR GUIDANCE REGARDING THE EXACT GREASE TYPE USED
DURING ORIGINAL MANUFACTURE.
Other things to consider.
Be ready to quote the generator’s Serial No’s to accurately identify exact build
and Year of Manufacture.
Check the content and process of our factory impregnation system to help with any
winding refurbishment, and then compatibility of any ‘overcoat’. The information
is within this document.
On reinstalling the alternator to any engine, the crankshaft end float must
be checked and the reading recorded on the relevant Service Sheet/CCAN
(See workshop manuals for engine manufacturing specifications). Contact
Technical Services if any Further guidance is required.
AVR’s
Standard connections…
Sensing is via terminals 6, 7, 8…
Power P2 P3, P4.
V. trim pot……connects to 1 & 2, 1k0 ohms for SX 460,SX 440, MX341 SA 465,
5k0 ohms for MX321 SX421
Quad-Droop CT always goes into W phase, and should be chosen to give a max
of 0.33A in secondary for rated max load. The secondary current will develop
a voltage across S1 – S2 of 10 x the rated secondary current, Example; 0.33A
equates to 3.3V across S1-S2.
Typical generator residual voltage is 10< 20% of rated output voltage.

Service Manual
Generator
13. Circuit Breaker Maintenance Procedure.
Before commencing with the below procedure a “Permit to Work” Ref

BOP/040 Section 7 MUST be raised and the necessary Isolations and
Precautions carried out as per the Permit.
1 Standard “B” Service
For Molded Casing Circuit Breakers:
• Check for obvious external damage to the Circuit Breaker.
• Remove the front cover and check all connections.
• All dust must be removed using a Clean, Soft and Dry Brush.
• Replace the front cover.
• Check the protection settings of the breaker are not exceeding the maximum
KVA rating of the alternator. (See Appendix: 1 of this document for Guidance)
For Air Circuit Breakers
• Check for obvious external damage to the Circuit Breaker.
• Rack out the Circuit Breaker – check that the shutters are closed (Where
applicable).
Before proceeding to the next step “Re-Prove the Bus Bar is Dead” as
per the Permit to Work
• Remove the Circuit Breaker from the chassis (Where applicable)

(WARNING: Use an Appropriate lifting Method)
• Check the inside of the chassis for cleanliness when the Circuit Breaker has
been removed, removing any dust and dirt that has accumulated.
• Manually open the shutters and check the clusters for signs of overheating.
• Remove the arc chutes; check the arc chutes and main contacts for signs of the
ACB having cleared a short circuit.
• Remove the front cover and check all connections.
• All dust must be removed using a Clean, Soft and Dry Brush.

Service Manual
Generator
• Review the Protection Settings:
PROJECT MAINTENANCE: Check the trip unit settings against the PDP /
Commissioning documentation.
DEPOT MAINTENANCE: Check the protection settings of the breaker are not
exceeding the maximum KVA rating of the alternator.
(See Appendix: 1 of this document for Guidance)
• Lubricate all chassis slides and Racking mechanism.
• Refit the Circuit Breaker (Where Applicable)

(WARNING: Use an Appropriate lifting Method)
• Prior to racking the Circuit Breaker back in ensure that the breaker is properly
located in the chassis.
Note: The use of excessive force while racking the Circuit Breaker back in will
result in damage to the chassis or racking mechanism!
2 Additional checks to be carried out ANNUALLY.
• Check the Busbar to ACB connections for tightness to the specified torque
figures.
• Check the trip units for correct operation against the published time/current
characteristics using the MG test kit.
• Check phase barrier location.
• Carry out an Insulation Resistance test between Phases to Earth on cable

terminations.
Any value below 1 Megohm should be investigated (without customers
cables connected).

Service Manual
Generator
Appendix: 1.
Example 1: 60kVA @ 415V- 50Hz
NS250 CB fitted with STR22SE Electronic trip unit.
I = 83.4A FLC x 120% O/L = 83.4 x 1.2 = 100A
Answer: In x Io x Ir =250x0.5x0.8 =100A
In =250A
Io =0.5
Ir = 0.8
Isd = 3
Example 2: NS400 CB Fitted with an STR23SE trip unit set with same
settings
Io = 0.5 and Ir = 0.8 ?
Answer: In x Io x Ir = 400 x 0.5 x 0.8 = 160 A.
Example 3: NS630 CB Fitted with an STR23SE trip unit set with same
settings
Answer: In x Io x Ir = 630 x 0.5 x 0.8 = 250 A.

Service Manual
Generator
Protection
Protection thresholds and delays are set using the
adjustment dials.
Overload protection
True rms long-time protection.
Thermal memory: thermal image before and after tripping.
Setting accuracy may be enhanced by limiting the setting
range using a different
long-time rating plug.
Overload protection can be cancelled using a specific LT
rating plug “Off ”.
Short-circuit protection
Short-time (rms) and instantaneous protection.
Selection of I2t type (ON or OFF) for short-time delay.
Earth-fault protection
Residual or source ground return earth fault protection.
Selection of I2t type (ON or OFF) for delay.
Residual earth-leakage protection (Vigi).
Operation without an external power supply.
Protected against nuisance tripping.
DC-component withstand class A up to 10 A.
Overload alarm
A red alarm LED goes on when the current exceeds the
long-time trip threshold.
“Ammeter” measurements
Micrologic A control units measure the true (rms) value of
currents.
A digital LCD screen continuously displays the most heavily
loaded phase (Imax) or displays the I1, I2, I3, IN, Ig,I n, stored-
current (maximeter) and setting values by successively
pressing the navigation button. The load on each phase is
indicated continuously by bargraphs.
The optional external power supply makes it possible to
display currents < 20% In.
Fault indications
LED’s indicate the type of fault:
b overload (long-time protection) or abnormal internal
temperature (Ir)
b short-circuit (short-time protection) or instantaneous (Isd)
b earth fault or earth leakage (Ig or I n)
b microprocessor malfunction (Ap).
Battery power
The fault indication LED’s remain on until the test/reset
button is pressed. Under normal operating conditions,
the battery supplying the LEDs has a service life of
approximately 10 years.
Test
A mini test kit or a portable test kit may be connected to
the test connector on the front to check circuit-breaker
operation. For Micrologic 6.0 A and 7.0 A control units, the
operation of earth-fault or earth-leakage protection can be
checked by pressing the test button located above the test
connector.

Service Manual
Generator
Example:
1250kVA @415V-50Hz
1740A FLC x 120% O/L = 2086A
In=2500A
2086 ÷ 2500= 0.83 Ir

Nearest Ir setting = 0.8
tr is @ 6 x Ir so the lowest
setting should be selected = 0.5

Service Manual
Generator
14. Cummins New Engine Inspection Procedure Guidance for

Aggreko Personnel
At the start of any project an approach Must be made to the Cummins Agent
who is responsible for the Area we are operating in to have these inspections
carried out.
This approach should be made by the person responsible for the project i.e.
O&M Manager, Project Manager Etc
If any assistance is required with this approach please contact T.S.S in

Jebel Ali.
This inspection when registered on the Cummins system kicks off our
Warranty Start Date.
• If the Cummins Agent attends site and completes the inspections a

copy of the original document MUST be:
Faxed to +97148834145
Or
Scanned and E-Mailed to Technical.Record@aggreko.ae
• If the Cummins Agent has not attended to these inspections within

2 days or 50 hours running from the initial commissioning of the
project please follow the procedure below:
• If there is No Cummins representation in the region, please carry

out the procedure below:
NEI Procedure
This document is to assist members of aggreko personnel who are required

to complete these New Engine Inspections in locations where there is No
Cummins Agent available or when the Cummins agent in country has not
attended our site within the agreed Time Frame.

Service Manual
Generator
Pre Run Inspection.
Record the following information before running the engine:
• Plant Number
• Engine Number
• Engine Type
• Fuel Pump Number
• Date of Commissioning (See Commissioning Documentation)
• SMR at Commissioning (See Commissioning Documentation)
The attached sample form explains where to insert the required information:
Check over the following items and tick the boxes where applicable:
Commissioning / Inspection
Run the engine up to rated speed and apply load in line with the site
requirements
Once rated temperature is achieved, check the following items and tick the
boxes where applicable:

Service Manual
Generator
Any Issues noted during the previous checks must be noted in the REMARKS
box.
With the Engine running on the Maximum site load, record the following details:
Tick off the remaining tick boxes as shown below:
Summary
Any Warranty Related Issues noted during this inspection Must be highlighted
to the Area Operations Manager or Project Manager for further action.
A copy of all completed New Engine Inspection forms MUST be delivered to the
Cummins Agent where applicable for their reference, this will give them a record
of what equipment we have operating in their region and allow them to make
sure there are spares available to cover any warranty issues we may have.
All completed New Engine Inspection forms must be sent to:
Technical.Records@aggreko.ae
All inspections received by Technical Record will be registered by

Cummins Dubai.
Having these unit registered is very important to allow us to track the warranty
through the life of the machine.

Service Manual
Generator
15. Engine Hot Shutdown Procedure (All Engines)
The following engine shutdown procedures must be adhered to at all times in

order to prevent premature failures. This allows gradual and uniform cooling down
of pistons, cylinder liners, bearings and turbocharger components.
Steps are as follows:
• Gradually decrease the kW load on the generator to a “no load” condition.
• Open the Main Circuit Breaker.
• Allow the engine to run for a minimum of 5 minutes to a maximum 15 minutes

unloaded.
• Monitor coolant temp gauge and ensure that there is a significant decrease in
coolant temperature as opposed to the full-load temperature.
• Once the coolant temperature has reduced and stabilized, turn off the engine.
Trip / Emergency Hot-Shutdown situations:
Assess the reason for the shutdown as soon as possible.
If the fault can be cleared immediately and is not being annunciated as an active
fault / oil pressure problem e.g. Over speed or Main Circuit Breaker opening,
the engine must be restarted immediately and run at no load in order to circulate
the coolant, which will prevent heat surges in the engine. Once the engine is
restarted, run with no load for 10 minutes, after which the generator can be put
back onto load.
If the engine cannot be restarted immediately due to an active fault shutdown, the
engine must be left to cool and dissipate the heat for at least 90 minutes. Once
the fault has been repaired “Barr the engine over 1 complete revolution” with
the barring tool to ensure that the engine turns freely and has not sustained any
seizure/bearing damage before attempting to start the engine.
Observe the engine and gauges for 10 minutes on load to ensure all is OK.

Service Manual
Generator
16. Cooling Testing Procedure

Service Manual
Generator
Testing Procedure:
FleetGuard DCA Test Kit must be used to test the cooling system for the required level
of Corrosion Inhibitor: (Cummins Engines Only)
x Allow the engine to cool down to room temperature before removing the radiator cap. As there
will be pressure in the cooling system and this could cause serious harm to the personnel
involved.
x Do not take coolant samples from the cooling system Top tank. All samples must be taken
direct from the cooling system i.e. Radiator Bottom tank or from the cylinder block of the
engine.
x To achieve the best results the coolant sample temperature must be between 10°c and 55°c
but room temperature is preferred before commencing with the test.
x Remove a test strip from the bottle without touching any of the three test pads as this will
affect the test results. Refit the cap to the bottle as moisture ingress can damage the strips. If
the Nitrite pad has turned brown the test strip can not be used and must be discarded.
x Place the test strip in the coolant sample for 1 second. Then remove test strip and shake to
remove any excess coolant.
x Wait 45 seconds to allow the test pads to change colour. Then compare the pads to the colour
charts (As Below) on the fleetguard bottle in the following order.
(a) The Lower End Pad relates to the Freezepoint colour chart on
the side of the bottle.
(b) The Middle Pad relates to the Molybdate colour chart on the
left hand side of the SCA chart (As Below).
(c) The Top Pad relates to the Nitrite colour chart on the bottom
of the SCA chart.
x All test pads must be compared to the colour charts no longer then 75 seconds after dipping
the strips. It is recommended to use a stopwatch for the best results.

Service Manual
Generator
x If a colour does not match the colour on the chart completely it is best to use the lower value
as underestimating is safer then overestimating the coolant levels.
x Using the SCA colour charts select the colour that matches the test pad for Molybdate and
Nitrite. Then find where both columns intersect and this will give you the SCA units per litre in
the cooling system. See the example below.
SCA Treatment Guidelines:
Refer to the Specific Engines O&M manual for the recommended levels of SCA per Ltr
of Coolant
x SCA below 0.3 units per litre
Add 473ml of DCA4 per 15 litres of coolant to maintain the desired level of protection.
x SCA 0.3 to 0.8 units per litre

Add SCA service dose at each Service interval to maintain the desired level of
protection.
x SCA above 0.8 units per litre

Do not add any DCA4 unit the coolant levels drop below 0.8 units per litre. Test
coolant at every Service interval.

Service Manual
Generator
Refractometer Instructions for measuring the Freeze/Boiling Protection Levels
(A) (B) (C) (D)
(A) (B) (C) (D)
(A) Eyepiece (Focus)

(B) Adjustment screw
(C) Cover Plate
(D) Lenses
x Before commencing with the test, check the Refractometer is adjusted correctly by placing one
to two drops of distilled water on the lenses. Close the cover plate and place refractometer to
your eye. The light/dark boundary line should line up with the waterline (zero). If not adjust
the screw on top of the refractometer until the lines meet.
x Clean the lenses with a soft cloth as any water on the lenses will affect the results of the test.
will be pressure in the cooling system and this could cause serous harm to the personnel
involved.
direct from the cooling system i.e. Radiator Bottom tank or the cylinder block of the engine.
x The temperature of the coolant is a very important part of obtaining the correct reading. The
coolant temperature must be between 10°c to 30°c before the coolant is placed on the lenses.

Service Manual
Generator
x Place 2 to 3 drops of coolant on the lenses and close the cover plate making sure that coolant
spreads evenly across the entire lenses surface. (As Below)
Lenses cover example
x Put the refractometer up to your eye and looking to a light source you should see a shadow
line across the scale this line will indicate the freezing point of the coolant. If the scale is out of
focus the eye piece can be adjusted by rotating it in ether direction. (As shown in the Scale
below)
x Prior to taking the reading it is important to establish which coolant is actually in the cooling
system, there are two types of Antifreeze available; Propylene Glycol and Ethylene Glycol as
these product have different properties there are slight differences in their performance.
x The desired antifreeze must be mixed at 50/50 ratio with good quality water. The 50/50
mixture gives a -36°c freezing point and a 110°c boiling point (Ethylene Glycol only).
x The antifreeze must be within the working range of 40% to 60% if not the levels must be
adjusted using the required specification of coolant. (See charts below for antifreeze
percentage to freezing point and boiling point)

Service Manual
Generator

Service Manual
Generator
Antifreeze % to Freezing point
Antifreeze % to Boiling point

Service Manual
Generator
PH Meter Instructions to measure the Acidic/Alkali Levels in the coolant
(A) (B) (C)

(A) Electrode
(B) pH display
(C) ON/OFF switch
Pre Test Set Up
x Before commencing with the test, check that the Ph Meter has been correctly adjusted; if the
unit is Brand New it will come with a set up certificate in the box to show it has been set up by
the manufacturer.
x If it is suspected the unit has not come pre set up, remove the protective cap and place the
meter in HI70300 storage solution for 2 hours to activate the electrode.
x To calibrate the pH meter place the electrode in pH 7.01 (hI7007) solution.
x Allow the pH reading on the display to stabilize then adjust the pH7 screw on the side of the
meter shown below in the picture. Set the meter to “7.0” pH. ( As Shown Below)
x Remove the meter from the pH 7.01 solution and wash it with tap water. Now place the pH
meter in pH 4.01 (HI7004) if measuring acidic and pH 10.01 (HI7010) for alkaline.
x Allow the pH reading on the display to stabilize then adjust the pH 4/10 screw on the side of
the meter (As Shown Below)
x Set the meter to “4.0” pH or “10.0” pH depending on the solution used.

Service Manual
Generator
PH Meter: Rear view
(A) (B) (C)

(A) pH 7.01 adjusting screw
(B) pH 4/10 adjusting screw
(C) Max level line
Test Procedure:
will be pressure in the cooling system and this could cause serous harm to the personnel
involved.
direct from the cooling system i.e. Radiator Bottom tank or the cylinder block of the engine.
x The temperature of the coolant is a very important part of obtaining the correct reading. The
coolant temperature must be between 10°c to 30°c before the test can be conducted.
x Remove the protective cap from the meter. Turn the switch on top of the pH meter to the on
position.
x Place the electrode in the test sample no higher then the line marked on the back side of the
pH meter shown in the picture above.
x Stir the pH meter slowly in the test sample and wait for the pH reading to stabilize. Record
your reading on the service sheet.
x After you have recoded the reading switch the meter off and wash it with tap water. Then
place a few drops of storage HI70300 or pH7 HI7007 solution in the protective cap and fit it to
the pH meter. Do not use Distilled or Deionized water for storage.
x The electrode must be keep moist at all times so it is recommended that a wet tissue is placed
inside the protective cap for storage.

Diesel Generator
Section 5
FORMS
Revision April 2008

Service Manual
Generator
FORMS
Table of Contents
1. Combined Service / CCAN report.
2. Service / CCAN report log for Electronic reporting
3. Wear check Sample Form
4. Oil Sample Spread sheet
5. Wear Check Feed Back Form
6. Oil Consumption Spread sheet
7. TBN Tests Details sheet
8. Service Sticker
9. Component Failure Report
10. Component Failure Report Log
11. Failed Component Tag
12. Failed Component Warranty Tag
13. On site Health check Form (QSK Engines) & Exhaust

Tempearatures Test Sheet
14. On site Health check Form (KTA Engines) & Exhaust

Tempearatures Test Sheet
15. Fleet Acceptance Form
16. Third Party Supply Acceptance Record
17. Cummins NEI form
18. Equipment Damage Report
19. Fuel Tank Cleaning Sticker

Service Manual
Generator
FORMS
Table of Contents
AME Forms
1. Service Report Generator
2. Depot Checklist and Load test Sheet
3. Service Report Generator Shipping Hire
4. Component Change Advice Note (CCAN)
5. Service / CCAN report log
6. Service Sticker Container English
7. Service Sticker Container Arabic
8. Installation and Commissioning Report
9. Green and Red Cards Generator
10. Maintenance Record Card

Diesel Generator
Technical Documentation &

Warranty Procedures
Revision April 2008
Prepared By Jethesh Aranha

Service Manual
Generator
Technical Documentation &

Warranty Procedures
TABLE OF CONTENTS
WORK INSTRUCTIONS
1. Introduction
2. Objective
3. Benefit
REPORTING PROCEDURES.
4. Component Changes
5. M06 / M07 Modifications
6. ‘A’ Service, ‘B’ Service, Health Checks
7. Warranty Claims.
8. New Engine Inspection & New Feet Acceptance Form
9. Procedures for Electronic Reporting
10. Supplier Warranty Terms.

Service Manual
Generator
1. INTRODUCTION.
The purpose of this instruction is to outline the requirements needed to report A & B
Services, Break Downs, Component Changes & Warranty Claims relating to Aggreko
equipment whether on site or in a depot and how the reports will be followed up by
Aggreko International Technical Services.
2. OBJECTIVE.
To identify and record failures and potential failures associated with Aggreko products
throughout their working lives by recording Component Changes and the reasons for
change in order to:
• Highlight premature component failures and thus have a concerted effort to

improve on Warranty Claim issues with component manufacturers.
• Highlight product design failures and thus have the ability to make changes at the
design stage that will reduce the lifetime costs associated with our product.
• Ensure that identified failures and potential failures are rectified in a logical and
timely manner.
• Provide records for audit and to allow analysis.
3. BENEFIT.
Central analysis of product failure will enable Identification/Rectification in other regions

before failure occurs reducing down time, costs and maximizing product utilization.
Product improvement will be centrally focused ensuring product design is tailored to

our business needs.
This instruction will cover all Aggreko products. It shall be followed at all times.

Service Manual
Generator
4. COMPONENT FAILURE REPORTING
Component change will be notified to the Technical Services department on

Component Change Advice Note Section of the “Service / CCAN” format for
Generators & “CCAN” format for Transformers, Load banks, Switch Gears, TC
equipments etc.
(Format Templates are in the FORMS Section of this Manual)
Reports are to be sent Technical Services, Jebel Ali or emailed to
Technical.Records@aggreko.ae
Indicate what component was changed and reason for change by completing the
relevant sections of the form. All fields must be completed and replacement and
original part serial numbers recorded. Failure analysis MUST be done, it is not
acceptable to simply write ’Failed’, a valid reason must be sought
Failed components shall be ‘Red’ tagged with plant number, hour meter reading,
date, component change advice number and engineer’s signature. The tagged
failed component shall be held in a quarantine area until further instruction from
Technical Services. Location Managers shall advise cost of returning unit to Jebel
Ali. If the failed component is under warranty, it is to be ‘Blue’ tagged and refer
Warranty Section for warranty process.
Technical Services department shall analyze the failures reported to determine if

there is common pattern which could affect the fleet in general
5. M06 / M07 SERVICE BULLETINS
Remedial action will be notified to Depots/ Operating sites in one of two methods,
either as:
M06 or M07 bulletin from Aggreko Manufacturing.
Service bulletin or directive from Aggreko International Technical Services.
On receipt of either of above the Depot/ Operating site shall ensure that the
scope detailed in the bulletin is carried out within the shortest reasonable time.
Whereupon remedial action has taken place the Depot/ Operating site shall inform
the Technical Services department by completing and returning a “Component
Change Advice Note’’, indicating that work carried out was under a M06/ Service
bulletin by specifying the M06 bulletin number.
Technical Services will, where necessary, take up Warranty issues with

manufacturer or advise Depot/ Operating site on course of action to take.
Product improvement/suggestions and risks can be notified to through the

“Continual Innovation Program” (CIP). In the case of risk, the CIP form should be
faxed immediately to Jebel Ali marked for the attention of the QHSE Manager.

Service Manual
Generator
On receiving a “CIP” relating to product, the Product Manager shall determine

the course of action. Where a risk has been highlighted, the Technical Director
shall issue a warning notice to all Operations Managers detailing risk and what
course of action to take. It is the Operations Manager’s responsibility to ensure
all staff under their control are informed of such risk. If it is deemed necessary
the Technical Director may issue a request for further information surrounding a
failure/ risk. This should be returned as soon as reasonably possible, taking into
consideration the location of the failure/ risk.
The risk will be investigated and a response shall be given within 7 working
days.
Whereupon remedial action is necessary it will be notified and followed up as per

items 3.4 to 3.6.
Under no circumstances shall modifications or unauthorized repairs be carried

out without the permission of the Technical Director or a designated member of
Technical Services.
6. MAINTENANCE REPORTING.
AI Projects to use Electronic Service Reporting using Excel Templates & Follow
the guide lines given in Templates.
Maintain Log of the all reports in Excel sheet as per the guide lines given in
Excel Templates.
Sent all maintenance Reports & Log Sheets to Technical Services, Jebel Ali or
Email to Technical.Records@aggreko.ae on a weekly basis
7. WARRANTY CLAIM REPORTING
Follow the warranty claim process as shown on Warranty Process Flow Chart.
Report all warranty claims through Component Failure Report Forms.
Maintain Component Failure Report Log to follow up on claims & close out claims
once done.
Email Component Failure Report Form Complete with digital photographs of the
failed component to Technical.Records@aggreko.ae
Under Warranty failed components are to be tagged with ‘Blue’ Tags and kept in
quaratine area till the claims are closed.
Refer DEIF warranty bulletin in Technical DVD for GEMPAC warranty failures
Refer Newage warranty bulletin in Technical DVD for AVR warranty failures

BREAK DOWN OCCURS

NO IDENTIFY YES / in Doubt Warranty Process Chart
WARRANTY
Inform / Contact
T.S, JA
Test Reports /
Warranty Claim
Investigate Cause Photos / Failure
CFR Log
Form// Log
& Prepare Report Analysis
Carry out Repair CCAN
Warranty
YES Support Available NO
through Local
NO Is Failed Agent
YES
Component
Reparable

Arrange for Repair Get it repaired and Can Repair
YES NO
DISCARD if Economical Close the Claim be Carried out
at Site ?
Repair & Record

CCAN Labor / Parts / OEM
Invoice / Photograph / NO Requesting Return YES
Test Reports Failed Comp for
Inspection
LOCAL OEM / JA
VENDOR
AOM / SM arrange
CLAIM return / inspection
CLOSED
Forward all
documents to TS,
NO YES OEM NO
NO Warranty YES YES Warranty JA
accepts warranty
Given Given from evidence
NO OEM accept YES
Generator
Warranty
NO YES
Repair & Agreed Period Dispute
Repair & TS Takes up
Return to with Vendor Return to Warranty with
Stock Stock OEM
CLAIM
CLOSED
CLAIM Repair & Return CLAIM
CLOSED to Stock CLOSED Rejected Claim Approved
approved /
Rejected
Replacement Receives Credit Notes

Replacement or
Update Warranty
Credit Notes
Log Update Warranty
Page No.144
Claim Log
Received at Credit Note received
Stores / taken to at Accounts Dept
Stores Stock & Credit the Project /
Credit the Project / Depot
Depot
CLAIM Inform TS
Inform CLOSED
TS
Update Warranty
Log
END
CLAIM
CLOSED
April 2008
Service Manual
Service Manual
Generator
8. NEW ENGINE INSPECTION & NEW FEET ACCEPTANCE FORM
CUMMINS :
All brand new Fleets and New Engines replaced are to have New Engine Inspection
(NEI) carried out by Cummins Dealer if available or complete by Aggreko as
required.
Send copies of NEI report to Technical.Records@aggreko.ae
Follow the procedures outlined in Work Instruction Section3, Appendix3, item 15

- Cummins New Engine Inspection Procedure
9. PROCEDURE FOR ELECTRONIC REPORTING
• A & B SERVICE ,
• COMPONENT CHANGES,
• HEALTH CHECKS &
• COMPONENT FAILURE REPORTS
- Use the Electronic Formats designed in Excel by Technical Services,
- Start a new serial number (001) for these electronic reports & continue this serial
unitl the project is completed.
- Electronic reports excel files are to be named as -
Repot No.,Fleet No.,Type of Service,Location
Example - 1,XAAB200,A,Uganda
2,XAAB375,B,Singapore,
3,XALW020,CCAN,Tanzania
4,CFR XAAB612,Cyl Head failure
- Maintain log sheet for Service/CCAN reports to Track Serial number of Reports.
- Keep log sheet for Warranty claims (Component Failure Reports) to track Serial
no. of reports & progress on claims
- Email the Reports and Log sheets to Technical.Records@aggreko.ae on a weekly
basis.
- Keep a print copy of these reports in Fleet file and another copy in Project office
file
- For any clarification please contact Technical.Records@aggreko.ae
Note : -
See the FORMS Section for all Forms Templates.
Contact Technical.Records@aggreko.ae for any clarification

Service Manual
Generator
10. SUPPLIER WARRANTY TERMS
MAJOR
COMPONENTS
COMPONENTS WARRANTY PERIOD
EXTENDED
WARRANTY
CUMMINS
24 Months & Unlimited Hours from NEI /
ENGINE ASSEMBLY
PDI Date
Engine Cylinder 24 Months & Unlimited Hours from NEI / 36 Months or
Block PDI Date 10,000 Hrs
24 Months & Unlimited Hours from NEI / 36 Months or
CRANK SHAFT
PDI Date 10,000 Hrs
24 Months & Unlimited Hours from NEI / 36 Months or
CAM SHAFT
PDI Date 10,000 Hrs
CONNECTING 24 Months & Unlimited Hours from NEI / 36 Months or
RODS PDI Date 10,000 Hrs

DC ALTERNATOR
PDI Date
TURBO CHARGER
PDI Date
STARTER MOTOR
PDI Date
ECM
PDI Date
INJECTORS
PDI Date
FUEL PUMP
PDI Date
WATER PUMP
PDI Date
CUMMINS
24 Months/2000
REPLACEMENT 12 Months
hrs of operation
SPARES

Service Manual
Generator
SCANIA
ENGINE 12 Months from Start Up /
ASSEMBLY Commissioning date
SCANIA TWO YEAR WARRANTY

ENGINES DC 12 ESN – 6513878
– DC 12 & DC 16 Onwards
Delivered after 1st DC 16 ESN – 1042011
April 2006, Onwards
24 Months or 12000 Hrs – 100%

Coverage
Cylinder Block 12 Months from Start Up / 36 Months or 12000 Hrs – 75%
Casting Commissioning date Coverage
48 Months or 12000 Hrs – 50%
Coverage
24 Months or 12000 Hrs – 100%
12 Months from Start Up / Coverage
Cylinder Heads
Commissioning date 36 Months or 12000 Hrs – 50%
Coverage
24 Months or 12000 Hrs – 100%
Coverage
Crank Shaft & 12 Months from Start Up / 36 Months or 12000 Hrs – 75%
Connecting Rods Commissioning date Coverage
48 Months or 12000 Hrs – 50%
Coverage
12 Months from Start Up /
DC Alternator
Commissioning date
Starter Motor - Commissioning date, Can
Bosch also be taken up with local
Bosh representative
Commissioning date, Can
Fuel Pump - Bosh
also be taken up with local
Bosh representative

Service Manual
Generator
IVECO
ENGINE ASSEMBLY 12 Months from PRA / Build Date
Engine Block 12 Months from PRA / Build Date 24 Months

Crank Shaft 12 Months from PRA / Build Date 24 Months
Bosh Electronic
12 Months from PRA / Build Date
Modules
FG WILSON
GENERATOR
(Engine & Alternator 12 Months from Date of Delivery
Assembly)
NEWAGE
ALTERNATOR 30 months from PRA / Build Date or 24

ASSEMBLY months from date of first commissioning
30 months from PRA / Build Date or 24

A.V.R
months from date of first commissioning
Power Factor 30 months from PRA / Build Date or 24

Controller (PFC) months from date of first commissioning
PMG
Main Stator
Main Rotor
EXCITOR ASSEMBLY
Excitation Loss 30 months from PRA / Build Date or 24
Module (ELM) months from date of first commissioning
RECTIFIER 30 months from PRA / Build Date or 24
ASSEMBLY months from date of first commissioning

Service Manual
Generator
MERLIN GERIN
24 Months from date of manufacture

MAIN CIRCUIT
or 12 month from date of Purchase
BREAKER
whichever is greater.
DEIF
24 Months for
GEMPAC 24 Months from the date of delivery the repaired item/
component
DEEP SEA
ELECTRONICS
CONTROL MODULE
24 Months from In Service Date
P2002 / P522 / 5310
RADIATOR - 18 months from dispatch from Bearward

Bearward or 12 months from PRA Date / In Service
18 months from the date of dispatch
RADIATOR - Covard from CovRad
(12 Month from PRA Date / In Service)
RADIATOR - Nissens 12 Months from PRA Date / In Service
FLAKT WOODS
24 months from dispatch / Supplier
RADIATOR FAN
Invoice date
RADIATOR FAN 24 months from dispatch / Supplier
MOTOR Invoice date
ENGINE SPACE FAN 24 months from dispatch / Supplier
(ESF) Invoice date
ENGINE SPACE FAN 24 months from dispatch / Supplier
MOTOR Invoice date
SILENCER – 12 Months from Dispatch / Supplier

Bradgate IMS Invoice date
SILENCER – 12 Months from Dispatch / Supplier
Discom B.V Invoice date

Service Manual
TRANSFORMER
HV / LV TRANSFORMERS
Revision April 2008
Prepared By Kobie Botha

Page No.1
Blank Page
Page No.2
Transformer Service Manual
TRANSFORMER
LV & HV TRANSFORMER
Table of Contents
WORK INSTRUCTIONS
1. Preventive Maintenance – LV & HV Transformers
2. “A” Service Standards Where Shutdown is Not Possible
3. “A” Service Standards For Low Voltage (Dry Type) Transformers
4. “A” Service Standards For High Voltage Transformers.
5. “B” Service Standards For High Voltage Transformers

Blank Page
Page No.4
LV & HV TRANSFORMER
1. Preventive Maintenance – LV & HV Transformers

• All transformers are to be “A” serviced on return from all hires.
• The service standards for “A” services are detailed on the following pages for
Low Voltage 220-400-600V and High Voltage 400-15kV, 400-22kV transformers.
Wherever possible these services should be carried out in depot. However, for
long-term hires, where a shutdown is possible they should be carried out every 3
months. Where a shutdown is not possible the Area Operations Manager must be
informed and the ‘A’ service standard detailed in section 2 must be carried out. A
planned shut down should be arranged with the client to carry out a full ‘A’ Service
within the next 3 month period. Service Sticker to be affixed on the transformer
panel (switch gear area) to indicate “A” Service status.
• All appropriate precautions shall be taken to ensure that transformer has been
made DEAD before carrying out “A” service following standard Lockout and Permit
to Work Procedure.(Ref:-BOP 040)
• Only engineers who have been trained and are AAP 1,2 & 3 certified shall be
permitted to carry out “A”&”B” services on LV & MV transformers.
• All Transformers are to be “B” serviced every 12 months. If transformer is on site

for more than 12 months and a shutdown is not possible then “B”service may be
delayed (up to a maximum of 6 months) with the approval of the Area Operations
Manager in conjunction with PRODUCT MANAGER until transformer is returned
to Base or a planned shut down can be arranged with the client. Service Sticker
to be affixed on the transformer panel to indicate the service status.
• Note: Safety guidance notes as referred to in BOP/40 shall be complied with at all
times. If in doubt please contact Technical Services/Engineering group.
• In case of hermetically sealed transformers (e.g.Aggreko 3.15 MVA), oil sampling

and BDV (Break down Voltage) tests shall be carried out ONLY at Base whenever
a major repair or service is due (this is to avoid testing of oil at site which is an
uncontrolled condition / environment that leads to oil degradation and spillage.
2. “A” SERVICE STANDARDS WHERE SHUTDOWN IS NOT

POSSIBLE
2.1 Check the transformer terminal connections, tank bottom and tank top with an
infrared thermometer looking for any hot spots in both HV and LV connections. If
necessary reduce the load to prevent situation from becoming worse and report
to Area Operations Manager. (Temperatures must not exceed 100°C)

2.2 Check oil level in sight glass and in the DGPT is in line with the Manufacturer`s
instructions and oil is transparent
2.3 Check the SF6 gas indication on circuit breaker shows “Green” always.
2. Monitor oil temperature at temperature gauge.(Alarm = 85° and Trip = 100°)
2.5 Advise Area Operations Manager of any discrepancies, who must then advise
further action to take.
2.6 Visually check LV terminals in circuit breakers and contactors for signs of
corrosion.
2.7 All above checks to be recorded using Transformer Service Reports (A Service
2.9kV – 20kV Transformer General Checks)
3. “A” SERVICE STANDARDS FOR LOW VOLTAGE

TRANSFORMERS
• Before commencing any work ensure transformer is DEAD and that all necessary
precautions have been taken to prevent transformer from becoming LIVE by
following Aggreko BOP.
• Discharge the transformer to earth before starting work.
• Review previous service report for any breakdowns / problems with transformer
3.1 Check link arrangement is suitable to current application (dry type only)
3.2 Check unused links are fitted at storage point (dry type only)
3.3 Check all connections for tightness
3.4 On dry type Transformers visually check winding core for damage / signs of stress
and/or burning.
3.5 Visually check container for damage
3.6 Check main connections have been fitted with nuts/bolts/washers
3.7 Check for any oil leaks
3.8 Check oil level of the transformer, at DGPT. Check physical condition of oil, it
should be transparent
3.9 Check the isolator operation on 400/600v side, where applicable check for any

discoloration of leads at the isolator end
3.10 Visually check that there are no cracks on the transformer tapping, terminals
3.11 Clean transformer and container
3.12 Check fan motors, bearings. Power up and check running current and rotation
3.13 Complete checklist
3.14 Green card transformer if all above is OK
4. “A” SERVICE STANDARDS FOR 6.3MVA / 5MVA CONTAINERISED

TRANSFORMERS.
following standard Lockout and Permit to Work Procedure.
• Review previous service report for any breakdowns / problems with transformer.
4.1 BOP/040 shall be complied with at all times.
4.2 Check all door seals, bund wall, locks, roof hatch seals and hinges are fully
operational.
4.3 Carry out visual inspection of the transformer container to establish the extent of
any damage due to transport or deterioration through age.
4.4 Ensure all restraining bolts are intact and correctly fitted.
4.5 Check oil level in DGPT and sight glass for both left and right hand
transformers.
4.6 Check for any oil leaks from transformer bushings, tank, drain valves, cooling fins
and DGPT unit.
4.7 Check insulators for signs of cracking, damage, tightness and clean with dry
solvent.
4.8 Inspect HV compartment. Clean the dirt /dust from switchgear, slipover
terminations, voltage transformers and insulators.
4.9 Check LV copper bus-bars are fitted with full complement of bolts/ nut/ washers
(M12 x 50)

4.10 Check LV connections from transformer to isolator are sound
4.11 Check mini circuit breakers at voltage transformer and the fan control supply
behind or above the doors are in good conditions.
4.12 Check circuit breaker operating handle is in good condition and is stored in
correct place.
4.13 Check operation of switchgear and isolators.(Open - Close - Open)
4.14 Visually check Fan motor bearings.
4.15 Record No Load currents before loading transformer including input voltage on
Transformer Service Report
4.16 After powering up the transformer check operation of fan motors and running
current using a Clampmeter in the Control panel wiring.
4.17 Check all container lighting and auxiliary electrical circuits are intact and
operational.
4.18 Check and ensure the battery charger voltage set to 27 volts and under voltage
level set to 18 volts.
4.19 Check all safety stickers are in place.
4.20 Check HV rubber gloves are in good condition supplied with talc powder and in
place.
4.21 Ensure all paint work is in good condition.
4.22 Prove that the protection relay trips the circuit breaker. (Refer to manufacturers
instructions for test procedure).
4.23 Complete service report and apply a service sticker on inside door to each
transformer. Green carding is applicable to depots and JA yard only.
Note:
Transformer Voltage taps and Relay settings should be confirmed with settings
in project design pack to ensure they meet the requirements of the intended
application.

5. “B” SERVICE STANDARDS FOR 6.3MVA / 5MVA CONTAINERISED

TRANSFORMERS
following standard Lockout and Permit to Work Procedure.
• Review previous service report for any breakdowns / problems with transformer.
5.1 BOP/040 shall be complied with at all times.
5.2 Check operation of DGPT (Alarm=85°, Trip=100°, Pressure setting 0.2bar. Refer
to manufacturer’s instructions for this procedure).
5.3 Check and record relay settings. Compare with commissioning documents
5.4 Check test function of relay trip (refer to manufacturers instructions).
5.5 Prove that the protection relay trips the circuit breakers.
5.6 Prove operation of Transformer to genset intertripping, if fitted.
5.7 Conduct insulation resistance test of HV and LV windings to earth and compare
with previous results. Record on test sheet.
5.8 Check and confirm the settings of CT and VT ratio in UPM 3000/MIQ96
5.9 Carry out all items as required by ‘A’ Service..
5.10 Complete service report and apply a service sticker on inside door to each
transformer. Green carding is applicable to depots and JA yard only.
5.8 Record No Load currents before loading transformer including input voltage
5.11 Oil samples will only be taken in Jebel Ali.

Blank Page
Page No.10
TRANSFORMER
11/33/66kV TRANSFORMER
Table of Contents
WORK INSTRUCTIONS
1. Service Intervals for 11/33/66kV Transformer.
2. Regular checks on 11/33/66kV transformers that are in service.
3. Tests to be done every Six months.
4. Tests to be done on a Yearly Basis
5. Storage Of Transformer Oil
6. Service Standards Where Shutdown is Not Possible
7. Oil Sampling Procedure.

Blank Page
Page No.12
11/33/66kV TRANSFORMER
1. Service intervals for11/33/66kV Voltage Transformers
1.1 All 11/33/66kV transformers are to be serviced on return from all hires.
1.2 The service standards for “6.6/11/33/66kV”Transformers are detailed on the

following pages.
1.3 Wherever possible these standards should be carried out in Base. However for
long-term hires where a shutdown is possible, they must be carried out every
12 months. If a shutdown is not possible within the 12 months then the Area
Operations Manager must be informed, who may then depending on contract
duration request a planned shutdown with the client.
1.4 All appropriate precautions shall be taken to ensure that transformer has been
made DEAD before carrying out service following standard Lockout and Permit to
Work Procedure.(Ref: - BOP 040)
1.5 Only engineers who have been trained to APP1 or 2 shall be permitted to carry
out services on “6.6/11/33/66kV”HV transformers. If AAp2 engineer is not familiar
with the servicing of HV transformer, he must contact SFSM for further advice.
1.6 Note: Safety guidance notes as referred to in BOP/040 shall be complied with at
all times.If in doubt please contact Technical Services/Engineering group.
2. Regular checks on High Voltage transformers that are in service.
2.1 The following checks should be carried out on a minimum of weekly basis:
2.2 The oil and winding temperatures should be checked on an hourly basis, Especially
when the transformer is heavily loaded (full load >90%).
• Oil Temperature settings: Alarm 85°C and Trip 105°C
• Winding Temperature settings: Alarm 105°C and Trip 115°C
The OT and WT indicators are mounted on the transformer or in the control

cubicle. There are two settings on the OT and WT indicators, an alarm and a trip
setting. Additional settings on the WTI are used to start the cooling fans and oil
pumps on some of the transformers.
2.3 Operation of the Cooling fans and oil pump where fitted, the fans and pumps are
controlled by temperature and will be switched off if the temperature is below 30
– 40°C.
2.4 Visual Check for gas in the Buchholz (gas) relay.

2.5 Check the condition of the Breather, the colour of the silica gel should be blue; in
the new type breathers the colour of dry silica gel is orange. The silica gel must
be replaced if colour changes from blue to pink or from orange to green.
2.6 Check the oil level on the side of the conservator tank. The level should be in the
middle of the gauge.
2.7 Check for any oil leaks.
2.8 Inspect cables for damage.
3. Tests to be done every Six months.
3.1 An oil sample of at least 500ml in a clean glass bottle must be taken and test the
dielectric strength.
3.2 An oil sample will be sent for dissolved gas analysis (DGA) and water content
only if the dielectric strength test fails. (See Oil sampling procedure in Section 7
of this document)
4. Tests to be done on a Yearly Basis

Note:- Test will be carried out by Specialist Support Group due to the Test
equipment required
4.1 Winding resistance
4.2 TTR (Ratio test)
4.3 PI Test – Megger test 1 minute and 10 minutes
4.4 HV Pressure test
4.5 Oil Analysis –oil sample to be sent to a lab.
4.6 Oil dielectric test, a Breakdown voltage should be higher than 30kV at 2.5mm.
4.7 Check oil and winding indicators
4.8 Check gas relay (buchholz).
4.9 Transformer test results to be logged on the test sheet and sent to Jebel Ali
Product records department and compared with previous results.

5. Storage of Transformer Insulating oil.
5.1 The oil drums should be stored lying down with the filling plugs horizontal to the
ground. The oil drums must NOT BE STORED UPRIGHT; this is to prevent any
moisture from entering through the filling plugs. These oil drums should be stored
indoors if possible.
5.2 Oil samples must be taken from each drum and dielectric test done prior to filling
the transformer with the oil from the drums.
5.3 Note:- Guidance on typical specification EN/BS -EN IEC 60296/BS 148.
6. Service Standards Where Shutdown is not Possible
6.1 Periodically reactivate or change silica gel provided in the breather. This can be
done with the transformer on load.
6.2 Check for any oil leakage.
6.3 Monitor oil & winding temperature.
6.4 Visual inspection of terminations for wear and damage.
6.5 Check oil levels.
6.6 Do dielectric strength test every six months.

7. Oil Sampling Procedure
7.1 Purpose:
• The purpose of oil sampling is to determine the condition of the oil in the
transformer, to build a database on the history of each transformer and to set a
standard of how it should be done.
7.2 Method:
• The oil sample of a transformer with a conservator tank must be taken from the
bottom valve of the transformer tank. The flange cover must be removed on
the sample valve, the valve must be cleaned before taking any sample. Sealed
transformers (transformers fitted in containers),need special tool for oil samples.
Drain at least 100ml into a clean dry glass or hard plastic sample container, rinse
the container with the oil and discard the oil in a safe manner, take a sample of
at least 500ml and seal the container with an air tight lid. Prolonged exposure to
direct sunlight should be avoided.
• After obtaining an oil sample, the valve should be tightened and the cover should
be fitted on the flange, care should be taken that no oil leaks from the valve and
that any spillage should be cleaned.
• Inspect the oil level of the transformer at the level indicator either at the
conservator tank or at the level indicator on top of the transformer. Topping up
of the transformer should only be done with new clean moisture free oil and is
done by filling the conservator or filling at the DGPT unit on sealed transformers
to the required level. Record the transformer details (Serial no and type)on the
container and the date when the sample was taken. The sample must be sent for
analysis.
• The results of the oil sample must be recorded in the commissioning document
before putting a transformer in service. Oil samples should be taken at least every
six months after date of commissioning due to the age and the high temperatures
of these transformers.
• All container-mounted transformers need to have their oil tested, topped up and
results recorded prior to being shipped out on a new project. The HV transformers
will have their tests done on site after erection of the transformer.

TRANSFORMER
FORMS
Table of Contents
FORMS
1. “A & B” Service Report for 2.9-20kV Transformer
2. “A & B” Service Report HV Transformer > 20kV
3. Green and Red Cards
4. Service Sticker
6. 11/33/66kV Transformer Test Report

Blank Page
Service Manual
LOADBANKS
Revision March 2007
Prepared By Gordon Slater

Loadbanks Service Manual
LOADBANKS
Table of Contents
COMMON WORK INSTRUCTIONS
1. Preventive Maintenance - Load banks
2. “A” Service Procedures For Standard Controlled Load banks
3. “A” Service Procedures For Computer Controlled Load banks
4. “B” Service Procedures For Standard Controlled Load Banks
5. “B” Service Procedures For Computer Controlled Load Banks
FORMS
1. Load bank “A & B” Service Report
2. Green and Red Cards
3. Installation & Commissioning Report
4. Load bank Safety Sticker (English Version)
5. Load bank Test Report
7. Service / CCAN Log.
Aggreko International Technical Services Page No.3 March 2007

1. Preventive Maintenance – Loadbanks
Service intervals for loadbanks
1.1 All loadbanks are to be “A” serviced on return from all hires.
1.2 The comment box on the Red Card is to be used for entering details of all loadbank
ancillary items returned with the loadbank i.e. controllers, control leads & H.V.
monitor etc.
1.3 The service standards for “A” services are detailed on the following pages for
all Aggreko computer controlled (IHT & laptop) and standard loadbanks. Due
to the nature of loadbank business it is assumed that the service will be carried
out in depot. On long-term hires they can be carried out at the customer’s site at
intervals of 3 months.
1.4 All load banks are to be “B” serviced every 12 months.
1.5 The service standards for “B” services are detailed on the following pages for all
ggreko computer controlled (IHT & laptop) and standard loadbanks.
1.6 The “B” service requires specialized instruments so shall be carried out in
depot.
1.7 Where applicable, these procedures should be read in conjunction with the
relevant transformer work instructions.

2. “A” SERVICE PROCEDURES FOR STANDARD LOADBANKS
2.1. Review the previous Service reports for any breakdowns/problems with
loadbank.
2.2. Ensure loadbank is isolated from all electrical supplies.
2.3. Check all door and panel seals, locks (keys to be fastened to lock using strong
cable tie) and hinges are sound and fully operational.
2.4. Carry out visual inspection of the loadbank to establish the extent of any physical
damage due to transport or deterioration through age.
2.5. Check all load step main electrical connections for tightness.
2.6. Remove all load step contactor flash shields and check condition of contacts.
Clean/Replace where necessary.
2.7. Visually check all load step resistors for stress.
2.8. Insulation resistance test at 500V (MEGGER) all load steps to earth. Record
readings on check sheet.
2.9. Check fan duct(s) for obstructions.
2.10 Check fan(s), grease bearings.
2.11 Check duct cover proximity sensor(s) (where fitted).
2.12 Check airflow paddle switch is operative, (where fitted)
2.13 Check all relays are fitted securely and the terminations are tight. Control wiring
is neat and contained within loom / trunking.
2.14.Check main load connections are fitted with nuts / bolts / washers and fully
marked up.
2.15 Check and fix suitable auxiliary supply plugs/sockets (wherever necessary)
2.16.Check main earth points for suitable nuts / bolts and markings.
2.17 Ensure proper grounding of container / canopy.
2.18.Power up loadbank with auxiliary supply.
2.19.Start loadbank and ensure fan(s) run.

2.20.Use a suitable generator to test all load steps at full load. Record readings on
load test report sheet (sample attached in FORM section)
2.21.Check load steps are balanced across all three phases.
2.22.Check emergency stop is operative.
2.23.Ensure all livery and Loadbank Safety Stickers (sample attached in forms section)
are secured.
2.24.Ensure all internal and external areas of the loadbank are clean.
2.25.Complete “A” Service Loadbank Service Sheet (sample attached in forms

section).
2.26.Green card loadbank

3. “A” SERVICE PROCEDURES FOR COMPUTER CONTROLLED

LOADBANKS
3.1. Review the previous Service reports for any breakdowns / problems with
loadbank.
3.2. Ensure loadbank is isolated electrically.
3.3. Check all door seals, bund walls, locks (keys to be fastened to lock using strong
cable tie) and hinges are sound and fully operational.
3.4. Carry out visual inspection of the load bank container to establish the extent of
any physical damage due to transport or deterioration through age.
3.5. Check all load step main electrical connections for tightness.
3.6. Remove all load step contactor flash shields and check condition of contacts.
Clean/replace where necessary.
3.7. Visually check all load step resistors and inductors for stress.
3.8. Check fan duct(s) for obstructions.
3.9. Check fan(s), grease bearings.
3.10.Check duct cover proximity sensor(s) (where fitted).
3.11. Check airflow differential switch setting. Record reading on check sheet.
3.12.Check all relays, control wiring and fuses.
3.13.Check end of line plug fitted.
3.14.Check main load connections are fitted with nuts/bolts/ washers and fully marked
up.
3.15.Check and fix suitable auxiliary supply plugs/sockets (w herever necessary)
3.16.Check main earth points for suitable nuts/bolts and markings. Ensure proper
grounding of container.
3.17.Ensure loadbank setup mode switch is turned off.
3.18.Power up load bank with auxiliary supply 400 - 440V / 50 - 60Hz.
3.19.Check circuit breaker operation (if available) and ensure correct protection
settings on CB and note the values.

3.20.Start loadbank and ensure fans run. Note fan run Amps ( Wherever necessary)
3.21.Check fan start up delay sequence.
3.22.Check Sigma self-test has functioned.
3.23.Set controller to default settings. Clear any auto set up.
3.24.Check all safeties are operational.
3.25.Test airflow sensor is operational, (where fitted).
3.26.Test duct cover proximity sensors (where fitted).
3.27.Test over temperature sensors are operational
3.28.Check emergency stop is operational.
3.29.Check anti con. Heaters and contactor compartment fans are operational
(where fitted).
3.30.Check DIL switches within the control compartment (I / O - 1) are in correct

position (3 & 4 on – 1, 2,5,6,7 & 8 off).
3.31.Connect a suitable generator to perform load step checks using Froment loadbank
setup program. Recommended minimum test supply ratings are as follows:
5MVA – E5767 & LB87 – 1250KVA @ 380V, 50HZ
5MVA – E918 Series & XABJ00 Series– 1250KVA @ 400V,
50HZ
2.5MVA – 1250KVA @ 415V, 50HZ
1.25MVA – 1250KVA @ 415V,50HZ
Below 1.25MVA – 325KVA @ 400V, 50HZ
3.32.Perform automatic load step checks on loadbanks using Froment setup

programme (Only authorized personnel who have been trained to use Froment
setup programme shall be allowed to perform these tests). Limit the current
to a suitable range to protect Generator and associated power cables from
overloading.

3.33.Ensure all load steps are operational, save log and setup files in the laptop for
records.
3.34.Exit from setup mode and connect IHT to loadbank and confirm operation with
IHT.
3.35.Ensure load bus bars have a full compliment of bolts fitted (M12 x 50mm long)
and are fully marked up.
3.36.Ensure all livery and safety labels / stickers are secured.
3.37.Ensure schematic drawings, IHT, communication cable and Fire extinguisher are
packed inside unit.
3.38.Ensure all panel doors / hatches are CLOSED AND SECURED.
3.39.Ensure all internal and external areas of the loadbank are clean.
3.40.Complete “A” Service Loadbank Service Sheet (sample attached in forms

section).
3.41.Green card loadbank.

4. “B” SERVICE PROCEDURES FOR STANDARD CONTROLLED

LOADBANKS
4.1. Review the previous Service reports for any breakdowns/problems with
loadbank.
4.2. Ensure load bank is isolated electrically.
4.3. Carry out steps 2.1 - 2.14 of “A” Service for non-computer controlled loadbanks.
4.4. Connect a generator suitable to carry full load of the loadbank.
4.5. Fit calibrated current transformers/tong tester around load cables.
4.6. Power up load bank with auxiliary supply 440V / 60Hz.
4.7. Ensure fans are running.
4.8. Toggle in load steps one at a time.
4.9. Using calibrated instruments measure volts across bus bar and current in
secondary of calibration CT’s. Record readings on calibration check sheet.
4.10.Calculate actual load from above readings.
4.11.Complete “B” Service Load bank Service Sheet (sample attached in forms
section)
4.12.Issue new calibration certificate.
4.13.Green card load bank.

5. “B” SERVICE PROCEDURES FOR COMPUTER CONTROLLED

LOADBANKS.
5.1. Only engineers who have been trained to carry out adjustments to loadbank set
up & calibration parameters shall be allowed to do ‘B’ services.
5.2. Review the previous Service reports for any breakdowns/ problems with load
bank.
5.3. Ensure loadbank is isolated electrically.
5.4. Carry out steps 3.1 - 3.31 of “A” service.
5.5. Carry out Insulation resistance test at 500V (Megger test) for all load steps,
contactors and Circuit breakers.
5.6. Carry out main circuit breaker current injection and protection trip tests (Wherever
necessary)
5.7. Use calibrated measuring instruments to measure load current and Voltage.
5.8. Using “Setup calibration” measure load bank instrumentation readings for Voltage
(Phase – Phase and Phase to Neutral) and enter new values as measured by the
calibrated instruments.
5.9. Manually close some resistive load contactors and perform the above procedure
to calibrate and adjust current readings
5.10.Perform automatic load step checks on load bank. Set the load step check time
to minimum 3 minutes to get accurate value of elements.
5.11.Re-enter the measured values in the actual configured value in case of any
changes which will be highlighted in bold in the measured value table. In case of
differences more than 10% please ensure corresponding contactors are operating
prior to enter new values. Save log files and setup files for Record.
5.12.Carry out steps 3.34 - 3.39 of “A” service.
5.13.Complete “B” Service Loadbank Service Sheet (sample attached in FORMS

section).
5.14.Green card loadbank.

Service Manual
SWITCHGEAR
Revision April 2008
Prepared By Kobie Botha

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Page No.2
Switchgears Service Manual
SWITCHGEAR
Table of Contents
WORK INSTRUCTIONS
1. Service Standards For 11/15/17.5/24kV Containerised

Switchgear

Blank Page
Page No.4
1. SERVICE STANDARDS FOR 11/15/17.5/24kV CONTAINERISED

SWITCHGEAR.
Before commencing any work ensure all switchgear is DEAD and that all necessary
precautions have been taken to prevent switchgear from becoming LIVE using
Standard Lockout and Permit to Work Procedures.
• Aggreko high voltage safety procedures, BOP40, MUST be complied with at all
times.
• Services on Switchgear must be done once per Calendar year.
• Inspection should be carried out frequently - (Minimum Weekly)
• Switchgear must be isolated, proved dead and PTW issued before work can
start.
1. Maintenance Procedure (De-energised)
1.1 Remove all circuit breaker covers
1.2 Check operation of each circuit breaker mechanism (Locally & Remotely).
1.3 Check operation of all earth switches including mimics and interlock keys
1.4 Remove switchboard end covers and visually inspect bus bar chamber from each
end. Replace covers upon completion.
1.5 Inspect relay cabinets on each circuit breaker cubicle. Check wiring and operation
of miniature circuit breakers and integrity of fuses.
1.6 Interrogate relays to determine settings and compare settings found with
commissioning documents (only applicable if servicing carried out on operational
site) Record all settings.
1.7 Secondary inject each protection relay at trip setting to confirm operation of circuit
breakers and to prove settings.
1.8 Test low resistance across each circuit breaker with the breaker in closed position
using Megger D70001 or equivalent.
1.9 Visually inspect all high voltage cable terminations for signs of corrosion and
damage. Check cable tightness on circuits where cables are fitted,
Check Torque as per OEM recommendations
1.10 Check that switchgear-operating handles are in satisfactory condition and stored
in a satisfactory manner.

1.11 Check batteries and test 30/48 or110 V DC supply.
1.12 Inspect and confirm operation of container low voltage distribution system, to
include air conditioning, lights, socket outlets and distribution board.
1.13 Inspect safety signs fitted to container are clear and in satisfactory condition
1.14 Check insulated floor mat is in satisfactory condition
1.15 Check insulated rescue stick is inside container and in satisfactory condition
1.16 Carry out visual inspection of container to include doors, door seals, locks, and
general container damage.
1.17 Record the results of above checks on the Switchgear Service Report.
1.18 Check SF6 gas pressure where a gauge is fitted.
1.19 Check all alarms (to Control room where fitted).
1.20 Check that Air conditioner functions properly.
1.21 Check that all cable entry points are sealed and vermin proof.
1.22 Check earthing connections to the switchgear container.

SWITCHGEAR
Table of Contents
FORMS
1. Service Report.
2. Component Change Advice Note ( CCAN )
3. Service / CCAN log.

Service Manual
TEMPERATURE CONTROL
EQUIPMENT
Revision March 2008
Prepared By Bill Kearns

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Page No.2
Temperature Control Equipments Service Manual
TEMPERATURE CONTROL
EQUIPMENT
Table of Contends
Work Insturctions
1. Preventive Maintenance – Temperature Control
2. ‘A’ Service Standards For Air Conditioners
3. ‘B’ Service Standards For Air Conditioners
4. ‘A’ Service Standards For Air Handling Units
5. ‘A’ Service Standards For Fluid Chillers
6. ‘B’ Service Standards For Fluid Chillers
7. A’ Service Standards For 75l/S Fluid Pumps
8. ‘A’ Service Standards For Cooling Tower Units
FORMS
1. Service Report
2. Green Card (AHU, Fluid Pump and Buffer Tank)
3. Green Card (Chiller and AC)
4. Red Card
5. Notice to Hirer
6. Component Change Advice Note ( CCAN )

Blank Page
Page No.4
1. PREVENTIVE MAINTENANCE – TEMPERATURE CONTROL
Service intervals for Air conditioners and chillers.
All temperature control equipments are to be “A” serviced every 3 months

and on return from all hires.
The service standards for “A” services are detailed on the following pages
for all Temperature control units.
Only Air Conditioners and Fluid Chillers are to be “B” serviced every 12
months.Other temperature control equipment do not require any B service.
The service standards for “B” services are detailed on the following pages
for all Temperature control units.
A competent engineer must carry out A/B service on temperature control

equipment.
In order to make Temperature Control equipment available for hire we

need to carry out a through check as per temperature control work
instructions and service report.Items requiring readings to be recorded
must be entered at appropriate section of the service report.Items not
applicable to be marked “N/A”.
The distribution of the service report will be as stipulated at the bottom of

the report.
2. ‘A’ SERVICE STANDARDS FOR AIR CONDITIONERS
• ‘A’ Service to Air Conditioners should be carried out after three (3)
calendar months and on return to depot after hire.
• Before commencing, complete a review of the most recent service

report sheets for any abnormalities or defects.
• EXERCISE CAUTION; ensure that the unit is isolated from its

electrical supply before commencing with the A service.
2.1 Complete thorough cleaning of condensers/evaporator
2.2 Check operation of condensor/evaporator fan/s
2.3 Check and replace air filters as required
2.4 Inspect and grease bearing/s as required

2.5 Check control panel/starter panel wiring
2.6 Check safety switches and interlocks
2.7 Complete full wash down of unit
2.8 Check emergency stop function
2.9 Complete thorough leak search
2.10 Check compressor oil level/s
2.11 Fill in temperature control service report
3 ‘B’ SERVICE STANDARDS FOR AIR CONDITIONERS
• ‘B’ Service to Air Conditioners should be carried out after 12

calendar months.


electrical supply before commencing with the shutdown inspections.
3.1 Carry out A service
3.2 Replace supply fan drive belts
3.3 Check/tighten all electrical terminals
3.4 Remove oil sample for analysis (hand to your service team leader)
3.5 Record full load current
3.6 Record unit line voltage/frequency/phase balance
3.7 Record operating pressures and temperature as specified
3.8 Fill in A and B service report

4 ‘A’ SERVICE STANDARDS FOR AIR HANDLING UNITS
• ‘A’ Service to Air Handling Units should be carried out after three (3)
• Before commencing, complete a review of the most recent service report

sheets for any abnormalities or defects.
• EXERCISE CAUTION; ensure that the unit is isolated from its electrical
supply before commencing with the shutdown inspections.
4.1 Complete thorough cleaning of cooling coil
4.2 Check operation of supply fan/s
4.3 Check and replace air filters as required
4.5 Check control panel/starter panel wiring
4.7 Flush through and clean drain pan
4.9 Check drive belt tension
4.11 Fill in A service report

5 ‘A’ SERVICE STANDARDS FOR FLUID CHILLERS
• ‘A’ Service of Fluid Chillers must be completed after 3 calendar

months and on return to depot after hire.


electrical supply before commencing with the A service.
5.1 Complete thorough cleaning of condensers
5.2 Check operation of condenser fan/s
5.3 Check control/starter panel wiring
5.5 Check/tighten all electrical terminals
5.6 Complete thorough system leak search

6 ‘B’ SERVICE STANDARDS FOR FLUID CHILLERS
• ‘B’ Service to Fluid Chillers should be carried out after 12 calendar months.

supply before commencing with the shutdown inspections.
6.1 Carry out A service
6.2 Check and record oil level/s
6.3 Remove oil sample for analysis (hand over to your service team leader)
6.5 Record full load current
6.6 Record unit line voltage/frequency/phase balance
6.7 Check load and unload performance of compressor/s
6.8 Record operating pressures and temperatures as specified

7 ‘A’ SERVICE STANDARDS FOR FLUID PUMPS
• ‘A’ Service to Fluid Pumps should be carried out after three (3) calendar
months and on return to depot after hire.

• EXERCISE CAUTION; ensure that the pump is isolated from its electrical
supply before commencing with the A service.
7.1 Complete thorough cleaning of pump housing and frame
7.2 Check for any visual damage
7.4 Check control panel wiring
7.5 Check safety interlocks
7.6 Flush through and clean drain valve
7.9 Observe for any abnormal sound
7.10 Check emergency stop action

8. ‘A’ SERVICE STANDARDS FOR COOLING TOWER UNITS
• ‘A’ Service to Cooling Tower Units should be carried out after three (3)

supply before commencing with the A service.
8.1 Complete thorough flushing of internal fill
8.2 Check operation of supply fan/s
8.4 Check control/ starter panel wiring
8.6 Flush through and clean tower sump
8.7 Complete full external wash down of units
8.8 Check drive belt tension
8.10 Observe for any abnormal search
8.11 Observe performance of VSD frequency inverter
8.12 Fill in A service Report
NOTE:- Same procedure must be followed for Reporting of Services carried out
(Service CCAN Log).

Section 11
Useful Technical Information
Revision April 2008

Technical Information Service Manual
Table of Contents
1. Fuel Tank Cylinder Capacity
2. Useful Equations for Testing Generators and UPS`s
3. Speed Switch On board Set Up and Calibration
4. Fly Wheel teeth and Magnetic pick up frequencies by engine type
5. L55 and TLL50 Installation Instructions
6. Tools List

1. Fuel Tank Cylinder Capacity
In order to find the capacity of fuel inside a cylindrical tank based on the
height of the fuel, we need to find the cross section area of the fuel. The cross
section area of the fuel is actually the area of sector of the circle where the
fuel lies subtracted by the area of the triangle. The fuel cross section area will
then be multiply to the length of the tank to get the volume of the fuel inside
the tank.
For the fuel below the center line (below 1075mm):

Fuel cross section area = (area of sector – area of triangle) x length of the tank
Example: From the drawing shown, what will be the capacity of fuel? Note: the
fuel height in the sight glass is 850mm.
Fuel tank dimensions: OD (outside diameter) = 2.162 m
ID (inside diameter) = 2.150 m
Length = 5.808 m
Secondary Tank
Primary Tank
center line X center line

α
θ
Y Z
W
Fuel level sight glass
Containerized Fuel Tank

Area of the triangle:

AT = (xy × xz )(sin θ )
1
2
r − 0.85
cos α =
xy
1.075 − 0.85
cos α =
1.075
α = 77.92 o , θ = 155.8 o
AT =
1
(
(1.075 × 1.075) sin 155.8 o )
2
AT = 0.2369m 2
Area of sector:
As = (r 2 )(θ ) , Note : θ , should be in radians
1
2
6.28 × θ (deg rees ) 6.28 × 155.8 o

θ (radians) = , θ (radians) = = 2.72rad
360 360
As =
1
( )
1.075 2 (2.72rad )
2
As =
1
( )
1.075 2 (2.72rad )
2
As = 1.57m 2
Fuel cross section area = ( As − AT ) × Length of the tan k

= (1.57 - 0.2369) x 5.808
= 7.743m 3, Note: 1m 3 = 1000L

Fuel capacity = 7,743 Liters

For the fuel above the center line (above 1075mm):
Fuel cross section area = 20 - [(area of sector – area of triangle) x length of the
tank]
Note: The fuel level height on the sight glass in now 1900mm.
Secondary Tank
Y Z
W
θ
Primary Tank r
α
center line center line
X
Fuel level sight glass
Containerized Fuel Tank
Area of the triangle:
AT =
1
(xy × xz )(sin θ )
2
1.9 − r
cos α =
xy
1.9 − 1.075
cos α =
1.075
α = 39.88 o θ = 79.75 o

AT =
1
(
(1.075 × 1.075) sin 79.75 o )
2
AT = 0.569m 2
Area of sector:
As =
1 2
( )
r (θ ) , Note : θ , should be in radians
2
6.28 × θ (deg rees ) 6.28 × 79.75 o

θ (radians) = , θ (radians) = = 1.39rad
360 360
As =
1
( )
1.075 2 (1.39rad )
2
As = 0.803 m 2
Fuel cross section area = 20 − [( As − AT ) × Length of the tan k ]

= 20 - [(0.803 - 0.569) x 5.808]
= 18.641 m 3, Note: 1m 3 = 1000L
Fuel capacity = 18,641 L

2. Useful Equations for Testing Generators and UPS`s

3. Speed Switch On board Set up and Calibration
Deep Sea Unit Crompton

Ensure engine is operating normally and will not over
Ensure engine is operating normally and will not over speed.
speed.
Run up engine. Check frequency at mag pick up connection is Run up engine. Check frequency at mag pick up
in line with table below. connection is in line with table below.
Set Multi meter to mA range. Connect Multi meter across Set Multi meter to mA range. Connect Multi meter across
terminal 15 & 16. terminal 15 & 16.
Trim the calibration pot on speed switch until multi meter is Trim the RANGE ADJUST on speed switch until multi
reading 1.30mA. meter is reading 0.75mA.
Stop engine and turn Governor fully back. Restart engine and Stop engine and turn Governor fully back. Restart engine
set speed to 30% (0.39mA) (450RPM) Trim CRANK pot on and set speed to 30% (450RPM) Trim CRANK pot on
speed switch until light just comes on. speed switch until light just comes on.
Set Speed to 90%(1.17mA) (1350RPM). Trim UNDERSPEED Set Speed to 90% (1350RPM). Trim UNDERSPEED pot
pot on speed switch until light just comes on. on speed switch until light just comes on.
Set Speed 110% (1.43) (1650RPM). Trim over speed pot on Set Speed 110%(1650RPM) Trim over speed pot on
speed switch until light just comes on. speed switch until light just comes on.
Recheck all settings. If incorrect start again at step 4. Recheck all settings. If incorrect start again at step 4.
For 60Hz redo step 7 setting speed at 110% 1800RPM

For 60Hz connect unmarked terminal to negative (J2)
(1980RPM)
Note at normal running speed Crank & Under speed

Note at normal running speed all lights are on.
lights are on
4. Fly Wheel teeth and Magnetic pick up frequencies by engine type
Flywheel MP Hz @
Engine model MP Hz @ 1500RPM
Teeth 1800RPM
IVECO 8025, IVECO 8031 I,

IVECO 8041 I, IVECO 8051i,
130 3250 3900
IVECO 8061i, IVECO 8061 si,
IVECO 8361i, IVECO 8361Sri15,
IVECO 8210i 161 4025 4830
IVECO 8210 Sri 15 165 4125 4950
IVECO 8220 I 144 3600 4320
IVECO 8280 I, IVECO 8280 Sri 15 167 4175 5010
CUMMINS 6BTA 159 3975 4770
CUMMINS 6CTA 127 3175 3810
CUMMINS NTA 855 118 2950 3540
CUMMINS KT(T)A 19,38,50. 142 3550 4260

5. L55 and TLL50 Installation Instructions
DESCRIPTION
Designed for the use with the Fozmula T/LL50 series of transducers, the Fozmula L55 Controller
not only monitors liquid level, but also controls the level as well.
The liquid level is displayed on a large built in meter as well as being represented by three industry
standard analogue outputs for remote monitoring and control.
Control of the liquid level is achieved by four internal change-over relays which can be set to
operate at any level from 0-100%. Typically two of the relays are used to control a latching pump
contactor and the other two relays used to give high and low level alarms.
The Fozmula L55 controller is factory set to operate from one of three AC voltage supplies. In
addition it can operate from a 24 Volt DC supply. If both supplies are connected simultaneously
then the controller will take its power from the AC supply and only if this supply fails will it draw any
power from the DC supply. If the controller is normally AC driven then providing battery backup
simply involves connecting the battery supply to the L55.
SPECIFICATION
Supply Voltage : 24/110/230 VAC, 50-60 Hz.(Supplied as requested)
: 24VDC. (Can be used as sole supply or as a battery backup)
Power : 6 W @ 240 VAC all relays on

: 2.5 W @ 24 VDC all relays on
Input : T/LL50 Level Transducer.

3 wire potentiometric . 5K norm.
Outputs : 4(0)-20mA R=600 Ohms max.

(Supplied as requested)
: 0-100 uA R=30K Ohms max.
(Auto calibrating)
: 0-10V R=1000 Ohms min.
(Short circuit protected)
Relays : Rating 10A @ 240 VAC/28 VDC

Switching capacity 2000 VA max.
Enclosure : Impact resistant Polycarbonate.

Double insulation (IEC 439, SEN 362130).
IP67 rated with IP68 cable glands.
: L = 230 W = 140 D = 95mm
: Fixing centres 212 x 122mm
Temperature Range : -25ºC to + 50ºC

INSTALLATION
1. Decide where to mount the controller and drill four fixing holes in the mounting surface. The
fixing hole centres are given on the back of the enclosure. Remove the lid to gain access to
the mounting holes and fix the box to the mounting surface using four M4 x 25mm screws
or similar.
2. Install the T/LL50 Transducer in the required measurement location. Connect the T/LL50
level transducer to the controller with terminal 1 of the transducer connected to terminal 1 of
the controller etc.
3. Connect any of the required outputs to remote metering, monitoring or recording

equipment, observing the polarity for each output as shown on the circuit board. Unused
outputs can be left unconnected.
4. Connect the relay contacts to external contactors to provide latching pump control and
alarm functions as required. (NB. Any inductive load connected to the controller such as a
contactor must have a suppression circuit fitted to its coil to prevent the inducted back EMF
from damaging the on board relays. The contactor supplier will normally supply these to
match).
5. Ensuring the supply is isolated connect the power cables to the controller. The polarity of
the AC supply is not important and because the enclosure is double insulated no earth
connection is required. The polarity of the DC supply must be observed.
6. All that remains is to set up the relay switching points. This should be done initially with
power isolated from the external pumps and alarms. Apply power to the unit. The meter
should now be displaying the liquid level.
7. Just to the right of centre of the circuit board are four black micro switches and to the right
of each of these is an adjuster labelled 1 – 4. These correspond to relays 1 – 4. To set relay
1, press and hold the top micro switch and look at the meter. It is now displaying the level at
which relay 1 is set to switch. Now gently turn adjuster 1 until the meter displays the
switching level you require. Release the micro switch. The meter automatically reverts back
to displaying liquid level.
8. Repeat the operation with each of the relay set points and finally re-check all four by
pressing each of the micro switches in turn.
9. Finally, screw the lid into position and apply power to any external circuitry.
10. Installation of the Model L55 Controller is now complete.
Date 3 March, 2005

6. Tools List
S.No Site Group Description Part Ref Manuf. Unit

Electrical
1 All Electrical 33KV Live Line Tester CAPEX ITEM Metrohm
2 All Electrical 5 K Megger BM11D AVO
3 All Electrical Clamp Meter 36 Fluke Ea
4 All Electrical Multimeter 187 Fluke Ea
5 All Electrical Phase rotation meter 3126 Hioke Ea
6 All Electrical Megger meter BM223 Megger Ea
7 All Electrical Hydraulic Crimper 240mm SC30 Hiforce Ea
8 All Electrical Electricians Tool Set Complete JA-ELE-7020
Specialist
9 All Diagnostic Borescope 8mmDia X 43mm Length R080-043-0455SW115-50 Olympus Ea
10 All Diagnostic Fiber Light Guide Cable 1.0M 7108699 Olympus Ea
11 All Diagnostic Light Source 3-ILK-6A Olympus Ea
12 All Diagnostic Light source spare bulbs Olympus Ea
13 All Diagnostic Cooling System Tester 3318000 Sykes Pik Ea
14 All Health check Cat Blow by test kit 8T-2700 Caterpillar Ea
15 All Health check Cat engine evaluation group 1U-5470 Caterpillar Ea
16 All Health check "K"type Surface probe 3164494 Cummins Ea
17 All Health check "K"type Probe Adaptor 222-0234 RS Ea
18 All Health check Raytek Infrared temperature Gun RaytekMX2 Raytek Ea
19 All Health check Oil Filter Cutter 4C-5084 CAT Ea
A & B Service
20 All Service Specific gravity tester (Refractometer) 1U-7298 CAT Ea
21 All Service PH Meter 4C-8503 CAT Ea
FG-K3-020-KW, FG-K1-004-KW,
22 All Service TBN test kit ( 3 Items ) FG-K2-002-KW Kittiwake Ea
23 All Service Oil sample taking valve G3 & QSK CAT Ea
24 All Service Oil Filter Wrench (Filter Straps) A91D SNAP ON Ea
25 All Service Oil Filter Cutter (see Health check also) 4C-5084 CAT Ea
26 G3 Service 3/8" Drive dial torque wrench TEC12A SNAP ON Ea
27 QSK D+G Service 3/8" Drive dial torque wrench TEC25A SNAP ON Ea
28 G3 Service 3/8" Drive x 1/16" Flat tip socket driver F31D SNAP ON Ea
29 G3 Service 3/8" Drive Ratchet Head TM67A SNAP ON Ea
30 G3 Service Valve Setting Gauge 3823557 Cummins Ea
31 QSK D Service Valve Setting Gauge 3824901 Cummins Ea
32 G3 Service Valve adjusting wrench M1322 SNAP ON Ea
33 All Service DCA test stick kits CC2602M Cummins Ea
34 Gas Service Engine Drawing 4021359 Cummins Ea
35 Gas Service Spark plug wrench 3162231 Cummins Ea
36 Gas Service Inline 5 Datalink adaptor kit 4918416 Cummins Ea

37 Gas Service Insite 7.0 software Kit 3886388 Cummins Ea

38 Gas Service Testo 335 Exhaust Gas anaylizer 335 with NO cell Testo Ea
39 Gas Service Fluke Mini current tongs i200s Fluke Ea
40 Gas Service Crowcon Gasman 2 GASMANII Crowcon Ea
41 Gas Service Spy Gas 4 leak detector SPYGAS Spy Gas Ea
Digitron 2026P differential pressure
42 Gas Service manometer 339-4140 Digitron Ea
43 Gas Service Valve Setting Gauge (Gas) 3164393 Cummins Ea
Engine Tools
44 All Repair Impact wrench 1/2" Drive IW50 Hiforce Ea
45 All Repair Torque Wrench 1/2" Drive (50-250 ft lbs) HWT330NT Hiforce Ea
46 All Repair Torque Wrench 3/4" Drive (100-550 ft lbs) 8563 10 Gedore Ea
47 All Repair Multiple Valve Spring Compression Tool 3163606+3163177 Cummins Ea
48 G3 Repair Fixture Liner Installation 3375422 Cummins Ea
49 QSK D+G Repair Fixture Liner Installation 3163329 Cummins Ea
50 All Repair Set Cylinder Liner Clamp 3822503 Cummins Ea
51 All Repair Liner puller 3376015 Cummins Ea
52 G3 Repair Injector Puller 3823024 Cummins Ea
53 QSK D Repair Injector Puller 3824830 Cummins Ea
54 All Repair Compressor Piston Ring 3823294 Cummins Ea
55 G3 Repair Wrench Injector Preload Torque 3376592+TM67A+TM82 Cummins Ea
56 All Repair Expander, Piston Ring ST-1269 Cummins Ea
57 G3 Repair Front and Rear oil seal tool R-ST1093,F-3163692+3375497 Cummins Ea
58 QSK D+G Repair Front and Rear oil seal tool 3163349 Cummins Ea
59 QSK D+G Repair Self Drilling Screws for 3163340 3163356 Cummins Ea
60 All Repair Straight edge 18" Long GA438 SNAP ON Ea
61 G3 Repair Fuel pump wrench M1328A SNAP ON Ea
62 G3 Repair Fuel pump wrench M1329 SNAP ON Ea
63 G3 Repair Cylinder Head Socket 3/4 AF 3/4 drive Proto 5524 Proto Ea
64 QSK D+G Repair Cylinder Head Socket 21mm 3/4 drive Proto 5521M Proto Ea
65 All Repair Magnetic DTI stand Mitutoyo 7010S Mitutoyo Ea
66 All Repair Dial Test Indicator Mitutoyo 2416S Mitutoyo Ea
67 All Repair O ring picker YA338 SNAP ON Ea
GENERAL
68 All General Tool Kit (see sperate list TK1) Mechanical Beta Ea
69 All General 14lb Hammer HAMMER14LBS
70 All General 4lb Lump Hammer HAMMER4LBS
71 All General Tommy Bars - 928/42 JA-TLS-1041
72 All General Drill Bits 1mm to 25mm 1M467
73 All General Drill Bits 1/16" to 1/2" JA-TLS-7123
74 All General Tap & Die Set,Metric,UNC JA-MEC-7123
75 All General Tap & Die Set,Metric,UNF JA-MEC-7122
76 All General Tap & Die Set,Metric,Metric 6 - 24 JA-MEC-7124
77 All General Tap & Die Set,Metric,BSP 1/4 to 1" JA-MEC-7114

WORKSHOP EQUIPMENT
78 All General Portable Invertor (Welding Machine) LHN 250 ESAB Ea
79 All General Air Compressor 150LT/3HP/1HP AB150-335 FIAC Ea
80 All General Airblow gun + Hose + Fittings UT11AS Ea
81 All General Hydraulic Cylinder 20ton jack HLS201 Hiforce Ea
82 All General Hydraulic hand Pump Manual HP110+HC2 Hiforce Ea
83 All General Pressure washer KEW30CA 240v KEW Ea
84 All General Vacuum Cleaner Wet/Dry 230v / 50Hz Mirage 1640 Portotechni Ea
85 All General Battery Charger Velox 650 Velox 650 Ea
86 All General Cutting & Welding set JA-TLS-2013 Victor Ea
87 All General Angle Grinder 230mm JA-TLS-2026
88 All General Angle Grinder 100mm JA-TLS-2025
89 All General Barrel pumps JA-TLS-2024
90 All General Battery Tester JA-TLS-2006
91 All General Bottle Jack 20 Ton BTTLJCK20T
92 All General Chain Blocks 2 Tons CHAINBLOCK2T
93 All General Lead Lamps JA-TLS-2008
94 All General Pistol Drill 1/2" cordless JA-TLS-2023
95 All General Rechargeable Torches JA-TLS-1039
MISC ITEMS
96 All General 1000 W flood lights FLDLGT1000W220V
97 All General Drip Trays 30" x 18" x 2 -1/2" JA-MEC-2012
98 All General 1 litre measuring Jug 7501 Pressol
101 All General 5 litre measure 7505 Pressol
102 All General Large funnel 2366 Pressol
103 All General Medium funnel 2365 Pressol
104 All General Small Funnel 2364 Pressol
105 All General Small Funnel 2363 Pressol
106 All General Jump Leads H/Duty 6Meters JA-ELE-7019
BOOKS / STICKERS/SERVICE INFO
107 All General Requisition pads N/A Aggreko Ea
108 All Service Service Report pads N/A Aggreko Ea
109 All Service Component Change advice pads CCAN Aggreko Ea
110 All Service Service stickers N/A Aggreko Ea
111 All Service Coolant test labels N/A Aggreko Ea
112 All Health Check Health check procedure N/A Aggreko Ea
113 All Health Check Health check reports N/A Aggreko Ea

Aggreko "Mechanics Tools Trolley Contents"

Item
Tool Description. Qty. Manufacturer Part/Ref. Number
No.
1 Toolbox on Wheels - 7 drawers. 1 Beta C24
2 Portable Toolbox 1 Beta C18
3 Adaptor 1/2" Female - 3/4" Male 1 Beta 920/16
4 Adaptor 3/4" Female - 1/2" Male 1 Beta 928/15
5 Adjustable Spanner - 24 2 Beta 110/200
6 Adjustable Spanner - 44 2 Beta 110/380
7 Allen Key Set 10pcs. Metric 1 Beta 96N/B10
8 Allen Key Set 11pcs. S.A.E 1 Beta 96ASB11
9 Ball Pein Hammer - 340gms. 1 Beta 1377/340
10 Ball Pein Hammer - 900gms. 1 Beta 1377/900
11 Chisel 1 Beta 1701E/5
12 Chisel Wide - 60mm (scraper) 1 Beta 1702/60
13 Circlip Pliers - Combination 1 Beta 1039
14 Circlip Pliers External - 175mm 1 Beta 1036/175
15 Circlip Pliers Internal - 180mm 1 Beta 1032/180
16 Combination Spanner - 10mm 6 Beta 42/10
23 Combination Spanners 5/16" - 15/16" 2 Beta 42AS/11
24 Combination Spanners 6mm - 22mm 1 Beta 42/S17
25 Dead-Blow Hammer - ø 50mm 1 Beta 1392/50
26 Deep Socket Set 1/2" Drive - 12 point. Metric 1 Beta 920B/C20
27 Deep Socket Set 1/2" Drive - 12 point. S.A.E 2 Beta 920AS/C17X
28 Deep Socket Set 3/8" Drive on rail 12 point. Metric 1 Beta 910L
29 Deep Socket Set 3/8" Drive on rail 12 point. S.A.E 1 Beta 910ASL
30 Drill Bit Set - 19pcs. 1 Beta 415/SP19
31 Files Set - 5pcs. 1 Beta 1719A/S5
32 Flexible Hexagon Nut Driver Set 5mm - 13mm 1 Beta 943FL/S8
33 Flexible Magnet Pick Up 1 Beta 1712/3
34 Hacksaw Blade (HSS-BIMETAL) 5 Beta 1728BM
35 Hacksaw Frame - 300mm 1 Beta 1725
36 Heavy Duty Pipe Wrench - ø 140mm 1 Beta 363/900
37 Holesaw Kit - ø 22mm - 64mm 1 Beta 450/C9
38 Knife - Utility Retractable Blade 3 Beta 1772B
39 Knife Blades - 10pcs. 3 Beta 1772RL/1
40 Lump Hammer - 2000gms. 1 Beta 1380/2000
41 Measuring Tape - 5mtrs. 1 Beta 1692/5
42 Nose Pliers - Long 1 Beta 1162IN200
43 O-Ring Picker / Scriber 1 Beta 1688
44 Pin Punch Set 1 Beta 31/B6
45 Pipe Wrench - ø 76mm 1 Beta 362/450
46 Pliers Adjustable Self Locking 1 Beta 1054
47 Pliers Combination - Insulated 2 Beta 1150MQ220
48 Pliers Slip Joint (water pump) 2 Beta 1044/240
49 Pry Bar 1 Beta 964
50 Ratchet 1/2" Drive 1 Beta 920M/55
51 Ratchet 3/8" Drive 2 Beta 910M/55
52 Ring Spanners 10pcs. 1/4x5/16 - 1.1/8x1.5/16 1 Beta 90AS/10
53 Screwdriver Large 2 Beta 1274L
54 Screwdriver Set (electrical terminal driver) 4 Beta 1290/0.4x2.5x75
55 Screwdriver Set 11pcs. 50mm - 200mm 1 Beta 1273/S11
56 Screwdriver Set Insulated - 6pcs. 1 Beta 1283MQ/D6
57 Socket Set 3/8" Drive - 12 point. Metric 1 Beta 910B/C17
58 Socket Set 3/8" Drive - 12 point. S.A.E 1 Beta 910AS/C13
59 Spanner Insulated - 13mm (for battery terminals) 1 Beta 52MQ/13
60 Steel Ruler - 300mm 1 Beta 1683/300
61 Tin Snips - 300mm 1 Beta 1112/300

62 Torque Angle Indicator 3/4" 1 Beta 600/2

63 Torque Wrench 3/8" Drive click-type 20 - 100Nm 2 Beta 606/10
64 Vernier - 300mm 1 Beta 1654
65 Wire Brush 1 Beta 1737AC
66 Wire Cutter / Snips - Diagonal Flush Cutting 2 Beta 1080/160
67 Wire Cutter / Snips - Insulated 1 Beta 1082MQ160
68 Wire Stripping Pliers - 0.5mm - 6mm 2 Beta 1142
69 Crimping Pliers 1 Crimpstar HP3
70 Torque Wrench 3/4" - 8563-10 s/n: 1 Gedore JA-TLS-1037
71 Torque Wrench 1/2" Drive ±250lbs - HTW330NT s/n: 1 Hi - Force JA-TLS-1011
72 Adaptor Ratchet 3/8" Drive 1 Proto 5247
73 Allen Key Socket 1/2' Drive - Metric 1 Proto 5441-SM
74 Allen Key Socket 1/2' Drive - S.A.E 1 Proto 5441-7
75 Impact Socket 1/2" Drive 5/8" (manifold bolts) 1 Proto 7420H
76 Impact Socket 1/2" Drive 9/16" (turbo bolts) 1 Proto 7418H
77 Power Bar / Lever 1/2" Drive - 18" 1 Proto 5468
78 Pry Bar - 30" 1 Proto 2125
79 Socket Set 3/4" Drive - 12 point. S.A.E 1 Proto 55102
80 Grease Gun 1 Prssol 12632
81 Grease Meter (alternator greasing) 1 SKF/SAMOA 411100
82 Dial Torque Wrench 3/8" Drive 0-150in/lbs - TEC12A - s/n: 1 Snap On JA-TLS-1033
83 Dial Torque Wrench Bit 3/8" Drive - F31E 2 Snap On JA-TLS-1023
84 Feeler Gauge Bent - FB307D 2 Snap On JA-TLS-1017
85 Fuel Pump Spanner - M1328A 1 Snap On JA-TLS-1019
86 Fuel Pump Spanner - M1329 1 Snap On JA-TLS-2020
87 Oil Filter Strap - A91D 1 Snap On JA-TLS-1020
88 Socket 1/2" Drive 11/16" (big end bolts) - SW221 2 Snap on JA-TLS-1021
89 Socket 3/4" Drive - (cylinder head bolts) - LDH242 2 Snap On JA-TLS-1024
90 Socket Extension 3/4" Drive 3" - L32 1 Snap On JA-TLS-2021

Section 12
Product Bulletins & Information
Revision April 2008

Table of Contents
1. Cummins KTA-50 Valve Spring Failure (TSS_2007_001) Rev A,B
2. QSK-45/60 LTA Pumps (TSS_2008_001) Rev A,B
3. QSK-45 Gempac Allen Bradley HMI Screen Replacement Procedure

(TSS_2008_002)
4. Turbocharger Oil feed line Upgrade KTA-50G3/QSK-45G4

(TSS_2008_003)
5. Engine Driven Fan Pulley Alignment instruction (TSS_2008_004)
6. QSK-45/60 Front & Rear Crankshaft Oil Seal(TSS_2008_005)
7. Racor/Baldwin Filter Element Changes
8. QSK-45 Fuel Pump Internal Filter
9. QSK-45 Pre-Low Oil Pressure Warning Set Point Adjustment Procedure
10. QSK45 Inpower Parameter adjustment Procedure
11. QSK45 Inpower Shutdown Testing Procedure
12. QSK Inpower Procedure for Saving a Capture file
13. QSK-45 Inpower Software Data Logging Procedure
14. Renold Hi Tec Alternator Drive Coupling Information
15. Drive Coupling Assembly Information for NHC20 –KTA19G4 Engine
16. Drive Coupling Assembly Information for KTA38G2/38G8 &KTA50G2/

50G3 Engines
17. Drive Coupling Assembly Information for NHC20 –QSK45G4 Engine
18. QST30 Electric Fuel Supply System Information
19. Container Fan Pitch Angle Procedure
20. Operation Padlocks (AI_TSD_2008_001)

1. Cummins KTA-50 Valve Spring Failure (TSS_2007_001) Rev A,B

Doc No. TSS_2007_001

Product Bulletin Date: 25 November 2007
Cummins KTA- 50
Page: 2 of 5
Aggreko International Valve Spring failure
Status: Final
Problem:
Cummins have identified a design issue with the KTA valve rotators which causes the valve
springs to break.
The reason for the valve spring failure is detailed below:
x The root cause of the failure is the (1) thickness of the valve rotator Part No 3081081,
causing (2) a high surface contact pressure on top coil of the spring (3) causing the
two surfaces to fret together and initiate a fracture point as shown below:
(1)
(2) (3)
Prepared By: Approved By: __________

Luke Tranter Jack Denz
Rev A
Date 14/11
Technical Service - Product Support


Cummins KTA- 50
Page: 3 of 5
Status: Final
Identification
With the rocker covers removed and the piston in the TDC position, inspect all valves springs for
signs of damage as shown in the picture below. Cummins have found that the majority of the
valve springs that have broken have been on the exhaust valves and all failure have been as
shown below on the first coil of the spring.

Rev A
Date 14/11


Cummins KTA- 50
Page: 4 of 5
Status: Final
Action Required
To limit the risk of further power cylinder failures the following inspections MUST be carried out:
¾ All engines over 6,000 hours MUST be inspected as soon as you receive this information
and then every 2000hr there after.
If any broken springs are found during the inspection the cylinder head MUST be removed and
the valves and piston crowns inspected, if a bore-o-scope is available this inspection may be done
through the injector hole.
If there HAS BEEN Valve to piston contact, Both inlet or both exhaust valves (which ever pair has
made contact with the piston crown) must be replaced using the latest Cummins Part numbers,
the relevant valve springs, rotators and collets MUST also be replaced
If there HAS NOT been any valve to piston contact, the valve springs, rotators and collets MUST
be replaced straight away and using the latest Cummins part numbers.
This inspection MUST be noted on the A Service sheet as being completed in the comments
section of the document.
All repairs carried out MUST be completed by a competent technician and Component Failure
Report completed and sent to technical.records@aggreko.ae
Cummins Part Numbers:
¾ Valve Rotator Part Number 3081081

¾ Valve Spring Part Number 3633840
¾ Inlet Valve Part Number 3631950
¾ Exhaust Valve Part Number 3088389
¾ Valve collet Part Number 205091

Rev A
Date 14/11


Cummins KTA- 50
Page: 5 of 5
Status: Final
Future Component Design Changes:
In 2008 Cummins will be introducing a reduced thickness valve rotator (-0.5 mm) to relieve the
pressure on the first coil of the valve spring, part number to be advised:
- 0.5 mm
Conclusion
While the actions above may not completely eliminate any further valve spring failures we hope to
minimize downtime and prolong engine life by completing these inspections.
If there any further questions on the information provided please contact Technical Services Jebel
Ali.

Rev A
Date 14/11

Revision B - 17th Mar 2008
Product Bulletin Date: 17 March 2008
Cummins KTA- 50
Page: 1 of 2
Status: Final
Objective
This document has been created to inform all project and depot personnel of the introduction and
availability of the revised Valve Spring Rotator for this engine node and also the additional
information that must be followed whilst installing the new rotators.
Cummins Service Parts Topic:
Component Design Changes:
As the previous notification stated Cummins have introduced a reduced thickness valve rotator to
relieve the pressure on the first coil of the valve spring:
- 0.5 mm

Allan Methven Jack Denz
Rev A B
Date 14/11 17/03

Product Bulletin Date: 17 March 2008
Cummins KTA- 50
Page: 2 of 2
Status: Final
Installation information:
If, during the 2000hr valve spring inspections, any springs are found to be broken, the complete
engine set of Valve rotators, Valve Springs and Collets MUST be changed using the following part
numbers:
Cummins Part Numbers:
¾ Valve Rotator Part Number 3640315

¾ Valve Spring Part Number 3633840
¾ Valve Collets Part Number 205091
At the point of Engine Overhaul the above parts MUST be utilized as part of the Spare Parts
Package
Complete a Component Failure Report and forward it to Technical.Records@aggreko.ae
Conclusion
This revised rotator will be fitted as standard on all engine build after May 2008.
Engine serial number cut in from both Cummins UK plants and Cummins India plants to be
advised upon by Cummins Engineering
If there any further questions on the information provided please contact Technical Services, Jebel
Ali.

Rev A B
Date 14/11 17/03

2. QSK-45/60 LTA Pumps (TSS_2008_001) Rev A,B


Revision B - 20th Jan 2008
Product Bulletin Date: 20-01-2008
QSK-45/60 LTA Pumps Page: 1 of 3
Status: Final
Objective:
This document has been created to advise all Project and Depot personnel of the changes to the
Pump assembly part number and the design changes to the component.
Component History:
See the attached document for reference which was previously sent out to the fleet.
Part Number Changes:
The previous part number 4085944 has now been superseded by Part number 3638083
The following extract was taken from SIMS:
Note the additional parts that MUST be ordered when initial upgrading the engine with this pump
assembly.
Component Changes:
The improvements include:
¾ Change from greased bearings to oil fed bearings, which has increased lubrication.
¾ Improved Water and Oil seals.
¾ Increased Body Strength (Stiffening Rib)
¾ Introduction of Cavitation plates
Prepared By: Approved By:

A Methven Jack Denz
Rev B
Date 20/01
Technical Service and Support


Status: Final
Stiffening Rib Lub Oil Feed to the bearings
Installation Information:
¾ Drain the cooling system and remove the previous revision of LTA Pump.
¾ Transfer the coolant pipes from the removed pump to the replacement pump
¾ Inspect the splined drive for wear; if the splines are worn the drive assembly must be
repaired before the new pump is fitted. Lubricate the splines with Lub oil before fitting.
¾ Fit the new O-ring to the spigot on the pump body.
¾ Position the gasket on the mating face of the pump body.
¾ Slide the pump into place and enter all four mounting bolts.
¾ Align and secure all cooling lines.
¾ Tighten all four mounting bolts to the required torque
¾ Using the parts provided, connect the Banjo Bolt end of the lubricating oil feed hose to the
connection point at the lower drive end of the pump as shown in the above picture.

A Methven Jack Denz
Rev B
Date 20/01


Status: Final
¾ Connect the supply end of the lubricating oil feed hose to the connection point highlighted
below on the front gear cover.
¾ Re fill the cooling system
¾ Run the engine and check the pump for coolant and oil leaks, correct as required.
¾ Complete a CCAN and return it the technical.records@aggreko.ae

A Methven Jack Denz
Rev B
Date 20/01

3. QSK-45 Gempac Allen Bradley HMI Screen Replacement Procedure
(TSS_2008_002)
Date: 23-Jan-08
aggreko QSK45 Gempac
Allen Bradley HMI Screen
Prepared By: A Methven
Replacement Procedure Page: 1 of 8 Rev:Final

TSS_2008_002
Objective:
This document has been created to assist with the conversion of any XADA QSK45 Gempac
machine that has suffered an Allen Bradley HMI Failure.
Product History:
The models of HMI Screen used in these machines are now obsolete and the alternative unit
offered by Allen Bradley would require the following:
1. A Purchase order for £4000!
2. The control panel to be modified to accommodate the larger screen.
3. The version of RS View software used in the previous screen is not compatible with
the new screen, in turn a further development of a new file to run on the new screen.
Aggreko International – Technical Services &

Support
Date: 23-Jan-08

TSS_2008_002
Solution:
The alternate solution to this issue has been supplied through Deif.
With the introduction to the fleet of the QST30-G2 & G4 an upgrade version of the Std
Gempac PPU has been supplied which incorporates a MODBUS Card this allows the unit to
convert the modbus signal from the engines GCS ECM and display the information on the
STD Deif display.
The original Gempac PPU that has to be removed as part of the conversion can also be
reused in an unconverted Gempac QSK or a Gempac G3 allowing us to recover this cost.
Parts Required:
x 1 of Gempac-PPU Mod Bus model Part Number 275158a Cost $2005.12
x 1 of Control Panel Stainless Steel Insert Part Number JA-ELE-7142 Cost $30.54
x 1 of Resistor 120ohm Part Number 305039a Cost $2.70
x 1mtr 4 core screen cable Part Number JA-MAC-7141 Cost $1.50
Consumables:
x 6 of self tapping screws to secure the Deif Display (Size 4mm-10mm long)
x Clear Silicone sealer
x Crimps and Ferrules (Quantity as required)

Support

Date: 23-Jan-08

TSS_2008_002
Conversion: Gem Pac Unit
x Isolate the Main Battery supply
x Disconnect the panel Nicad Batteries
x Unplug all connections from the Gempac PPU and remove the unit from the control
panel (Carefully so not to damage the unit!)
x Remove the Replacement unit Part No 275158a from its packaging, remove all green
plugs from the new unit and fit them to the unit just removed from the control panel,
in the correct sequence?
x Place the Removed unit Part No 275128a into the packaging that the new unit was
removed from, clearly mark on the out side of the box that it now contains Part
number 275128a?
x Return this item to the site or project stores for safe keeping.
x Fit the Replacement unit Part No 275158a into the control panel and reconnect all the
green plugs into there relative ports.

Support

Date: 23-Jan-08

TSS_2008_002
x There will be one green plug left to plug in to the Mod Bus card connect the resistor
supplied and two cores of the screen cable as detailed below:
x Resistor to be crimped and fitted between terminals 127 & 129
x White core of the screen cable to be ferruled MOD (-) and connected to terminal 131.
x Black core of the screen cable to be ferruled MOD (+) and connected to terminal 133.
x As shown above the outer sheath of the screen cable should be crimped and
connected to terminal 132.
x Remove the UDAM converter and RS232 cable shown below as this is no longer
required:

Support

Date: 23-Jan-08

TSS_2008_002
x During the removal of the Udam unit the power supply cables feeding this unit will
have to be either terminated into the appropriate terminals or removed depending on
how the panel has been wired :
x Run the screen cable form the Mod Bus reading card within the panel trunking to 06
Interface card and connect as follows:
x White core of the screen cable to be ferruled MOD(-) and connected to terminal 18
x Black core of the screen cable to be ferruled MOD (+) and connected to terminal 21.
x The outer sheath of the screen cable should be only connected at the Gempac End.

Support

Date: 23-Jan-08

TSS_2008_002
x An additional cable link should be fitted between terminal 19 and 22 on this 06

interface module.
Conversion: HMI Screen
x Remove the Faulty HMI Screen from the control panel Door.
x Remove the power supply cables running the HMI screen as they are no longer
required.
x Attached the Deif display to the stainless steel inset using the 6 self tapping screws.
x Apply a small bead of clear silicone sealer all the way round the outside edge of the
stainless steel insert.
x Mount the inset into the control panel opening and secure with the nuts and washers
supplied.
x Remove any excess silicone sealer.
x Connect the 9 pin Display cable to the back of the Deif display.

Support

Date: 23-Jan-08

TSS_2008_002
x Display as mounted on the control panel door:
Operational Test:
x Reconnect the Control Panel Nicad Batteries
x Turn on the Main Battery isolator.
x Turn on the control panel key switch and allow the Deif unit to boot up.
x Press Jump, scroll to 5000 and select application no 1 for QSK45, then save.
x The unit will now reconfigure its self for the QSK45 set up, all nominal settings and
operational settings will have to be adjusted as the project requires i.e. Base Load or
Load sharing.
x Start the engine and follow the instruction from the QST30 User manual below to
prove all data is being read by the Mod Bus card:

Support

Date: 23-Jan-08

TSS_2008_002

Support

4. Turbocharger Oil feed line Upgrade KTA-50G3/QSK-45G4(TSS_2008_003)
Date: 23-Jan-08
Product Bulletin
aggreko EH&S Prepared By: L. Tranter
Turbocharger Oil feed line Upgrade Page: 1 of 4 Rev: Final
Aggreko International KTA-50-G3 / QSK-45-G4
TSS_2008_003
Objectives
This Product Bulletin has been created to highlight to all depots and projects changes made to the
turbocharger oil feed lines for the KTA-50-G3 & the QSK-45-G4 series engines.
The new oil feed line aims to prevent:
- Further equipment damage and the potential fire risk.

- Oil from the turbocharger feed line leaking onto the turbocharger exhaust turbine
housing.
- The risk of the pipe clamp rubbing through the turbocharger oil feed line.
- Down time of machines.
Product History
The turbocharger oil feed line used on the KTA-50-G3 and QSK-45-G4 engines, has shown to have
had a high failure rate due the design of the pipe and the way that the turbocharger oil feed line
was secured to the engine, the turbocharger oil feed line clamps rub through the hose causing oil
to spray onto the turbocharger exhaust turbine housing, which then could cause a potential fire
hazard.
MO60189 was released to cover this modification on all QSK-45-G4 engines and MUST be quoted
on all Component Change Notes completed for these engines.
New Design
Oil Feed Pipe
Old Design
Oil Feed Pipe
Failure Area
Fig. 1

Support
Date: 23-Jan-08
Product Bulletin
TSS_2008_003
Fig.2 Fig.3
New Turbocharger oil feed line Old Turbocharger oil feed line
clamping for the KTA-50-G3. clamping for the KTA-50-G3.
Design Changes & Recommendations
There has now been a solution introduced by extending the adapter into the turbocharger,
replacing the turbocharger oil feed line (As Required), Kevlar wrapping all turbocharger oil feed
lines, re clamping and positioning the turbo feed line so that it is not disturbed during
maintenance of the valves and injectors.
During the installation of these components the “Viton” O-rings must be replaced.
If the turbocharger oil feed line is over 12000 hours, replace the feed line with the latest design.
Fig.3 Fig.4
Extended Adapter fitted to turbocharger Kevlar wrap fitted to turbocharger
and the New Design Oil feed line. Oil feed line
Parts Required
Description KTA 50 G3 Part No. QSK 45 Part No. Qty/ Length
Adaptor ADAPTOR-TS-G3 ADAPTOR-TS-QSK 2
Kevlar Wrap SHS-PJ-14 SHS-PJ-14 2 ×11/2 Meter
Feed Line Left 3635033 4100966 1
Feed Line Right 3635032 4100965 1
Return Line Left 3632337 4065493 1
Return Line Right 3632336 4065492 1
Viton O'ring Seal 3922794 3922794 4
Return Line O'ring 216187 216187 2
Return Line Gasket 3630742 3630742 2
Adaptor to Turbo O'ring 3037537 3679139 2

Support

Date: 23-Jan-08
Product Bulletin
TSS_2008_003
Fig. 5 Extended Turbocharger Adaptor & O rings Part Numbers
O' ring part number -3883963 [3922794]

[50 G3 and QSK 45]
Adaptor part number for 50 G3 – ADAPTER-TS-G3

Adaptor part number for QSK 45 – ADAPTOR-TS-QSK
O' ring part number for 50 G3 - 3037537

O' ring part number for QSK 45 - 3679139
Installation Procedure
- Isolate the main battery supply.
- Remove existing turbocharger feed line

and the adaptor from the turbocharger.
- Place Kevlar wrap over the new

turbocharger feed line.
- Fit the extended adaptor to the

turbocharger, making sure the O-ring is
fitted and seats correctly.
- Connect the new Oil feed line to cylinder

block then to turbocharger, making sure
the “Viton” O-ring is fitted in the adaptor
correctly.
- Position the Extended end of the new line

centrally between the Exhaust and Inlet
housings of the Turbocharger.
- Tighten the Feed Line in this position.
- Push the Kevlar cover all the way over the Extended end of the oil feed line and the
extended
adaptor.

Support

Date: 23-Jan-08
Product Bulletin
TSS_2008_003
- Place pipe clamps over the feed line and

secure the clamps using the rocker cover
bolts. (As per picture provided)
- Take care not to bend the Oil Feed Line

or allow the line to rub on any objects.
- Cut the Kevlar cover to length.
- Tighten the supply end of the Oil feed

hose to the oil supply connection on the
engine cylinder block.
- Turn battery isolator switch to the on position and start the engine.
- Allow the engine to run for 5 to 10 minutes and check for any oil leaks.
Complete a CCAN and forward a copy to Technical.Records@aggreko.ae

Support

5. Engine Driven Fan Pulley Alignment instruction (TSS_2008_004)
Engine Driven Fan Pulley Alignment
Instruction Page: 1 of 4
Status: Final
Objective:
This document has been created to highlight to all operations personnel the need to check the
Radiator Cooling Fan drive pulley alignment on all generators with mechanically driven cooling
fans to prolong the life of the drive belts.
Equipment involved:
All CPG and SAKR generators in the AIP/AME fleet.
Inspection and adjustment procedure:
¾ Isolate the main starting batteries of the Generator and lock off where possible.
¾ Remove the control panel key and apply a “Do Not Start” tag to the main control panel.
¾ Remove all relevant guards to gain access to the cooling fan drive.
¾ Using an appropriate tool, relieve the pressure from the belt tensioner and remove the
drive belt. Check belt for cracks, cuts etc. and replace if required.
¾ Important: Before you check the drive pulley alignment, the following must be checked:
The Generator container must be level, over it’s length.

The radiator must be perpendicular to the container (90° to the container)
¾ The above checks must be done using a good quality spirit level
¾ Manually rotate the fan drive assembly, check that it rotates freely and listen for any
rumbling noises from both support bearings, replace as required.

A Methven Jack Denz
Rev A
Date 27/01


Status: Final
¾ Using the spirit level, check that both the fan pulley and the engine pulleys are level
¾ If the fan drive pulley is found not to be level, loosen the fan drive shaft bearing block
retaining bolts (4 of) and shim the bearing blocks as required with shimstock. Retighten the
retaining bolts. (shimstock can be made from tin cans. Do NOT use aluminium cans)
¾ The belt tensioner must be held to one side to allow the pulley alignment to be checked.
Using the appropriate spanner, ease the tensioner back and place a block of wood between
the tensioner and the crankshaft damper, as shown below:

A Methven Jack Denz
Rev A
Date 27/01


Status: Final
¾ The pulley alignment can be check using a Laser Pulley Alignment tool as shown below or
by using a good quality straight edge:
Cummins Pulley Alignment Tool
Gates EZ Alignment tool
¾ If the alignment of the pulleys is found to be off centre, loosen the taper lock bush securing
the pulley to the shaft and adjust the alignment as required:

A Methven Jack Denz
Rev A
Date 27/01


Status: Final
¾ If the alignment of the pulleys is found to be out of parallel, there is an adjustment on each
end of the cross brace that the fan drive assembly sits on , as detailed below:
¾ Once the alignment has been achieved, all bolts on the cross brace and the retaining grub
screws on the taper Lock bush should be rechecked. Remember that once the fan
guards are replaced there will be no access to them.
¾ Manually rotate the fan drive assembly, check that it still rotates freely.
¾ Refit the drive belt and release the previously secured belt tensioner by removing the
wooden block.
¾ Check the fan space for any debris that should not be in there i.e. rags and tools
¾ Replace all fan guards and brackets previously removed.
¾ Run the engine up and check that there are no issues before returning the unit to service.

A Methven Jack Denz
Rev A
Date 27/01

6. QSK-45/60 Front & Rear Crankshaft Oil Seal(TSS_2008_005)

QSK45/60 Date: 17 March 2008
Front & Rear Crankshaft Oil Seal
Page: 1 of 4
Aggreko International Service Bulletin
Status: Final
Objectives
This document has been created to inform all project and depot personnel of the design changes
incorporated in the latest revision of Front and Rear Crankshaft Oil Seal for this engine node and
also the additional installation information that must be followed whilst installing the new seals.
Component History
Cummins incorporated a cartridge style Oil seal assembly for its QSK45/60 engine front and rear
crankshaft seals.
Early revisions of the assembly have proven to be very unreliable and the source of many oil
leaks.
Any of the old design oil seals with the following part numbers held in the Depot or Project stock
MUST be returned to Jebel Ali stores and the latest part numbers re-ordered to replenish the
stock levels:
¾ Front Crankshaft Seals, part number: 3089142

3171910
4066222
¾ Rear Crankshaft Seals, Part Number: 3089094
3171911
4066223
Old style Crankshaft seal (Black)

Rev A
Date 17/03


Page: 2 of 4
Status: Final
Component Improvements:
2
1
New Front crankshaft seal (RED) New Rear Crankshaft Seal (Blue)
New Component Part Numbers:
x Front Crankshaft oil seal (Red) 4100624

x Rear Crankshaft oil seal (Blue) 4100625
The pictures above show the Revised Front and Rear Oil seal assemblies; the following
improvements have been incorporated:
¾ 1 - Improved seal geometry

¾ 2 - Internal bore coating is color coded for ease of identification.
¾ 3 - Improved external sealing arrangement
¾ 4 - Improved Rotational identification
By introducing these revised seals Cummins hope this component will deliver improved durability
and minimize equipment downtime.

Rev A
Date 17/03

Page: 3 of 4
Status: Final
Installation Information
Additional Equipment required:
x Installation Tools 3163349

x Loctite RTV 5699 sealant 3164067
6177 sealant 3163358
x Isolate the battery supply to the starter motor and lock it off.
x Remove the Crankshaft Dampers and old oil seal as described in the
Engines Workshop Manual or Quick serve on line.
x Clean all the components and prepare all surfaces prior to the installation of the new seal
x Before installing the crankshaft seal make sure all surfaces are completely clean from dirt
and oil.
x The seal MUST to be installed dry (Do not lubricate any surface)
x Install the guide pin in the top mounting screw hole to

help align the seal.
x Place a small bead of Loctite RTV sealer to the outside

diameter of the seal, between the mounting flange
and the square section silicone seal (As shown
opposite).
x Place the seal in position using the locating pin to

align the screw holes.

Rev A
Date 17/03

Page: 4 of 4
Status: Final
x Install the seal; pushing it in as far as it will go by hand.
x Use the installation tool Part Number 3163349 to install the seal to the correct position.
x Remove the locating pin.
x Fit the mounting screws and torque the setscrews to 10 Nm (89 in-lb).
x Re-install the Crankshaft Vibration Dampers etc that had been previously removed and
tighten all bolts in line with the specification laid out in Engines Workshop Manual or as
described on Quick Serve On Line.
x Re Install all Guards prior to running the engine.
x Complete a CCAN and forward it to Technical.Records@aggreko.ae

Rev A
Date 17/03

7. Racor/Baldwin Filter Element Changes
Date: 28-May-06
aggreko Product Bulletin Prepared By: AMethven
Racor / Baldwin Filter Element Changes Page: 1 of 6 Rev: 1

TSS
Objective
The objective of this Service Bulletin is to highlight to all Projects and Depots the recent
changes in design to the Racor filter assemblies used within our fleet and the impact it
may have on your operations.
Product History
For many years we have used the 1000FG unit below (left) in all our nodes above 320kva
in various configurations.
Racor discontinued this unit in December 2004.
In January 2005, we introduced the 1000FH unit below (right) in all containerized nodes.
Aggreko International – Technical Services & Support

Date: 28-May-06

TSS
Design Changes by Baldwin Filters
As Baldwin is our world wide supplier of filters in response to the above model change
they cut in the PF7790-30 replaceable element to accommodate the design changes that
Racor had made with the introduction of the FH unit.
With the introduction of this element incorporating the added features of the FH unit we
have had full cross compatibility between the FG and the FH range of filter assemblies
until recently….

Date: 28-May-06

TSS
FH Model Design changes by Racor
During the period of the last year Racor introduced this UN-ANNOUNCED design change
to there FH range of filter housings.

Date: 28-May-06

TSS
Baldwin Filters Response to the above;
As described below:

Date: 28-May-06

TSS
Baldwin PF7890-30 Introduction.
Baldwin have modified there tooling and discontinued producing the PF7790-30.
The replacement element will be the PF7890-30.
This new design filter element has given us back our full cross compatibility between both
styles of unit, that we had previously.

Date: 28-May-06

TSS
As we have No Cut in Date or Plant Number for the introduction of this Design Change
we thought it was best to highlight this issue to you as early as possible and explain the
changes as best we could.
Operational issues and considerations
The issue will be relevant to three nodes of machine, the 500kva Scania, 800kva Cummins
QST30 and 1250kva Cummins KTA-50-G3.
Racor have not changed the part no of there Standard fitted element so the only time you
will know you have a problem is when you go to change the filters….
The picture above shows the difference between the three elements (Left to Right):
1. The New PF7890-30 Element.

2. The STD fitment 100 micron washable Racor element
3. And the discontinued PF7790-30 Element.
The above mentioned 100micron Racor element could be cleaned and if need be refitted
until you receive the correct elements.
All orders placed on Baldwin for PF7790-30 will automatically be replaced with PF7890-30
All orders placed on Jebel Ali will have to be monitored and corrected by the amount of
Post 01-2005 machines you have in your fleet.

8. QSK-45 Fuel Pump Internal Filter
Doc No.
Product Bulletin Date: 02/04/2005
QSK45 Fuel Pump Internal Filter Page: 1 of 2
Status: Final.
Objective.
The objective of this bulletin is to make our engineers aware of the fact that the fuel pump on the
QSK45 engine is fitted with an internal fuel filter.
We have had occasions where fuel pump actuators and complete fuel pump assemblies have been
changed and all that was required was the internal filters required to be cleaned.
If the engine suffers from “Fuel Pump Pressure Issue’s”, “High Fuel Pump Actuator Currents”,
Hunting etc even after all fuel filters have been changed please carry out the following step before
changing any further components :-
Fuel Pump Actuator Filter screen.

1. Isolate the fuel supply at the Racor filter outlet valves and remove the control panel key.
2. Unplug the control harness from the fuel pump actuator and unscrew the actuator from the
fuel pump.
3. Between the two Green O-Rings you will see a black Gauze, Un-clip the Gauze and spray the
actuator and Gauze with an Aerosol lubricant i.e. WD40 to remove any debris, repeat as
required.
4. Re fit the Gauze, lubricate the O-ring with Aerosol lubricant and refit, Do Not Over tighten,
refer to the Workshop Manual for torque setting.
5. Reconnect the wiring Extension Harness.
Fuel Pump Internal Cleanable Fuel filter
1. Remove the Fuel Pump Internal filter by removing the plug as shown below:-.

Rev A
Date 02/04

Doc No.
Product Bulletin Date: 02/04/2005
QSK45 Fuel Pump Internal Filter Page: 2 of 2
Status: Final.
x Remove the filter and clean it using a can of Aerosol Lubricant i.e. WD40.
x There is also a magnet contained within the filter, check and remove any metal particals.
x The filter is retained in place by a “Coil Wound Spring” which fits within the retaining plug, be
sure to refit this spring, as shown in the following pictures :-
x Grease the threads of the plug and refit.

x Turn on all fuel supply lines.
Internal System Diagram
Fuel Outlet
PRESSURE
SENSOR
36 micron Bypass Valve Actuator fitted with

Fuel Tank Internal Filter 105 micron filter
Table of Contents useful info

Rev A
Date 02/04

9. QSK-45 Pre-Low Oil Pressure Warning Set Point Adjustment Procedure
Date: 7-Dec-05
QSK45 Pre-Low Oil Pressure Warning Set Report By: A Methven
Point Adjustment Procedure. Page: 1 of 3 Rev: 1
TSS
Set up.
1. Attach the Dongle to the computer.

2. Boot up the computer
3. Attach the communication cable between the Engine and the computer.
Procedure
4. Double click on the In power icon on the desktop.
5. Double click on
6. This will run the program and communicate with the engine.
7. Once communication is complete the following

icons are displayed.
8. Click on Adjustments and the following

Icon will now be displayed.
9. Click on Engine Protection Adjustments

and the following will
appear.
10. Click on the following Icon.
11. The Standard graph will now be

displayed.

Date: 7-Dec-05
TSS
12. Un tick the Graph mode box.
13. The following chart will show the

RPM to Low Pressure Warning
relationship.
14. To edit the pressure set points

highlight the set point for
adjustment and edit the setting
in the centre box as detailed in the
following chart save each
adjustment by clicking on the
15. Revised Pressure set point chart.
16. Re-tick the Graph mode box.

Date: 7-Dec-05
TSS
17. The Modified graph will now be

displayed.
18. Close the graph, Click on Device

On the top task bar and click
Save Adjustments.
19. A Capture File should now be taken from the system which should be
named Ex “XADA074mod”. This should be returned to T.S.S so that the
machine files can be updated.
See separate procedure for “Saving a Capture File”.

10. QSK45 Inpower Parameter adjustment Procedure

“XAAA”,”XADA” and “P” Prefix Date: 7-Dec-05
QSK45 In power Parameters Report By: A Methven
adjustment Procedure. Page: 1 of 2 Rev: 1
TSS
In power Settings:
Over speed:
Adjustments-Engine Protection Adjustments-Over speed Shutdown Threshold:
Set to 1980 for 60 Hz
Set to 1650 for 50 Hz (Calibration dependant)
LOP Warning Threshold Adjustment:

Adjustments-Engine Protection Adjustments-LOP Warning Threshold Table-
<XY Table>- Graph Mode:(See separate procedure)
RPM PSI
0.0 0.00
800.0 25.00
1200.0 39.00
1700.0 54.00
1800.0 55.00
2200.0 55.00
Frequency trim
Adjustments-Governor-Frequency-Frequency Adjust Trim:
Set to Minus 2.400 Hz for 60 Hz
Set to Minus 2.000 Hz for 50 Hz
Frequency Bias (GEMPAC XADA PREFIX ONLY)

Adjustments-Features-Inputs-Frequency Bias Select: Set to Barber Colman
Adjustments-Features-Inputs-Barber Colman frequency Bias Enable: Set to Enable.
Gain Pot:
Adjustments-Features-Inputs-Governor Gain Adjust Select: Set To Pot
Adjustments-Features-Inputs-Governor Gain Pot Enable: Set To Enabled
Panel mounted pot should be adjusted to give 0.900v of gain

“XAAA”,”XADA” and “P” Prefix Date: 7-Dec-05

QSK45 In power Parameters Report By: A Methven
adjustment Procedure. Page: 2 of 2 Rev: 1
TSS
Droop Pot:
Adjustments-Features-Inputs-Governor Droop Adjust Select: Set To Pot
Adjustments-Features-Inputs-Governor Droop Pot Enable: Set To Enabled
Panel mounted pot should be adjusted to give 4% droop
Frequency Pot:
Adjustments-Features-Inputs-Frequency Adjust Select: Set to Pot
Adjustments-Features-Inputs-Frequency Pot Enable: Set To Enabled
Crank Switch:
Adjustments-Starting-Crank Switch Enable: Set To Enabled
Meter Drivers
Engine Speed:
Adjustments-Features-Meter Drivers-Engine Speed Meter Full Scale: Set To 2000rpm
Oil Pressure:
Adjustments-Features-Meter Drivers-Oil Pressure Meter Full Scale: Set To 145PSI
Coolant Temp:
Adjustments-Features-Meter Drivers-Coolant Temp Meter Full Scale: Set To 120°C
Ramp Times
Adjustments-Governor-Idle and Ramping-Idle To Rated Ramp Time: Set To 15s
Adjustments-Governor-Idle and Ramping-Rated To Idle Ramp Time: Set To 15s
Adjustments-Governor-Idle and Ramping-Start to Rated Ramp Time: Set To 8s
After the settings are entered, clicking Device on the top menu bar and then
selecting Save Adjustments, All adjustments will now be saved to the ECM
memory.

11. QSK45 Inpower Shutdown Testing Procedure
Date: 7-Dec-05
QSK45 In power Shutdown Testing Report By: A Methven
Procedure. Page: 1 of 4 Rev: 1
TSS
Engine Shutdown Procedure
Set up.

Procedure
5. Double click on

Icons are displayed.
8. Click on Test and the following

Icon will now be displayed

Date: 7-Dec-05
TSS
9. Click on
Overspeeding
and the
following
will be
Displayed
Before this test can be initiated on XADA GEMPAC machines “Gen high
frequency 1 and 2, Bus bar high frequency 1 and 2”have to be changed to
IN ACTIVE in the Dief parameters. See Deif instructions.
These MUST be reset after the test has been completed
10. With the engine running at rated speed and the Circuit breaker racked
out to the test position, Close the circuit breaker and Double click on
E.S.R.O Command Value and type in 1655 for 50Hz operation or 1985 for
60Hz operation, This function on early engine only operated with 60Hz
protection,(Calibration Generated)
11. Double click on E.S.R.O Enable Value, Click on the arrow within the box
and select Enable.
The engine will now increase in speed until the E.S.R.O Command Value
has been exceeded, Annunciate the Fault, trip the Air flaps if fitted and
shutdown.
If the protection upgrade of the control panel has been completed the
breaker will open as soon as the shutdown sign is received.
If the control panel has not been upgraded the breaker relies on the
under voltage coil to drop out to activate the trip so there will be a delay
in the breaker opening.

Date: 7-Dec-05
TSS
12. Double click on E.S.R.O Enable Value, Click on the arrow within the box
and select Disable , Reset the control panel with the Alarm reset button
and Control panel auto/off/on key switch.
13. Click on
Oil Pressure
and the
following will
be
Displayed.
14. With the engine running at rated speed and the Circuit breaker racked
out to the test position, Close the circuit breaker and Double click on
O.P.O Command Value and type in 2.3 volts for a Warning at 60hz or 1.9
volts for 50hz , For a Emergency Shutdown type in 1.9 volts for 60hz and
1.5 volts for 50hz.
15. Double click on O.P.O Enable Value, Click on the arrow within the box
and select Enable.
The system will now simulate a Low Oil Pressure out put from the engine
as indicated on the control panel Gauge.
If the protection upgrade of the control panel has been completed and a
Warning signal is received the breaker will open after the fault has been
annunciated for 5 seconds continue to run off load to cool down for 5
minutes then stop.
If a Shutdown signal is received the breaker will trip and the machine
will stop as soon as the signal is present.
If the control panel has not been upgraded and a Warning signal is
received the panel will annunciate the fault and continue to run.
If a Shutdown signal is received the machine will stop as soon as the

signal is present and the Circuit Breaker will trip through the Under
Voltage coil function as previously mentioned.

Date: 7-Dec-05
TSS
16. Double click on O.P.O Enable Value, Click on the arrow within the box
and select Disable , Reset the control panel with the Alarm reset button
and Control panel auto/off/on key switch.
17. The remainder of the engine shutdowns all can be tested as previously
mentioned.
All figures quoted for shutdown testing are approximate and may require
to be altered to activate Warning and Shutdown functionality.

12. QSK Inpower Procedure for Saving a Capture file
Date: 7-Dec-05
QSK In Power Procedure for Saving a Report By: A Methven
Capture file. Page: 1 of 2 Rev: 1
TSS
Set up.

Procedure
5. Double click on

8. Click on Monitor and the following Icon’s will be

displayed.
9. Click on Engine Data , then Sensors and actuators
10. Click on Device in the top task Bar and the

following Box will appear.

Date: 7-Dec-05
QSK In Power Procedure for Saving a Report By: A Methven
Capture file. Page: 2 of 2 Rev: 1
TSS
11. Click on Capture to File and this box will be displayed.
12. Type in a file name i.e. XADA057test and then click Save.
13. Any files that are stored within this program can be found by right
clicking on Start, Then Explore.
14. Look for a folder called Power Generation
15. Click on Shared then Capture files, you will find all .CAP files stored here.

13. QSK-45 Inpower Software Data Logging Procedure

Date: 7-Dec-05
QSK45 In power Software Data Logging Report By: A Methven
TSS
Set up.

Procedure
5. Double click on

8. Click on Monitor and the following Icon’s will be

displayed.
9. Click on Engine Data , then Sensors and actuators
10. Click on the Monitor Icon on the top task bar.
11. The following box will open.

Date: 7-Dec-05
TSS
12. Minimize this box and click on the restore down button
On the main page of In power Sensors and actuators
Restore down
13. The main page will reduce in size, now restore the Monitor page to its
original size, Click on the top task bar of this page and drag it to the left
hand side of the screen.
14. Click on the top task bar on the In power page and drag it to the right
hand side of the screen, the screen should now look as follows:-
15. Select the parameter’s you require monitoring i.e. Engine Speed etc while
holding down the Control Key on the computer select each parameter
and Drag and Drop the selected item over to the monitor page.
16. Once you have all the parameters required in the monitor page click File
then Save As, Name the file for future use and Click Save.

Date: 7-Dec-05
TSS
17. You will now have to set the Sampling Rate to the required rate, normal
operation a sampling speed of 1.00sec is sufficient.
18. Click on the Sampling Enable box and the readings on the screen will
start sampling the data.
19. To capture the sampled data to a file you have to first name the file, Click
Browse as shown above.
20. The following box will now open where you can name the file.
21. Click Open and the Monitor page will now display the file name, when
you require the Data Logging Period to start all you have to do is tick the
Logging Enabled box and the software will store the information.

Date: 7-Dec-05
TSS
22. Once you have competed the given sampling periods to stop the software
Logging all you have to do is Un-tick the Logging Enable box and close
the Monitor window.
23. The Software Automatically has saved your data to a file :-
24. The Software stores the file as a .LOG file extension which can be opened
using Excel , The following steps will explain how to open the file using
Excel:-
25. Open the Excel program using the icon on the computer
task bar
26. Once the program opens click on File open, scroll through the files until
you come to Program Files, within this folder you will find another folder
called Monitor. Select File type to All Files as shown below.
27. You will now find your named file saved within this folder, Double click
on it. Select Delimited Click Next.

Date: 7-Dec-05
TSS
28. Once the following box opens select Tab and Coma then click Next.
29. The final box in the data conversion will now open and all you have to do
is select General and Click Finish and the data will be displayed in an
Excel Spreadsheet and using Graph function you can plot any changes in
pressure , engine speed etc.

14. Renold Hi Tec Alternator Drive Coupling Information
Date: 26-Sep-05
aggreko Renold Hi Tec Alternator Drive Coupling Prepared By: AMethven
Information. Page: 1 of 6 Rev: 1
TSS
The following information should be used as guidance when carrying out any Repairs or
Maintenance involving the Alternator drive coupling on both KTA50 and QSK45 NHC20
containers:
x If the coupling is dismantled for the replacement of the drive elements all parts
should be thoroughly cleaned and the drive elements replaced as a Complete Set,
There have been occasions noted where only the worn drive side elements have
been renewed, this mismatch of the elements may lead to added stresses being put
on the alternator bearings and may be contributing to early life failures.
x All new elements must be coated with the Renold Silicone Lubricant before fitting.
x The following part no should be used when ordering replacement drive elements:
KTA50-G3 14 of Part No 555267

QSK45-G4 16 of Part No 555378
Renold Silicone Lubricant Part No 3568588/00/401
x If for any reason the Drive Coupling has to be removed from the Alternator Drive
Shaft the following procedure should be followed:
Removal
1. Dismantle the drive coupling assembly, retain all parts.
2. Mount the coupling puller as shown in drawing below:
3. Position the 20/50 ton Hydraulic Jack in the centre of the shaft.
4. Clean the Drive Shaft and lubricate the surface with oil to ease the removal of the
Drive Member.

Date: 26-Sep-05
TSS
5. Caution, The Drive Member of the G3 coupling weighs 63Kg

QSK coupling weighs 103Kg
6. Before commencing to the next step, set up a suitable lifting device to support the
coupling as it is removed (Corner Post crane, chain block and wire sling).
7. Apply the pressure with the Hydraulic Jack and remove

the drive member.
8. Remove the Coupling back plate and retain.
Assembly
1. Clean the surface of the drive shaft and key,

IMPORTANT Mount the coupling back plate as shown:
2. Position the Distance Spacer and fit the drive Key as

shown:
HC7 and P7 Dimensions
3. To allow these spacers to be made the drawing is attached.

Date: 26-Sep-05
TSS
4. Before commencing to the next step, set up a suitable lifting device to lift the
coupling from the Oil Bath or Oven (Corner Post crane, chain block and wire sling).
5. Heat the coupling drive member to 120˚C in either an Oil Bath or an Oven, this
temperature must be maintained to allow the coupling to expand enough to slide
freely onto the shaft, the Infra Red Heat Gun on site can be used to check this
temperature.
6. Finally clean the Drive Shaft and lubricate the shaft with a thin coating of anti seize
copper grease.
7. Have a 14lb hammer and a block of hard wood next to the alternator in case the
coupling binds to the shaft during fitting.
8. Lift the coupling using the drive blades as shown opposite,

Key way to the top:
9. Taking GREAT care, position the coupling on to the shaft,

using a suitable insulated pair of Gloves or blanket push the coupling all the way
onto the shaft until it is hard against the shaft spacer.
10. The coupling will now have to be left to cool, Place a “HOT” sign on the alternator
so that everyone is aware of the hazard.
11. Once the coupling has cooled to normal temperature, assemble the drive coupling
as shown below:

Date: 26-Sep-05
TSS
12. Once all Rubber/ Silicone elements are fitted refit the coupling back plate and fit all
retaining bolts.
13. After the coupling has been reassembled ALL coupling bolts must be torqued to
the specified torque settings as described on the attached sheet.
14. The Crankshaft end float must be checked Before the alternator is connected to
the engine and the reading recorded on the Component Change/Service sheet:
QSK45 dimension:
Crankshaft End Clearance Mm In

0.13 Min 0.005
0.51 Max 0.020
KTA50 Dimension:
Crankshaft End Clearance Mm In

0.13 Min 0.005
0.51 Max 0.020
15. To check this dimension, position the Dial/Clock Gauge on the magnetic stand as
shown below:
16. Access to the crankshaft can be gained by removing any clear crankcase door.

Date: 26-Sep-05
TSS
17. The crankshaft should be carefully prised as far forward as it will go with reasonable
force with a suitable crow bar as shown below:
18. The Dial/Clock gauge should now be set at the zero point and the Crankshaft moved
towards the alternator, with reasonable pressure maintained on the crankshaft
towards the alternator the reading should be taken from the Dial/Clock gauge, this
reading should be check more than once to have a clear reading.
19. Once this clearance has been measured, the Alternator can be connected to the
engine and ALL Drive coupling and Bell housing bolts torgued in line with the
attached sheet.
20. Steps 15 to 18 must now be repeated to verify there is no pressure being applied to
the Crankshaft thrust bearings, the reading recorded must be recorded again on the
Component Change/Service sheet.
21. If the measurement recorded corresponds with the previous reading then clearly
there is no issue with the coupling assembly.
22. Replace the crankcase door Gasket/seal and replace the door.
If any further guidance is required please contact Technical Services, Jebel Ali
BEFORE running the engine.

Date: 26-Sep-05
TSS
Equipment List
1. Fabricated coupling puller. (Drawing attached)

2. ENER PAC Hydraulic Jack 20-50Ton.
3. Chain Block.
4. Suitable wire sling.
5. Coupling Distance spacer. (Drawing attached)
6. Heating rose.
7. Fabricated oil Bath.
8. Insulated Gloves.
9. ½ drive torque wrench. (Torque setting sheet attached)
10. Infra Red Heat Gun.
11. Magnetic Clock Gauge stand.
12. Clock Gauge.
13. Crowbar.








15. Drive Coupling Assembly Information for NHC20 –KTA19G4 Engine
Service Manual
Useful Technical Date: 01-12-2005
Page: 1 of 1 Controlled
Information
AI Depots and AIP Projects
5. Drive Coupling Assembly Information for NHC20 – KTA19G4 Engine
Reviewed By: Ray McElhinney Aggreko International Approved By: Jack Denz

16. Drive Coupling Assembly Information for KTA38G2/38G8 &KTA50G2/
50G3 Engines
Service Manual
Information
4. Drive Coupling Assembly Information for KTA38G2/38G8 &

KTA50G2/50G3 Engines

17. Drive Coupling Assembly Information for NHC20 –QSK45G4 Engine

Service Manual
Information
3. Drive Coupling Assembly Information for NHC20 – QSK45G4 Engine

18. QST30 Electric Fuel Supply System Information

Date: 25-Jan-06
aggreko QST30 Electric Fuel Supply System Prepared By: AMethven
TSS

Date: 25-Jan-06
TSS

Date: 25-Jan-06
TSS

Date: 25-Jan-06
TSS

Date: 25-Jan-06
TSS

Date: 25-Jan-06
TSS

Date: 25-Jan-06
TSS

Date: 25-Jan-06
TSS

Date: 25-Jan-06
TSS

Date: 25-Jan-06
TSS

Date: 25-Jan-06
TSS

19. Container Fan Pitch Angle Procedure

Date: 28-Jun-06
aggreko Radiator Cooling Fan Prepared By: A Methven
Pitch Angle Assessment Page: 1 of 4 Rev: 1
TSS
Preparation:
Before proceeding to check the pitch angle run the machine and record the following:
x Three Phase running Current

x Three Phase Voltage.
x Frequency
Procedure:
1. Stop the machine and isolate the Battery supply.
2. Remove the Outlet grill from the roof of the container.
3. Find a level point on the roof of the container using the Angle indicator supplied
and mark it with a marker pen so all checks are made at the same point:
Check this
position in
both
directions
for level
4. Turn the first blade in line with this point as shown above:

Date: 28-Jun-06
TSS
5. Attach the Level indicator to a 12” Steel ruler and lay it across the end of the blade
as shown below:
6. What you will notice is that the fan Blade has a “Thick” edge and a “Thin” edge?
The Thick edge will always be towards the Air “ON” side of the fan
The Fan Blade will also have an arrow on it pointing in the direction of rotation as
shown in the above picture.
7. Hold the ruler flat against the “Thick” edge of the blade and square against the
outer plenum ring.
8. While holding the ruler in this state, check the Angle and write it on the blade with
a marker pen.

Date: 28-Jun-06
TSS
9. Repeat the above steps on all 8 blades.
10. The Pitch Angle for the QST30 800kva should have 8 blades at a pitch angle of 12
deg.
11. Fan Assembly information:

Date: 28-Jun-06
TSS
The following points will explain how to adjust the pitch angle if required:
1. Slacken the only three bolts on the fan hub at a time!
Mallet
Area!
2. Tap the blade with a plastic Mallet until the desired pitch is achieved, Retighten the
three bolts and recheck the pitch angle.
3. Once all blades have been adjusted and checked, finally tighten all the hub bolts.
4. Replace the roof mounted Grill.
5. Close the battery isolator
6. Start the machine and measure and the record the following:
x Three Phase running Current

x Three Phase Voltage.
x Frequency
7. Reset the Fan over load to 19 amps (QST30 Only)
Forward all details to Allan.methven@aggreko.ae

20. Operation Padlocks (AI_TSD_2008_001)

Doc No. AI_TSD_2008_001
Date: 10th June 2008
OPERATION PADLOCKS
Page: 1 of 1
Status: Final.
In line with BOP040 (HV Procedures) Section 9.0 paragraphs 9.1 through to 9.5, please be
advised that Operation padlocks (figure 1) are available from stores in Jebel Ali and can be
ordered through SIMS. These locks are purely to prevent unauthorized access to HV equipment
and to identify HV Switchgear that is not in service and form no part of any PTW system. Project
Managers/Site Supervisors are requested to order a quantity of padlocks depending on their site
requirements.
An AAP1 or 2 may remove these locks for access but MUST always replace them afterwards.
These locks are to be used on project sites for restricting access but not limited to the following:-
1. Transformer container personnel and end cargo doors.

2. Unused HV switchgear (locked in open position).
3. Neutral Earthing Resistor cabinet door and/or isolator (locked in closed position).
4. Earthing Transformer cabinet door and/or switchgear (locked in closed position).
5. When the system is energised, mechanical isolators in HV compounds should be locked in
the closed position.
6. When the system is energised, mechanical earth switches in HV compounds should be
locked in the open position.
The Master keys for these padlocks are issued separately to personnel who have attended the
E1/E9 training module and achieved AAP1 or 2 classifications. We are in the process of issuing
Master keys to those already in possession of an AAP1/2 certificate but can also be obtained by
contacting walid.draou@aggreko.ae Tel: +97148086607
Any work on HV equipment MUST always be covered by a PTW.
Figure 1 (Orange coloured Operation padlock p/n JA-HSE-1054

G Slater Jack Denz
Rev A
Date 24/08
Technical Service Directive

Section 13
Revision Status
Revision April 2008

Service Manual - Revision Status
Section Issue Date Revision Date Revisions / Additions Remarks
Main Index Mar-07 Apr-08 ( + ) Rev Status Previous Manual had only 7 sections and no Revision Status.
( + ) Product Bulletins & Information Current Manual has 13 sections / Order of the manual has been reshuffled as per
(Section 12) requirement.
( + ) Revision History / Status( Section 13) All Procedural changes done to the sections are Highlighted in Red.
Section 1 Mar-07 Apr-08 Table of Contents 2 sections clubbed into 1 with sub-sections.Minor Changes highlighted in red
Section 2 Mar-07 Apr-08 Table of contents Changed as separate section (previously part of service procedure as Appendix 1)
2-Appendix 1-Maintenance Schedule,2-Maintenance Procedures.
( - ) Editions done in text Highlighted in red
Section 3 Mar-07 Mar-07 Table of contents Changed as separate section((previously part of service procedure as Appendix 2)
No revisions in content
Section 4 Mar-07 Apr-08 Table of contents Changed as separate section((previously part of service procedure as Appendix 3)
( - ) Oil sampling procedure on KTA50G3

with puradyn As per Allan Methven`s instructions,
( + ) Coolant Test Procedure Added coolant test procedure.
Changed as separate section((previously part of service procedure as Appendix
Section 5 Mar-07 Apr-08 Table of contents 4),Coomon Forms & AIP forms added in 1 section.
( - ) Warranty Claim form, Claim Log Replaced with Component Failure Report & Component Failure Log.
Health Check Forms(QSK45G4,KTA50G3) Revised date 10/04/08
( - ) 6 forms in AME forms. Service Sticker Standardised from 8 different ones to 2(1-English,1-Arabic)
Service records Tracking sheet replaced with Service / CCAN log.
Section 6 Mar-07 Apr-08 ( - ) Prepared by name changed Name Changed from Gopal Krishnan to Jethesh Aranha
Warranty Claim reporting & Flow Chart (7) Warranty claim form & Reporting changed with Component Failure Report and
Technical Information
update done in Warranty Process Flow chart.

Section 7 Mar-07 Apr-08 MV changed in HV MV replaced with HV in all instructions.
1.Some notes have removed and changes highlighted in red.
HV changed to 11/33/66kV ( - )Instruction 5 Recording of any disturbances removed.
Page No.113
Oil sampling procedure Work Instruction 7
Forms Separate section created for forms.( + )HV Transformer Report for A service
Section 8 Mar-07 Mar-07 NO REVISIONS DONE
Section 9 Mar-07 Apr-08 Work instructions & Forms(Separate Changes in procedure highlighted in Red.
sections
Forms Revised Service report form.
C service standards for all TC equipment,A service standard for cooling Tower
Section 10 Mar-07 Apr-08 ( - ) 3 work instructions units,Load test -Fluid chillers & Air Conditioners.
( - ) 2 Forms(Load Test & Start up Log
April 2008
sheets) Load Test & Start up Log sheets removed,Revised Service Report (Rev 01-03-08),
Section 11 Mar-07 Mar-07 ( - ) 12 Procedures Section divided in 2(Useful Information & Product Bulletins & Information)
Section 12 Apr-08 ( + ) 20 Instructions Full section added (20) instructions.(7 Instructions-issued product bulletins)
Service Manual
(13 Instructions-Product Information)

Section 13 Apr-08 ( + ) Revision History / Status Status and Description of the revised sections.

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SERVICE MANUAL

Tel : +971 (0)4 8834059

Service Manual Index

Section 1. (A) Projects Operational Overview April 2008

(B) Depots Operational Overview April 2008

Section 2. Maintenance Procedures & Schedules April 2008

Section 3. Approved Service Consumables March 2007

Section 4. Work Instructions April 2008

Section 5. Forms April 2008

Section 6. Technical Documentation April 2008

Section 7. Transformer April 2008

Section 8. LoadBank March 2007

Section 9. Switchgear April 2008

Section 10. Temperature Control April 2008

Section 11. Useful Information March 2007

Section 12. Product Bulletins & Information April 2008

Section 13. Revision Status April 2008

All Procedural Changes Highlighted in Red

Aggreko International Technical Services

Section 1 (A)- Projects Operational Overview

(B)- Depots Operational Overview

Section 2 - Maintenance Schedule and Procedures

Aggreko International Technical Services Page No.7 April 2008

Revision April 2008

Prepared By Allan Methven

Reviewed By Ray McElhinney Approved By Jack Denz

Aggreko International Technical Services

2. Project / Operations Service Responsibilities

4. Field Service Checks

Aggreko International Technical Services Page No.11 April 2008

• Maximise the operational effectiveness of our equipment.

• Prolong and maximise the economic life of our equipment

Act as a professional quality conscious company at all times

2 Project/ Operations Service Responsibilities

Each Project is responsible for:

• Maintaining in good condition all the equipment and ancillaries as long as it is on

Aggreko International Technical Services Page No.13 April 2008

• Equipment will always be kept well painted

• Equipment will carry all necessary decals & signboards

4 Field Service Checks

Receiving of Equipment at Project Site.

Aggreko International Technical Services Page No.14 April 2008

Form and send to Technical Records Dept, Jebel Ali.

• Commissioning Manual covers commissioning in more detail.

4.1 Decommissioning / Transfer To Jebel Ali or Another Project Checks

4.1.1 Engine oil pressure

4.1.2 Water temperature

4.1.3 DC charging circuit

4.1.4 AC voltage and Operating Hz is stable.

4.1.6 Fan & alternator belts for tightness

4.1.7 Water & Antifreeze level

4.1.8 Battery water level

4.1.9 Battery cables (apply grease/vasaline to cable ends)

4.1.10 Water hoses & connections for leaks

4.1.11 DC wiring (loose connections)

4.1.13 Exhaust connections

4.1.14 Engine / Generator mounts

4.1.15 Oil level

4.1.16 Racor bowl cleanliness

4.1.17 All necessary sea fastening has been carried out

Aggreko International Technical Services Page No.15 April 2008

Aggreko International Technical Services Page No.16 April 2008

Revision April 2008

Prepared By Allan Methven