Document No.: M02.

0204
Document Title: USER MANUAL
GHP / DC12-54 (Int & AUS)
Issue: B
Date: 31/08/05

USER MANUAL
FOR
GHP / DC12-54 (INTERNATIONAL & AUSTRALIA)
Document M02.0204
 Document No.: M02.0204
Document Title: USER MANUAL
GHP / DC12-54 (Int & AUS)
Issue: B
Date: 31/08/05

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

5.0 GENERAL DATA

5.1. GENERAL OPERATION.........................................................................................................7
5.2. DESIGN LOAD CAPACITY ....................................................................................................7
5.3. DESIGN TEMPERATURES ....................................................................................................7
5.4. CANOPY & BASE FRAME.....................................................................................................7
5.5. DIESEL ENGINE .....................................................................................................................8
5.6. ENGINE LUBRICATION SYSTEM .........................................................................................8
5.7. ENGINE COOLING SYSTEM .................................................................................................8
5.8. ENGINE FUEL SYSTEM.........................................................................................................8
5.9. EXHAUST SYSTEM................................................................................................................9
5.10. ENGINE CONTROL SYSTEM ................................................................................................9
5.11. GENERATOR..........................................................................................................................9
5.12. MAIN CIRCUIT BREAKER .....................................................................................................9

6.0 OPERATING INSTRUCTIONS

6.1 OPERATING CONTROLS AND INSTRUMENTS
6.2. OPERATING PROCEDURE .................................................................................................15

-i-
 Document No.: M02.0204
Document Title: USER MANUAL
GHP / DC12-54 (Int & AUS)
Issue: B
Date: 31/08/05

6.3. ALARM FUNCTIONS............................................................................................................16

6.4. CHANGING PARAMETERS.................................................................................................16

7.0 MAINTENANCE
7.1. GENERAL .............................................................................................................................19
7.2. MAINTENANCE SCHEDULE ...............................................................................................20
7.3. DAILY MAINTENANCE ........................................................................................................21
7.4. WEEKLY MAINTENANCE....................................................................................................22

8.0 LUBRICATION
8.1. GENERAL INFORMATION...................................................................................................23
8.2. GENERATOR OIL CHANGE ................................................................................................23
8.3. OIL SPECIFICATION ............................................................................................................23

9.0 TROUBLE SHOOTING

9.1. INTRODUCTION ...................................................................................................................24
9.2. ACTION PLAN ......................................................................................................................24
9.3. TROUBLE SHOOTING CHART ...........................................................................................25

APPENDIX A: Material Safety Data Sheets

APPENDIX B: Equipment Data Sheet
Document No. Rev.
G080267 SHT. 1 to 3 A

APPENDIX C: Installation Outline Drawing

Drawing No. Rev.
A050187 SHT. 1 of 1 A

APPENDIX D: Control Panel Layout

Drawing No. Rev.
D210620 SHT. 1 of 1 A

APPENDIX E: Electrical Schematics

Drawing No. Rev. Title
D080837 SHT. 1 of 4 B Alternator & AVR MX341
D080837 SHT. 2 of 4 D Main Load & Metering Schematic Diagram
D080837 SHT. 3 of 4 E Deep Sea 5310 Controller
D080837 SHT. 4 of 4 A Engine Controller DC Control Schematic
D140198 SHT. 1 of 1 C Engine Wiring Plug and Terminal Layout

APPENDIX F: Livery Layout

Drawing No. Rev.
D200160 SHT. 1 of 1 A

APPENDIX G: Manufacturers Component Data

Document No. Rev.
M040103 SHT. 1 of 1 A

- ii -
 Document No.: M02.0204
Document Title: USER MANUAL
GHP / DC12-54 (Int & AUS)
Issue: B
Date: 31/08/05

APPENDIX H: Lifting Beam Certificate – 14700842/001

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

- iii -
 Document No.: M02.0204
Document Title: USER MANUAL
GHP / DC12-54 (Int & AUS)
Issue: B
Date: 31/08/05

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 canopy/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.

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.

-1-
 Document No.: M02.0204
Document Title: USER MANUAL
GHP / DC12-54 (Int & AUS)
Issue: B
Date: 31/08/05

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

-2-
 Document No.: M02.0204
Document Title: USER MANUAL
GHP / DC12-54 (Int & AUS)
Issue: B
Date: 31/08/05

CAUTION
Hot

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

-3-
 Document No.: M02.0204
Document Title: USER MANUAL
GHP / DC12-54 (Int & AUS)
Issue: B
Date: 31/08/05

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:
• Fan shroud
• Vibration mounts
• 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 CANOPY 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.

-4-
 Document No.: M02.0204
Document Title: USER MANUAL
GHP / DC12-54 (Int & AUS)
Issue: B
Date: 31/08/05

3.0 HANDLING
3.1. LIFTING / HANDLING
The generator set includes 1 lifting beam and forklift pockets. There is the option for a two-point lift
configuration suitable for offshore service.
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 14528 lbs (6590 kgs)

Complete Package Without Fuel 12787 lbs (5800 kgs)

Bolt on steel plate buffers are located at the front and rear of the base to protect the body of the
International generator. The Australian generator is fitted with bolt on steel drag bars.
Where 2 point lifting is provided, ensure that the correct length of strop / wire rope is used on each
lifting beam to ensure a level lift. Also ensure that the included angle does not exceed 90°.

CAUTION: THE GENERATOR SET SHOULD NOT BE LIFTED OR DRAGGED BY THE END
BUFFERS.
3.2. STORAGE / TRANSPORT
Carry out the following points before transporting the generator or preparing the generator for
storage.
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.

-5-
 Document No.: M02.0204
Document Title: USER MANUAL
GHP / DC12-54 (Int & AUS)
Issue: B
Date: 31/08/05

4.0 INSTALLATION
4.1. UNPACKING
Ensure that the correct fork lift truck slots or 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 1 metre (3 ft) all round the generator is recommended. Hot air
will exit from the roof outlet. It is important that this hot air does not re-circulate to the
package inlet.
The generator must be allowed sufficient space all round and above, to enable the effective removal
of the cooling air which, in turn, will reduce the risk of 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 base frame at the control panel end of the set. This allows
a dedicated earthing connection if required.

-6-
 Document No.: M02.0204
Document Title: USER MANUAL
GHP / DC12-54 (Int & AUS)
Issue: B
Date: 31/08/05

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 with cooler
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 GHP/DC12-54 (350kVA) generator set can be run up to a maximum of 350 kVA at prime power
rating.
5.3. DESIGN TEMPERATURES
The GHP/DC12-54 (350kVA) generator set can operate through an ambient temperature range of:
-10°C (14°F) to 38°C (100°F)
5.4. CANOPY & BASE FRAME
The overall dimensions for the generator set are 4640 X 1500 X 2565 mm.
The canopy is manufactured from welded Zintec and has access to the inside of the generator
through lockable doors.
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.

-7-
 Document No.: M02.0204
Document Title: USER MANUAL
GHP / DC12-54 (Int & AUS)
Issue: B
Date: 31/08/05

5.5. DIESEL ENGINE

The generator set uses a Scania DC12-54 diesel engine, which is capable for either 50 Hz or 60 Hz.
Details of the engine are outlined below.
Four Stroke, 6 Cylinder In-line, Water Cooled,
Type:
Turbo charged, C/A Aftercooler
Model: Scania DC12-54
RPM: 1500 / 1800
Nominal Engine Output @ 1500rpm: 283kW @ Prime Power
Governor: S6 EMS (Engine Management System)
Starting System: 24V Battery System with Fitted Isolator
Fuel Consumption @ Continuous 1500rpm: 64 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: 28 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 Ball valve.
Refer to manufacturers data for all filter information.

NOTE: The oil centrifuge will continue to rotate after the engine has been switched off. Care
should be taken that it has stopped rotating before any maintenance is carried out on it.
5.7. ENGINE COOLING SYSTEM
The engine cooling consists of a pump, thermostat, heater and radiator assembly.
Cooling fluid is from the radiator, through the pump, which is belt driven from the engine pulley. The
thermostat controls the flow to the radiator. The radiator assembly is mounted at the front of the
engine, with the fan mounted on the front of the engine.
Cooling air enters the generator through the canopy end louvers and noise attenuation baffles. This
air then passes into the canopy
space then across the radiator
assembly.
The cooling air exits through the
roof of the package.
The coolant 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.
There is a radiator expansion tank
fitted to this unit that should be
checked, prior to starting the unit,
that it is filled between the ‘min’ and Figure 5.1 – Radiator Expansion Tank
‘max’ lines on the tank (see Figure
5.1).
5.8. ENGINE FUEL SYSTEM
The engine fuel system consists of an internal fuel tank, Racor filter (see Figure 5.2), fine fuel filter,
fuel pump, injection pump and nozzles.

-8-
 Document No.: M02.0204
Document Title: USER MANUAL
GHP / DC12-54 (Int & AUS)
Issue: B
Date: 31/08/05

Fuel can be taken from either an external or the internal fuel tank. Fuel is then pumped through the
Racor filter 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 930 Litres. Low warning and low shut-off sensors are
fitted in the internal fuel tank. The fuel tank fill point is internal. There are 2 cleaning ports on the fuel
tank that are all accessible through the canopy doors.
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.
5.9. EXHAUST SYSTEM
The exhaust system consists of the exhaust ducting, exhaust silencer complete with spark arrestor
and rain cap assembly. The exhaust gases exit the engine and are passed through the exhaust
ducting and exhaust, out the top of the canopy through the rain cap assembly. 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 M9801

5.10. ENGINE CONTROL SYSTEM

An Engine Management System (S6 Controller) controls the engine output.
A Deep Sea Electronic 5310 control module is used to monitor the safety circuits and set the
operation mode of the generator. See section 6.1.2 Control Module for more detail.
5.11. GENERATOR
Manufacturer: Newage Stamford
Type: HCI434F1
50Hz: 380-440 Volts
Voltage Range
60Hz: 416-480 Volts
Voltage Regulator within 1% from no load to full load MX341 + PMG
1 Phase configurable on Alternator TB
5.12. MAIN CIRCUIT BREAKER
Manufacturer: Merlin Gerin
NS 1000N Fixed Four Pole, Electronic Overload
Type:
Protection, Micrologic 5.0

-9-
 Document No.: M02.0204
Document Title: USER MANUAL
GHP / DC12-54 (Int & AUS)
Issue: B
Date: 31/08/05

TEMPERATURE
GAUGE

OIL CENTRIFUGE

K1 PUMP

MASTER
BATTERY SWITCH

RACOR FUEL FILTER

Figure 5.2 - 320 kVA Generator Part Locations

- 10 -
 Document No.: M02.0204
Document Title: USER MANUAL
GHP / DC12-54 (Int & AUS)
Issue: B
Date: 31/08/05

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.

2 3 4 5

Figure 6.1 – Control Panel Exterior

Deep Sea 5310 Keyswitch Local / off

1 2
Controller / Remote
Eart Leakage Off
3 4 Circuit Breaker Open
Reset / On
Circuit Breaker
5
Close

Key for figure 6.1

- 11 -
 Document No.: M02.0204
Document Title: USER MANUAL
GHP / DC12-54 (Int & AUS)
Issue: B
Date: 31/08/05

5 1

7 11
13 2
8
3
12
9

10
16
4
13

14 18
17
15

Figure 6.2 – Control Panel Interior

Relay R1/R15
AVR 11
1 Run Relay
2 1200/1A CT,s 12 Diodes D1 + D2

3 1200/5A CT,s 13 Terminals

4 Merlin Gerin 1000A 14 Relays
4P MCCB R2/R25/R3/R4/R5
Earth Leakage MCB6 (Current
5 Relay 15 Limiter Supply)
MCB4 Current Limiter
6 (MCCB Controls) 16 Device
MCB5 Volts Trim /
7 17
(S6 Controls) Speed Trim
MCB1
8 18 Earth Bar
(E-Stop Supply)
9 MCB2 (5310 Volts) 19

10 Excitation Switch
20

Key for figure 6.2

- 12 -
 Document No.: M02.0204
Document Title: USER MANUAL
GHP / DC12-54 (Int & AUS)
Issue: B
Date: 31/08/05

6.1.2. SAFETY MODULE

The control module used on Aggreko canopy generator sets is the 5310 control module by Deep
Sea. Figure 6.3 below shows the front panel layout of the 5310 control module.

1 10

2 9

3 8

4 5 6 7

Figure 6.3 – 5310 Generator controller

1. Auto select
Display scroll buttons 6
1 2. Accept setpoint value

2 CB indication 7 Mute alarm/lamp test

3 Stop button/alarm accept 8 Manual start

1. Manual select Generator available

4 9
2. Scroll down/reduce setpoint indication
1. –
5 10 Status LEDs
2. Scroll up/increase setpoint

1 – in normal mode
2 – in configuration mode
Key for figure 6.3

The 5310 generator control module has the following features:

• Text based LCD (supporting multiple languages)
• Comprehensive metering of electrical parameters (voltage, current, power)
• Engine parameter monitoring
• Manual and remote/standby operation
• Basic control of motorised circuit breakers
• Comprehensive range of alarms
• Compatible with different alternator configurations
• Support of electronic engines via J1939 CANBUS interface
• On Aggreko canopy sets, binary inputs are configured for remote start input, circuit breaker
status and alarms, e.g. Low fuel level or Air flap closed. Where a motorised breaker is
fitted, 2 binary inputs are configured for circuit breaker open and circuit breaker close.

- 13 -
 Document No.: M02.0204
Document Title: USER MANUAL
GHP / DC12-54 (Int & AUS)
Issue: B
Date: 31/08/05

• Analogue inputs are configured for low oil pressure, high water temperature (either senders
or discrete switches) and fuel gauge (where fitted).
• Binary outputs are configured for Air flap closed (on offshore sets) and, where a motorised
breaker is fitted, for circuit breaker open and close outputs. In addition, one output is
dedicated to provide a common alarm output which provides a positive DC signal in the
event of any alarm.

6.1.3. DISPLAY PAGES

The 5310 module displays the following pages on the LCD. Pressing the green info button will scroll
between these pages.
1. Status page
This shows the current status of the generator; e.g. stop mode, waiting in manual, running in
manual. When the generator is running, generator parameters are also shown (as displayed in
figure 6.3).
2. Parameter pages
The following parameters are displayed via the parameter pages. Pressing the Down arrow
button will scroll between the parameter pages. Holding down the Down arrow button for 2
seconds will start auto-scroll through the parameter pages.
- RPM
- Frequency
- Engine run time
- Battery voltage
- Generator phase voltages
- Generator line voltages
- Generator currents
- Generator real power/apparent power and power factor
- Number of starts
- Oil pressure (if sensor fitted)
- Coolant temperature (if sensor fitted)
If used in conjunction with an electronic engine (e.g. Cummins QSM11 or Scania DC12), a range
of engine parameters are also displayed.
3. Current alarm page
Displays the current alarms in clear text. Shutdowns which have not been acknowledged are
displayed as flashing text. Shutdowns which have been acknowledged and warnings are
displayed as constantly lit text.
4. Alarm log page
Stores the last 15 shutdown conditions. Pressing the Down arrow button will scroll through the
shutdown log.

6.1.4. FRONT PANEL LEDS

The following LEDs are provided.
• Green LED to indicate circuit breaker closed [symbol 2 in figure 6.3]
• Green LED to indicate Generator available (lit after warm-up timer has expired) [symbol 9 in
figure 6.3]
• Red LEDs for stop, manual and auto indication
• Status LEDs to indicate:
- Remote start input signal present.

- 14 -
 Document No.: M02.0204
Document Title: USER MANUAL
GHP / DC12-54 (Int & AUS)
Issue: B
Date: 31/08/05

- Alternative voltage selected. When alternative voltage is selected, under and

overvoltage protection is halved. In addition, overcurrent protection is doubled.
Alternative voltage is intended for use when the generator set alternator windings are
configured in parallel, as opposed to series configuration.
- Alternative frequency selected. For US generator sets, normal frequency is 60Hz and
alternative frequency is 50Hz. For European and AI generator sets, normal frequency is
50Hz and alternative frequency is 60Hz. When alternative frequency is selected
protection settings for over/under frequency and over/under speed are moved
accordingly.
- Common alarm indication. This LED is lit if any alarm condition is detected.

6.2. OPERATING PROCEDURE

CAUTION:- Always open the battery isolator switch to avoid unauthorised starting
during transport and maintenance.
6.2.1. MANUAL OPERATION
To start generator:
1. Prior to starting, exercise daily maintenance. See section 7.1.
2. Turn on DC power.
3. Check that no alarms are present. If a shutdown condition is present, the generator set will not
be allowed to start.
4. Press the manual select button. The display will read “Waiting in Manual”
5. Press the manual start button.
6. Once the generator has run-up to speed, check the frequency and voltage and adjust if
necessary, either using the potentiometers or the Governor/AVR adjustment.
7. Walk around the engine and check for any leakages.
8. After the warm-up timer has expired, close the circuit breaker.

To stop generator:
1. Open circuit breaker.
2. Allow the engine to cool down for at least 5 minutes, especially when the set has been running
with a high load.
3. Press engine stop.

6.2.2. REMOTE/STANDBY OPERATION

NOTE: When setting up for remote operation with a manual breaker, the generator set
should be started with the breaker closed. Remove the link between terminals 18 and 19 so
that the breaker can be closed when the generator set is stopped.

CAUTION: In remote operation, motorised breakers will close automatically after the
warm-up period. The 5310 controller is for single set use only and no synchronising facility is
provided. When synchronising capability is required, POWERLINK, or an alternative system,
must be used.

1. Turn on DC power
2. Check for alarms
3. Press Auto select. The display will read “Waiting in Auto”
4. The generator set can be started by providing a connection between terminals 2 and 3.

- 15 -
 Document No.: M02.0204
Document Title: USER MANUAL
GHP / DC12-54 (Int & AUS)
Issue: B
Date: 31/08/05

5. Generator set can be stopped by removing the connection between terminals 2 and 3.
6. A test run should be carried out at least once a week.

6.3. ALARM FUNCTIONS

When an alarm condition has been detected, the alarm page will be automatically displayed.
Depending upon the severity of the alarm, the 5310 control module will take one of the following
courses of action.
1. Warning
- Display the alarm in clear text
and sound an audible alarm

2. Shutdown
- Display the alarm in clear text
and sound an audible alarm
- Trip the circuit breaker
- Shutdown the generator set

3. Controlled shutdown
- Display the alarm in clear text
and sound an audible alarm
- Trip the circuit breaker Figure 6.4 – Alarm page display
- Cooldown the generator set
for the cooldown period and
shutdown the machine

Shutdowns which have not been acknowledged are displayed as flashing text. Shutdowns which
have been acknowledged and warnings are displayed as constantly lit text.
• The audible alarm can be muted using the mute alarm button [symbol 7 in figure 6.3].
• Warnings will be automatically removed when the relevant parameter has returned to within its
normal operating range.
• Shutdowns require to be acknowledged using the stop button. If the shutdown condition is still
present, the shutdown will continue to be displayed.
• When a shutdown condition is still present after the machine has shutdown, e.g. Emergency stop
or Air flap closed, the module will prevent the generator set from cranking and starting until the
condition has been removed and the shutdown has been acknowledged. “Generator Locked-out”
will be displayed on the LCD.
• In the event of an alarm, the Common alarm LED will light
• A common alarm output, terminal 8, is provided, which will turn high (+12v DC or +24V DC) when
any alarm is detected.
• The last 15 shutdown conditions will be stored in the shutdown log.

6.4. CHANGING PARAMETERS

6.4.1. GENERAL

For most applications, required parameter changes can be undertaken from the front fascia. Full
configuration can be undertaken using the configuration software.

- 16 -
 Document No.: M02.0204
Document Title: USER MANUAL
GHP / DC12-54 (Int & AUS)
Issue: B
Date: 31/08/05

To access the front panel editor

Press the Stop/Reset and Info buttons simultaneously.
Enter PIN Number

With the limited access pin number, the following can be adjusted:
Language
Alternative Frequency – Enable/Disable
Alternative Voltage – Enable/Disable
AC System
Droop – Enable/Disable (electronic engines only)
Droop percentage (electronic engines only)
Contrast
Date and Time

With the full access pin number, in addition to the above, the full range of alarm setpoints and timers
can also be adjusted. Pressing the + and - buttons will scroll up and down through the parameters.

To adjust a parameter
Scroll to the desired parameter using the + and - buttons
Press the tick button and the parameter will start to flash
Press the + or - button to adjust the parameter to the desired value
Press the tick button to save the value
To select another parameter to edit, press the + or – button
To exit the front panel configuration editor at any time, press the Stop/Reset button
When adjusting the date and time, the Down arrow is used to scroll between minutes, hours, day,
month and year

- 17 -
 Document No.: M02.0204
Document Title: USER MANUAL
GHP / DC12-54 (Int & AUS)
Issue: B
Date: 31/08/05

6.4.2. PARAMETER ADJUSTMENT FOR ALTERNATIVE ALTERNATOR CONFIGURATIONS

The Deep Sea 5310 module is designed to be used with different alternator configurations. When
changing the alternator configuration, it may be necessary to adjust the AC System and/or
Alternative Voltage within the Deep Sea module, depending upon how the alternator is being
configured. The table below outlines the most common alternator configurations and the
corresponding Deep Sea set up.

Alternator Deep Sea set-up

configuration AC System Alternative Voltage
Series star 3 phase, 4 wire No
Parallel star 3 phase, 4 wire Yes

1 phase, 2 wire or 2 phase, 3 wire Yes for 120V Ph-N

Parallel zig-zag
depending upon output configuration No for 220-240V Ph-N

1 phase, 2 wire or 2 phase, 3 wire Yes for 120V Ph-N

Double delta
depending upon output configuration No for 220-240V Ph-N
1 phase, 2 wire or 2 phase, 3 wire
Series zig-zag No
depending upon output configuration
Series Delta 3 phase, 3 wire No

Table 0-1 Deep Sea controller set up for different alternator configurations

By selecting alternative voltage the voltage protection is halved. The actual output voltage value is
adjusted separately via the AVR.
When 1 phase 2 wire or 2 phase 3 wire ac systems are selected on the Deep Sea 5310 controller,
the number of phase voltage and current readings which are displayed changes to 1 or 2
respectively. When 3 phase 3 wire ac system is selected, only line voltages are displayed. This
configuration can be used with a mid-winding or floating neutral.

- 18 -
 Document No.: M02.0204
Document Title: USER MANUAL
GHP / DC12-54 (Int & AUS)
Issue: B
Date: 31/08/05

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, canopy 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.
Loose or damage parts.
Worn or damaged belts, change in engine appearance.

- 19 -
 Document No.: M02.0204
Document Title: USER MANUAL
GHP / DC12-54 (Int & AUS)
Issue: B
Date: 31/08/05

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
500 Hrs 1000 Hrs / 2000 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* 1000 Hrs / 2000 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.

- 20 -
 Document No.: M02.0204
Document Title: USER MANUAL
GHP / DC12-54 (Int & AUS)
Issue: B
Date: 31/08/05

7.3. DAILY MAINTENANCE

7.3.1. CHECK THE ENGINE OIL LEVEL:
C. Stop the engine and wait 5 minutes to allow the oil to drain to the oil pan.
D. Remove the dipstick and check the oil level.
E. 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 85 & 95psi.
After 5 minutes check that the cooling water temperature gauge reads between 45 & 55°C.
The voltage and frequency gauges are within specification.
Fuel gauge indicates the tank is not empty.
Engine hours display increases after 10 minutes.
Safety module has no alarm indicators on.
Press the “LAMP TEST” button on the control panel and confirm that all indicator lamps are working.
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.

- 21 -
 Document No.: M02.0204
Document Title: USER MANUAL
GHP / DC12-54 (Int & AUS)
Issue: B
Date: 31/08/05

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.

- 22 -
 Document No.: M02.0204
Document Title: USER MANUAL
GHP / DC12-54 (Int & AUS)
Issue: B
Date: 31/08/05

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 6 months or 400 hours, although this should be in line with the current service best
practise. The unit will however need to be topped up with oil during this period. If a unit has been
completely drained of all oil, it must be refilled with new oil before it is placed in operation. Refer to
specifications in Lubrication Table.

NOTICE: Some oil types are incompatible when mixed and result in the formation of varnishes,
shellacs, or lacquers that may be insoluble. Such deposits can cause serious problems including
clogging of the filters. Where possible, do NOT mix oils of different types and avoid mixing different
brands. A type or brand change is best made at the time of a complete oil drain and refill.
If the unit has been operated for the time/ hours mentioned above, it should be completely drained of
oil. If the unit has been operated under adverse conditions, or after long periods in storage, an earlier
change period may be necessary as oil deteriorates with time as well as by operating conditions.
An oil change is good insurance against the accumulation of dirt, sludge, or oxidized oil products.
Completely drain the reservoir, piping, and Purafiner system. If the oil is drained immediately after
the unit has been run for some time, most of the sediment will be in suspension and, therefore, will
drain more readily. However, the fluid will be hot and care must be taken to avoid contact with the
skin or eyes.
After the unit has been completely drained of all old fluid, close the drain valve. Add oil in the
specified quantity at the filler plug. Tighten the filler plug and run the machine to circulate the oil.
Check the oil level when unit is warm and not running. If not near the middle of the dipstick, stop the
unit and make corrections. DO NOT OVERFILL.
8.3. OIL SPECIFICATION
The oil required for this engine is:
Manufacturer: 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

- 23 -
 Document No.: M02.0204
Document Title: USER MANUAL
GHP / DC12-54 (Int & AUS)
Issue: B
Date: 31/08/05

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
1) 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?
F. 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 D.
G. 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.
H. 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.

- 24 -
 Document No.: M02.0204
Document Title: USER MANUAL
GHP / DC12-54 (Int & AUS)
Issue: B
Date: 31/08/05

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
Mini circuit breaker of 10A in
Reset.
terminal box is 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 0 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.

- 25 -
 Document No.: M02.0204
Document Title: USER MANUAL
GHP / DC12-54 (Int & AUS)
Issue: B
Date: 31/08/05

SYMPTOM POSSIBLE CAUSE CORRECTIVE ACTION

Measure voltage at outlet
Voltmeter defective. terminals of alternator. If voltage
measured replace voltmeter.
ALTENATOR 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.
ALTENATOR VOLTAGE TOO
HIGH / LOW Incorrect voltage setting. Adjust voltage regulator.
No identifiable cause. Consult AGGREKO.
Engine speed not stable. Check stability of engine speed.
ALTENATOR VOLTAGE NOT
STABLE Adjust stability on the voltage
Incorrect stability adjustment.
regulator.
Circuit breaker control switch
Select local position.
(Figure 6.1) 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.

- 26 -
 Document No.: M02.0204
Document Title: USER MANUAL
GHP / DC12-54 (Int & AUS)
Issue: B
Date: 31/08/05

APPENDIX A
MATERIAL SAFETY DATA SHEETS

Appendix A - i
 Document No.: M02.0204
Document Title: USER MANUAL
GHP / DC12-54 (Int & AUS)
Issue: B
Date: 31/08/05

CASTROL TECTION T 15W-40

Appendix A - ii
 Document No.: M02.0204
Document Title: USER MANUAL
GHP / DC12-54 (Int & AUS)
Issue: B
Date: 31/08/05

Appendix A - iii
 Document No.: M02.0204
Document Title: USER MANUAL
GHP / DC12-54 (Int & AUS)
Issue: B
Date: 31/08/05

Appendix A - iv
 Document No.: M02.0204
Document Title: USER MANUAL
GHP / DC12-54 (Int & AUS)
Issue: B
Date: 31/08/05

Appendix A - v
 Document No.: M02.0204
Document Title: USER MANUAL
GHP / DC12-54 (Int & AUS)
Issue: B
Date: 31/08/05

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
 Document No.: M02.0204
Document Title: USER MANUAL
GHP / DC12-54 (Int & AUS)
Issue: B
Date: 31/08/05

[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.

Appendix A - vii
 Document No.: M02.0204
Document Title: USER MANUAL
GHP / DC12-54 (Int & AUS)
Issue: B
Date: 31/08/05

SUPERCOOLMASTER ANTIFREEZE

Appendix A - viii
 Document No.: M02.0204
Document Title: USER MANUAL
GHP / DC12-54 (Int & AUS)
Issue: B
Date: 31/08/05

Appendix A - ix
 Document No.: M02.0204
Document Title: USER MANUAL
GHP / DC12-54 (Int & AUS)
Issue: B
Date: 31/08/05

Appendix A - x
 Document No.: M02.0204
Document Title: USER MANUAL
GHP / DC12-54 (Int & AUS)
Issue: B
Date: 31/08/05

Appendix A - xi
 Document No.: M02.0204
Document Title: USER MANUAL
GHP / DC12-54 (Int & AUS)
Issue: B
Date: 31/08/05

Appendix A - xii
 Document No.: M02.0204
Document Title: USER MANUAL
GHP / DC12-54 (Int & AUS)
Issue: B
Date: 31/08/05

APPENDIXCB
APPENDIX
EQUIPMENT DATA SHEET

Appendix B - i
 Document No.: M02.0204
Document Title: USER MANUAL
GHP / DC12-54 (Int & AUS)
Issue: B
Date: 31/08/05

Appendix B - ii
 Document No.: M02.0204
Document Title: USER MANUAL
GHP / DC12-54 (Int & AUS)
Issue: B
Date: 31/08/05

Appendix B - iii
 Document No.: M02.0204
Document Title: USER MANUAL
GHP / DC12-54 (Int & AUS)
Issue: B
Date: 31/08/05

Appendix B - iv
 Document No.: M02.0204
Document Title: USER MANUAL
GHP / DC12-54 (Int.)
Issue: B
Date: 31/08/05

APPENDIX C
INSTALLATION OUTLINE DRAWING

Appendix C - i
 Document No.: M02.0204
Document Title: USER MANUAL
GHP / DC12-54 (Int.)
Issue: B
Date: 31/08/05

Appendix C - ii
 Document No.: M02.0204
Document Title: USER MANUAL
GHP / DC12-54 (Int.)
Issue: B
Date: 31/08/05

APPENDIX D
CONTROL PANEL LAYOUT

Appendix D - i
 Document No.: M02.0204
Document Title: USER MANUAL
GHP / DC12-54 (Int.)
Issue: B
Date: 31/08/05

Appendix D - ii
 Document No.: M02.0204
Document Title: USER MANUAL
GHP / DC12-54 (Int.)
Issue: B
Date: 31/08/05

APPENDIX E
ELECTRICAL SCHEMATICS

Appendix E - i
 Document No.: M02.0204
Document Title: USER MANUAL
GHP / DC12-54 (Int.)
Issue: B
Date: 31/08/05

Appendix E - ii
 Document No.: M02.0204
Document Title: USER MANUAL
GHP / DC12-54 (Int.)
Issue: B
Date: 31/08/05

Appendix E - iii
 Document No.: M02.0204
Document Title: USER MANUAL
GHP / DC12-54 (Int.)
Issue: B
Date: 31/08/05

Appendix E - iv
 Document No.: M02.0204
Document Title: USER MANUAL
GHP / DC12-54 (Int.)
Issue: B
Date: 31/08/05

Appendix E - v
 Document No.: M02.0204
Document Title: USER MANUAL
GHP / DC12-54 (Int.)
Issue: B
Date: 31/08/05

Appendix E - vi
 Document No.: M02.0204
Document Title: USER MANUAL
GHP / DC12-54 (Int.)
Issue: B
Date: 31/08/05

APPENDIX F
LIVERY LAYOUT

Appendix F - i
 Document No.: M02.0204
Document Title: USER MANUAL
GHP / DC12-54 (Int.)
Issue: B
Date: 31/08/05

Appendix F - ii
 Document No.: M02.0204
Document Title: USER MANUAL
GHP / DC12-54 (Int.)
Issue: B
Date: 31/08/05

APPENDIX G
MANUFACTURERS COMPONENT DATA

Appendix H - i
 Document No.: M02.0204
Document Title: USER MANUAL
GHP / DC12-54 (Int.)
Issue: B
Date: 31/08/05

Document No. M04.0103

Revision B Date 29/09/05
DC12 54A 350kVA Genset INTERNATIONAL

Description Quantity Supplier Suppliers Part Aggreko Part

Per Set No. No.
Radiator 1 Nissens 230051 N/A
Radiator Fan 1 Scania / Multi-Wing 9128835SGB N/A
Coupling, Disc 3 Newage 350-11580 N/A
Charging Belt / Fan 1 530990
1 Scania N/A
Belt 1 530987
Starter Motor 1 Scania 571 463 N/A
Battery Charging
1 Scania 571 498 N/A
Alternator
Circuit Breaker
NS1000N 4P Refer to Description
Micrologic 5.0 1 Merlin Gerin (Complete Assembly 293440A
Electronic Protection 33304)
Motortmech
Current Transformer
3 Raytel Tasso Refer to Description 273154A
1200/1A
Water Temperature
1 Scania 1 539107 N/A
Sensor
Oil Pressure Switch 1 Scania 1 535521 N/A
Lube Oil Filter 2 Scania 1 117285 N/A
Combustion Air Filter
Technical Filtration
(Element & Safety 1 FRG15-0097 N/A
Systems
Element)
Secondary Fuel Filter 2 Scania 1 411894 N/A
Primary Fuel Filter for
1 Racor 2040PM-OR N/A
900FG
Fuel level alarm 1 Fozmula T/LL70/11841 269069A
Fuel level sender
Float arm type to 1 Datcon / Fozmula Refer to description 269065A
230mm
Battery 2 DB Wilson 324 339002A

Appendix H - ii
 Document No.: M02.0204
Document Title: USER MANUAL
GHP / DC12-54 (Int.)
Issue: B
Date: 31/08/05

APPENDIX H
LIFTING BEAM CERTIFICATE

Appendix H - i
 Document No.: M02.0204
Document Title: USER MANUAL
GHP / DC12-54 (Int.)
Issue: B
Date: 31/08/05

Appendix H - ii
 Document No.: M02.0204
Document Title: USER MANUAL
GHP / DC12-54 (Int.)
Issue: B
Date: 31/08/05

APPENDIX J
DNV SPARK ARRESTOR CERTIFICATE

Appendix J- i
 Document No.: M02.0204
Document Title: USER MANUAL
GHP / DC12-54 (Int.)
Issue: B
Date: 31/08/05

Appendix J- ii
 Document No.: M02.0204
Document Title: USER MANUAL
GHP / DC12-54 (Int.)
Issue: B
Date: 31/08/05

Appendix J- iii
 Document No.: M02.0204
Document Title: USER MANUAL
GHP / DC12-54 (Int.)
Issue: B
Date: 31/08/05

APPENDIX K
INTERNATIONAL CONTACT INFORMATION

Appendix K- i
 Document No.: M02.0204
Document Title: USER MANUAL
GHP / DC12-54 (Int.)
Issue: B
Date: 31/08/05

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 K- ii