Document No.: M02.

0208
Document Title: USER MANUAL
NHC20/DC16 43A(10.22)
Issue: A
Date: 07/10/05

USER MANUAL
FOR
NHC20/DC16 43A (Middle East)
Document M02.0208

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 Document No.: M02.0208
Document Title: USER MANUAL
NHC20/DC16 43A(10.22)
Issue: A
Date: 07/10/05

TABLE OF CONTENTS
1.0 SAFETY
1.1. GENERAL INFORMATION.....................................................................................................1
1.2. ELECTRICAL POWER ...........................................................................................................1
1.3. MATERIALS............................................................................................................................1
1.4. OPERATIONAL PRECAUTIONS ...........................................................................................1
1.5. SAFETY LABELS ...................................................................................................................2

2.0 NOISE EMISSION

2.1. NOISE CONTROL PROHIBITED ACTS.................................................................................4
2.2. GENERATOR NOISE EMISSION CONTROL INFORMATION .............................................4

3.0 HANDLING
3.1. LIFTING / HANDLING.............................................................................................................5
3.2. STORAGE / TRANSPORT .....................................................................................................5

4.0 INSTALLATION
4.1. UNPACKING ...........................................................................................................................6
4.2. LOCATION OF THE PLANT...................................................................................................6
4.3. COMMISSIONING...................................................................................................................6
4.4. PRIOR TO STARTING ............................................................................................................6
4.5. ELECTRICAL CONNECTION.................................................................................................6
4.6. EARTHING ..............................................................................................................................6
4.7. REMOTE FUELLING ..............................................................................................................7

5.0 GENERAL DATA

5.1. GENERAL OPERATION.........................................................................................................8
5.2. DESIGN LOAD CAPACITY ....................................................................................................8
5.3. DESIGN TEMPERATURES ....................................................................................................8
5.4. CONTAINER & BASE FRAME...............................................................................................8
5.5. DIESEL ENGINE .....................................................................................................................9
5.6. ENGINE LUBRICATION SYSTEM .........................................................................................9
5.7. ENGINE COOLING SYSTEM .................................................................................................9
5.8. ENGINE FUEL SYSTEM.........................................................................................................9
5.9. EXHAUST SYSTEM..............................................................................................................10
5.10. ENGINE CONTROL SYSTEM ..............................................................................................10
5.11. GENERATOR........................................................................................................................10
5.12. MAIN CIRCUIT BREAKER ...................................................................................................10

6.0 OPERATING INSTRUCTIONS

6.1. OPERATING CONTROLS AND INSTRUMENTS ................................................................14

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 Document No.: M02.0208
Document Title: USER MANUAL
NHC20/DC16 43A(10.22)
Issue: A
Date: 07/10/05

6.2. PRIOR TO START ................................................................................................................21

6.3. STARTING ............................................................................................................................21
6.4. LOADING ..............................................................................................................................21
6.5. SHUT-DOWN ........................................................................................................................21
6.6. AUTO OPERATION (OPTIONAL) ........................................................................................21

7.0 MAINTENANCE
7.1. GENERAL .............................................................................................................................22
7.2. MAINTENANCE SCHEDULE ...............................................................................................23
7.3. DAILY MAINTENANCE ........................................................................................................24
7.4. WEEKLY MAINTENANCE....................................................................................................25
7.5. ADDITIONAL MAINTENANCE.............................................................................................26

8.0 LUBRICATION
8.1. GENERAL INFORMATION...................................................................................................32
8.2. GENERATOR OIL CHANGE ................................................................................................32
8.3. OIL SPECIFICATION ............................................................................................................32

9.0 TROUBLE SHOOTING

9.1. INTRODUCTION ...................................................................................................................33
9.2. ACTION PLAN ......................................................................................................................33
9.3. TROUBLE SHOOTING CHART ...........................................................................................34

APPENDIX A: Material Safety Data Sheets

APPENDIX B: Operating Instruction Sheet
APPENDIX C: Equipment Data Sheet
Document No. Rev.
G080270 SHT. 1 to 3 A

APPENDIX D: Installation Outline Drawing

Drawing No. Rev.
A050189 SHT. 1 of 4 A
A050189 SHT. 2 of 4 A
A050189 SHT. 3 of 4 A
A050189 SHT. 4 of 4 A

APPENDIX E: Control Panel Layout

Drawing No. Rev.
D210630.1 SHT. 1 of 1 A Control Panel Layout (internal)

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 Document No.: M02.0208
Document Title: USER MANUAL
NHC20/DC16 43A(10.22)
Issue: A
Date: 07/10/05

APPENDIX F: Electrical Schematics

Drawing No. Rev. Title
D080833 SHT. 1 of 5 B Electrical Schematic for Generator connections
D080833 SHT. 2 of 5 C Electrical Schematic for Gen. Measuring-Fan controls
D080844 SHT. 3 B Electrical Schematic for C.B. Control
D080844 SHT. 4 A Electrical Schematic for Cooling Fan(s) Schematic
D080833 SHT. 5 of 5 C Wiring for Auxiliary Panel

D140203 SHT 1 of 1 C Control Panel Terminal Layout and Engine wiring

D210630 SHT 1 of 1 A Control Panel Layout
D210628 SHT 1 of 1 A Auxiliary Box Layout

APPENDIX G: Livery Layout

Drawing No. Rev.
D200164 SHT. 1 of 1 A

APPENDIX H: Manufacturers Component Data

Document No. Rev.
M040098 SHT. 1 of 1 C

APPENDIX J: Container Certificate – GB-LR 60536 10/04

APPENDIX K: DNV Spark Arrestor Certificate – M9801
APPENDIX L: International Contact Information

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 Document No.: M02.0208
Document Title: USER MANUAL
NHC20/DC16 43A(10.22)
Issue: A
Date: 07/10/05

1.0 SAFETY
1.1. GENERAL INFORMATION
• Ensure that the operator reads and understands the decals and consults the manuals before
maintenance or operation.
• Ensure that the Operation and Maintenance manual, and the manual holder, are not removed
permanently from the machine.
• Ensure that maintenance personnel are adequately trained, competent and have read the
Maintenance Manuals.
• Make sure that all protective covers are in place and that the container doors are closed during
operation.
• The specification of this machine is such that the machine is not suitable for use in flammable gas
risk areas. WARNING: NO ATTEMPT SHOULD BE MADE TO OPERATE IN SUCH
AREAS WITHOUT THE EXPRESS AUTHORITY FROM AGGREKO.
• Installation of this generator must be in accordance with recognised electrical codes and any
local Health and Safety Codes.
1.2. ELECTRICAL POWER
• Prior to installation of the generating set you should check that the electrical load to be applied is
within the rated output of the machine at the site ambient conditions.
• Before carrying out any maintenance or repairs to the Engine/Alternator assembly disconnect the
starting battery and isolate the alternator from the switchboard.
• Before carrying out any maintenance repair to the AC and DC circuits, isolate these from external
control panel and power supplies.
• Ensure that the generator set and the load it is connected to are properly earthed.
• The generating set should be connected to the load only by a qualified electrician and in
accordance with the applicable regulations.
1.3. MATERIALS
The following substances are used in the manufacture of this machine and may be hazardous to
health if used incorrectly:
• Antifreeze
• Engine Lubricating Oil
• Preservative Grease
• Rust Preventative
• Diesel Fuel
• Battery Electrolyte.

AVOID INGESTION, SKIN CONTACT AND INHALATION OF FUMES.

When handling fuel, lubricating oil, cooling fluid and battery electrolyte, wear appropriate personal
protection equipment.
For further information, consult Material Safety Data Sheet contained in this manual.
Avoid build-up of Engine Exhaust Fumes in confined spaces.
Avoid breathing Exhaust Fumes.
1.4. OPERATIONAL PRECAUTIONS
Never operate unit without first observing all safety warnings and carefully reading the operation and
maintenance manual shipped from the factory with this machine.

IF IN DOUBT CONTACT AGGREKO.

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 Document No.: M02.0208
Document Title: USER MANUAL
NHC20/DC16 43A(10.22)
Issue: A
Date: 07/10/05

Never operate the engine of this machine inside a building without adequate ventilation. Avoid
breathing exhaust fumes when working on or near the machine. Do not alter or modify this machine.
A battery contains sulphuric acid and can give off gases, which are corrosive and potentially
explosive. Avoid contact with skin, eyes and clothing. In case of contact, flush area immediately with
water.
Exercise extreme caution when using booster battery. To jump battery, connect ends of one booster
cable to the positive (+) terminal of each battery. Connect one end of other cable to the negative (-)
terminal of the booster battery and other end to a ground connection away from dead battery (to
avoid a spark occurring near any explosive gases that may be present). After starting unit, always
disconnect cables in reverse order.
Never operate unit without first observing all safety warnings and carefully reading the operation
manual.
This machine may include such materials as oil, diesel fuel, antifreeze, brake fluid, oil/air filters and
batteries which may require proper disposal when performing maintenance and service tasks.
Contact local authorities for proper disposal of these materials.
This machine produces loud noise with the doors open. Extended exposure to loud noise can cause
hearing loss. Always wear hearing protection when doors are open.
Never inspect or service unit without first disconnecting battery cable(s) or using the battery isolator
switch to prevent accidental starting.
Do not remove the pressure cap from a HOT radiator. Allow radiator to cool down before removing
pressure cap.
Do not use petroleum products (solvents or fuels) under high pressure as this can penetrate the skin
and result in serious illness. Wear eye protection while cleaning unit with compressed air to prevent
debris from injuring eye(s).
Hot pressurized fluid can cause serious burns. Do not open radiator while hot.
Rotating fan blade can cause serious injury. Do not operate without guard in place.
Use care to avoid contacting hot surfaces (engine exhaust manifold and piping, etc.).
Never operate unit with guards, covers or screens removed. Keep hands, hair, clothing, tools, etc.
well away from moving parts.
1.5. SAFETY LABELS
Look for these signs on machine, which point out potential hazards to the safety of you and others.
Read and understand thoroughly. Heed warnings and follow instructions.

DANGER
FIRE RISK

(Risk of electric shock)

DO NOT STAND IN
FRONT OF ALTENATOR
AIR OUTLETS WHEN
UNIT IS RUNNING

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 Document No.: M02.0208
Document Title: USER MANUAL
NHC20/DC16 43A(10.22)
Issue: A
Date: 07/10/05

CAUTION
Hot

DISCONNECT STARTING
BATTERY AND ISOLATE
LOAD BEFORE WORKING
ON ENGINE /
ALTENATOR ASSEMBLY

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 Document No.: M02.0208
Document Title: USER MANUAL
NHC20/DC16 43A(10.22)
Issue: A
Date: 07/10/05

2.0 NOISE EMISSION

2.1. NOISE CONTROL PROHIBITED ACTS

WARNING
Tampering with noise control system prohibited
The following acts or misuse of the unit are prohibited:
1) The removal or rendering inoperative by any persons, other than for purposes of maintenance,
repair, or replacement, of any device or element of design incorporated into any new generator
for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is
in use
Or
2) The use of the generator after such device or element of design has been removed or rendered
inoperative by any person.
Among those acts included in the prohibition against tampering are these:
• Removal or rendering inoperative any of the following:
a) The engine exhaust system or parts thereof.
b) The air intake system or parts thereof.
c) Enclosure or parts thereof.
• Removal of any of the following:
a) Fan shroud
b) Vibration mounts
c) Sound absorption material
• Operation of the generator with any of the enclosure doors open.
2.2. GENERATOR NOISE EMISSION CONTROL INFORMATION
A. The removal or rendering inoperative, other than for the purpose of maintenance, repair, or
replacement of any noise control device or element of design incorporated into this generator in
compliance with the noise control act;
B. The use of this generator after such device or element of design has been removed or rendered
inoperative.
THIS GENERATOR HAS BEEN SPECIFICALLY DESIGNED WITH A SOUND ATTENUATING
ENCLOSURE. THE CONTAINER DOORS SHOULD REMAIN LOCKED SHUT UNDER NORMAL
OPERATING CONDITIONS. UNDER ANY OTHER CONDITIONS EXCESSIVE NOISE LEVELS
CAN BE PRODUCED AND PROLONGED EXPOSURE IS HAZARDOUS TO HEARING.

FOR SAFETY, EAR PROTECTION SHOULD ALWAYS BE

WORN WHEN WORKING IN THE VICINITY OF AN
OPERATING GENERATOR SET.

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 Document No.: M02.0208
Document Title: USER MANUAL
NHC20/DC16 43A(10.22)
Issue: A
Date: 07/10/05

3.0 HANDLING
3.1. LIFTING / HANDLING
• The generator set is enclosed in a standard size ISO 20ft container with integrated lifting forgings
on the corners.
• All lifting and handling equipment must be adequately rated for applicable weights.
• During all lifting and handling operations the following weights must be considered.

Complete Package Max. Fuel 10800 kgs (23810 lbs)

Complete Package Without Fuel 9700 kgs (21385 lbs)

•
• Ensure that the correct lengths of strop / wire rope is used to ensure a level lift. Also ensure that
the included angle does not exceed 90°.

CAUTION: THE GENERATOR SET SHOULD NOT BE DRAGGED.

3.2. STORAGE / TRANSPORT
• Carry out the following points before transporting the generator or preparing the generator for
storage.
• Open the battery isolator switch.
• Empty the fuel tank (in case of overseas transport).
• Disconnect the battery terminals (in case of overseas transport).
• Close all fuel valves.
• Seal the remote fuel connection with a blind stop.
• Ensure that the radiator cap is fitted securely and the exhaust rain cap is closed.
• Close all doors.
All units are to be loaded flat onto transport and properly secured.

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 Document No.: M02.0208
Document Title: USER MANUAL
NHC20/DC16 43A(10.22)
Issue: A
Date: 07/10/05

4.0 INSTALLATION
4.1. UNPACKING
Ensure that the correct marked lifting / tie down points are used whenever the machine is lifted or
transported.
4.2. LOCATION OF THE PLANT
The generator can be installed on any solid, flat and level surface capable of supporting the full
operating load of the package. A dry, well-ventilated area where the atmosphere is as clean as
possible is recommended. Ensure that the machine is positioned securely and on a stable
foundation.

CAUTION: A minimum of 3 metres (9 ft) all round the generator is recommended. Hot air
will exit from the roof & air outlet. It is important that this hot air does not re-circulate to the
package inlet.
The generator must be allowed sufficient space all round and above, to enable the effective removal
of the cooling air which, in turn, will reduce the risk of re–circulating the cooling air back through the
generator. Adequate clearance needs to be allowed around and above the machine to permit safe
access for specified maintenance tasks. Hard surfaces may reflect noise with an apparent increase
in the decibel level. It is recommended that provision be made for lifting heavy components during
major overhaul.

NOTE: When operating at elevated altitude please refer to engine manufacturer’s

guidelines for power deration.
4.3. COMMISSIONING
Upon receipt of the unit, and prior to putting it into service, it is important to adhere strictly to the
instructions given below in section 4.4 PRIOR TO STARTING.
• Ensure all persons concerned are suitably competent with generator installations.
• Ensure that the operator reads and understands the decals and consults the manuals before
maintenance or operation.
• Ensure that the position of the emergency stop device is known and recognised by its markings.
Ensure that it is functioning correctly and that the method of operation is known.
4.4. PRIOR TO STARTING
• Ensure that the unit is clean, free from debris and fluids. All connections, joints, seals must be
correctly fitted and tightened. All filters, louvers and air inlets are free and open.
• Ensure that there is a safe working procedure which has been issued by supervisory personnel,
and that all persons concerned with the operation of the generator understand it.
• Ensure that the safety procedure to be applied is based on the appropriate national and local
regulations.
• Ensure that the safety procedure is followed at all times.
4.5. ELECTRICAL CONNECTION
• A suitably trained electrician should carry out all electrical connections.
• Ensure the generator main isolator is off and that the power cables are in good condition.
• Ensure that the phases are correct after the cables have been connected.
• Ensure all safety covers are back in place after electrical connection is complete.
4.6. EARTHING
An external earthing boss is fitted onto the container at each corner of the set. This allows a
dedicated earthing connection if required.

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 Document No.: M02.0208
Document Title: USER MANUAL
NHC20/DC16 43A(10.22)
Issue: A
Date: 07/10/05

4.7. REMOTE FUELLING

External fuel tank supply can be connected to the generator set.
• 1” Female Connector (supply)
• ½” Female Connector (Return)
The fuel connections for external supply are located on the side & air inlet end of the container.

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 Document No.: M02.0208
Document Title: USER MANUAL
NHC20/DC16 43A(10.22)
Issue: A
Date: 07/10/05

5.0 GENERAL DATA

NOTE: Each generator of this type is uniquely identified by a Plant Number and Serial Number
indicated on the identification plate affixed to the outside of the control panel. This information is
required when ordering spare parts. Major component serial numbers are contained within the
manual.
The technical data defining the generator and the limits on its operating environment are tabulated in
the Equipment Data Sheet. A copy of the Equipment Data Sheet has been included in the manual.
In order to assist in the operation and maintenance of the generator, a full set of electrical and
installation drawings has been included in the manual.
5.1. GENERAL OPERATION
The generator is a diesel engine driven alternator with control electronics, mounted on a bedplate
with internal fuel tank. The standard package is composed of the following:
• Alternator and engine assembly
• Pressurised oil system
• Automated control system
• Instrumentation
• Safety provisions
• Engine cooler pack
• Spark arrestor / Silencer
• Internal fuel tank
The engine and alternator are integrally mounted. This assembly is isolated from the base by rubber
isolation mounts.
5.2. DESIGN LOAD CAPACITY
The NHC20/DC16 43A (10.22), (500kVA) generator set can be ran up to a maximum of 505kVA at
prime power rating 50Hz and 493kVA at prime power rating 60Hz.
5.3. DESIGN TEMPERATURES
The NHC20/ DC16 43A (10.22), (500kVA) generator set can operate through an ambient
temperature range of:
• -10°C (14°F) to 45°C (113°F)
5.4. CONTAINER & BASE FRAME
The overall dimensions for the generator set are 6060 X 2440 X 2600 mm.
The container is manufactured from welded steel and has access to the inside of the generator
through lockable doors. Access to the roof of the container can be gained by using the integral steps
on the end of the container.
The base frame has 120% capacity of the fuel tank to prevent fuel leaking out of the generator set in
the event of a fuel leakage inside the generator. A level switch is fitted inside the bund for spillage
indication. This will shut down the engine when activated.

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 Document No.: M02.0208
Document Title: USER MANUAL
NHC20/DC16 43A(10.22)
Issue: A
Date: 07/10/05

5.5. DIESEL ENGINE

The generator set uses a Scania DC16 45A (10.26) diesel engine, which is capable for either 50 Hz
or 60 Hz. Details of the engine are outlined below.

Type: V8 - 90°, Water Cooled, Turbo charged, and

Aftercooled.
Model: Scania DC16 43A (10.22)
RPM: 1500 / 1800
Nominal Engine Output @ 1800rpm: 394kW @ Prime Power
Governor: S6 Controller
Starting System: 24V Battery System with Fitted Isolator
Fuel Consumption @ Continuous 1800rpm: 93 L/Hr @ 100% Prime Power

5.6. ENGINE LUBRICATION SYSTEM

The engine oil lubrication system includes pump, strainer and sump all fitted internally within the
engine block. Oil filtration is fitted to the side of the engine block for ease of access and
maintenance.
Total Oil Capacity: 47 Litres

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

Recommended oils are Castrol Tection T 15W-40 (previously called RX Super Plus), Shell Rimula
15W 40.
The sump can be drained using the K1 pump via a Wallminster valve.
Refer to manufacturers data for all filter information.
5.7. ENGINE COOLING SYSTEM
The engine cooling consists of a pump, thermostat, heater and radiator assembly.
Cooling fluid is fed from the radiator, through the pump, which is belt driven from the engine pulley.
The thermostat controls the flow to the radiator. The radiator & fan assembly is mounted at the front
of the engine.
Cooling air enters the generator through the container end louvers and noise attenuation baffles.
This air then passes into the container space then across the radiator assembly.
The cooling air exits through the outlet louvres at the end of the container / cargo doors.
The radiator is factory filled with Shell anti-freeze and anti-corrosion coolant, in 50-50 water-coolant
concentration, providing protection to –32°C. Please consult Aggreko if filling is required.
5.8. ENGINE FUEL SYSTEM
The engine fuel system consists of an internal fuel tank, Racor filters (see Figure 5.2), fine fuel filter,
fuel pump, injection pump and nozzles.
Fuel can be taken from either an external or the internal fuel tank. Fuel is then pumped through the
Racor filters to the fine fuel filters and then passed to the injectors and then to the injection nozzles.
The internal fuel tank has a fuel capacity of 1289 Litres. A fuel level mechanical gauge is also fitted in
the internal tank. The fuel tank fill point is external. There are 2 cleaning ports on the fuel tank that
are all fully accessible.
External fuel supply can be connected to the package using the quick release connections at the
side of the container & inlet louvre end. Internal supply and return fittings/valves must be re-
configured to ensure that the engine fuel is not drawn from the onboard supply.
The use of ASTM No. 2D fuel is recommended for optimum engine performance. At operating
temperatures below 0°C, acceptable performance can be obtained using blends of No. 1 and No. 2D.
The use of lighter fuels can reduce economy. The viscosity of fuels must be kept above 1.3 cSt to
provide adequate lubrication.
Refer to manufacturers data for all filter information.

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 Document No.: M02.0208
Document Title: USER MANUAL
NHC20/DC16 43A(10.22)
Issue: A
Date: 07/10/05

5.9. EXHAUST SYSTEM

The exhaust system consists of the exhaust ducting, exhaust silencer complete with spark arrestor
and 8” NB Table ‘D’ flanged connections / bellows. The exhaust gases exit the engine and are
passed through the exhaust ducting and exhaust, out the end of the container through the flanged
connection. Insulation and heat shields are fitted to the exhaust ducting to prevent user contact with
high temperature surfaces.
Manufacturer: Discom
Spark Arrestor: DNV Certificate No M9149

5.10. ENGINE CONTROL SYSTEM

An S6 controller controls the engine output.

5.11. GENERATOR
Manufacturer: Newage Stamford
Type: HCI 534 E23
50Hz: 380-440 Volts
Voltage Range
60Hz: 416-480 Volts
Rotating Field powered by Permanent Magnet
Excitation System:
Pilot Exciter
• Voltage Regulator within 1% from no load to full load MX341+PMG + Droop CT.
• 3 Phase & Neutral configurable Parallel Star & Series Star on Alternator winding leads.
5.12. MAIN CIRCUIT BREAKER
Manufacturer: Merlin Gerin
NS1600N 4-Pole MCCB.
Micrologic 5.0 Overload Unit.
Type: Motormech Operated.
(Breaker rating is suitable for full current at low
voltage, if alternator windings are reconfigured).

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 Document No.: M02.0208
Document Title: USER MANUAL
NHC20/DC16 43A(10.22)
Issue: A
Date: 07/10/05

Figure 5.1 – Right Bank Side 500 kVA Generator Part Locations

RADIATOR COOLANT
TOP-UP TANK

EXHAUST MANIFOLD GUARDS

BATTERY BOX

ALTERNATOR FILTER BATTERY ISOLATOR

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 Document No.: M02.0208
Document Title: USER MANUAL
NHC20/DC16 43A(10.22)
Issue: A
Date: 07/10/05

Figure 5.2 –Left Bank Side 500 kVA Generator Part Locations

FUEL TANK BREATHER

EXTERNAL FUEL FILL PIPE

OIL FILL

RACOR FUEL FILTER

K1 - PUMP INTERNAL FUEL FILL

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 Document No.: M02.0208
Document Title: USER MANUAL
NHC20/DC16 43A(10.22)
Issue: A
Date: 07/10/05

Figure 5.3 – Additional 500 kVA Generator Part Locations

BLANKED OFF EXHAUST OUTLET - SHIPBOARD OPTION PERSONNEL ACCESS DOOR, INLET LOUVRE

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 Document No.: M02.0208
Document Title: USER MANUAL
NHC20/DC16 43A(10.22)
Issue: A
Date: 07/10/05

6.0 OPERATING INSTRUCTIONS

6.1. OPERATING CONTROLS AND INSTRUMENTS

6.1.1. CONTROL PANEL

The operating controls and instruments are arranged on the control panel as shown in figure 6.1. A
description of each panel device is given in the key below.

1 2

3 4 5 6 7 8

9 10 11 12 13

Figure 6.1 – Control Panel Exterior

Manual Voltage
1 Fuel Gauge* 7 13 Earth Leakage Switch
Increase / Decrease
2 Hours Run Gauge* 8 Spare#
Automatic / Manual
3 Local / Remote Switch 9
Switch.
4 Engine Start 10 C.B. Open

5
Engine Stop 11
C.B. Close
Manual Speed
6 12 Alarm Reset
Increase / Decrease
* On earlier generator sets – XALR001 to XALR006, an oil pressure gauge and a water temperature
gauge were also fitted. This information is displayed on the GEMPAC unit.
# On earlier generator sets – XALR001 to XALR006, this warning lamp was used to indicate charge
alternator failure. From XALR007 onwards, this warning is displayed via the GEMPAC unit.

Key for figure 6.1

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 Document No.: M02.0208
Document Title: USER MANUAL
NHC20/DC16 43A(10.22)
Issue: A
Date: 07/10/05

1 8

2 3

Figure 6.2 – Control Panel Internals

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 Document No.: M02.0208
Document Title: USER MANUAL
NHC20/DC16 43A(10.22)
Issue: A
Date: 07/10/05

Figure 6.3 - 1600A Breaker

10

1 AVR 341 9 1600 / 5A

Earth Leakage
2 10 NS1600N MCCB
Relay
Generator
3
Controll DEIF
4 MCB’s

5 Relays

6 Current Limiter
7 Terminals
8 Earth Bar

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 Document No.: M02.0208
Document Title: USER MANUAL
NHC20/DC16 43A(10.22)
Issue: A
Date: 07/10/05

6.1.2. DEIF INTERFACE

Line 1 displays the mode of operation, as shown in Figure 6.3 below. If SETUP is selected, it is
possible to toggle through the display options for line 1 by repeatedly pressing the VIEW button. 7
options are available:
• Generator voltage L1 L2 L3 (Vac)
• Bus voltage L1 L2 L3 (Vac)
• Generator current (A)
• Generator power factor and active
power (kW)
• Generator apparent power (kVA)
and reactive power (kVAr)
• Generator L1 frequency (Hz) and
voltage (Vac) Figure 6.3 – DEIF Interface
• Bus L1 frequency (Hz) and voltage (Vac)
The default setting of line 2 is Generator L1 frequency and voltage, as shown above in figure 3. It is
possible to change the display option for line 2 using the up/down scroll keys, while in the SETUP
menu. A number of options are available, including:
F, P, Q, S, cos φ, angle between phases, V, I, frequency deviation, analogue inputs
The fourth line gives 4 options as shown in figure 3: SETUP, V1, V2, and V3. SETUP is used to
enter the SETUP page; position the cursor beneath SETUP (using the left/right scroll keys) and
press SEL. V1, V2 and V3 are different display options. V2 and V3 are fixed (but can be configured
in the utility software). V1 is selectable from 15 views using the up/down scroll keys (each view can
be separately configured using the utility software).
In addition to electrical parameters, the GEMPAC unit also displays engine parameters from the
Scania S6 via the CANBUS connection. These are displayed in views contained within V1. The
following engine parameters are displayed:
- Speed
- Pressure oil
- Temperature coolant
- Fuel rate
- Pressure boost
- Temperature manifold
- Droop

6.1.3. ALARMS & SHUTDOWNS

When a warning or a shutdown is detected, the DEIF PPU display jumps to the alarm page and the
fault is displayed in clear text. This is shown in Figure 6.4. If one or more alarms have not been
acknowledged, the red LED at the top
left-hand corner of the display flashes.
If all alarms have been acknowledged
but one or more are still present, the
red LED will be constantly lit. To reset
alarms, the alarm reset button on the
front panel should be used.
To jump to the alarm page at any time,
press the alarm INFO button. To scroll
through the alarms use the up/down
scroll keys. It is possible to jump
directly to the first or last alarm and to Figure 6.4 – Typical Alarm Page
acknowledge an alarm by using the
left/right scroll keys and the select button.

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Issue: A
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Depending upon the fault condition detected, the GEMPAC unit will carry out one of 6 fail classes,
and these are listed below.
Fail Class 0 – Warning
Fail Class 1 – Engine Stop
Fail Class 2 – Emergency Stop
Fail Class 3 – Shutdown
Fail Class 4 – Emergency Shutdown
Fail Class 5 – Electrical Fault
The table below shows the function of each fail class.

FC0 FC1 FC2 FC3 FC4 FC5

Log Alarm X
Display Alarm X X
Log Event X X X X
Deload X X
Open CB X X X X X
CB Feedback X X X X X
Timeout Cooling
X
Delay
Engine Stop X X X X
Emergency Stop /
Fuel Solenoid X X
Close
Close Air Flaps X
Trip CB X X X

Scania S6 generated faultcodes

When the S6 controller detects a fault, one of two messages is displayed on the GEMPAC display:
- EMS Warning
- EMS Shutdown
EMS warning is classed as fail class 0 and will be displayed and logged by the GEMPAC unit. EMS
Shutdown is classed as fail class 2 and the generator set will shutdown. Note that this is in addition
to any action that the S6 controller will take, e.g. reduce the maximum power available or shut the
engine down. For action that the S6 will take, refer to the Scania technical documentation on EMS
fault codes. Once an EMS alarm has been detected, it is possible to display the fault code and
associated text.

To display the list of fault codes within the S6, press and hold the INFO button for a
minimum of 2 seconds. Current S6 fault codes will then be displayed. These can either be
active (fault condition still present) or passive (fault condition no longer present). To clear S6
fault codes, select CLRALL, which will clear all passive faultcodes.
The GEMPAC unit can display the following S6 faultcodes.

Displayed text Comments

No Scania DTC No Diagnostic Trouble Codes (DTC) fault codes present
1 10## Overreving ## - number displayed depending upon specific fault code
detected. Check Scania documentation for description of fault and
2 11## Speed sensor 1
suggested course of action.
3 12## Speed sensor 2
4 20## Water T sen.
5 21## Char. air T sen
6 22## Char. air P sen
7 23## Oil temp. sen.
8 24## Oil pres. sen.
9 28## Extra ana. inp.

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10 31## Throttle pedal

11 32## Battery voltage
12 33## CAN mess. DLN1
13 34## Wrong CAN ver.
14 40## CAN-cir. defect
15 41## System shutdown
16 42## Fault in RAM
17 43## HW watchdog
18 66## Starter fault
19 B0## Oil Pres. prot.
20 B1## Coola. l. prot.
21 B2## Coola. shut off
22 B3## Emerg. stop o.r
23 B4## Wrong parameter
24 C0## Un. inj. cyl. 1
25 C1## Un. inj. cyl. 2
26 C2## Un. inj. cyl. 3
27 C3## Un. inj. cyl. 4
28 C4## Un. inj. cyl. 5
29 C5## Un. inj. cyl. 6
30 C6## Un. inj. cyl. 7
31 C7## Un. inj. cyl. 8
32 E0## Fault in TPU
33 E2## Over heat prot.
34 E3## Seal
35 E5## Oil Pres. prot.
36 E6## Emerg. stop cor
37 FF## Fault in cor.
Error detected other than those displayed above.
#### - number displayed depending upon specific fault code
38 #### S6 Fault code
detected.
Check Scania documentation.

KWP2000 Error No response detected from S6 ECM when fault codes requested.

6.1.4. DC12 GENERATOR SETS FITTED WITH COORDINATOR

Early DC12 generator sets were fitted with a Scania supplied coordinator (plant numbers XALR001
to XALR006). This was an interface between the S6 controller and the GEMPAC unit and can be
identified by an addition box attached to the rear of the control panel and 2 additional gauges on the
front panel.
Reading of coordinator flash codes
Coordinator fault codes are displayed as flash codes from the lamp inside the panel.
When the unit is running, press the diagnostic switch (inside panel) for 1 s
When the unit is stopped, hold down the ignition bypass switch and press the diagnostic switch for 1
s. Long flashes indicate tens and short flashes indicate units, e.g. long + long + short shows flash
code 21. Pressing the diagnostic switch again displays the next flash code. When the last flash
code is flashed out, the sequence starts again. If no flash code is present, the diagnostic lamp will
be lit for 4 seconds.
See the table on the next page for a list of flash codes.

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Clearing of fault codes

Clearing of fault codes should only be undertaken when the unit is stopped.
Hold down the diagnostic switch. Press the ignition switch for 3 to 10 s. All present flash codes are
now erased.
List of flash codes (Coordinator)

Code Trouble Reason Action Comment

11 Incorrect signals from The flash code is set when the Check the fine tune nominal See also EMS
fine tune nominal speed voltage from fine tune nominal speed speed potentiometer, Engine.
signal signal is out of range connectors and cables.
12 Wrong connection There is a faulty value on the resistor Check connection between
between pin 29 and pin between pin 29 and pin 48. pin 29 and pin 48.
48.
13 No communication from The flash code is set when the Check CAN connectors and When this fault
engine. communication from EMS breaks. cables. occurs the EMS
diagnostic lamp is
also lit.
14 Short circuit on The flash code is set when there is a Check instrument panel,
Tachometer signal wire. short circuit between the output and connectors and cables.
ground or supply. The flash code is
set after 10 seconds.
15 Defect atmosphere The signal from the internal sensor is Replace the Coordinator. See also EMS
pressure sensor. out of range. Engine. The signal
is not always
needed, check with
Scania service.
16 Wrong connection to pin Pin 52 is not connected to U31. The Check pin 52, connectors See also EMS
52. flash code is set after 5 minutes. and cables. Engine.
17 Short circuit on engine The flash code is set when there is Check instrument panel, When a fault
temp gauge signal wire. short circuit between the output and connectors and cables. occurs, the gauge
supply. The flash code is set after 10 will indicate low
seconds. temperature.
18 Short circuit on engine The flash code is set when there is a Check instrument panel, When a fault occurs
oil pressure gauge short circuit between the output and connectors and cables. the gauge will
signal wire. supply. The flash code is set after 10 indicate high
seconds. pressure.
19 Short circuit on engine The flash code is set when there is a Check instrument panel, When a fault occurs
oil pressure lamp signal short circuit between the output and connectors and cables. the lamp will not be
wiring. supply. The flash code is set after 10 lit.
seconds.
21 Different version of The EMS does not have the same Replace Coordinator with
communication protocol version of communication protocol as matching unit.
between Coordinator the Coordinator.
and EMS.
23 Supply voltage too high. Supply voltage over 35 volts for more Check alternator. Certain in- and
than 2 seconds. outputs become
inactive.
Coordinator might
become damaged.
24 Supply voltage too low. Supply voltage under 18 volts for Check battery and Certain in- and
more than 2 seconds. alternator. outputs become
inactive.

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6.2. PRIOR TO START

Execute Daily Maintenance see section 7.1.
6.3. STARTING

If in doubt, contact your local Aggreko agent

1) Close the battery isolator switch.
2) Put Remote-Off-Local key switch to LOCAL.
3) Put Manual-Auto switch in MANUAL position (Counter-clockwise).
4) Press the ENGINE START button.
5) Check voltmeter, Hz meter, oil pressure and coolant temperature.
6) Check the frequency and voltage on the control panel and adjust if necessary with the SPEED or
VOLTS LOWER/RAISE switch.
7) Walk around the engine and check for any leakages.
6.4. LOADING
1) Allow the engine to warm-up prior to applying load.
2) Press CB CLOSE button on the control panel; signal lamp on GEMPAC unit should light,
indicating that the main circuit breaker is closed. Note that the GEMPAC will perform a check-
sync function before allowing the circuit breaker to close.
6.5. SHUT-DOWN
1) Remove load from the generator.
2) Open the circuit breaker by pushing the CB OPEN button. Allow the engine to run for
approximately 5 minutes to cool down.
3) Stop the engine by pressing the ENGINE STOP button.

CAUTION: - Always open the battery isolator switch to avoid unauthorised starting
during transport and maintenance.
6.6. AUTO OPERATION (OPTIONAL)

CAUTION: - Note that in auto, the circuit breaker will automatically close once the engine
reaches running frequency and voltage
1) Close the battery isolator switch.
2) Put Remote-Off-Local key switch to LOCAL.
3) Put Manual-Auto key switch in AUTO position (Clockwise).
4) Press the ENGINE START button.
5) When engine runs up to speed the circuit breaker will automatically close. If voltage is detected
on the bus bars, the generator will automatically synchronise to the bus voltage.
6) The generator will now regulate to the mode of operation selected.
7) Stop the engine by pressing the ENGINE STOP button. Note that in auto, the generator set will
de-load, open breaker and cooldown automatically.

A test run should be carried at least once a week.

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Issue: A
Date: 07/10/05

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

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• Loose or damage parts.

• Worn or damaged belts, change in engine appearance.
• Refer to the Maintenance Schedule for quick reference.
Report unusual noise/vibration and/or exhaust smoke and ensure the generator set is kept clean,
both inside and out.
7.2. MAINTENANCE SCHEDULE
7.2.1. INSPECTION CRITERIA

3 Months / 6 Months / 12 Months

Daily Weekly Monthly
400 Hrs 800 Hrs / 1200 hrs
Engine Oil Level C
Fuel Tank (Fill at end of
C
day)
Gauges / Lamps C
Air Filter C
Fuel / Water Separator
C
Drain
Battery Connections /
C
Electrolyte
Radiator Coolant Level C
Fan / Alternator Belts C
Hoses (oil, air, intake, etc.) C
Automatic Shutdown
C
System Visual
Fasteners / Guards C
Engine Coolant Test C
Shutdown Switch Settings
C
Test
C=check (adjust if necessary)
Refer to manufacturers operating and maintenance instructions for additional information and all
other maintenance.
7.2.2. SERVICE CRITERIA

3 Months / 6 Months / 12 Months

Daily Weekly Monthly
400 Hrs* 800 Hrs / 1200 hrs
Engine Oil & Filters R
Air Filter Element R
Fuel / Water Separator
R
Element
Fine Fuel Element R
Engine Coolant R
R=replace
Refer to manufacturers operating and maintenance instructions for additional information and all
other maintenance.
* This figure should be in line with current service best practise.

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7.3. DAILY MAINTENANCE

7.3.1. CHECK THE ENGINE OIL LEVEL:
1) Stop the engine and wait 5 minutes to allow the oil to drain to the oil pan.
2) Remove the dipstick and check the oil level.
3) Replenish if necessary using a recommended grade of engine oil (see section 8).

CAUTION: Never operate the engine with the oil level below the ‘L’ mark or above the ‘H’
mark. See FIG. 7.1 below.

Figure 7.1 - Engine Oil Level Check

7.3.2. CHECK THE FUEL TANK LEVEL.

Check the fuel level gauge on the control panel.
Replenish as necessary using clean, good quality, diesel/Derv/Gas Oil that conforms to ISO or
equivalent. Always ensure that the filler cap is replaced after replenishment.
7.3.3. CHECK THAT ALL METERS AND GAUGES FUNCTION CORRECTLY.
Start the generator and inspect the following items:
• Oil pressure gauge is between 60 & 70psi.
• After 5 minutes check that the cooling water temperature gauge reads between 85 & 95°C.
• The voltage and frequency gauges are within specification.
• Fuel gauge indicates the tank is not empty.
• Engine hours display increases after 10 minutes.
• The DEIF Interface has no alarm indicators on.
7.3.4. CHECK THE AIR FILTER.

NOTE: In dusty conditions clean the primary filters regularly.

Check the air filter restriction indicator next to the air filter above the engine. If this has changed to
the restricted position, then the filter will need replaced.

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7.3.5. CHECK THE BATTERY.

Check that the battery connections are properly installed and that the electrolyte level in each cell
covers the top plates. If necessary, top up with clean distilled water.
7.3.6. CHECK FOR LEAKS.
There are several fluids used inside the generator, e.g. diesel, oil, coolant. Look for signs of leakage
all around the engine.
Any source of leak should be checked and fixed. Clean up any fluid lying inside the generator and
dispose of according to the appropriate local regulations.
Recurring leaks should be reported to AGGREKO.
7.4. WEEKLY MAINTENANCE
7.4.1. CHECK THE WATER/ANTIFREEZE LEVEL.
Stop the engine and wait for the temperature to cool before checking the coolant level.
Remove the pressure cap slowly to relieve the pressure of the cooling system. Failure to do so could
result in personal injury from heated coolant spray (See Figure 7.2).
Check the coolant level. Replenish with the correct coolant fluid as necessary (see section 8).

Figure 7.2 - Coolant Level Check

7.4.2. CARRY OUT A VISUAL CHECK OF THE DRIVE BELTS.

The cooling pump, alternator and radiator fan are driven by a single belt arrangement from the
engine pulley. Check the belts for signs of wear. Check the belt tension.

NOTE: Do not remove guards.

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7.5. ADDITIONAL MAINTENANCE

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8.0 LUBRICATION
8.1. GENERAL INFORMATION
Lubrication is an essential part of preventive maintenance, affecting to a great extent the useful life of
the unit. Different lubricants are needed and some components in the unit require more frequent
lubrication than others. Therefore, it is important that the instructions regarding types of lubricants
and the frequency of their application be explicitly followed. Periodic lubrication of the moving parts
reduces to a minimum the possibility of mechanical failures.
The Preventive Maintenance Schedule shows those items requiring regular service and the interval
in which they should be performed. A regular service program should be developed to include all
items and fluids. These intervals are based on average operating conditions. In the event of
extremely severe (hot, cold, dusty or wet) operating conditions, more frequent lubrication than
specified may be necessary. Details concerning lubrication of the running gear are in Maintenance
Section.
8.2. GENERATOR OIL CHANGE
These units are normally furnished with an initial supply of oil sufficient to allow operation of the unit
for approximately 3 months or 400 hours, although this should be in line with the current service best
practise. The unit will however need to be topped up with oil during this period. If a unit has been
completely drained of all oil, it must be refilled with new oil before it is placed in operation. Refer to
specifications in Lubrication Table.

NOTICE: Some oil types are incompatible when mixed and result in the formation of varnishes,
shellacs, or lacquers that may be insoluble. Such deposits can cause serious problems including
clogging of the filters. Where possible, do NOT mix oils of different types and avoid mixing different
brands. A type or brand change is best made at the time of a complete oil drain and refill.
If the unit has been operated for the time/ hours mentioned above, it should be completely drained of
oil. If the unit has been operated under adverse conditions, or after long periods in storage, an earlier
change period may be necessary as oil deteriorates with time as well as by operating conditions.
An oil change is good insurance against the accumulation of dirt, sludge, or oxidized oil products.
Completely drain the reservoir & piping. If the oil is drained immediately after the unit has been run
for some time, most of the sediment will be in suspension and, therefore, will drain more readily.
However, the fluid will be hot and care must be taken to avoid contact with the skin or eyes.
After the unit has been completely drained of all old fluid, close the drain valve. Add oil in the
specified quantity at the filler plug. Tighten the filler plug and run the machine to circulate the oil.
Check the oil level when unit is warm and not running. If not near the middle of the dipstick, stop the
unit and make corrections. DO NOT OVERFILL.
8.3. OIL SPECIFICATION
The oil required for this engine is:
Manufacturer: Castrol
Product Name: Tection T 15W-40 (Formerly RX Super Plus)
Relative Density @ 25°C 0.89 g/cm³
Viscosity @ 40°C 110 mm²/s
Viscosity @ 100°C 14.5 mm²/s
Viscosity Index 135
CCS –20ºC 6450 mPA.s
Total Base Number (TBN) 11.6 mgKOH/g
Flash Point (COC) 228 °C
Pour Point -36 °C
Sulphated Ash 1.5 %m

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9.0 TROUBLE SHOOTING

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

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9.3. TROUBLE SHOOTING CHART

SYMPTOM POSSIBLE CAUSE CORRECTIVE ACTION
Battery isolator switch not
Close battery isolator switch.
closed.
Batteries flat or bad. Read
value on battery voltage meter Replace or charge batteries.
ENGINE DOES NOT CRANK (must be 24V or more).
WITH 24V ELECTRIC MOTOR
MCB 10A in Control Panel is
Reset.
open.
Start relay at cranking motor Measure the voltage over the
defective. start relay.
Fuel tank empty. Fill up fuel tank.
Check system for leaks. Bleed
Air in the fuel system.
the fuel system.
Dirty fuel filters. Replace fuel filters.
ENGINE CRANKS BUT DOES Check voltage (24V) over fuel
NOT START Call for AGGREKO support.
shut-off valve during crank.
Optional air shutdown valve
Open air shutdown valve.
closed.
Overspeed protection is Put key back to OFF and try to
activated. start the engine again.
Check system for leaks. Bleed
Air in the fuel system.
the fuel system.
Dirty fuel filters. Replace fuel filters.
ENGINE STARTS UP BUT Overspeed during acceleration. Decrease frequency setting.
STOPS AFTERWARDS
Check safeties:
Oil pressure – Water
Shutdown after 6 seconds.
temperature – Water pressure –
Oil temperature (option)
Adjust frequency to the correct
Frequency too high.
level.

ENGINE OVERSPEEDS Connection between governor

Repair connection.
and fuel pump interrupted.
Check system for leaks. Bleed
Air in the fuel system.
the fuel system.
Wait until engine has reached
Engine not yet at operating
the normal operating
temperature.
temperature of 80-90ºC.
ENGINE SPEED NOT
STABLE Dirty fuel filters. Replace fuel filters.
Wear in ball eyes, linkage
Replace ball eyes.
governor / fuel pump.
Dirty air filters. Replace air filters.

ENGINE SHOWS EXCESS Dirty fuel filters. Replace fuel filters.

SMOKE AND / OR LACK OF Check system for leaks. Bleed
POWER Air in the fuel system.
the fuel system.
Overload. Check load.

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SYMPTOM POSSIBLE CAUSE CORRECTIVE ACTION

Measure voltage at outlet
Voltmeter defective. terminals of alternator. If voltage
measured replace voltmeter.
ALTERNATOR DOESN’T
GENERATE VOLTAGE Voltage regulator defective. Replace voltage regulator,
Check system for leaks. Bleed
Air in the fuel system.
the fuel system.
Speed frequency too high / Check frequency meter and
low. adjust if required.
ALTERNATOR VOLTAGE
TOO HIGH / LOW Incorrect voltage setting. Adjust voltage regulator.
No identifiable cause. Consult AGGREKO.
Engine speed not stable. Check stability of engine speed.
ALTERNATOR VOLTAGE
NOT STABLE Adjust stability on the voltage
Incorrect stability adjustment.
regulator.
Circuit breaker control switch
Select local position.
set remote control.
Circuit breaker tripped. Reset circuit breaker.
MAIN CIRCUIT BREAKER
WILL NOT CLOSE Circuit breaker not charged, Charge motor mechanism
motor mechanism broken. manually, inform AGGREKO.
Lamp ‘CIRCUIT BREAKER
Replace lamp.
CLOSED’ defective.
MAIN CIRCUIT BREAKER Switch on overload or short
Remove load.
CLOSES BUT TRIPS AGAIN circuit.

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APPENDIX A
MATERIAL SAFETY DATA SHEETS

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CASTROL TECTION T 15W-40

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LEAD ACID BATTERIES

HEALTH & SAFETY

LEAD ACID BATTERIES
#############

The handling and proper use of lead-acid batteries is not hazardous provided sensible precautions are observed and
that Operatives having been trained in their use are adequately supervised.

The purpose of this letter is threefold:-

[ i] to indicate potential hazards that may arise.
[ ii] to outline the precautions to be taken to minimise such hazards.
[iii] to indicate action to be taken in the event of an accident.

1. SULPHURIC ACID [S.G. 1.260 - 1.300]

Batteries contain sulphuric acid which may leak for a variety of reasons and may be given off as droplets and/or
spray during recharging.
[The Hazards]
Sulphuric Acid is a poisonous and corrosive clear liquid which can burn/irritate skin and eyes and could burn clothing.
[Precautions]
Always handle batteries with care
Always store upright
Never over-fill with acid
Always charge in a well ventilated area. Maximum voltage 15v per each 12v Battery.
Use eye protection and protective clothing if there is any risk of acid splashing.
[Emergency Action]
Skin Contact: Immediately wash the affected area with copious amounts of
clean water. Remove any contaminated clothing.

Eye Contact Immediately irrigate eyes for at least 10 minutes with clean
water.
Swallowing Make the victim drink volumes of water, milk or milk of
magnesia.
DO NOT GIVE EMETIC
In all cases seek medical attention. Speed of action is vital.
[Spillages]
Small spillages can be swilled away with volumes of water.
[Disposal]
See Section 5.
2. ELECTRICAL ENERGY
[The Hazards]
The accidental connection of battery terminals by conductive objects, e.g. metal tools or metal personal jewellery etc.,
may generate sufficient heat to cause burns, create arcing or cause molten metal to splash.

Appendix A - vi -
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[PAGE TWO].
[Precautions]
Always ensure correct installation. The positive cable must be attached to the terminal marked [+] and the negative
to the terminal marked [-]. Cables and terminals should be kept clean and securely fitted.

Before using metallic tools on a battery remove metallic objects from hands and wrists.

Before working on a vehicle electrical system disconnect the Battery, disconnecting the earth strap first and
reconnecting last. Do not place tools on top of batteries.
[Emergency Action]

Burns: Apply sterile bandage.

Electric Shock: Approach victim with care. Switch off or otherwise break
current. If not possible, detach victim from contact by means
of insulating material [wood, rubber or plastic hosepipe, folded
newspaper etc]
Do not touch with bare hands.
In each case seek medical advice. Speed of action is vital.

3. EMISSION OF GASES
A mixture of oxygen and hydrogen is emitted during charging and may be emitted if a battery is moved or shaken.
[The Hazards]
An explosive atmosphere exists if the concentration of hydrogen exceeds 4%.
[Precautions]
Always charge in a well ventilated environment.
No naked flames NO SMOKING
Be certain that current is switched off before making breaking connection. Always remove earth strap first and re-
connect last.
[Emergency Action]
Explosion: Seek medical advice remembering that acid may have been sprayed.

4. WEIGHT
In general terms batteries are heavy and awkward to handle. Care should be taken and correct lifting techniques
employed.

5. DISPOSAL
Batteries, Battery Acid, Lead and Lead compounds must be disposed of in accordance with:
[a] The deposit of Poisonous Waste Act 1972
[b] The Control of Pollution Act 1974
[c] Consumer Protection Act 1987
If in doubt, consult the Environmental Department of your Local Authority.
For further information refer to:- BRITISH STANDARD BS 6604; 1985
SAFE OPERATION OF STARTER BATTERIES.SUPERCOOLMASTER
ANTIFREEZE

Appendix A - vii -
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Issue: A
Date: 07/10/05

APPENDIX B
OPERATING INSTRUCTION SHEET

Appendix B - i -
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Issue: A
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Appendix B - ii -
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Issue: A
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APPENDIX C
EQUIPMENT DATA SHEET

Appendix C - i
 Document No.: M02.0208
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Issue: A
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Appendix C - ii
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Issue: A
Date: 07/10/05

Appendix C - iii
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Issue: A
Date: 07/10/05

Appendix C - iv
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Issue: A
Date: 07/10/05

APPENDIX D
INSTALLATION OUTLINE DRAWING

Appendix D - i
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NHC20/DC16 43A(10.22)
Issue: A
Date: 07/10/05

Appendix D - ii
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Issue: A
Date: 07/10/05

Appendix D - iii
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Issue: A
Date: 07/10/05

Appendix D - iv
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Issue: A
Date: 07/10/05

Appendix D - v
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Issue: A
Date: 07/10/05

APPENDIX E
CONTROL PANEL LAYOUT

Appendix E - i
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Issue: A
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Appendix E - ii
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Issue: A
Date: 07/10/05

APPENDIX F
ELECTRICAL SCHEMATICS

Appendix F - i
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Issue: A
Date: 07/10/05

Appendix F - ii
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Issue: A
Date: 07/10/05

Appendix F - iii
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Issue: A
Date: 07/10/05

Appendix F - iv
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Issue: A
Date: 07/10/05

Appendix F - v
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Issue: A
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Appendix F - vi
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Issue: A
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Appendix F - vii
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Appendix F - viii
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Issue: A
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Appendix F - ix
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Issue: A
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APPENDIX G
LIVERY LAYOUT

Appendix G - i
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Issue: A
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Appendix G - ii
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Issue: A
Date: 07/10/05

APPENDIX H
MANUFACTURERS COMPONENT DATA

Appendix H - i
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Issue: A
Date: 07/10/05

Document No.: M040098 Date: Aug ‘05

Rev: C
Title: NHC20 / DC16 - Spares List & Manufacturers Data.

SUPPLIER / SUPPLIER PART AGGREKO

DESCRIPTION QTY
MANUFACTURER No. PART No.
Radiator 1 Scania 201 883 N/A
Radiator Fan 1 Scania 1506288 N/A
Coupling, Disc 1 Newage 350-11580 N/A
Battery 128Ah C20 12v 2 D.B. Wilson 324 339002A
Charging Belt / Fan Belt 1 Scania 1509710 N/A
Starter Motor – Pre Can Start 1 Scania 571463 N/A
Battery Charging Alternator 1 Scania 571617 N/A
Circuit Breaker NS1000N 4P Refer to Description
Micrologic 5.0 electronic 2 Merlin Gerin (Complete Assembly 293440A
protection Motortmech 33304)
Current Transformer 1200/5A 3 Raytel Tasso Refer to Description 273084A
Lube Oil Filter Kit 1 Scania 1439036 N/A
Secondary Fuel Filter 1 Scania 1 446 432 N/A
Primary Fuel Filter for 1000FG 1 Racor 2020PM-OR N/A
Bund Level Switch 1 Fozmula T/E-C/13 269057A
Fuel level sender
1 Datcon / Fozmula Refer to description 269062A
Float arm type to 375mm
Starter Motor – Can Start 1 Scania 1447912 N/A
Crank Case Breather Filter Kit 1 Scania 1486634 N/A
Induction Air Filter 1 Scania 1421021 N/A
Induction Safety Cartridge(option) 1 Scania 1335680 N/A

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APPENDIX J
CONTAINER CERTIFICATE

Appendix J - i
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Issue: A
Date: 07/10/05

Appendix J - ii
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Issue: A
Date: 07/10/05

APPENDIX K
DNV SPARK ARRESTOR CERTIFICATE

Appendix K - i
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Issue: A
Date: 07/10/05

Appendix K - ii
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Issue: A
Date: 07/10/05

Appendix K - iii
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Issue: A
Date: 07/10/05

APPENDIX L
INTERNATIONAL CONTACT INFORMATION

Appendix L - i
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Issue: A
Date: 07/10/05

In case of emergencies please contact the nearest service department of AGGREKO. They can be reached 24 hours
a day and are operational at any place in the world

CANADA
BELGIUM
Aggreko Inc.
Aggreko N.V.
300 Clarence Street
Smallandlaan 7
Brampton,
2660 Hoboken
ONTARIO
Belgium
L6W 1T5
Tel: (+32) 03 825 02 71
Tel: (+1) 905 459 3321
Fax: (+32) 03 825 11 81
Fax: (+1) 905 459 3392
NORTH AMERICA
U.S.A.
FRANCE
Aggreko Inc.
Aggreko S.a.r.l.
4607 W Admiral Doyle Drive
1 Chemin de l’Ancien Parc
PO Box 100004
91220 Bretigny Sur Orge
NEW IBERIA, LA
France
79562-0004
Tel: +33 (0)825 008007
Tel: (+1) 318 365 5479
Fax: +33 (0)1 69 737119
Fax: (+1) 318 367 0870
GREAT BRITAIN REPUBLIC OF SINGAPORE
Aggreko Generators Ltd. Aggreko Singapore Pte Ltd
Overburn Avenue 10 Pioneer Sector 1
DUMBARTON SINGAPORE
ASIA
G82 2RL 62844

Tel: (+44) 1389 767821 Tel: (+65) 6862 1501

Fax: (+44) 1389 761577 Fax: (+65) 6862 0182
AUSTRALIA/PACIFIC
EUROPE NETHERLANDS
Aggreko Generator Rentals Pty
Aggreko International (Ned) B.V.
Ltd
Ketelweg 77
101 Woodlands Drive
3356 LD Papendrecht
AUSTRALA / Braeside Victoria
Netherlands
PACIFIC 3195
MELBOURNE
Tel: (+31) 078 64 41 441
Fax: (+31) 078 642 80 83
Tel: (+61) 03 586 5050
Fax: (+61) 03 586 50514
NORWAY
Aggreko Norway A.S.
Sorlandsveien 318
Postboks 543
EGERSUND
N-4379
Norway

Tel: (+47) 810 00 333

Fax: (+47) 051 46 45 90
SPAIN
Aggreko Iberia S.A.
Avda. Torre Mateu, 35-37
Polg. Industrial Can Salvatella
08210 Barbera del Valles
BARCELONA

Tel: (+34) 93 747 93 90

Fax: (+34) 93 729 02 83

Appendix L - ii