Doc.

Type: Standard Work Instruction

Doc. Title: Diesel Generator “50A” KTA50G3 A Service (Planned) Area Operations

Scope: This document is applicable to any 1250kVA (Aggreko manufacturing built) Diesel Generator fitted with a KTA50G3 engine incorporating a GEMPAC control system (on operational sites). Doc. No. P04300001
This document describes the steps involved in performing a “50A” A Service on an Aggreko diesel generator. As this work instruction is based around a 3-man team, for clarity each step is broken
Purpose: down to Operator 1 (OP1), Operator 2 (OP2) and Aggreko Authorised Person Level 2 (AAP2). Rev. No. C
NOTE: OP1 & OP2 MUST be trained in every step of this work instruction.

Related Docs. BOP's (08, 26, 28, 38,49), Service Manual 08 - Section 4: WI 02 & WI16 Issue Date: 07 August 2012

Step No. /
Main Steps Detailed Steps Key Points Photos / Comments
(Responsibility)

1 (OP1) Take Job Card from control room
or if Service Mobility (Handheld
Device) has been implemented
follow all service mobility
instructions.
NOTE: The Site OS is responsible
for opening and closing job cards
and following all MOVEX
procedures.
• Check details on Job Card or Handheld device. Wear appropriate PPE in
• Check the physical plant number matches the plant number on the job card. accordance with Aggreko
• Open personnel door on LHS of the container. BOP.
• Check the service is due by checking the last SMR reading displayed on the service sticker, if there is
any discrepancy in the meter reading this must be reported to the OS to reschedule service otherwise Refer to BOP-08.
continue.
• Leave door open. Conduct “Tool box talk”.

2 (OP2) Prepare PPE, tools and
consumables required for the task.
If service mobility has been
implemented please refer to the
relevant service kit.
Tools required to complete the A Service:
• Filter-strap.
• 7/16 AF Spanner (for Puradyn lid).
• 13mm socket and ratchet. (Radiator
compartment side cover).
• 2 x 13mm spanners (Battery connections).
• 2 x 19mm spanners (electrical connections).
• 12’” adjustable spanner.
• Flat blade insulated screwdriver.
• Filter piercing tool (Part No: 20-0019580).
• Fluke meter.
• Refractometer.
• Drip trays for fuel and oil.
• Lube Oil hand pump & hose.
• 2 x Buckets for oil /oil & fuel filters.
• Waste oil drum.
• Steam cleaner.
• Wire brush (Battery terminals).
• Ladder.
• Anti Corrosive spray (Battery Terminals).
• Clean oil can.
• Torch or inspection lamp.
• Non Contact Voltage Indicator.
• Locks and tags.
Spares required to complete the A Service: CAUTION: Wear nitrile
• 5 x B96SS Oil filter. gloves for changing fuel and
• 2 x B7577 Bypass filter or 1 x Puradyn filter lubrication filters. This form
whichever is applicable. of synthetic rubber glove is
• 2 x BF7764 Fuel filter (if required). generally resistant to oil,
• 2 x RS3982 Air filter (if required). fuel, and other chemicals.
• 3 x PF7890-30 Racor Filters (if required).
• 8 x PA3873 Door filters (if required).
• 2 x B5088 (every 3000Hrs).
• 180 Lts Engine oil.
• Oil Sample bottle.
• Oil Sample probe with hose.
• DCA test strips.
• Alternator filter cloth (if required).
• 50/50 Coolant mixture (if required).
• Service sticker.
• Desalinated water (Lead acid batteries only)
• Nitrile gloves

Equipment Position: Key Points: Page 1 of 11

CP = Control Panel Safety
LH = Left Side Environmental
RH= Right Side
 Step No. /
Main Steps Detailed Steps Key Points Photos / Comments
(Responsibility)

3 (OP1) Visual check. • The engine must be left running until the instruction advises to shut the engine down. CAUTION: Surfaces will be Engine rear view with back
• Walk around the container and listen for any abnormal engine noises. hot, ensure full PPE is worn. doors open
• While standing at the LHS container door check the condition of the exhaust silencer mounted above Definition for SOP:
the engine for signs of exhaust gas leaks. Part of this inspection is to also to check the left bank All container internal checks
exhaust bellows for signs of exhaust gas leaks. must be made while LH = Left hand side looking from
• Carry out a visual inspection of the internal area of the container for any fluid leaks, use a torch as standing outside the alternator non-drive end.
required. container personnel doors.
• Carry out a visual inspection of all external fuel pipe work for any fluid leaks. RH = Right hand side looking
• Check the exhaust emissions condition for signs of abnormal engine performance (Black/Blue/ White from alternator non-drive end
Smoke). Refer to BOP-08.
• On containers fitted with cargo doors at the radiator end open the cargo doors and check the radiator
core for damage, blockages and leaks.
• Open fully the RHS personnel door.
• While standing at the container door check the condition of the exhaust silencer mounted above the
engine for signs of exhaust gas leaks. Part of this inspection is to also to check the right bank exhaust
bellows for signs of exhaust gas leaks.
• Open the rear cargo doors.
• Check all AC /DC lighting, metering and switches on both control panels mounted above the alternator
ensuring they are operational.

NOTE: Any abnormalities must be reported to OS & recorded on job card.

4 (OP1) Stop generator and allow the • Press “engine stop” push button. CAUITON: Stand clear of
engine to cool down. • The generator will de-load and open circuit breaker. circuit breaker & alternator
• Allow generator to go through engine cool down period of 300 seconds (5 minutes). outlet.

5 (OP1) Take an oil sample
NOTE: The operator must be
familiar with Service Manual 08 -
Section 4: WI 02 to fully
understand the oil sample
procedure.
• Engine running in cool down mode. CAUTION: The engine oil
• Prepare oil sample bottle. will be very hot ensuring
• Complete form and bottle label. suitable gloves are worn.
• Remove rubber sample point cover.
• Fit clean tube to sample valve operating nipple. Refer to BOP-08.
• Fit sample valve operating nipple to sample valve.
• Press down on valve.
• Allow ¼ litre of oil to flow into a waste container.
• Stop flow by releasing pressure on valve.
• Place sample bottle at end of tube.
• Repeat steps above to get oil to flow.
• Fill ¾ of bottle.
• Remove sample tube, clean sample point and refit rubber sample cover.

NOTE: The operator must be familiar with Service Manual 08 - Section 4: WI 02 to fully
understand the oil sample procedure.

Equipment Position: Key Points: Page 2 of 11

CP = Control Panel Safety
LH = Left Side Environmental
RH= Right Side
 Step No. /
Main Steps Detailed Steps Key Points Photos / Comments
(Responsibility)

6 (OP2) Inspect / Change Rear Container • Inspect the condition of the container door air filters, if they require to be changed: CAUTION: In extreme dust
door filters. • Release the wire mesh retaining tags. areas such as cement
• Remove wire mesh grill. plants, wear a dust mask
• Remove the used container door air filters. when removing door filters.
• Clean louver area of loose dirt/ dust.
• Write SMR and date onto new filter. Refer to BOP-08.
• Fit the clean door filters ensuring that all pleats are vertical and the arrow on the side of the filters
point in the direction of the container air flow.
• Refit wire mesh grill and secure all retaining tags.

Note: Replace if required while engine is in ‘cool down mode’

7 (OP1) Fill fuel tank. • Hold the manual fuel fill switch on the generator control panel to the ON position. CAUTION: Under no
• Listen for the solenoid opening and the fuel filling the tank circumstances must the
• Fill tank until the High-High alarm is present. manual switch be interfered
• Fuel filling of the tank should automatically stop at High-High (85%) with that would allow fuel
filling to be left unattended.
NOTE: 85% = 100mm from the top of the fuel tank. E.g. tying back switch with
tie-wrap or jamming switch
• If auto fuel does not stop filling the tank at High-High alarm the OS must be informed and fault finding in the manual position with
conducted to understand what is wrong with the system, the system must be repaired or adjusted as stone or any other object.
soon as possible.

NOTE: This procedure is to test the auto fuel high alarm and also to ensure enough fuel is in tank to
allow the fuel filters to be filled during the service.

8 (AAP2) Electrical / Mechanical Isolation. • Switch the control panel key to the off position. LV ISOLATOR
Fit the “Do not operate” sign to key switch. (Picture 1) The operation of this LV
Isolator requires some force
• Switch off the transformer LV isolator by turning anti clock-wise. (Picture 2) to operate. Ensure your
Lock off switch. hands are as far down the
Fit “Do not operate” sign to the LV Isolator. handle as possible so that
your hands do not get
• Turn off the fuel supply valve by turning the handle 90° from the outlet. (Picture 3) jammed between the handle
Fit “Do not operate” sign to the handle. and the container.

• Switch off battery isolator by turning handle anti clockwise. (Picture 4) Issue ‘Permit to Work’ in
Fit the lock off cover and “Do not operate” sign. accordance with BOP 49. (Picture 1) (Picture 2)

• Prove the system being worked on is dead with a non-contact voltage indicator. Permit should be put into a
clear plastic wallet and
• Issue permit to work in line with BOP 49. displayed at all times during
• Fit permit to work notice on to the front of the control panel. service.( Picture 1)

(Picture 3) (Picture 4)

Equipment Position: Key Points: Page 3 of 11

CP = Control Panel Safety
LH = Left Side Environmental
RH= Right Side
 Step No. /
Main Steps Detailed Steps Key Points Photos / Comments
(Responsibility)

9 (OP1) Prepare oil filters for removal. • Fit oil drain trays below the oil filters. CAUTION: The engine oil
• Pearce filters with filter piercing tool (Part No: 20-0019580) will be hot ensure suitable
• Allow filters to drain into the drain trays. gloves are worn

10 (OP1) Prepare Racor filter for removal. • Place drain trays below the Racor filters. CAUTION: While priming /
• Close all 6 valves (3 in front of Racor filters and 3 behind Racor filters). filling the filter bowls with
• Remove drain cocks at bottom of filter. clean fuel do not leave the
• Loosen filter bowl lids. units unattended.
• Allow filters to drain.
• Clean the filter bowls if required.
• Fit drain cocks.
• Fit new filter.
• Open front ball valve (fuel inlet) and allow each filter to fill to the top.
• Replace the lid sealing ring and refit lid.
• Open the drain valve on the bottom of the internal fuel tank and check for water and contamination. (If
applicable).
• Drain off as required.

11 (OP1) Changing engine mounted fuel
filters during service or breakdown.
• Loosen right hand filter using the filter strap. CAUTION: When changing
• Remove fuel filter by using both hands turning clockwise. the elements please
• Once the filter has been removed place it in waste bucket. remember both the filter and
•
nd
Loosen the 2 filter using filter strap. the fuel in the filter will be
• Prepare the new fuel filters. hot!
• Smear oil around the rubber seal on the top of the filters.
• Replace both fuel filters by turning them anticlockwise until the filter seal touches the filter head, turn
each filter s further ¾ of a turn by hand. Do not over tighten.
• Remove the fuel feed hose from the fuel pump inlet connection using an adjustable wrench.
• Open the outlet ball valves (rear) on the Racor filters and allow fuel to flow and fill the on engine filters.
• Purge the fuel system of air and then reconnect the fuel supply hose to the fuel pump inlet connection
and tighten securely. Do not over tighten.

12 (OP2) Pump out the old engine oil. • Open the valve on engine sump by pulling out lever and turning 90° anti clockwise. CAUTION: Inside of
• Insert the pump discharge hose into the waste oil drum positioned at door. container is hot. Ensure you
• Position yourself on bed plate so that you can freely pull and push oil pump handle. have plenty of ventilation
• Pull and push handle to operate pump until the sump is empty. and if necessary take breaks
• Once the sump is empty close the sump drain valve by turning it through 90° clockwise. during pumping out the old
• Coil up the pump discharge hose. oil.
• Replace the waste oil drum plugs and tighten them securely.

Equipment Position: Key Points: Page 4 of 11

CP = Control Panel Safety
LH = Left Side Environmental
RH= Right Side
 Step No. /
Main Steps Detailed Steps Key Points Photos / Comments
(Responsibility)

13 (OP1) Inspect / Check combustion air • Check that the air inlet restriction indicator on each bank induction pipework is at or near to 20 Inches CAUTION: In extreme dust
filter elements. of H2O to confirm that the filters need to be changed. areas such as cement
• Reset restriction gauge by pressing on the rubber button on the top of the gauge. plants, wear dust mask
• Open the 4 latches on the first air filter canister lid. when removing air filters.
• Slide air filter out of fitting by pulling it towards the rear doors.
• Clean and inspect inside of filter casing.
• Replace with new filter unit by sliding it into position.
• Refit the canister lid and secure the 4 latches.
• Proceed with the same procedure on second filter element.
• Fit a filter service sticker to both filter canisters.

Note: Best practice is to replace both filters together even if only one requires changing.

14 (OP1) Prepare oil filters. • Break plastic cover of oil filters. (Do not remove plastic completely this will be removed once filter is Minimize oil spillage when
fitted). removing filters from
• Fill oil filters with clean oil. container.
• Apply oil to the each filter seal.
• Cover filter to prevent any dust or dirt entering filter before fitting. BLANK

15 (OP1) Change the Oil Filters. • Kneel down parallel to filters facing towards the exit door. Minimize oil spillage when
• Loosen right hand filter using filter strap. removing from container.
• Remove oil filter by using both hands turning clockwise.
• When removed place in a waste tray. CAUTION: When changing
the filter elements please
• Loosen 2nd filter using filter strap. remember both the filter and
• Remove oil filter by using both hands turning clockwise. the oil drained from them will
• When removed place in a waste tray. be hot!

• Loosen 3rd filter using filter strap.

• Remove oil filter by using both hands turning clockwise.
• When removed place in a waste tray.

• Loosen 4th filter using filter strap.

• Remove oil filter by using both hands turning clockwise.
• When removed place in a waste tray.

• Loosen 5th filter using filter strap

• Remove oil filter by using both hands turning clockwise
• When removed place in a waste tray.

• Clean area of any spilled oil.

• Check the filter seals are coated with oil prior to fitting.
• Fit new oil filters (starting from left to right) and turn anticlockwise until touching filter head, rotate the
filter a further ¾ of a turn. Do not over tighten.

Equipment Position: Key Points: Page 5 of 11

CP = Control Panel Safety
LH = Left Side Environmental
RH= Right Side
 Step No. /
Main Steps Detailed Steps Key Points Photos / Comments
(Responsibility)

16 (OP2) Change the By-pass Oil Filters. • Kneel down parallel to the bypass filtration in the generator facing towards the door. Minimize oil spillage when
• Loosen the rear filter using filter strap. removing from container.
• Remove oil filter by using both hands turning clockwise.
• When removed place in waste tray. CAUTION: When changing
the filter elements please
• Loosen using filter strap. remember both the filter and
• Remove oil filter by using both hands turning clockwise. the oil drained from them will
• When removed place in waste tray. be hot!

• Clean area of spilled oil.

• Take new filters and place them with open end facing upwards in box.
• Fill the bypass oil filters with fresh oil prior to fitting them.
• Apply oil to the each filter seal.
• Fit new oil filters (starting from left to right) and turn anticlockwise until touching filter head, then rotate
the filter 1 full rotation. Do not over tighten.

NOTE: Latest specification of KTA50 G3 will have a centrifuge filter fitted removing the need for
bypass filters. This will be cover by separate WI.

17 (OP1) Empty the crankcase breather • Remove the two inch rubber hoses. Minimize oil spillage when
bottle if applicable • Remove the fixing bolts. removing from container.
• Remove the tank.
• Pour any oil or condensate into waste oil drum.

Note: latest specification of KTA50G3 will have an OCV breather filter fitted removing the need for
breather bottle. The maintenance of this will be covered by SWI P04300019A.

18 (OP2) Check / Replace alternator filter
cloth if applicable
• Release the latch on each side of the main alternator to allow access to the filter cloth. CAUTION: In extreme dust
• Remove the used filter cloth. areas such as cement
• Cut the new filter to the required size . plants, wear dust mask
• Carry out visual inspection of the alternator windings and rotating diode assembly, this can be done by when removing alternator
shining a torch through the grill as shown in the attached picture. filters
• Fit the new filter cloth.
• Refit the mesh and secure in place with both latches.

NOTE: If there is substantial dust / black carbon build up on any of these internal components this
issue MUST be reported to the OS.

19 (OP1 & OP2) Refill the sump with new oil. • Remove engine oil filler cap and oil level dipstick
• Place oil hose into fill tube.
• Pump oil in to sump by rotating the pump handle clockwise.
• Check oil level on the dipstick, stop filling once the level reaches the Max level shown on the dipstick.
• 180 L Oil = Dipstick Max.
• Replace the dipstick.
• Replace the oil filer cap and tighten by hand.

Equipment Position: Key Points: Page 6 of 11

CP = Control Panel Safety
LH = Left Side Environmental
RH= Right Side
 Step No. /
Main Steps Detailed Steps Key Points Photos / Comments
(Responsibility)

20 (OP1 & OP2) Check the level of the coolant in
the radiator top tank.
• Check coolant level on the radiator sight glass at front end of container. Coolant will be hot and
• If the level is low in the sight glass the system will require topping up. under pressure, take extra
• Place the ladder next to container. precaution when removing
• OP1 must support the ladder. cap.
• Climb the ladder and release radiator cap by turning it anti clockwise slowly to allow the pressure to
vent. Follow QHSE instructions for
• Check the cap seal for any damage. using ladder.
• Check the coolant level by inserting a dipstick into radiator, withdraw and measure this against sight
glass level. Refer to BOP-28.
• Top up the system as required with the approved pre mix coolant.
• Replace the radiator cap and tighten securely.

21 (OP2) Check coolant condition. To test the coolant concentration: CAUTION: Do not mix
• Take coolant sample from bottom of radiator or water pump drain tap. coolant types:
• Allow sample to cool to room temperature (20°C). Valvoline Coolant (Red)
• Drop a small amount of the coolant mixture onto lens of the refractometer. must not be mixed with other
• Close flap, view and take reading, where the dark line crosses bright. manufacturers coolants
• A healthy mixture will measure -32 °C / -34 °F. these coolants are normally
NOTE: -32°C on a 50/50 mix is acceptable. Ethylene glycol based (Blue
or Green) but used different
To test the Test PH value: technology additive packs.
• Insert the PH meter into drinking water to confirm the unit is operational, the reading should measure:
PH 7 +/- 0.2.
• Insert the PH meter into the coolant sample until the reading stabilises.
• The reading will be shown on the digital display.

NOTE: The PH level must be between 8.0 -10.5.

• For Coolant system filled with any coolant APART from Valvoline coolant (Red Colour), A DCA units
per litre test must be carried out and the SCA level replenished as required.
(Service Manual 08 - Section 4: WI16).

NOTE: Operator must be familiar with Service Manual 08 - Section 4: WI16 to fully understand the
refractometer and PH and DCA strip readings.

22 (OP1) Coolant filters change. • Close isolation valves on both the coolant supply and return hoses to the filter housing. CAUTION: When changing
• Using filter strap, remove filter on RHS. the elements please
• Using filter strap, remove filter on LHS. remember both the filter and
• Dispose of old filters. the coolant in the filter will
• Fill new filters with coolant. be hot!
• Install both filter elements and then rotate the filter 1 full rotation. Do not over tighten.
• Open both the supply and return isolation valves.

NOTE: Replace if required - these filters should be changed every 3000Hrs.

23 (OP2) Check and clean the radiator
compartment & radiator fan.
• Remove the side panel with 13mm socket and ratchet. CAUTION: When entering
• Inspect all hoses for cracks and leaks and record defects on the Job card also report any repairs the radiator compartment
required to OS. care must be taken to avoid
• Steam clean radiator from the compartment side to the outside as this will remove any dirt or dust in damage to the radiator core
opposite direction of air flow. or drain valves.
• Check Radiator/ Engine space fan bearing by pushing on blade to check for any upward or downward .
movement.
• Turn fan and feel for any sticking points also listen out for any squeaks or grinding sounds.
• Grease bearing if applicable.
• Refit the side panel with 13mm socket and ratchet.

Equipment Position: Key Points: Page 7 of 11

CP = Control Panel Safety
LH = Left Side Environmental
RH= Right Side
 Step No. /
Main Steps Detailed Steps Key Points Photos / Comments
(Responsibility)

24 (OP1) Visually check DC alternator drive
Belt and check all safety guards
are in place and secure.
• Remove battery charge alternator guard.
• Check belt tension by turning belt half way with your Finger and Thumb.
• Check for any cracks or frays of the drive belt.
• Report any defects to the OS.
• Replace battery charge alternator guard.

NOTE: Replace the guard when checking is completed.

25 (OP1) Check all safety guards are in • Physically check that all safety guards are in place and secure :
place and secure. • Main alternator Air Inlet / Outlet deflectors and Exhaust Manifold heat shields.

NOTE: Any Guards that are missing or broken MUST be reported to OS & recorded on job card.

BLANK

26 (OP2) Check the electrolyte level in each Lead Acid Batteries: CAUTION: In addition to
battery cell: • Carefully unscrew or pop out cap. normal PPE when working
• Use 0.5L jug to top up with distilled water and replace cap. with batteries wear full face
• Replace caps. shield and rubber apron.

Optima Batteries – Spiral wound Lead acid batteries can emit

• Remove any corrosion with wire brush and spray terminals with battery protect spray. explosive gases while
• Replace battery box lid. charging, ensure area is well
ventilated.
NOTE: Optima batteries are sealed and do not require topping up, cleaning is still required.
Refer to BOP-26.

Never top up batteries with

Acid, only use distilled
water.

Equipment Position: Key Points: Page 8 of 11

CP = Control Panel Safety
LH = Left Side Environmental
RH= Right Side
 Step No. /
Main Steps Detailed Steps Key Points Photos / Comments
(Responsibility)

27 (AAP2) Prepare to put machine back into • Review the task has been completed LV ISOLATOR
operation by removing all • Check that all electrical panel doors are closed The operation of this LV
isolations. Isolator requires some force
• Remove the “Do not operate”
operate sign from the LV Isolator switch. (Picture 1) to operate, ensure your
Remove the isolation from the LV isolator switch. hands are as far down the
Close LV isolator to reinstate the back feed to the generator. handle as possible so that
your hands do not get
• Remove the cover and “DoDo not operate” sign. (Picture 2) jammed between the handle
Switch ON the battery isolator by turning handle clockwise. and the container.

• Remove the “Do operate sign from the key switch. (Picture 3)
Do not operate”
Switch control key to the Local position. Sign off/ Cancel the Permit
to Work in accordance with (Picture 1) (Picture
Picture 2)
• operate sign from the fuel isolation valve handle. (Picture 4)
Remove the “Do not operate” BOP 49
Turn on the fuel supply valve by turning the handle in line with the outlet.

• Remove the permit to work notice from the front of the control panel.

• Sign off/Cancelation of the permit to work in line with BOP 49.

.
(Picture 3) (Picture
icture 4)
4

28 (OP1) Pre Engine start checks: • ter service interval stickers on the following as applicable:
Replace all relevant filter
o Racor fuel filters.
o Engine fuel filters. s.
o Engine full flow oil filters.
filter
o By-pass
pass oil filters, Centrifuge,
C Puradyn filter (whichever is applicable). BLANK
o Air filters.
o Coolant test sticker on radiator next to sight glass.
glass
o Alternator cloth.
o ‘A’ service sticker on control panel door.
door
• All tools must now be cleaned and cleared away.

29 (OP1) Start the engine. • Press alarm reset. CAUTION: Stand clear of
• Turn the control panel Key switch to ‘Local’.
‘ circuit breaker & alternator
• Switch to toggle switch on the control panel from Auto to Manual. outlet.
• Press start button.
• Allow engine start and stabilise.
• Check for leaks and abnormal noises.

• OP1 Left hand side OP2 right hand side.

Equipment Position: Key Points: Page 9 of 11

CP = Control Panel Safety
LH = Left Side Environmental
RH= Right Side
 Step No. /
Main Steps Detailed Steps Key Points Photos / Comments
(Responsibility)

30 (OP2) Check the Battery Charge
Alternator Voltage with multi-meter.
• Set multi-meter to VDC CAUTION: Ensure meter
• Place red lead onto positive terminal on battery isolator. leads are in the right socket
• Place black lead onto negative terminal on starter motor. to measure VDC
• Voltage should read approximately 27 VDC +/- 1.5v.
BLANK

31 (OP1) Operate Emergency Stop. • With the engine running, push the “Emergency Stop” button on left hand side of the container.
• The Gempac should display an alarm and the machine should shut down.
• Reset the alarm by pulling out the Emergency Stop Button.

NOTE: If there is air shut off valves are fitted they will need to be reset.

32 (OP1) Start up machine. • Reset the alarm messages displayed on the GEMPAC unit by pushing the Alarm reset button on the CAUTION: Stand clear of
control panel. circuit breaker & alternator
• Press “start” button. outlet.
• Allow engine to start and stabilise.

33 (OP2) Operate emergency stop. • With the engine running, push the “Emergency Stop” button on the right hand side of the container.
• The Gempac should display an alarm and the machine should shut down.
• Reset the alarm by pulling out the ‘Emergency Stop’ button.

NOTE: If there is air shut off valves are fitted they will need to be reset.

34 (OP1) Start up machine. • Reset the alarm messages displayed on the GEMPAC unit by pushing the “Alarm reset” button on the CAUTION: Stand clear of
control panel. circuit breaker & alternator
• Press start button outlet.
• Allow engine to start and stabilise.

Equipment Position: Key Points: Page 10 of 11

CP = Control Panel Safety
LH = Left Side Environmental
RH= Right Side
 Step No. /
Main Steps Detailed Steps Key Points Photos / Comments
(Responsibility)

35 (OP2) Test bund level alarm. • Locate the float switch which is mounted on the bed plate on the right hand side of the container CAUTION: Stand clear of
below the engine starter motors, lift the switch by hand (Hold up till the engine stops). circuit breaker & alternator
• The Gempac should display an alarm and the machine should shut down. outlet.
• Release the float to normal position.

36 (OP1) Pre Engine start checks: • Remove the dip stick.

• Clean the dipstick with a cloth and refit the dip stick.
• Remove the dip stick and check the oil level.
• Top up the level to bring the sump level back to the MAX on the dip stick, if necessary.
•
NOTE: Allow the engine to stand for 10mins to allow the oil level in the sump to settle prior to re-
checking oil level. Level should be on the max mark.

37 (OP1) Re-start the engine. • Reset the alarm messages displayed on the GEMPAC unit by pushing the Alarm reset button on the CAUTION: Stand clear of
control panel. circuit breaker & alternator
• Press start button. outlet.
• Allow engine to stabilise.
• Visually check the Rain Cap and Exhaust stack extension guide ropes are secure.

NOTE: If there are any issues noted with the Exhaust Stack Extension or Rain Cap the OS must be
informed and the equipment repaired or adjusted as soon as possible.

38 (OP1 & OP2) Put the machine back on load. Pre load Actions: CAUTION: Stand clear of
• Check the Machine is running at correct voltage and frequency. circuit breaker & alternator
• Check pressure gauges, temperature gauges and service meter are all working. outlet.
• From the door of the container visually check the machine for any fluid leaks.
All waste to be disposed of
Once all the above have been completed: in line with BOP38
• Switch to toggle switch on the control panel from Manual to Auto.
• The machine will auto synchronise and automatically close the main circuit breaker.
• The machine will now ramp up to predefined site load. BLANK
• Complete job card with the job completion time or if using service mobility update the material
consumed, accurate labour and lead technician signs off completed assignment.
• Ensure all doors are closed.
• Clean and account for all tools.
• Return all tools to the store or the shadow board.
• All waste to be disposed of in line with BOP38.

Add Row Delete Row

REVISION HISTORY
Rev. No. Rev. Date Details of Changes Prepared By Reviewed By Approved By
A 02 February 12 Document Release Robert Philip Allan Methven Ron Sams
B 09 May 12 Amendment to Step 2, 5 and 29. Robert Philip Allan Methven Ron Sams
C 07 August 12 Amendment to Step 1, 3, 4, 6, 8,16, 22, 24, 28, 31, 33, 35, 37 Robert Philip Allan Methven Ron Sams

Equipment Position: Key Points: Page 11 of 11

CP = Control Panel Safety
LH = Left Side Environmental
RH= Right Side