Document No.: M02.

0172
Document Title: USER MANUAL
GHP / 8065E(Int.)
Issue: A
Date: 09/01/04

USER MANUAL
FOR
GHP / 8065E (INTERNATIONAL)
Document M02.0172
 Document No.: M02.0172
Document Title: USER MANUAL
GHP / 8065E(Int.)
Issue: A
Date: 09/01/04

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. CANOPY & 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 ................................................................12

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 Document No.: M02.0172
Document Title: USER MANUAL
GHP / 8065E(Int.)
Issue: A
Date: 09/01/04

6.2. PRIOR TO START ................................................................................................................14

6.3. STARTING ............................................................................................................................14
6.4. LOADING ..............................................................................................................................15
6.5. SHUT-DOWN ........................................................................................................................15
6.6. STANDBY OPERATION (OPTIONAL).................................................................................15

7.0 MAINTENANCE
7.1. GENERAL .............................................................................................................................16
7.2. MAINTENANCE SCHEDULE ...............................................................................................17
7.3. WEEKLY MAINTENANCE....................................................................................................19

8.0 LUBRICATION
8.1. GENERAL INFORMATION...................................................................................................20
8.2. GENERATOR OIL CHANGE ................................................................................................20
8.3. OIL SPECIFICATION ............................................................................................................20

9.0 TROUBLE SHOOTING

9.1. INTRODUCTION ...................................................................................................................21
9.2. ACTION PLAN ......................................................................................................................21
9.3. TROUBLE SHOOTING CHART ...........................................................................................22

APPENDIX A: Material Safety Data Sheets

APPENDIX B: Equipment Data Sheet
Document No. Rev.
G080242 SHT. 1 to 3 A

APPENDIX C: Installation Outline Drawing

Drawing No. Rev.
A050090 SHT. 1 of 1 C

APPENDIX D: Control Panel Layout

Drawing No. Rev.
D210477 SHT. 1 of 1 G

APPENDIX E: Alternator & AVR Schematic Diagram

Drawing No. Rev. Title
D080814 SHT. 1 of 1 B Alternator & AVR Schematic Diagram

APPENDIX F: Main Load & Metering Schematic Diagram

Drawing No. Rev. Title
D080719 SHT. 2 of 3 E Main Load & Metering Schematic Diagram

APPENDIX G: DC Control Schematic Diagram

Drawing No. Rev. Title
D080817 SHT. 3 of 3 B DC Control Schematic Diagram

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 Document No.: M02.0172
Document Title: USER MANUAL
GHP / 8065E(Int.)
Issue: A
Date: 09/01/04

APPENDIX H: Terminal Layout & Engine Wiring

Drawing No. Rev. Title
D140132 SHT. 1 of 1 F Terminal Layout & Engine Wiring

APPENDIX J: Livery Layout

Drawing No. Rev.
D200093 SHT. 1 of 1 C

APPENDIX K: Manufacturers Component Data

Document No. Rev.
M040087 SHT. 1 of 1 A

APPENDIX L: Lifting Beam Certificate 14702176/001

APPENDIX M: DNV Spark Arrestor Certificate M9149
APPENDIX N: International Contact Information

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 Document No.: M02.0172
Document Title: USER MANUAL
GHP / 8065E(Int.)
Issue: A
Date: 09/01/04

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.

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 Document No.: M02.0172
Document Title: USER MANUAL
GHP / 8065E(Int.)
Issue: A
Date: 09/01/04

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.: M02.0172
Document Title: USER MANUAL
GHP / 8065E(Int.)
Issue: A
Date: 09/01/04

CAUTION
Hot

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

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 Document No.: M02.0172
Document Title: USER MANUAL
GHP / 8065E(Int.)
Issue: A
Date: 09/01/04

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 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.

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 Document No.: M02.0172
Document Title: USER MANUAL
GHP / 8065E(Int.)
Issue: A
Date: 09/01/04

3.0 HANDLING
3.1. LIFTING / HANDLING
The generator set includes 1 lifting beam and forklift pockets.
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 5393 lbs (2446 kgs)

Complete Package Without Fuel 4786 lbs (2171 kgs)

Bolt on steel plate buffers are located at the front and rear of the base to protect the body of the
generator.
Where 2 point lifting is provided, ensure that the correct length of strap / 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).
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.: M02.0172
Document Title: USER MANUAL
GHP / 8065E(Int.)
Issue: A
Date: 09/01/04

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 recirculating the cooling air back through the
generator. Adequate clearance needs to be allowed around and above the machine to permit safe
access for specified maintenance tasks. Hard surfaces may reflect noise with an apparent increase
in the decibel level. It is recommended that provision be made for lifting heavy components during
major overhaul.

NOTE: When operating at elevated altitude please refer to engine manufacturers

guidelines for power deration.
4.3. COMMISSIONING
Upon receipt of the unit, and prior to putting it into service, it is important to adhere strictly to the
instructions given below in section 4.4 PRIOR TO STARTING.
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. This allows a dedicated earthing connection if
required.

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 Document No.: M02.0172
Document Title: USER MANUAL
GHP / 8065E(Int.)
Issue: A
Date: 09/01/04

4.7. REMOTE FUELLING

External fuel tank supply can be connected to the generator set.
One 3/8 Female Coupling (supply)
One 3/8 Male Coupling (Return)
There is an access hole in the base frame to allow access to the internal fuel connections.

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 Document No.: M02.0172
Document Title: USER MANUAL
GHP / 8065E(Int.)
Issue: A
Date: 09/01/04

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 GHP/8065E (60kVA) generator set can be ran up to a maximum of 62.8 kVA at prime power
rating 50hZ.
5.3. DESIGN TEMPERATURES
The GHP/8065E (60kVA) generator set can operate through an ambient temperature range of:
-10C (14F) to 35C (95F)
5.4. CANOPY & BASE FRAME
The overall dimensions for the generator set are 3020 X 1200 X 2100 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.

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 Document No.: M02.0172
Document Title: USER MANUAL
GHP / 8065E(Int.)
Issue: A
Date: 09/01/04

5.5. DIESEL ENGINE

The generator set uses an Iveco 8065E diesel engine, which is capable for either 50 Hz or 60 Hz.
Details of the engine are outlined below.
Type: Four Stroke, 6 Cylinder In-line, Water Cooled
Model: Iveco 8065E
RPM: 1500 / 1800
Nominal Engine Output @ 1500rpm: 50.5kW @ Prime Power
Governor: GAC Electronic
Starting System: 12V Battery System
Fuel Consumption @ Continuous 1500rpm: 13.1 L/Hr @ 100% Prime Power

5.6. ENGINE LUBRICATION SYSTEM

The engine oil lubrication system includes pump, strainer, oil-water heat exchanger 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. To give extra time between oil changes, a Puradyn filter is also fitted (see
Figure 5.1).
Sump Capacity: 15 Litres
Puradyn Filter Capacity: 3.8 Litres
Total Oil Capacity: 18.8 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.
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 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 pump.
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 heated air from the radiator 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 38C. Please consult Aggreko if filling is required.
5.8. ENGINE FUEL SYSTEM
The engine fuel system consists of an internal fuel tank, Racor filter (see Figure 5.1), fine fuel filter,
fuel pump, injection pump & nozzles.
Fuel can be taken from either an external or the internal fuel tank. Fuel is 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 300 Litres. A low warning sensor is fitted in the internal
fuel tank. The fuel tank fill point is internal. There is 1 cleaning port on the fuel tank that is accessible
through the canopy doors.
External fuel supply can be connected to the package by disconnecting the internal tank supply and
return hoses at the Racor filter and the internal tank connection. External hoses can then be
connected to the Racor filter inlet and the hose connection from the gallery return (see Figure 5.1).
The use of ASTM No. 2D fuel is recommended for optimum engine performance. At operating
temperatures below 0C, acceptable performance can be obtained using blends of No. 1 and No. 2D.
The use of lighter fuels can reduce economy. The viscosity of fuels must be kept above 1.3 cSt to
provide adequate lubrication.
Refer to manufacturers data for all filter information.

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 Document No.: M02.0172
Document Title: USER MANUAL
GHP / 8065E(Int.)
Issue: A
Date: 09/01/04

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: IMS
Spark Arrestor: DNV Certificate No M9149

5.10. ENGINE CONTROL SYSTEM

An Electronic GAC governor controls the engine output.
A Deep Sea Electronic P552 protection module is used to monitor the safety circuits and set the
operation mode of the generator. See section 6.1.2 Safety Module for more detail.
5.11. GENERATOR
Manufacturer: Newage Stamford
Type: UCI224F16
50Hz: 380-440 Volts
Voltage Range
60Hz: 440-480 Volts
Excitation System: Self Excited
Voltage Regulator within 1% from no load to full load SX460
1 Phase configurable on Alternator TB
5.12. MAIN CIRCUIT BREAKER
Manufacturer: Merlin Gerin
NS 250N Fixed Four Pole, Electronic Overload
Type:
Protection STR22SE

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 Document No.: M02.0172
Document Title: USER MANUAL
GHP / 8065E(Int.)
Issue: A
Date: 09/01/04

RACOR FUEL EXTERNAL FUEL

FILTER RETURN

EXTERNAL FUEL
SUPPLY

OIL PRESSURE
GAUGE

PURADYN OIL
FILTER

Figure 5.1 - 60 kVA Generator Part Locations

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 Document No.: M02.0172
Document Title: USER MANUAL
GHP / 8065E(Int.)
Issue: A
Date: 09/01/04

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 table 6.1.

1 2 3

4 5

6
7

8 9

Figure 6.1 Control Panel Exterior

V Meter 522 EPM

1 6

A Meter Breaker Handle

2 7

Hz Meter Lamp Test Push

3 8
Button
Fuel Gauge Earth Leakage Reset
4 9

Hrs Run
5

Key for figure 6.1

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 Document No.: M02.0172
Document Title: USER MANUAL
GHP / 8065E(Int.)
Issue: A
Date: 09/01/04

8 10

3
9

Figure 6.2 Control Panel Internals

Term 1-4 Diodes 6

MCB5
1

Terminals 3-38 373-ELR

2 7

MCB1 8
PSR
3

MCB2 9
Merlin Gerin MCCB
4

MCB3 10
Governor Controller
5

Key for figure 6.2

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 Document No.: M02.0172
Document Title: USER MANUAL
GHP / 8065E(Int.)
Issue: A
Date: 09/01/04

6.1.2. SAFETY MODULE

The safety module for the generator is a Deep Sea Electronics P522 shown in figure 6.3. The
module consists of the following items:
Safety On indicator
Fail to start indicator
Underspeed indicator
Overspeed indicator
Earth Leakage
Common alarm
Charge Fail indicator
High Water Temperature indicator
Low Oil Pressure indicator
AUTO/OFF/MANUAL switch
Start button Figure 6.3 Safety Module

6.1.3. ALARM FUNCTIONS

The table below lists alarm indicators and the point at which the individual alarm function is activated.
The LEDs indicate the fault condition and will activate with one of the following characteristics:
A flashing LED. - Indicates a first up fault with subsequent faults that occur simultaneously
indicated by steady LED.
A steady LED - Indicates warnings. The LED will remain illuminated until the input is cleared.
This feature also allows the module to be operated as an enunciator.
Alarm Activation Point
This will illuminate green continuously and, for a default 10 secs at initial start up,
Safety On
allows the various inputs to stabilise without tripping the associated alarm.
Will illuminate if the engine fails to fire after the one local or 3 remote cranks, the
Fail to Start
start sequence is terminated and the LED will flash.
When the engine speed falls below the pre-set trip after the Safety On timer has
Underspeed
expired. The LED will flash and a shutdown initiated.
When the engine speed exceeds the pre-set trip. A shutdown is initiated. The
Overspeed Overspeed LED will flash. Overspeed is not delayed, and will initiate an immediate
shutdown.
Will illuminate to indicate all shutdown and warning faults. Mainly used to indicate
Common
fault conditions that do not have their own individual LED to indicate the fault. A
Alarm
warning indication is illuminated steady, while shutdown indications flash.
When charge alternator voltage falls below the pre-set trip voltage after the end of
Charge Fail
the Safety On timer. The LED will illuminate steady.
High Water When the water temperature is too high after the safety on timer has expired. The
Temperature LED will flash and a shutdown initiated.
Low Oil When the oil pressure is too low after the safety on timer has expired. The LED will
Pressure flash and a shutdown initiated.

6.2. PRIOR TO START

Execute Daily Maintenance see section 7.1.
6.3. STARTING
1) Put the switch in MANUAL position (Clockwise).
2) Press the START button and hold until the motor starts running.

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 Document No.: M02.0172
Document Title: USER MANUAL
GHP / 8065E(Int.)
Issue: A
Date: 09/01/04

3) Check the frequency on the control panel and adjust if necessary with the frequency
potentiometer.
4) Check the voltage and if necessary adjust using the potentiometer.
5) Walk around the engine and check for any leakages.
6.4. LOADING
1) Allow the engine to warm-up prior to applying load.
6.5. SHUT-DOWN
1) Open the circuit breaker.
2) Allow the engine to cool down for at least 5 minutes. Especially when the set has been running at
high level.
3) Stop the engine by returning the switch to the OFF position.

CAUTION:- Always open the battery isolator switch to avoid unauthorised starting
during transport and maintenance.
6.6. STANDBY OPERATION (OPTIONAL)
1) Put the contact key to AUTO position.
2) Select the circuit breaker to closed.
3) Refer to separate manual for operation of remote option.
4) A test run should be carried at least once a week.

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 Document No.: M02.0172
Document Title: USER MANUAL
GHP / 8065E(Int.)
Issue: A
Date: 09/01/04

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 antistart devices.
All residual electrical power sources (mains and battery) are isolated.
Prior to opening or removing panels or covers to work inside a machine, ensure that:
Anyone entering the machine is aware of the reduced level of protection and the additional
hazards, including hot surfaces and intermittently moving parts.
The machine cannot be started accidentally or otherwise, by posting warning signs and/or fitting
appropriate antistart devices.
Prior to attempting any maintenance work on a running machine, ensure that:
The work carried out is limited to only those tasks which require the machine to run.
The work carried out with safety protection devices disabled or removed is limited to only those
tasks which require the machine to be running with safety protection devices disabled or
removed.
All hazards present are known (e.g. pressurised components, electrically live components,
removed panels, covers and guards, extreme temperatures, inflow and outflow of air,
intermittently moving parts, safety valve discharge etc.).
Appropriate personal protective equipment is worn.
Loose clothing, jewellery, long hair etc. is made safe.
Warning signs indicating that Maintenance Work is in Progress are posted in a position that can
be clearly seen.
Upon completion of maintenance tasks and prior to returning the machine into service, ensure that:
The machine is suitably tested.
All guards and safety protection devices are refitted.
All panels are replaced, 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.

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GHP / 8065E(Int.)
Issue: A
Date: 09/01/04

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
Up to 6
3 Months / 12 Months
Daily Weekly Monthly Months /
500 Hrs / 2000 hrs
1000 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
Up to 6
3 Months / 12 Months
Daily Weekly Monthly Months /
500 Hrs / 2000 hrs
1000 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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 Document No.: M02.0172
Document Title: USER MANUAL
GHP / 8065E(Int.)
Issue: A
Date: 09/01/04

7.2.3. DAILY MAINTENANCE

1) Check the engine oil level:
2) Stop the engine and wait 5 minutes to allow the oil to drain to the oil pan.
3) Remove the dipstick and check the oil level.
4) 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

7.2.4. 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.
7.2.5. CHECK THAT ALL METERS AND GAUGES FUNCTION CORRECTLY.
Start the generator and inspect the following items:
Oil pressure gauge is between 65 & 75psi.
After 5 minutes check that the engine oil temperature gauge reads between 45C & 55C.
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.
7.2.6. CHECK THE AIR FILTER.

NOTE: In dusty conditions clean the primary filters regularly.

Check the air filter restriction indicator (if fitted) 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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 Document No.: M02.0172
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GHP / 8065E(Int.)
Issue: A
Date: 09/01/04

7.2.7. 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.
7.2.8. 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.
7.3. WEEKLY MAINTENANCE
7.3.1. 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

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

The cooling pump, alternator and radiator fan are driven by a dual 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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 Document No.: M02.0172
Document Title: USER MANUAL
GHP / 8065E(Int.)
Issue: A
Date: 09/01/04

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 up to 1000 hours in line with current service recommendations,
whichever comes first. 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 @ 25C 0.89 g/cm
Viscosity @ 40C 110 mm/s
Viscosity @ 100C 14.5 mm/s
Viscosity Index 135
CCS 20C 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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 Document No.: M02.0172
Document Title: USER MANUAL
GHP / 8065E(Int.)
Issue: A
Date: 09/01/04

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 logbook.
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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Document Title: USER MANUAL
GHP / 8065E(Int.)
Issue: A
Date: 09/01/04

9.3. TROUBLE SHOOTING CHART

SYMPTOM POSSIBLE CAUSE CORRECTIVE ACTION
Batteries flat or bad. Read
value on battery voltage meter Replace or charge batteries.
(must be 12V or more).
ENGINE DOES NOT CRANK
WITH 12V 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 (12V) 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 80-90C.
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.

ALTENATOR DOESNT Measure voltage at outlet

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

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Issue: A
Date: 09/01/04

SYMPTOM POSSIBLE CAUSE CORRECTIVE ACTION

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
MAIN CIRCUIT BREAKER Select local position.
(Figure 6.1) set remote control.
WILL NOT CLOSE
Circuit breaker tripped. Reset circuit breaker.
MAIN CIRCUIT BREAKER Switch on overload or short
Remove load.
CLOSES BUT TRIPS AGAIN circuit.

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Document Title: USER MANUAL
GHP / 8065E(Int.)
Issue: A
Date: 09/01/04

APPENDIX A
MATERIAL SAFETY DATA SHEETS

Appendix A - i
 Document No.: M02.0172
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GHP / 8065E(Int.)
Issue: A
Date: 09/01/04

CASTROL TECTION T 15W-40

Appendix A - ii
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Issue: A
Date: 09/01/04

Appendix A - iii
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Appendix A - iv
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Appendix A - v
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Issue: A
Date: 09/01/04

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 attatched 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
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SUPERCOOLMASTER ANTIFREEZE

Appendix A - viii
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Appendix A - ix
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Appendix A - x
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Appendix A - xi
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Appendix A - xii
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APPENDIX B
EQUIPMENT DATA SHEET

Appendix B - i
 EQUIPMENT DATA SHEET No. G08.0242
Rev. A
M anuf act ur ing
B ir ch Road
Diesel Generating Set Date Jan 2004
Dumbar t on, G8 2 2 RF 50Hz 60kVA
Tel: 0 0 4 4 (0 )1 3 8 9 7 4 2 2 1 4 60Hz 50kW Page 1 of 3
Fax: 0 0 4 4 (0 )1 3 8 9 7 4 2 5 5 4

1 Model Ref GHP/8065E (INT)

2 Part Number Ref 601191

3 Specification Ref G32.0012

4 Installation Drawing Ref A050090

5 Maximum Ambient C (F) 35 (95) 35 (95)

6 Electrical Output Hz 50 60

ISO 8528-1

- Continuous Power (COP) kW (kVA) 45.2 (56.6) 50.1 (62.6)

- Prime Power (PRP) kW (kVA) 50.5 (63.0) 57.1 (71.4)

- Permissible average of PRP % 65 65

ISO3046/1

- Fuel Stop Power/Standby kW (kVA) 55.7 (69.6) 62.0 (77.5)

Single Step load application % 100 100

7 Alternator

Class F Temp. Rise (105C)

- Three phase kW (kVA) 52 (65.0) 60.0 (75.0)

- Single phase kW (kVA) 34.8 (43.5) 38 (47.5)

Ends Out 12

Make & Type Newage UCI224F16

AVR SX460

Regulation % 1.0

8 Circuit Breaker

Make & Type Merlin Gerin NS250N

Number of poles 4

Rating Amps 250

Trip Unit Type STR22SE

Overload Protection Range Amps 100-250

Short Circuit Protection Range Amps 200-2500

9 Load Terminals

Type M10/12 Studs

10 Fuel Consumption

Standby/Fuel Stop lit/hr(US gal/hr) 14.5 (3.8) 18.3 (4.8)

100% Prime Power " " 13.1 (3.5) 16.7 4.4)

75% " " 10.3 (2.7) 13.1 (3.5)

50% " " 7.6 (2.0) 9.5 (2.5)

Technical Department - Dumbarton Approved by

 EQUIPMENT DATA SHEET No. G08.0242
Rev. A
M anuf act ur ing
B ir ch Road
Diesel Generating Set Date Jan 2004
Dumbar t on, G8 2 2 RF 50Hz 60kVA
Tel: 0 0 4 4 (0 )1 3 8 9 7 4 2 2 1 4 60Hz 60kW Page 2 of 3
Fax: 0 0 4 4 (0 )1 3 8 9 7 4 2 5 5 4

11 Running Hours

100% Prime Power Hours 22.9 18

75% 29.1 22.9

50% 39.5 31.6

12 Exhaust Emissions

Measurement Method TA-Luft EPA-MOH/CARB

Specific Load 100% Load 2% 1S0 8178D2

3
NOx - Oxides of Nitrogen 4000 mg/nm 7.6 g/kWh
3
PM - Particulate Matter 130 mg/nm 0.2 g/kWh
3
CO - Carbon Monoxide 650 mg/nm 0.7 g/kWh
3
HC - Unburnt Hydrocarbons 150 mg/nm 0.7g/kWh

13 Exhaust Silencer

Make & Type IMS

Certificate DNV M-9149

Permissible back pressure mm (ins) Hg 12.7 (0.5) 12.7 (0.50)

14 Noise

Sound Power - EEC dBA (Lw) 94.6

Sound Pressure at 1 metre dBA 76.2 75.6

Sound Pressure at 7 metre dBA 71.0 70.8

15 Engine

Make & Type Iveco 8065E.00

Cylinders & Form 6 in Line

Aspiration Natural

Fuel Pump Bosch Type VE (Rotary)

Governor Type Electronic

Make & Model G.A.C ESD 5500

Steady State frequency % 0.5

Battery Voltage Volts 12

16 Overall Dimensions

- Length Metres (feet) 3.02 (9 11)

- Width Metres (feet) 1.20 (311)

- Height Metres (feet) 2.10 (6 10)

17 Weight

- Without fuel Kg (lbs) 2171 (4786)

- With fuel Kg (lbs) 2446 (5393)

Technical Department - Dumbarton Approved by

 EQUIPMENT DATA SHEET No. G08.0242
Rev. A
M anuf act ur ing
B ir ch Road
Diesel Generating Set Date Jan 2004
Dumbar t on, G8 2 2 RF 50Hz 60kVA
Tel: 0 0 4 4 (0 )1 3 8 9 7 4 2 2 1 4 60Hz 60kW Page 3 of 3
Fax: 0 0 4 4 (0 )1 3 8 9 7 4 2 5 5 4

18 Capacities

- Fuel gross Litres (US gall) 340 (90)

usable 300 (79)

- Lub oil total 18.8 (5)

pan 8.8 (2.3)

Purifiner 3.8(1)

- Coolant 80.0 (21.1)

19 External fuel supply

- maximum above base Metres (feet) 1.5 (50)

- maximum below base Metres (feet) 0.3 (10)

Technical Department - Dumbarton Approved by

 Document No.: M02.0172
Document Title: USER MANUAL
GHP/8065E(Int.)
Issue: A
Date: 09/01/04

APPENDIX C
INSTALLATION OUTLINE DRAWING

Appendix C - i
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Appendix C - ii
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APPENDIX D
CONTROL PANEL LAYOUT

Appendix D - i
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Appendix D - ii
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APPENDIX E
ALTERNATOR & AVR SCHEMATIC DIAGRAM

Appendix E - i
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Appendix E - ii
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APPENDIX F
MAIN LOAD & METERING SCEMATIC DIAGRAM

Appendix F - i
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Appendix F - ii
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APPENDIX G
DC CONTROL SYSTEM SCHEMATIC DIAGRAM

Appendix G - i
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Appendix G - ii
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APPENDIX H
TERMINAL LAYOUT & ENGINE WIRING

Appendix H - i
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Appendix H - ii
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APPENDIX J
LIVERY LAYOUT DRAWING

Appendix J - i
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Appendix J - ii
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APPENDIX K
MANUFACTURERS COMPONENT DATA

Appendix K - i
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Document Title: USER MANUAL
GHP/8065E(Int.)
Issue: A
Date: 09/01/04

Document No.: M040087 Date: 09/01/04

Rev: A
Title: GHP / 8065E (International) Spares List & Manufacturers Data.

SUPPLIER / AGGREKO PART

DESCRIPTION QTY SUPPLIER PART No.
MANUFACTURER No.
Radiator 1 Iveco A22010054 N/A
Radiator Fan 1 Iveco A08010007 N/A
Coupling, Disc 2 Newage 230-01202 N/A
Battery 128Ah C20 12v 1 D.B. Wilson 656AG 339009A
Charging Belt / Fan Belt 2 (Common) Iveco 98473886 N/A
Starter Motor 1 Iveco/Bosch A10010005 N/A
Battery Charging Alternator 1 Iveco/Marelli A14020002 N/A
Earth Leakage Protector 1 Crompton 373-ELR 275149A
Toroidal Transformer 50mm 1 Merlin Gerin 50438 273080A
Deep Sea
Engine Protection Module 1 27510 275103A
Electronics
Circuit Breaker NS250N with Trip 1 Merlin Gerin Refer to Description 293289A
Unit STR22SE (31780,31480,31408,
29382,29315,29450,29322)
Current Transformer 200/5A 3 Crompton M53J-94F 273130A
Water Temperature Switch 1 Iveco A38610005 N/A
Oil Pressure Switch 1 Iveco A38610005 N/A
Lube Oil Filter 2 Iveco 1907587 N/A
Combustion Air Filter 1 Iveco A21210006 N/A
Secondary Fuel Filter 2 Iveco 1902138 N/A
Primary Fuel Filter for 500FGS/S 1 Racor 2010-PM N/A
Puradyn Filter Element 1 Puradyn 040-11030A 060011A

Appendix K - ii
 Document No.: M02.0172
Document Title: USER MANUAL
GHP/8065E(Int.)
Issue: A
Date: 09/01/04

APPENDIX L
LIFTING BEAM CERTIFICATE

Appendix L - i
 Document No.: M02.0172
Document Title: USER MANUAL
GHP/8065E(Int.)
Issue: A
Date: 09/01/04

Appendix L - ii
 Document No.: M02.0172
Document Title: USER MANUAL
GHP/8065E(Int.)
Issue: A
Date: 09/01/04

APPENDIX M
DNV SPARK ARRESTOR CERTIFICATE

Appendix M - i
 Document No.: M02.0172
Document Title: USER MANUAL
GHP/8065E(Int.)
Issue: A
Date: 09/01/04

Appendix M - ii
 Document No.: M02.0172
Document Title: USER MANUAL
GHP/8065E(Int.)
Issue: A
Date: 09/01/04

Appendix M - iii
 Document No.: M02.0172
Document Title: USER MANUAL
GHP/8065E(Int.)
Issue: A
Date: 09/01/04

APPENDIX N
INTERNATIONAL CONTACT INFORMATION

Appendix N - i
 Document No.: M02.0172
Document Title: USER MANUAL
GHP/8065E(Int.)
Issue: A
Date: 09/01/04

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.
40A Racine Road
Elektronikalaan 4-6
Etobicoke
2610
TORONTO
WILRIJK
M9W 2Z3
Tel: (+32) 03 825 02 71
Tel: (+1) 416 477 9355
Fax: (+32) 03 825 11 81
Fax: (+1) 416 744 9358
NORTH AMERICA
U.S.A.
FRANCE
Aggreko Inc.
Aggreko S.a.r.l.
4054 W Admiral Doyle Drive
1 Chemin de lAncien Parc
PO Box 100004
91220
NEW IBERIA, LA
BRITTANY SURORGE
79562-0004
Tel: (+33) 1608 47749
Tel: (+1) 318 365 5479
Fax: (+33) 1608 40978
Fax: (+1) 318 367 0870
GREAT BRITAIN REPUBLIC OF SINGAPORE
Aggreko Generators Ltd. Yeow Kong Electrical Ltd.
Overburn Avenue 5 Tuas Drive 1
DUMBARTON SINGAPORE
ASIA
G82 2RL 2263

Tel: (+44) 1389 767821 Tel: (+65) 862 1501

Fax: (+44) 1389 761577 Fax: (+65) 862 0182
NETHERLANDS AUSTRALIA
Aggreko International (Ned) B.V. Aggreko Inc.
Ketelweg 77u 305 / 307 Boundary Road
3356 LD Breaside Victoria
PAPENDRECHT AUSTRALASIA 3195
MELBOURNE
Tel: (+31) 078 153211
Fax: (+31) 078 151677 Tel: (+61) 03 587 5011
Tlx: 044 29002 Fax: (+61) 03 587 5054
NORWAY
Aggreko A.S.
Krossmoen
4390
HELLELAND (Egursund)

Tel: (+47) 0449 7388

Fax: (+47) 0449 7389
SPAIN
Aggreko S.A.
C/Can Fanosa s/n
Poligono Industrial de Martorellas
BARCELONA

Tel: (+34) 3 570 6464

Fax: (+34) 3 570 7208

Appendix N - ii