Service Manual 311 Pages PDF

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
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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
Page No.7
April 2008
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Page No.8
Section 1(A)
PROJECT
Operational Overveiw
Revision April 2008
Prepared By Allan Methven
Reviewed By Ray McElhinney
Approved By Jack Denz

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Generator
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
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 Oclock 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.
Equipment Appearance
Equipment will always be kept clean
Equipment will always be kept well painted
Equipment will carry all necessary decals & signboards
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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Page No.16
April 2008
Section 1(B)
DEPOT
Operational Overview
Revision April 2008
Reviewed By Garry McMahon

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Service Manual
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Section 1(B)
DEPOT
Operational Overview
Table of Contents
1.
Purpose
2.
Depot Service Responsibilities
3.
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
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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Service Manual
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 Oclock
positions to prevent ingress of moisture.
For Brands of oil recommended by Aggreko, please see Appendix 1 of (Section

3 -Approved Service Consumables)
Equipment will always be kept clean
Equipment will always be kept well painted
Equipment will carry all necessary livery &signboards.
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.
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 Customers 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).
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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Service Manual
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 URfrom 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 units 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 combustionrelated 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.
6.3
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.
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 Bservice.
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

Manufacturers 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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Generator
8.
Service Manual
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 customers 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 customers 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 Engineers 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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Generator
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 customers 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 customers 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 customers
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 customers
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
equipments circuit breaker, ensure that the customers equipment/switchgear is
OFF. Close the Aggreko equipments circuit breaker and check the voltage,
frequency and phase rotation at the customers 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, hirers name, installation address and installation description and signed
by the customers 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.
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Page No.30
Section 2
Project and Depot
Maintenance Schedule and Procedures
Revision April 2008

Page No.31
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Page No.32
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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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Page No.34
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Generator
1.
Generator Type
Maintenance Schedule - 2008
A Service
Fuel Sulphur
Interval
(High is 0.5%+)
Comments
All Containers
(Without Puradyn)
High or Low
400 Hours
Includes KTA ,QST, MTU &

DC Series.
All Containers
(With Puradyn)
High or Low
400 Hours
Unless On Site Oil Sampling

indicates extension to 800
Hours *
QSK 45 only
High or Low
250 Hours
QSK 45 Only
All Canopies
High or Low
400 Hours
Unless oil sampling indicates an

extension *
B Service including top settings

Generator Type
KTA Only
QSK45 only
MTU & QST30
Scania DC9, 12 & 16
All Non Scania
Canopies
Interval
First B Service at 1,000 Hours, second at 5,000 Hours and then
every 5,000 hours onwards (1000,5000,10000,15000 etc)
These engines only require One B Service between 1000 and
1500hr only.
First B Service at 2,000 Hours and then every 2,000 hours onwards
(4000, 6000, 8000, 10000 etc)
First B Service at 400 Hours and then every 2,000 hours onwards
(2400, 4400, 6400, 8400 etc.)
First B Service at 1,000 Hours, Second at 3,000 Hours and then
every 2,000 hours onwards (1000, 3000, 5000, 7000 etc.)
Injector Change
Generator Type
All Containers
All Canopies
Comments
Change only if Health Check indicates change is required
Every 2,000 Hours or at the discretion of an authorized person
Health Check
Generator Type
All 1250KVA
GENSETS
Other than 1250KVA
Sets
Comments
First Health Check at 5,000 hours to establish base line and then
every 5,000 hours onwards until 20,000hrs & then very 2000hrs.
At the discretion of Area Operations Managers or as required
Alternator Greasing
Alternator Type
Interval
Repack grease qty.
Newage - HC7 / PI7 /

PE7
Every 5000 hrs
NDE- 75gms, DE - 89gms
Newage HC6
Every 5000 hrs
NDE -53gms, DE - 66gms
Newage HC5
Every 5000 hrs
NDE -29gms, DE - 41gms
Every 3000 hrs -60Hz,

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

Page No.35
April 2008
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
manufacturers 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)
Page No.36
April 2008
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)
Page No.37
April 2008
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.
Page No.38
April 2008
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.
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
manufacturers 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)
Page No.39
April 2008
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)
Page No.40
April 2008
Generator
Service Manual
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.
Page No.41
April 2008
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)
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)
Page No.42
April 2008
Generator
Service Manual
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.
Page No.43
April 2008
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)
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
Operating Practise)
BOP38 (Best
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
Page No.44
April 2008
Generator
Service Manual
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.
Page No.45
April 2008
Blank Page
Page No.46
Diesel Generator
Section 3
Approved Service Consumables
Revision March 2007

Page No.47
Blank Page
Page No.48
Service Manual
Generator
Table of Contents
1. Grades of Engine Oil recommended by Aggreko
2. Fuel Specifications for Aggreko Fleet
3. Coolant Specification
Page No.49
April 2008
Service Manual
Generator
Page No.50
April 2008
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
CALTEX
DELO 400 GOLD

MULTIGRADE
CH4
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
VALVOLINE
PREMIUM BLUE
Part No.17718
CH4
Brand
VALVOLINE
QSK60 Gas engine oils
SAE grade
Valvoline GEO 40
SAE40
Page No.51
April 2008
Service Manual
Generator
2.
Fuel Specifications for Aggreko Fleet

Aggreko diesel engines have been developed to take advantage of the highenergy 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
(ASTM D-445)
Centistokes 1.3 to 5.8 @ 40C (104F) (30 to 45

SUS)
Cetane Number
(ASTM D-613)
40 Minimum except in cold weather or in service

with prolonged idle, a higher cetane number is
desirable.45 Minimum below 0C (32F)
Sulfur Content
(ASTM D-129 or 1552)
Not to exceed 0.5 mass percent
Water and Sediment (ASTM

D-1796)
Not to exceed .05 volume percent
Carbon Residue
(Ramsbottom ASTM D-524 or
D-189)
Not to exceed 0.35 mass percent on 10 volume

percent residuum
Specific Gravity (ASTM D-287)
42 to 30 API gravity (0.816 to 0.876 g/cc at 15C)

at 60F
Pour / Cloud Point (ASTM D-97)
6C (10F) below lowest ambient temperature at

which the fuel is expected to operate.
Active Sulfur - Copper Strip CorNot to exceed No.2 rating after 3 hours at 50C
rosion
(122F)
(ASTM D-130)
Ash
(ASTM D-482)
Not to exceed 0.02% by weight (0.05 mass percent

with lubricating oil blending)
Distillation (ASTM D-86)
The distillation curve should be smooth and continuous. At least 90% of the fuel should evaporate
at less than 360C. (680F) All of
the fuel should evaporate at less than 385C
(725F)
Lubricity SLBOCLE or HFRR

ASTM D-6078
3100 grams or greater SLBOCLE, or 0.45 mm

maximum:
Wear Scar Diameter (WSD) at 60C [140F] HFRR
10-01-07
Always submit Fuel Sample results to Technical Services Department Jebel
Ali at the start of a new project.
Page No.52
April 2008
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 SCAs (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

(ppm)
2.4 (40) max
D512b, D512d, D4327
Sulphate (SO4), gr/gal

(ppm)
5.9 (100) max
D516b, D516d, D4327
Total Hardness, pr/gal

(ppm)
10 (170) max
D1126b
Total Solids, gr/gal

(ppm)
20 (340) max
D1888a
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)
Page No.53
April 2008
Blank Page
Page No.54
Section 4
Work Instructions
Revision April 2008

Page No.55
Blank Page
Page No.56
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
Page No.57
April 2008
Service Manual
Generator
Page No.58
April 2008
Generator
1.
Service Manual
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.
Page No.59
April 2008
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.
Page No.60
April 2008
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.
Page No.61
April 2008
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
Page No.62
April 2008
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.
Page No.63
April 2008
Service Manual
Generator
Operation
And
Maintenance
Requirements
(Purifi
ner)
Operation
And
Maintenance
Requirements
(Purifi
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.
Page No.64
April 2008
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.
Page No.65
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4.
Kittiwake TBN Setup
Page No.66
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Page No.67
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Kittiwake TBN Test Procedure
Page No.68
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5.
Kittiwake Oil Viscosity Test Procedure
Page No.70
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6.
Wear Check Oil Sample Summary Sheets Details
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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 @ 20C. 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
27
30
35
40
45
50
55
60
65
1.262
1.260
1.258
1.254
1.250
1.247
1.243
1.240
1.236
1.232
70
1.229
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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.
Page No.75
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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 units
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.
Page No.76
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Set Up of the Test Gauges

o
Fit the CAT Pressure Gauge set as follows:-
Fit the CAT blow-by meter as shown in the

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

must NOT be cut.
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.
Oil pressure gauge connect to port shown

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

must be connected to both left and right
connections on the test set and both
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 connection on the fuel pump outlet and to the Gauge indicated.
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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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)
Page No.79
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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
FT/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)
Page No.80
April 2008
Generator
9.
Service Manual
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.
Page No.81
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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)
Page No.82
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Service Manual
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 carriers 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)
Page No.92
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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
FRAME
5
5
6
6
7
7
BEARING
POSITION
BEARINGS
CM2
GRAMS
Non-Drive End
Drive End
Non-Drive End
Drive End
Non-Drive End
Drive End
65
92
121
156
174
208
58
82
111
139
154
185
GREASE QUANTITY
CARTRIDGE
CM2
GRAMS
33
46
63
78
87
104
CM2
29
41
56
69
77
92
33
46
63
78
87
104
CAP
GRAMS
29
41
56
69
77
92
Lubricant : KLUBER ASONIC GHY 72 (Aggreko Part Number GHY72)
Page No.93
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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 25C above ambient with an induction heater (Do not
exceed 100C)
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.
Page No.94
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Assemble Bearing onto the Shaft

Bearing Cartridge:
1) Heat the Bearing and Cartridge assembly to 80C 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) 45 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 120C 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;
Page No.95
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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
HC / HCK
5
5
6
6
7
7
BEARING
POSITION
Non-Drive End
Drive End
Non-Drive End
Drive End
Non-Drive End
Drive End
GREASE QUANTITY
CM3
33
45
60
75
85
100
Grams
29
41
53
66
75
89
4,500 Hrs
4,500 Hrs
4,500 Hrs
4,500 Hrs
4,500 Hrs
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:
Page No.96
April 2008
Generator
11.
Service Manual
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 individuals 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.
Page No.97
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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 1M 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 MCBs in panel.
Connect a Mega-ohm meter set to 500V (Megger) to U1 V1, V1- W1, W1U1 in turn & then each to earth (generator frame) Maintain voltage for 1minute
and ensure resistance is greater than 1 M. 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 1M 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 1M.
Page No.98
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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 M.
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 80-100
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 1M. 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 1M refer
to Newage fault finding manual.
Page No.99
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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.
Page No.100
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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.
Page No.101
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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 manufacturers 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.
Page No.102
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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.
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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.
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Service Manual
Drying Out Procedure.

The washed components must be thoroughly dried out in temperature-controlled oven.
The winding assembly should be slowly heated to 105C, 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.
Page No.105
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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 circlip 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.
Page No.106
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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.
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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 assemblers 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 builders production line with IR values still at the factory test
levels of above 100 Mega-Ohms cannot be guaranteed.
At GenSet 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.
Page No.108
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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 GenSet is operating in Rain, Fog, or Sea Mist etc. Then also carefully consider
the microclimate conditions that occur inside a typical GenSet 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 GenSet is at rest. This will maintain a high
value of IR for windings that are already in a clean and dry condition.
GenSet 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 110C 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
Page No.109
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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 4850 < 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.
Page No.110
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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 generators Serial Nos 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.
AVRs
Standard connections
Sensing is via terminals 6, 7, 8
Power P2 P3, P4.
V. trim potconnects 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.
Page No.111
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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.
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.
Page No.112
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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!
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).
Page No.113
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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:
Example 3:
In x Io x Ir = 400 x 0.5 x 0.8 = 160 A.
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.
Page No.114
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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, storedcurrent (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
LEDs 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 LEDs 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.
Page No.115
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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
Page No.116
April 2008
Generator
14.
Service Manual
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.
Page No.117
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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:
Page No.118
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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.
Page No.119
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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.
Page No.120
April 2008
Generator
16.
Service Manual
Cooling Testing Procedure
Page No.121
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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.
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.
To achieve the best results the coolant sample temperature must be between 10c and 55c
but room temperature is preferred before commencing with the test.
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.
Place the test strip in the coolant sample for 1 second. Then remove test strip and shake to
remove any excess coolant.
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.
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.
Page No.122
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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.
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.
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.
Page No.123
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Generator
Refractometer Instructions for measuring the Freeze/Boiling Protection Levels
(A)
(A)
(A)
(B)
(C)
(D)
(B)
(B)
(C)
(C)
(D)
(D)
Eyepiece (Focus)
Adjustment screw
Cover Plate
Lenses
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.
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.
The temperature of the coolant is a very important part of obtaining the correct reading. The
coolant temperature must be between 10c to 30c before the coolant is placed on the lenses.
Page No.124
April 2008
Generator
Service Manual
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)
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.
The desired antifreeze must be mixed at 50/50 ratio with good quality water. The 50/50
mixture gives a -36c freezing point and a 110c boiling point (Ethylene Glycol only).
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)
Page No.125
April 2008
Service Manual
Generator
Page No.126
April 2008
Generator
Service Manual
Antifreeze % to Freezing point
Antifreeze % to Boiling point
Page No.127
April 2008
Service Manual
Generator
PH Meter Instructions to measure the Acidic/Alkali Levels in the coolant
(A)
(A) Electrode
(B) pH display
(C) ON/OFF switch
(B)
(C)
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.
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.
To calibrate the pH meter place the electrode in pH 7.01 (hI7007) solution.
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)
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.
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)
Set the meter to 4.0 pH or 10.0 pH depending on the solution used.
Page No.128
April 2008
Generator
Service Manual
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:
x
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.
The temperature of the coolant is a very important part of obtaining the correct reading. The
coolant temperature must be between 10c to 30c before the test can be conducted.
Remove the protective cap from the meter. Turn the switch on top of the pH meter to the on
position.
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.
Stir the pH meter slowly in the test sample and wait for the pH reading to stabilize. Record
your reading on the service sheet.
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.
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.
Page No.129
April 2008
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Page No.130
Diesel Generator
Section 5
FORMS
Revision April 2008

Blank Page
Page No.131
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Page No.132
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
Page No.133
April 2008
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Page No.134
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
Page No.135
April 2008
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Page No.136
Diesel Generator
Technical Documentation &

Warranty Procedures
Revision April 2008
Prepared By Jethesh Aranha
Blank Page
Page No.138
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.
Page No.139
April 2008
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Page No.140
Generator
Service Manual
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.
Page No.141
April 2008
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 engineers 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.
Page No.142
April 2008
Generator
Service Manual
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 Managers 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 &
the guide lines given in Templates.
Follow
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
Page No.143
April 2008
DISCARD
NO
CLAIM
CLOSED
Repair &
Return to
Stock
NO
Is Failed
Component
Reparable
CCAN
YES
Page No.144
END
Inform
TS
Warranty
Given
OEM / JA
Update Warranty
Log
Repair & Return

to Stock
Agreed Period
with Vendor
YES
VENDOR
Arrange for Repair

if Economical
YES
LOCAL
Warranty
Given
Carry out Repair
NO
CLAIM
CLOSED
Repair &
Return to
Stock
NO
IDENTIFY
WARRANTY
BREAK DOWN OCCURS
CLAIM
CLOSED
Inform / Contact
T.S, JA
Claim
approved /
Rejected
TS Takes up
Warranty with
OEM
Replacement
Approved
Received at
Stores / taken to
Stores Stock &
Credit the Project /
Depot
Forward all
documents to TS,
JA
YES
Can Repair
be Carried out
at Site ?
CLAIM
CLOSED
Update Warranty
Log
Inform TS
Receives
Replacement or
Credit Notes
Dispute
YES
YES
Credit Note received

at Accounts Dept
Credit the Project /
Depot
Credit Notes
CLAIM
CLOSED
NO
NO
OEM
Requesting Return
Failed Comp for
Inspection
OEM
accepts warranty
from evidence
NO
NO
NO
OEM accept
Warranty
AOM / SM arrange
return / inspection
YES

Warranty Process Chart
Test Reports /
Photos / Failure
Analysis
NO
Repair & Record

Labor / Parts /
Invoice / Photograph /
Test Reports
YES
Warranty
Support Available
through Local
Agent
Investigate Cause
& Prepare Report
Rejected
Update Warranty
Claim Log
CLAIM
CLOSED
CCAN
Get it repaired and

Close the Claim
YES
Warranty Claim
Form// Log
Log
CFR
YES / in Doubt
Generator
Service Manual
April 2008
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
Page No.145
April 2008
Service Manual
Generator
10.
SUPPLIER WARRANTY TERMS
COMPONENTS
MAJOR
COMPONENTS
EXTENDED
WARRANTY
WARRANTY PERIOD
CUMMINS
ENGINE ASSEMBLY
24 Months & Unlimited Hours from NEI /

PDI Date
Engine Cylinder
Block

PDI Date
36 Months or
10,000 Hrs
CRANK SHAFT

PDI Date
36 Months or
10,000 Hrs
CAM SHAFT

PDI Date
36 Months or
10,000 Hrs
CONNECTING
RODS

PDI Date
36 Months or
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
REPLACEMENT
SPARES
12 Months
24 Months/2000
hrs of operation
Page No.146
April 2008
Generator
Service Manual
SCANIA
ENGINE
ASSEMBLY
12 Months from Start Up /

Commissioning date
SCANIA
ENGINES
DC 12 & DC 16
Delivered after 1st
April 2006,
TWO YEAR WARRANTY

DC 12 ESN 6513878
Onwards
DC 16 ESN 1042011
Onwards

Commissioning date
24 Months or 12000 Hrs 100%

Coverage
Coverage
Coverage

Commissioning date

Coverage
Coverage
Crank Shaft &

Connecting Rods

Commissioning date

Coverage
Coverage
Coverage
DC Alternator

Commissioning date
Starter Motor Bosch

Commissioning date, Can
also be taken up with local
Bosh representative
Fuel Pump - Bosh

Commissioning date, Can
also be taken up with local
Bosh representative
Cylinder Block
Casting
Cylinder Heads
Page No.147
April 2008
Service Manual
Generator
IVECO
ENGINE ASSEMBLY
12 Months from PRA / Build Date
Engine Block
24 Months
Crank Shaft
24 Months
Bosh Electronic
Modules
FG WILSON
GENERATOR
(Engine & Alternator
Assembly)
12 Months from Date of Delivery
NEWAGE
ALTERNATOR
ASSEMBLY
30 months from PRA / Build Date or 24

months from date of first commissioning
A.V.R

Power Factor
Controller (PFC)

PMG

Main Stator

Main Rotor

EXCITOR ASSEMBLY

Excitation Loss
Module (ELM)

RECTIFIER
ASSEMBLY

Page No.148
April 2008
Service Manual
Generator
MERLIN GERIN
MAIN CIRCUIT
BREAKER
24 Months from date of manufacture

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

or 12 months from PRA Date / In Service
RADIATOR - Covard
18 months from the date of dispatch

from CovRad
(12 Month from PRA Date / In Service)
RADIATOR - Nissens
12 Months from PRA Date / In Service
FLAKT WOODS
RADIATOR FAN
24 months from dispatch / Supplier

Invoice date
RADIATOR FAN
MOTOR

Invoice date
ENGINE SPACE FAN

(ESF)

Invoice date
ENGINE SPACE FAN

MOTOR

Invoice date
SILENCER
Bradgate IMS
12 Months from Dispatch / Supplier

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

Invoice date
Page No.149
April 2008
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
Page No.3
April 2008
Blank Page
Page No.4
Transformer
Service Manual
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 Bservice 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 100C)
Page No.5
April 2008
Service Manual
Transformer
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
TRANSFORMERS
STANDARDS
FOR
LOW
VOLTAGE
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
Page No.6
April 2008
Transformer
Service Manual
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
transformers.
left and right hand
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)
Page No.7
April 2008
Transformer
Service Manual
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.
Page No.8
April 2008
Transformer
Service Manual
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 manufacturers 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.
Page No.9
April 2008
Blank Page
Page No.10
Transformer
Service Manual
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.
Page No.11
April 2008
Blank Page
Page No.12
Transformer
Service Manual
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 6.6/11/33/66kVTransformers 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 6.6/11/33/66kVHV 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 85C and Trip 105C
Winding Temperature settings: Alarm 105C and Trip 115C

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
40C.
2.4 Visual Check for gas in the Buchholz (gas) relay.
Page No.13
April 2008
Transformer
Service Manual
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.
Page No.14
April 2008
Transformer
Service Manual
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.
Page No.15
April 2008
Transformer
Service Manual
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.
Page No.16
April 2008
Transformer
Service Manual
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
5.
6.
11/33/66kV Transformer Test Report
Page No.17
April 2008
Blank Page
Service Manual
LOADBANKS
Revision March 2007
Prepared By Gordon Slater
Blank Page
Page No.2
Service Manual
Loadbanks
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
6.
7.
Service / CCAN Log.
Page No.3
March 2007
Blank Page
Page No.4
Service Manual
Loadbanks
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 customers 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.
Page No.5
March 2007
Service Manual
Loadbanks
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.
Page No.6
March 2007
Service Manual
Loadbanks
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
Page No.7
March 2007
Service Manual
Loadbanks
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.
Page No.8
March 2007
Service Manual
Loadbanks
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,
2.5MVA
1250KVA @ 415V, 50HZ
1.25MVA
1250KVA @ 415V,50HZ
Below 1.25MVA
325KVA @ 400V, 50HZ
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.
Page No.9
March 2007
Service Manual
Loadbanks
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.
Page No.10
March 2007
Service Manual
Loadbanks
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 CTs. 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.
Page No.11
March 2007
Service Manual
Loadbanks
5.
B
SERVICE
LOADBANKS.
PROCEDURES
FOR
COMPUTER
CONTROLLED
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.
Page No.12
March 2007
Service Manual
SWITCHGEAR
Revision April 2008
Prepared By Kobie Botha
Blank Page
Page No.2
Switchgears
Service Manual
SWITCHGEAR
Table of Contents
WORK INSTRUCTIONS
1.
Service Standards For 11/15/17.5/24kV Containerised

Switchgear
Page No.3
April 2008
Blank Page
Page No.4
Switchgears
1.
Service Manual
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.
Page No.5
April 2008
Switchgears
Service Manual
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.
Page No.6
April 2008
Switchgears
Service Manual
SWITCHGEAR
Table of Contents
FORMS
1.
Service Report.
2.
Component Change Advice Note ( CCAN )
3.
Service / CCAN log.
Page No.7
April 2008
Service Manual
TEMPERATURE CONTROL
EQUIPMENT
Revision March 2008
Prepared By Bill Kearns
Blank Page
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 )
Page No.3
March 2008
Blank Page
Page No.4
1.
Service Manual
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
Page No.5
March 2008

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
Service Manual
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
Page No.6
March 2007
Service Manual
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
4.4
4.5
Check control panel/starter panel wiring
4.6
4.7
Flush through and clean drain pan
4.8
4.9
Check drive belt tension
4.10
4.11
Fill in A service report
Page No.7
March 2008
Service Manual
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
5.4
5.5
Check/tighten all electrical terminals
5.6
Complete thorough system leak search
5.7
5.8
5.9
Page No.8
March 2007
Service Manual
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)
6.4
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
Page No.9
March 2008
Service Manual
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
7.3
7.4
Check control panel wiring
7.5
Check safety interlocks
7.6
Flush through and clean drain valve
7.7
7.8
7.9
Observe for any abnormal sound
7.10
Check emergency stop action
7.11
Page No.10
March 2007
8.
Service Manual
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
8.3
8.4
Check control/ starter panel wiring
8.5
8.6
Flush through and clean tower sump
8.7
Complete full external wash down of units
8.8
Check drive belt tension
8.9
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).
Page No.11
March 2008
Section 11
Useful Technical Information
Revision April 2008
Blank Page
Page No.2
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
Page No.3
April 2008
Blank Page
Page No.4
1.
Service Manual
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
center line
Fuel level sight glass

r
Containerized Fuel Tank
Page No.5
April 2008
Service Manual
Area of the triangle:

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

360
As =
1
1.075 2 (2.72rad )
2
As =
1
1.075 2 (2.72rad )
2
(radians) =
6.28 155.8 o
= 2.72rad
360
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
Page No.6
April 2008
Service Manual
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
Z
W
Primary Tank
center line
center line
X
Fuel level sight glass
Containerized Fuel Tank
Area of the triangle:

AT =
1
(xy xz )(sin )
2
cos =
1.9 r
xy
cos =
1.9 1.075
1.075
= 39.88 o = 79.75 o
Page No.7
April 2008
AT =
1
(1.075 1.075) sin 79.75 o
2
Service Manual
AT = 0.569m 2
Area of sector:
As =
( )
1 2
r ( ) , Note : , should be in radians
2
(radians) =
As =
6.28 (deg rees )
360
(radians)
6.28 79.75 o
=
= 1.39rad
360
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
Page No.8
April 2008
2.
Service Manual
Useful Equations for Testing Generators and UPS`s
Page No.9
April 2008
Service Manual
3.
Speed Switch On board Set up and Calibration

Deep Sea Unit
4.
Crompton
Ensure engine is operating normally and will not over speed.
Ensure engine is operating normally and will not over

speed.
Run up engine. Check frequency at mag pick up connection is

in line with table below.
Run up engine. Check frequency at mag pick up

connection is in line with table below.
Set Multi meter to mA range. Connect Multi meter across

terminal 15 & 16.
Set Multi meter to mA range. Connect Multi meter across

terminal 15 & 16.
Trim the calibration pot on speed switch until multi meter is

reading 1.30mA.
Trim the RANGE ADJUST on speed switch until multi

meter is reading 0.75mA.
Stop engine and turn Governor fully back. Restart engine and
set speed to 30% (0.39mA) (450RPM) Trim CRANK pot on
speed switch until light just comes on.
Stop engine and turn Governor fully back. Restart engine

and set speed to 30% (450RPM) Trim CRANK pot on
Set Speed to 90%(1.17mA) (1350RPM). Trim UNDERSPEED

pot on speed switch until light just comes on.
Set Speed to 90% (1350RPM). Trim UNDERSPEED pot

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

Recheck all settings. If incorrect start again at step 4.
Recheck all settings. If incorrect start again at step 4.
For 60Hz connect unmarked terminal to negative (J2)
For 60Hz redo step 7 setting speed at 110% 1800RPM

(1980RPM)
Note at normal running speed Crank & Under speed

lights are on
Note at normal running speed all lights are on.
Fly Wheel teeth and Magnetic pick up frequencies by engine type

Flywheel
Teeth
MP Hz @ 1500RPM
MP Hz @
1800RPM
IVECO 8025, IVECO 8031 I,

IVECO 8041 I, IVECO 8051i,
IVECO 8061i, IVECO 8061 si,
IVECO 8361i, IVECO 8361Sri15,
130
3250
3900
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
Engine model
Page No.10
April 2008
5.
Service Manual
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
-25C to + 50C
Temperature Range
Page No.11
April 2008
Service Manual
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
Page No.12
April 2008
6.
Service Manual
Tools List
S.No
Site
Group
1
2
3
4
5
6
7
8
All
All
All
All
All
All
All
All
Electrical
Electrical
Electrical
Electrical
Electrical
Electrical
Electrical
Electrical
9
10
11
12
13
14
15
16
17
18
19
All
All
All
All
All
All
All
All
All
All
All
Diagnostic
Diagnostic
Diagnostic
Diagnostic
Diagnostic
Health check
Health check
Health check
Health check
Health check
Health check
20
21
All
All
Service
Service
Description
Electrical
33KV Live Line Tester
5 K Megger
Clamp Meter
Multimeter
Phase rotation meter
Megger meter
Hydraulic Crimper 240mm
Electricians Tool Set Complete
Specialist
Borescope 8mmDia X 43mm Length
Fiber Light Guide Cable 1.0M
Light Source
Light source spare bulbs
Cooling System Tester
Cat Blow by test kit
Cat engine evaluation group
"K"type Surface probe
"K"type Probe Adaptor
Raytek Infrared temperature Gun
Oil Filter Cutter
A & B Service
Specific gravity tester (Refractometer)
PH Meter
Service
Service
Service
Service
Service
Service
Service
Service
Service
Service
Service
Service
Service
Service
Service
TBN test kit ( 3 Items )

Oil sample taking valve
Oil Filter Wrench (Filter Straps)
Oil Filter Cutter (see Health check also)
3/8" Drive dial torque wrench
3/8" Drive dial torque wrench
3/8" Drive x 1/16" Flat tip socket driver
3/8" Drive Ratchet Head
Valve Setting Gauge
Valve Setting Gauge
Valve adjusting wrench
DCA test stick kits
Engine Drawing
Spark plug wrench
Inline 5 Datalink adaptor kit
22
All
23
All
24
All
25
All
26
G3
27 QSK D+G
28
G3
29
G3
30
G3
31 QSK D
32
G3
33
All
34
Gas
35
Gas
36
Gas
Manuf.
Part Ref
Unit
CAPEX ITEM
BM11D
36
187
3126
BM223
SC30
JA-ELE-7020
Metrohm
AVO
Fluke
Fluke
Hioke
Megger
Hiforce
Ea
Ea
Ea
Ea
Ea
R080-043-0455SW115-50
7108699
3-ILK-6A
Olympus
Olympus
Olympus
Olympus
Sykes Pik
Caterpillar
Caterpillar
Cummins
RS
Raytek
CAT
Ea
Ea
Ea
Ea
Ea
Ea
Ea
Ea
Ea
Ea
Ea
CAT
CAT
Ea
Ea
Kittiwake
CAT
SNAP ON
CAT
SNAP ON
SNAP ON
SNAP ON
SNAP ON
Cummins
Cummins
SNAP ON
Cummins
Cummins
Cummins
Cummins
Ea
Ea
Ea
Ea
Ea
Ea
Ea
Ea
Ea
Ea
Ea
Ea
Ea
Ea
Ea
3318000
8T-2700
1U-5470
3164494
222-0234
RaytekMX2
4C-5084
1U-7298
4C-8503
FG-K3-020-KW, FG-K1-004-KW,
FG-K2-002-KW
G3 & QSK
A91D
4C-5084
TEC12A
TEC25A
F31D
TM67A
3823557
3824901
M1322
CC2602M
4021359
3162231
4918416
Page No.13
April 2008
Service Manual
37
38
39
40
41
Gas
Gas
Gas
Gas
Gas
Service
Service
Service
Service
Service
42
43
Gas
Gas
Service
Service
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
61
62
63
64
65
66
67
All
All
All
All
G3
QSK D+G
All
All
G3
QSK D
All
G3
All
G3
QSK D+G
QSK D+G
All
G3
G3
G3
QSK D+G
All
All
All
Repair
Repair
Repair
Repair
Repair
Repair
Repair
Repair
Repair
Repair
Repair
Repair
Repair
Repair
Repair
Repair
Repair
Repair
Repair
Repair
Repair
Repair
Repair
Repair
68
69
70
71
72
73
74
75
76
77
All
All
All
All
All
All
All
All
All
All
General
General
General
General
General
General
General
General
General
General
Insite 7.0 software Kit

Testo 335 Exhaust Gas anaylizer
Fluke Mini current tongs
Crowcon Gasman 2
Spy Gas 4 leak detector
Digitron 2026P differential pressure
manometer
Valve Setting Gauge (Gas)
Engine Tools
Impact wrench 1/2" Drive
Torque Wrench 1/2" Drive (50-250 ft lbs)
Torque Wrench 3/4" Drive (100-550 ft lbs)
Multiple Valve Spring Compression Tool
Fixture Liner Installation
Fixture Liner Installation
Set Cylinder Liner Clamp
Liner puller
Injector Puller
Injector Puller
Compressor Piston Ring
Wrench Injector Preload Torque
Expander, Piston Ring
Front and Rear oil seal tool
Front and Rear oil seal tool
Self Drilling Screws for 3163340
Straight edge 18" Long
Fuel pump wrench
Fuel pump wrench
Cylinder Head Socket 3/4 AF 3/4 drive
Cylinder Head Socket 21mm 3/4 drive
Magnetic DTI stand
Dial Test Indicator
O ring picker
GENERAL
Tool Kit (see sperate list TK1)
14lb Hammer
4lb Lump Hammer
Tommy Bars - 928/42
Drill Bits 1mm to 25mm
Drill Bits 1/16" to 1/2"
Tap & Die Set,Metric,UNC
Tap & Die Set,Metric,UNF
Tap & Die Set,Metric,Metric 6 - 24
Tap & Die Set,Metric,BSP 1/4 to 1"
3886388
335 with NO cell
i200s
GASMANII
SPYGAS
Cummins
Testo
Fluke
Crowcon
Spy Gas
Ea
Ea
Ea
Ea
Ea
339-4140
3164393
Digitron
Cummins
Ea
Ea
IW50
HWT330NT
8563 10
3163606+3163177
3375422
3163329
3822503
3376015
3823024
3824830
3823294
3376592+TM67A+TM82
ST-1269
R-ST1093,F-3163692+3375497
3163349
3163356
GA438
M1328A
M1329
Proto 5524
Proto 5521M
Mitutoyo 7010S
Mitutoyo 2416S
YA338
Hiforce
Hiforce
Gedore
Cummins
Cummins
Cummins
Cummins
Cummins
Cummins
Cummins
Cummins
Cummins
Cummins
Cummins
Cummins
Cummins
SNAP ON
SNAP ON
SNAP ON
Proto
Proto
Mitutoyo
Mitutoyo
SNAP ON
Ea
Ea
Ea
Ea
Ea
Ea
Ea
Ea
Ea
Ea
Ea
Ea
Ea
Ea
Ea
Ea
Ea
Ea
Ea
Ea
Ea
Ea
Ea
Ea
Beta
Ea
Mechanical
HAMMER14LBS
HAMMER4LBS
JA-TLS-1041
1M467
JA-TLS-7123
JA-MEC-7123
JA-MEC-7122
JA-MEC-7124
JA-MEC-7114
Page No.14
April 2008
78
79
80
81
82
83
84
85
86
87
88
89
90
91
92
93
94
95
All
All
All
All
All
All
All
All
All
All
All
All
All
All
All
All
All
All
96
97
98
99
100
101
102
103
104
105
106
All
All
All
All
All
All
All
All
All
All
All
107
108
109
110
111
112
113
All
All
All
All
All
All
All
WORKSHOP EQUIPMENT
Portable Invertor (Welding Machine)
Air Compressor 150LT/3HP/1HP
Airblow gun + Hose + Fittings
Hydraulic Cylinder 20ton jack
Hydraulic hand Pump Manual
Pressure washer
Vacuum Cleaner Wet/Dry 230v / 50Hz
Battery Charger
Cutting & Welding set
Angle Grinder 230mm
Angle Grinder 100mm
Barrel pumps
Battery Tester
Bottle Jack 20 Ton
Chain Blocks 2 Tons
Lead Lamps
Pistol Drill 1/2" cordless
Rechargeable Torches
MISC ITEMS
General 1000 W flood lights
General Drip Trays 30" x 18" x 2 -1/2"
General 1 litre measuring Jug
General 5 litre measure
General Large funnel
General Medium funnel
General Small Funnel
General Small Funnel
General Jump Leads H/Duty 6Meters
BOOKS / STICKERS/SERVICE INFO
General Requisition pads
Service
Service Report pads
Service
Component Change advice pads
Service
Service stickers
Service
Coolant test labels
Health Check Health check procedure
Health Check Health check reports
General
General
General
General
General
General
General
General
General
General
General
General
General
General
General
General
General
General
Service Manual
LHN 250
AB150-335
UT11AS
HLS201
HP110+HC2
KEW30CA 240v
Mirage 1640
Velox 650
JA-TLS-2013
JA-TLS-2026
JA-TLS-2025
JA-TLS-2024
JA-TLS-2006
BTTLJCK20T
CHAINBLOCK2T
JA-TLS-2008
JA-TLS-2023
JA-TLS-1039
FLDLGT1000W220V
JA-MEC-2012
7501
7502
7503
7505
2366
2365
2364
2363
JA-ELE-7019
N/A
N/A
CCAN
N/A
N/A
N/A
N/A
Page No.15
ESAB
FIAC
Hiforce
Hiforce
KEW
Portotechni
Velox 650
Victor
Ea
Ea
Ea
Ea
Ea
Ea
Ea
Ea
Ea
Pressol
Pressol
Pressol
Pressol
Pressol
Pressol
Pressol
Pressol
Aggreko
Aggreko
Aggreko
Aggreko
Aggreko
Aggreko
Aggreko
April 2008
Ea
Ea
Ea
Ea
Ea
Ea
Ea
Service Manual
Aggreko "Mechanics Tools Trolley Contents"

Item
No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
61
Tool Description.
Toolbox on Wheels - 7 drawers.
Portable Toolbox
Adaptor 1/2" Female - 3/4" Male
Adaptor 3/4" Female - 1/2" Male
Adjustable Spanner - 24
Adjustable Spanner - 44
Allen Key Set 10pcs. Metric
Allen Key Set 11pcs. S.A.E
Ball Pein Hammer - 340gms.
Ball Pein Hammer - 900gms.
Chisel
Chisel Wide - 60mm (scraper)
Circlip Pliers - Combination
Circlip Pliers External - 175mm
Circlip Pliers Internal - 180mm
Combination Spanner - 10mm
Combination Spanners 5/16" - 15/16"
Combination Spanners 6mm - 22mm
Dead-Blow Hammer - 50mm
Deep Socket Set 1/2" Drive - 12 point. Metric
Deep Socket Set 1/2" Drive - 12 point. S.A.E
Deep Socket Set 3/8" Drive on rail 12 point. Metric
Deep Socket Set 3/8" Drive on rail 12 point. S.A.E
Drill Bit Set - 19pcs.
Files Set - 5pcs.
Flexible Hexagon Nut Driver Set 5mm - 13mm
Flexible Magnet Pick Up
Hacksaw Blade (HSS-BIMETAL)
Hacksaw Frame - 300mm
Heavy Duty Pipe Wrench - 140mm
Holesaw Kit - 22mm - 64mm
Knife - Utility Retractable Blade
Knife Blades - 10pcs.
Lump Hammer - 2000gms.
Measuring Tape - 5mtrs.
Nose Pliers - Long
O-Ring Picker / Scriber
Pin Punch Set
Pipe Wrench - 76mm
Pliers Adjustable Self Locking
Pliers Combination - Insulated
Pliers Slip Joint (water pump)
Pry Bar
Ratchet 1/2" Drive
Ratchet 3/8" Drive
Ring Spanners 10pcs. 1/4x5/16 - 1.1/8x1.5/16
Screwdriver Large
Screwdriver Set (electrical terminal driver)
Screwdriver Set 11pcs. 50mm - 200mm
Screwdriver Set Insulated - 6pcs.
Socket Set 3/8" Drive - 12 point. Metric
Socket Set 3/8" Drive - 12 point. S.A.E
Spanner Insulated - 13mm (for battery terminals)
Steel Ruler - 300mm
Tin Snips - 300mm
Qty.
Manufacturer
Part/Ref. Number
1
1
1
1
2
2
1
1
1
1
1
1
1
1
1
6
6
6
6
4
6
6
2
1
1
1
2
1
1
1
1
1
1
5
1
1
1
3
3
1
1
1
1
1
1
1
2
2
1
1
2
1
2
4
1
1
1
1
1
1
1
Beta
Beta
Beta
Beta
Beta
Beta
Beta
Beta
Beta
Beta
Beta
Beta
Beta
Beta
Beta
Beta
Beta
Beta
Beta
Beta
Beta
Beta
Beta
Beta
Beta
Beta
Beta
Beta
Beta
Beta
Beta
Beta
Beta
Beta
Beta
Beta
Beta
Beta
Beta
Beta
Beta
Beta
Beta
Beta
Beta
Beta
Beta
Beta
Beta
Beta
Beta
Beta
Beta
Beta
Beta
Beta
Beta
Beta
Beta
Beta
Beta
C24
C18
920/16
928/15
110/200
110/380
96N/B10
96ASB11
1377/340
1377/900
1701E/5
1702/60
1039
1036/175
1032/180
42/10
42/13
42/17
42/19
42/24
42/6
42/7
42AS/11
42/S17
1392/50
920B/C20
920AS/C17X
910L
910ASL
415/SP19
1719A/S5
943FL/S8
1712/3
1728BM
1725
363/900
450/C9
1772B
1772RL/1
1380/2000
1692/5
1162IN200
1688
31/B6
362/450
1054
1150MQ220
1044/240
964
920M/55
910M/55
90AS/10
1274L
1290/0.4x2.5x75
1273/S11
1283MQ/D6
910B/C17
910AS/C13
52MQ/13
1683/300
1112/300
Page No.16
April 2008
62
63
64
65
66
67
68
69
70
71
72
73
74
75
76
77
78
79
80
81
82
83
84
85
86
87
88
89
90
Torque Angle Indicator 3/4"

Torque Wrench 3/8" Drive click-type 20 - 100Nm
Vernier - 300mm
Wire Brush
Wire Cutter / Snips - Diagonal Flush Cutting
Wire Cutter / Snips - Insulated
Wire Stripping Pliers - 0.5mm - 6mm
Crimping Pliers
Torque Wrench 3/4" - 8563-10 s/n:
Torque Wrench 1/2" Drive 250lbs - HTW330NT s/n:
Adaptor Ratchet 3/8" Drive
Allen Key Socket 1/2' Drive - Metric
Allen Key Socket 1/2' Drive - S.A.E
Impact Socket 1/2" Drive 5/8" (manifold bolts)
Impact Socket 1/2" Drive 9/16" (turbo bolts)
Power Bar / Lever 1/2" Drive - 18"
Pry Bar - 30"
Socket Set 3/4" Drive - 12 point. S.A.E
Grease Gun
Grease Meter (alternator greasing)
Dial Torque Wrench 3/8" Drive 0-150in/lbs - TEC12A - s/n:
Dial Torque Wrench Bit 3/8" Drive - F31E
Feeler Gauge Bent - FB307D
Fuel Pump Spanner - M1328A
Fuel Pump Spanner - M1329
Oil Filter Strap - A91D
Socket 1/2" Drive 11/16" (big end bolts) - SW221
Socket 3/4" Drive - (cylinder head bolts) - LDH242
Socket Extension 3/4" Drive 3" - L32
1
2
1
1
2
1
2
1
1
1
1
1
1
1
1
1
1
1
1
1
1
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1
1
1
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2
1
Service Manual
Beta
Beta
Beta
Beta
Beta
Beta
Beta
Crimpstar
Gedore
Hi - Force
Proto
Proto
Proto
Proto
Proto
Proto
Proto
Proto
Prssol
SKF/SAMOA
Snap On
Snap On
Snap On
Snap On
Snap On
Snap On
Snap on
Snap On
Snap On
Page No.17
600/2
606/10
1654
1737AC
1080/160
1082MQ160
1142
HP3
JA-TLS-1037
JA-TLS-1011
5247
5441-SM
5441-7
7420H
7418H
5468
2125
55102
12632
411100
JA-TLS-1033
JA-TLS-1023
JA-TLS-1017
JA-TLS-1019
JA-TLS-2020
JA-TLS-1020
JA-TLS-1021
JA-TLS-1024
JA-TLS-2021
April 2008
Blank Page
Page No.18
Section 12
Product Bulletins & Information
Revision April 2008
Blank Page
Page No.20
Service Manual
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)
Page No.21
April 2008
Blank Page
Page No.22
1.
Service Manual
Cummins KTA-50 Valve Spring Failure (TSS_2007_001) Rev A,B
Page No.23
April 2008
Service Manual
Doc No. TSS_2007_001
Product Bulletin
Cummins KTA- 50
Valve Spring failure
Date: 25 November 2007

Page: 2 of 5
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)
Prepared By:
Approved By:
Luke Tranter
Rev
Date
14/11
(3)
__________
Jack Denz
Technical Service - Product Support

Page No.24
April 2008
Service Manual
Product Bulletin
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.
Prepared By:
Approved By:
Luke Tranter
Rev
Date
14/11
__________
Jack Denz

Page No.25
April 2008
Service Manual
Product Bulletin
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:
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:
Valve Rotator Part Number 3081081

Valve Spring Part Number 3633840
Inlet Valve
Part Number 3631950
Exhaust Valve Part Number 3088389
Valve collet Part Number 205091
Prepared By:
Approved By:
Luke Tranter
Rev
Date
14/11
__________
Jack Denz

Page No.26
April 2008
Service Manual
Product Bulletin
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.
Prepared By:
Approved By:
Luke Tranter
Rev
Date
14/11
__________
Jack Denz

Page No.27
April 2008
Service Manual
Revision B - 17th Mar 2008

Product Bulletin
Cummins KTA- 50
Date: 17 March 2008

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
Prepared By:
Allan Methven
Rev
Date
14/11
17/03
Approved By:
__________
Jack Denz

Page No.28
April 2008
Service Manual
Product Bulletin
Cummins KTA- 50
Date: 17 March 2008

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:
Valve Rotator
Valve Spring
Valve Collets
Part Number 3640315

Part Number 3633840
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.
Prepared By:
Allan Methven
Rev
Date
14/11
17/03
Approved By:
__________
Jack Denz

Page No.29
April 2008
2.
Service Manual
QSK-45/60 LTA Pumps (TSS_2008_001) Rev A,B
Page No.30
April 2008
Page No.31
Service Manual
April 2008
Service Manual
Revision B - 20th Jan 2008

Product Bulletin
QSK-45/60 LTA Pumps
Date: 20-01-2008
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:
Change from greased bearings to oil fed bearings, which has increased lubrication.
Improved Water and Oil seals.
Increased Body Strength (Stiffening Rib)
Introduction of Cavitation plates
Prepared By:
Rev
Date
20/01
A Methven
Approved By:
Jack Denz
Technical Service and Support

Page No.32
April 2008
Service Manual
Product Bulletin
QSK-45/60 LTA Pumps
Date: 20-01-2008
Page: 2 of 3
Status: Final
Stiffening Rib
Lub Oil Feed to the bearings
Installation Information:
Drain the cooling system and remove the previous revision of LTA Pump.
Transfer the coolant pipes from the removed pump to the replacement pump
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.
Fit the new O-ring to the spigot on the pump body.
Position the gasket on the mating face of the pump body.
Slide the pump into place and enter all four mounting bolts.
Align and secure all cooling lines.
Tighten all four mounting bolts to the required torque
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.
Prepared By:
Rev
Date
20/01
A Methven
Approved By:
Jack Denz

Page No.33
April 2008
Service Manual
Product Bulletin
QSK-45/60 LTA Pumps
Date: 20-01-2008
Page: 3 of 3
Status: Final
Connect the supply end of the lubricating oil feed hose to the connection point highlighted
below on the front gear cover.
Re fill the cooling system

Run the engine and check the pump for coolant and oil leaks, correct as required.
Complete a CCAN and return it the technical.records@aggreko.ae
Prepared By:
Rev
Date
20/01
A Methven
Approved By:
Jack Denz

Page No.34
April 2008
3.
Service Manual
QSK-45 Gempac Allen Bradley HMI Screen Replacement Procedure

(TSS_2008_002)
aggreko
Date: 23-Jan-08
QSK45 Gempac
Allen Bradley HMI Screen
Replacement Procedure
Prepared By: A Methven

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
Page No.35
April 2008
Service Manual
aggreko
Date: 23-Jan-08
QSK45 Gempac

Page: 2 of 8
Rev:Final
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
1 of Control Panel Stainless Steel Insert Part Number JA-ELE-7142 Cost $30.54
1 of Resistor 120ohm
Part Number 305039a
1mtr 4 core screen cable
Part Number JA-MAC-7141 Cost $1.50
Part Number 275158a
Cost $2005.12
Cost $2.70
Consumables:
x
6 of self tapping screws to secure the Deif Display (Size 4mm-10mm long)
Clear Silicone sealer
Crimps and Ferrules (Quantity as required)

Support
Page No.36
April 2008
aggreko
Service Manual
Date: 23-Jan-08
QSK45 Gempac

Page: 3 of 8
Rev:Final
TSS_2008_002
Conversion: Gem Pac Unit

x
Isolate the Main Battery supply
Disconnect the panel Nicad Batteries
Unplug all connections from the Gempac PPU and remove the unit from the control
panel (Carefully so not to damage the unit!)
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?
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?
Return this item to the site or project stores for safe keeping.
Fit the Replacement unit Part No 275158a into the control panel and reconnect all the
green plugs into there relative ports.

Support
Page No.37
April 2008
Service Manual
aggreko
Date: 23-Jan-08
QSK45 Gempac

Page: 4 of 8
Rev:Final
TSS_2008_002
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:
Resistor to be crimped and fitted between terminals 127 & 129
White core of the screen cable to be ferruled MOD (-) and connected to terminal 131.
Black core of the screen cable to be ferruled MOD (+) and connected to terminal 133.
As shown above the outer sheath of the screen cable should be crimped and
connected to terminal 132.
Remove the UDAM converter and RS232 cable shown below as this is no longer
required:

Support
Page No.38
April 2008
aggreko
Service Manual
Date: 23-Jan-08
QSK45 Gempac

Page: 5 of 8
Rev:Final
TSS_2008_002
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 :
Run the screen cable form the Mod Bus reading card within the panel trunking to 06
Interface card and connect as follows:
White core of the screen cable to be ferruled MOD(-) and connected to terminal 18
x
x
Black core of the screen cable to be ferruled MOD (+) and connected to terminal 21.
The outer sheath of the screen cable should be only connected at the Gempac End.

Support
Page No.39
April 2008
Service Manual
aggreko
Date: 23-Jan-08
QSK45 Gempac

Page: 6 of 8
Rev:Final
TSS_2008_002
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.
Remove the power supply cables running the HMI screen as they are no longer
required.
Attached the Deif display to the stainless steel inset using the 6 self tapping screws.
Apply a small bead of clear silicone sealer all the way round the outside edge of the
stainless steel insert.
Mount the inset into the control panel opening and secure with the nuts and washers
supplied.
Remove any excess silicone sealer.
Connect the 9 pin Display cable to the back of the Deif display.

Support
Page No.40
April 2008
aggreko
Service Manual
Date: 23-Jan-08
QSK45 Gempac

Page: 7 of 8
Rev:Final
TSS_2008_002
Display as mounted on the control panel door:
Operational Test:
x
Reconnect the Control Panel Nicad Batteries
Turn on the Main Battery isolator.
Turn on the control panel key switch and allow the Deif unit to boot up.
Press Jump, scroll to 5000 and select application no 1 for QSK45, then save.
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.
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
Page No.41
April 2008
Service Manual
aggreko
Date: 23-Jan-08
QSK45 Gempac

Page: 8 of 8
Rev:Final
TSS_2008_002

Support
Page No.42
April 2008
4.
Service Manual
Turbocharger Oil feed line Upgrade KTA-50G3/QSK-45G4(TSS_2008_003)

Product Bulletin
EH&S
Turbocharger Oil feed line Upgrade
KTA-50-G3 / QSK-45-G4
aggreko
Date: 23-Jan-08
Prepared By: L. Tranter
Page: 1 of 4
Rev: Final
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
Page No.43
April 2008
Service Manual
Product Bulletin
EH&S
KTA-50-G3 / QSK-45-G4
aggreko
Fig.2
New Turbocharger oil feed line
clamping for the KTA-50-G3.
Date: 23-Jan-08
Page: 2 of 4
Rev: Final
TSS_2008_003
Fig.3
Old Turbocharger oil feed line
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
Extended Adapter fitted to turbocharger
and the New Design Oil feed line.
Parts Required
Description
Adaptor
Kevlar Wrap
Feed Line Left
Feed Line Right
Return Line Left
Return Line Right
Viton O'ring Seal
Return Line O'ring
Return Line Gasket
Adaptor to Turbo O'ring
KTA 50 G3 Part No.

ADAPTOR-TS-G3
SHS-PJ-14
3635033
3635032
3632337
3632336
3922794
216187
3630742
3037537
Fig.4
Kevlar wrap fitted to turbocharger
Oil feed line
QSK 45 Part No.

ADAPTOR-TS-QSK
SHS-PJ-14
4100966
4100965
4065493
4065492
3922794
216187
3630742
3679139
Qty/ Length
2
2 11/2 Meter
1
1
1
1
4
2
2
2

Support
Page No.44
April 2008
aggreko
Product Bulletin
EH&S
KTA-50-G3 / QSK-45-G4
Service Manual
Date: 23-Jan-08
Page: 3 of 4
Rev: Final
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
Page No.45
April 2008
Service Manual
aggreko
Product Bulletin
EH&S
KTA-50-G3 / QSK-45-G4
engine cylinder block.
Date: 23-Jan-08
Page: 4 of 4
Rev: Final
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
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
Page No.46
April 2008
5.
Service Manual
Engine Driven Fan Pulley Alignment instruction (TSS_2008_004)

Product Bulletin
Engine Driven Fan Pulley Alignment
Instruction
Date: 27-01-2008
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:
Isolate the main starting batteries of the Generator and lock off where possible.
Remove the control panel key and apply a Do Not Start tag to the main control panel.
Remove all relevant guards to gain access to the cooling fan drive.
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.
Important: Before you check the drive pulley alignment, the following must be checked:
The Generator container must be level, over its length.
The radiator must be perpendicular to the container (90 to the container)

The above checks must be done using a good quality spirit level
Manually rotate the fan drive assembly, check that it rotates freely and listen for any
rumbling noises from both support bearings, replace as required.
Prepared By:
Rev
Date
27/01
A Methven
Approved By:
Jack Denz

Page No.47
April 2008
Service Manual
Product Bulletin
Instruction
Date: 27-01-2008
Page: 2 of 4
Status: Final
Using the spirit level, check that both the fan pulley and the engine pulleys are level
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)
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:
Prepared By:
Rev
Date
27/01
A Methven
Approved By:
Jack Denz

Page No.48
April 2008
Service Manual
Product Bulletin
Instruction
Date: 27-01-2008
Page: 3 of 4
Status: Final
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
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:
Prepared By:
Rev
Date
27/01
A Methven
Approved By:
Jack Denz

Page No.49
April 2008
Service Manual
Product Bulletin
Instruction
Date: 27-01-2008
Page: 4 of 4
Status: Final
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:
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.
Manually rotate the fan drive assembly, check that it still rotates freely.
Refit the drive belt and release the previously secured belt tensioner by removing the
wooden block.
Check the fan space for any debris that should not be in there i.e. rags and tools
Replace all fan guards and brackets previously removed.
Run the engine up and check that there are no issues before returning the unit to service.
Prepared By:
Rev
Date
27/01
A Methven
Approved By:
Jack Denz

Page No.50
April 2008
6.
Service Manual
QSK-45/60 Front & Rear Crankshaft Oil Seal(TSS_2008_005)

QSK45/60
Front & Rear Crankshaft Oil Seal
Service Bulletin

Date: 17 March 2008
Page: 1 of 4
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:
Front Crankshaft Seals, part number: 3089142
3171910
4066222
Rear Crankshaft Seals, Part Number: 3089094
3171911
4066223
Old style Crankshaft seal (Black)

Prepared By:
Rev
Date
17/03
Allan Methven
Approved By:
__________
Jack Denz

Page No.51
April 2008
Service Manual
QSK45/60
Service Bulletin

Date: 17 March 2008
Page: 2 of 4
Status: Final
Component Improvements:
New Front crankshaft seal (RED)
New Rear Crankshaft Seal (Blue)
New Component Part Numbers:

x
x
Front Crankshaft oil seal (Red)

Rear Crankshaft oil seal (Blue)
4100624
4100625
The pictures above show the Revised Front and Rear Oil seal assemblies; the following
improvements have been incorporated:
1
2
3
4
Improved seal geometry

Internal bore coating is color coded for ease of identification.
Improved external sealing arrangement
Improved Rotational identification
By introducing these revised seals Cummins hope this component will deliver improved durability
and minimize equipment downtime.
Prepared By:
Rev
Date
17/03
Allan Methven
Approved By:
__________
Jack Denz

Page No.52
April 2008
Service Manual
QSK45/60
Service Bulletin

Date: 17 March 2008
Page: 3 of 4
Status: Final
Installation Information
Additional Equipment required:
x
x
Installation Tools
Loctite RTV 5699 sealant
6177 sealant
Isolate the battery supply to the starter motor and lock it off.
Remove the Crankshaft Dampers and old oil seal as described in the
Engines Workshop Manual or Quick serve on line.
Clean all the components and prepare all surfaces prior to the installation of the new seal
Before installing the crankshaft seal make sure all surfaces are completely clean from dirt
and oil.
The seal MUST to be installed dry (Do not lubricate any surface)
Install the guide pin in the top mounting screw hole to

help align the seal.
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).
Place the seal in position using the locating pin to

align the screw holes.
Prepared By:
Rev
Date
17/03
Allan Methven
3163349
3164067
3163358
Approved By:
__________
Jack Denz

Page No.53
April 2008
Service Manual
QSK45/60
Service Bulletin

Date: 17 March 2008
Page: 4 of 4
Status: Final
Install the seal; pushing it in as far as it will go by hand.
Use the installation tool Part Number 3163349 to install the seal to the correct position.
Remove the locating pin.
Fit the mounting screws and torque the setscrews to 10 Nm (89 in-lb).
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.
Re Install all Guards prior to running the engine.
Complete a CCAN and forward it to Technical.Records@aggreko.ae
Prepared By:
Rev
Date
17/03
Allan Methven
Approved By:
__________
Jack Denz

Page No.54
April 2008
7.
Service Manual
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

Page No.55
April 2008
Service Manual
Date: 28-May-06
aggreko
Product Bulletin
Page: 2 of 6
Rev: 1
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.
Page No.56
April 2008
Date: 28-May-06
aggreko
Service Manual
Product Bulletin
Page: 3 of 6
Rev: 1
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.
Page No.57
April 2008
Service Manual
Date: 28-May-06
aggreko
Product Bulletin
Page: 4 of 6
Rev: 1
TSS
Baldwin Filters Response to the above;

As described below:
Page No.58
April 2008
Date: 28-May-06
aggreko
Service Manual
Product Bulletin
Page: 5 of 6
Rev: 1
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.
Page No.59
April 2008
Service Manual
Date: 28-May-06
aggreko
Product Bulletin
Page: 6 of 6
Rev: 1
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.
Page No.60
April 2008
8.
Service Manual
QSK-45 Fuel Pump Internal Filter

Doc No.
Product Bulletin
QSK45 Fuel Pump Internal Filter
Date: 02/04/2005
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 Issues, 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:-.
Prepared By:
Rev
Date
02/04
Allan Methven
Approved By:
Jack Denz

Page No.61
April 2008
Service Manual
Doc No.
Product Bulletin
QSK45 Fuel Pump Internal Filter
Date: 02/04/2005
Page: 2 of 2
Status: Final.
x
x
x
Remove the filter and clean it using a can of Aerosol Lubricant i.e. WD40.
There is also a magnet contained within the filter, check and remove any metal particals.
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
x
Grease the threads of the plug and refit.

Turn on all fuel supply lines.
Internal System Diagram

Fuel Outlet
PRESSURE
SENSOR
Fuel Tank
36 micron
Internal Filter
Bypass Valve
Actuator fitted with

105 micron filter
Table of Contents useful info

Prepared By:
Rev
Date
02/04
Allan Methven
Approved By:
Jack Denz

Page No.62
April 2008
9.
Service Manual
QSK-45 Pre-Low Oil Pressure Warning Set Point Adjustment Procedure

Date: 7-Dec-05
QSK45 Pre-Low Oil Pressure Warning Set

Point Adjustment Procedure.
Report By: A Methven

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.

Page No.63
April 2008
Service Manual
Date: 7-Dec-05


Page: 2 of 3
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.

Page No.64
April 2008
Rev: 1
Service Manual
Date: 7-Dec-05


Page: 3 of 3
Rev: 1
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.

Page No.65
April 2008
Service Manual
10.
QSK45 Inpower Parameter adjustment Procedure

XAAA,XADA and P Prefix
QSK45 In power Parameters
adjustment Procedure.
Date: 7-Dec-05
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
0.0
800.0
1200.0
1700.0
1800.0
2200.0
PSI
0.00
25.00
39.00
54.00
55.00
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

Page No.66
April 2008
XAAA,XADA and P Prefix

QSK45 In power Parameters
adjustment Procedure.
Service Manual
Date: 7-Dec-05
Page: 2 of 2
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 120C
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.

Page No.67
April 2008
Rev: 1
Service Manual
11.
QSK45 Inpower Shutdown Testing Procedure

Date: 7-Dec-05
QSK45 In power Shutdown Testing

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

Page No.68
April 2008
Service Manual
Date: 7-Dec-05

Procedure.

Page: 2 of 4
Rev: 1
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 2have 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.
Page No.69
April 2008
Service Manual
Date: 7-Dec-05

Procedure.

Page: 3 of 4
Rev: 1
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.

Page No.70
April 2008
Service Manual
Date: 7-Dec-05

Procedure.

Page: 4 of 4
Rev: 1
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.

Page No.71
April 2008
Service Manual
12.
QSK Inpower Procedure for Saving a Capture file

Date: 7-Dec-05
QSK In Power Procedure for Saving a

Capture file.

Page: 1 of 2
Rev: 1
TSS
Set up.
Procedure
5. Double click on
8. Click on Monitor and the following Icons 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.

Page No.72
April 2008
Service Manual
Date: 7-Dec-05
QSK In Power Procedure for Saving a

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.

Page No.73
April 2008
Service Manual
13.
QSK-45 Inpower Software Data Logging Procedure

Date: 7-Dec-05
QSK45 In power Software Data Logging

Procedure.

Page: 1 of 5
Rev: 1
TSS
Set up.
Procedure
5. Double click on
8. Click on Monitor and the following Icons 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.

Page No.74
April 2008
Service Manual
Date: 7-Dec-05

Procedure.

Page: 2 of 5
Rev: 1
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 parameters 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.

Page No.75
April 2008
Service Manual
Date: 7-Dec-05

Procedure.

Page: 3 of 5
Rev: 1
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.

Page No.76
April 2008
Service Manual
Date: 7-Dec-05

Procedure.

Page: 4 of 5
Rev: 1
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.

Page No.77
April 2008
Service Manual
Date: 7-Dec-05

Procedure.

Page: 5 of 5
Rev: 1
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.

Page No.78
April 2008
14.
Service Manual
Renold Hi Tec Alternator Drive Coupling Information
aggreko
Date: 26-Sep-05
Renold Hi Tec Alternator Drive Coupling

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.
All new elements must be coated with the Renold Silicone Lubricant before fitting.
The following part no should be used when ordering replacement drive elements:
KTA50-G3
QSK45-G4
Renold Silicone Lubricant
14 of Part No 555267
16 of Part No 555378
Part No 3568588/00/401
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.
Page No.79
April 2008
Service Manual
aggreko
Date: 26-Sep-05

Information.

Page: 2 of 6
Rev: 1
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.

Page No.80
April 2008
aggreko
Service Manual
Date: 26-Sep-05

Information.

Page: 3 of 6
Rev: 1
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 120C 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:

Page No.81
April 2008
Service Manual
aggreko
Date: 26-Sep-05

Information.

Page: 4 of 6
Rev: 1
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
0.13
0.51
Min
Max
In
0.005
0.020
Min
Max
In
0.005
0.020
KTA50 Dimension:
Crankshaft End Clearance
Mm
0.13
0.51
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.

Page No.82
April 2008
aggreko
Service Manual
Date: 26-Sep-05

Information.

Page: 5 of 6
Rev: 1
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.

Page No.83
April 2008
Service Manual
aggreko
Date: 26-Sep-05

Information.

Page: 6 of 6
Rev: 1
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. drive torque wrench. (Torque setting sheet attached)
10. Infra Red Heat Gun.
11. Magnetic Clock Gauge stand.
12. Clock Gauge.
13. Crowbar.

Page No.84
April 2008
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Service Manual
April 2008
Service Manual
15.

Service Manual
Useful Technical
Information
5.
Date: 01-12-2005
Page: 1 of 1
Controlled
AI Depots and AIP Projects
Reviewed By:
Ray McElhinney
Approved By: Jack Denz

Page No.92
April 2008
16.
Service Manual
Drive Coupling Assembly Information for KTA38G2/38G8 &KTA50G2/

50G3 Engines
Service Manual
Useful Technical
Information
4.
Date: 01-12-2005
Page: 1 of 1
Controlled
Drive Coupling Assembly Information for KTA38G2/38G8 &

KTA50G2/50G3 Engines
Reviewed By:
Ray McElhinney
Page No.93
April 2008
Service Manual
17.

Service Manual
Useful Technical
Information
3.
Date: 01-12-2005
Page: 1 of 1
Controlled
Reviewed By:
Ray McElhinney
Page No.94
April 2008
18.
Service Manual
QST30 Electric Fuel Supply System Information
aggreko
Date: 25-Jan-06
QST30 Electric Fuel Supply System

Information.

Page: 1 of 11
Rev: 1
TSS

Page No.95
April 2008
Service Manual
aggreko
Date: 25-Jan-06

Information.

Page: 2 of 11
Rev: 1
TSS

Page No.96
April 2008
aggreko
Service Manual
Date: 25-Jan-06

Information.

Page: 3 of 11
TSS

Page No.97
April 2008
Rev: 1
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aggreko
Date: 25-Jan-06

Information.

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Rev: 1
TSS

Page No.98
April 2008
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Service Manual
Date: 25-Jan-06

Information.

Page: 5 of 11
TSS

Page No.99
April 2008
Rev: 1
Service Manual
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Date: 25-Jan-06

Information.

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Rev: 1
TSS

Page No.100
April 2008
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Service Manual
Date: 25-Jan-06

Information.

Page: 7 of 11
TSS

Page No.101
April 2008
Rev: 1
Service Manual
aggreko
Date: 25-Jan-06

Information.

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Rev: 1
TSS

Page No.102
April 2008
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Service Manual
Date: 25-Jan-06

Information.

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TSS

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April 2008
Rev: 1
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Date: 25-Jan-06

Information.

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TSS

Page No.104
April 2008
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Service Manual
Date: 25-Jan-06

Information.

Page: 11 of 11 Rev: 1
TSS

Page No.105
April 2008
Service Manual
19.
Container Fan Pitch Angle Procedure
aggreko
Date: 28-Jun-06
Radiator Cooling Fan

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
x
x
Three Phase running Current

Three Phase Voltage.
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:

Page No.106
April 2008
aggreko
Service Manual
Date: 28-Jun-06


Page: 2 of 4
Rev: 1
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.
Page No.107
April 2008
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aggreko
Date: 28-Jun-06


Page: 3 of 4
Rev: 1
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:

Page No.108
April 2008
Service Manual
Date: 28-Jun-06
aggreko


Page: 4 of 4
Rev: 1
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
x
x
Three Phase running Current

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

Page No.109
April 2008
Service Manual
20.
Operation Padlocks (AI_TSD_2008_001)

Doc No. AI_TSD_2008_001
OPERATION PADLOCKS
Date: 10th June 2008

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.
2.
3.
4.
5.
Transformer container personnel and end cargo doors.

Unused HV switchgear (locked in open position).
Neutral Earthing Resistor cabinet door and/or isolator (locked in closed position).
Earthing Transformer cabinet door and/or switchgear (locked in closed position).
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
Prepared By:
Approved By:
G Slater
Rev
Date
24/08
Jack Denz
Technical Service Directive

Page No.110
April 2008
Section 13
Revision Status
Revision April 2008
Blank Page
Page No.112
Mar-07
Mar-07
Section 5
Section 6
Page No.113
April 2008
Apr-08
Section 13
Mar-07
Apr-08
Mar-07
Section 11
Apr-08
Apr-08
Mar-07
Apr-08
Apr-08
Apr-08
Apr-08
Mar-07
Apr-08
Apr-08
Apr-08
Remarks
As per Allan Methven`s instructions,

Added coolant test procedure.
Changed as separate section((previously part of service procedure as Appendix 3)
Changed as separate section((previously part of service procedure as Appendix 2)
Changed as separate section (previously part of service procedure as Appendix 1)

1-Maintenance Schedule,2-Maintenance Procedures.
Highlighted in red
2 sections clubbed into 1 with sub-sections.Minor Changes highlighted in red
Previous Manual had only 7 sections and no Revision Status.

Current Manual has 13 sections / Order of the manual has been reshuffled as per
requirement.
All Procedural changes done to the sections are Highlighted in Red.
( + ) Revision History / Status
( + ) 20 Instructions
( - ) 12 Procedures
( - ) 3 work instructions
( - ) 2 Forms(Load Test & Start up Log
sheets)
Work instructions & Forms(Separate

sections
Forms
NO REVISIONS DONE
HV changed to 11/33/66kV
Oil sampling procedure
Forms
MV changed in HV
( - ) Prepared by name changed

Warranty Claim reporting & Flow Chart
Status and Description of the revised sections.
Full section added (20) instructions.(7 Instructions-issued product bulletins)

(13 Instructions-Product Information)
Section divided in 2(Useful Information & Product Bulletins & Information)
Load Test & Start up Log sheets removed,Revised Service Report (Rev 01-03-08),
C service standards for all TC equipment,A service standard for cooling Tower
units,Load test -Fluid chillers & Air Conditioners.
Revised Service report form.
Changes in procedure highlighted in Red.
MV replaced with HV in all instructions.

1.Some notes have removed and changes highlighted in red.
( - )Instruction 5 Recording of any disturbances removed.
Work Instruction 7
Separate section created for forms.( + )HV Transformer Report for A service
Name Changed from Gopal Krishnan to Jethesh Aranha

(7) Warranty claim form & Reporting changed with Component Failure Report and
update done in Warranty Process Flow chart.
Changed as separate section((previously part of service procedure as Appendix

4),Coomon Forms & AIP forms added in 1 section.
Table of contents
( - ) 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.
Table of contents
( - ) Oil sampling procedure on KTA50G3
with puradyn
( + ) Coolant Test Procedure
Table of contents
No revisions in content
Table of contents
2-Appendix
( - ) Editions done in text
Table of Contents
( + ) Rev Status
( + ) Product Bulletins & Information
(Section 12)
( + ) Revision History / Status( Section 13)
Revision Date Revisions / Additions
Section 12
Mar-07
Section 10
Mar-07
Mar-07
Section 4
Section 9
Mar-07
Section 3
Mar-07
Mar-07
Section 2
Section 8
Mar-07
Section 1
Mar-07
Mar-07
Section 7
Issue Date
Section
Main Index
Service Manual - Revision Status
Service Manual
Blank Page
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SERVICE MANUAL

Service Manual Index

(B) Depots Operational Overview

Section 2. Maintenance Procedures & Schedules

Section 3. Approved Service Consumables

Section 4. Work Instructions

Section 6. Technical Documentation

Section 10. Temperature Control

Section 11. Useful Information

Section 12. Product Bulletins & Information

Section 13. Revision Status

All Procedural Changes Highlighted in Red

Aggreko International Technical Services

Aggreko International Technical Services

Prepared By Allan Methven

Reviewed By Ray McElhinney

Approved By Jack Denz

Aggreko International Technical Services

Aggreko International Technical Services

Maximise the operational effectiveness of our equipment.

Prolong and maximise the economic life of our equipment

Project/ Operations Service Responsibilities

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

Aggreko International Technical Services

Equipment will always be kept clean

Equipment will always be kept well painted

Equipment will carry all necessary decals & signboards

Field Service Checks

ALL Commissioning sheets must be completed. The information contained in the

Aggreko International Technical Services

Commissioning Manual covers commissioning in more detail.

4.1 Decommissioning / Transfer To Jebel Ali or Another Project Checks

Engine oil pressure

AC voltage and Operating Hz is stable.

Hour meter is running, note the hours on the dispatch/delivery note

Fan & alternator belts for tightness

Water & Antifreeze level

Battery water level

Battery cables (apply grease/vasaline to cable ends)

Water hoses & connections for leaks

DC wiring (loose connections)

Engine / Generator mounts

Racor bowl cleanliness

All necessary sea fastening has been carried out

Aggreko International Technical Services

Aggreko International Technical Services

Revision April 2008

Prepared By Allan Methven

Reviewed By Garry McMahon

Approved By Jack Denz

Aggreko International Technical Services

Depot Service Responsibilities

Off Shore Rentals

In Depot Service Checks

Installation & Commissioning of Equipment

Aggreko International Technical Services

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

Depot Service Responsibilities

Maintaining a full history of service records of all equipment by Plant Number

Component Change Advice Notes must be sent to the Technical Records