P06300493-A Mantenimiento Motores HT

QSK60 Gas – Replacement of Radiator Fan Bearings
Document ID: P06300493

Revision: A
Created: A. Giron
Approved: J. Pearson
Issue Date: 22/02/2022
APPLICABILITY
Product QSK60 Gas Generators

Part Number N.A.
SCOPE
This document provides the detailed instructions required to carry out replacement of QSK60 Gas
Radiator Fan Bearings.
PLANNING
Competency
Intermediate
Advanced
Task Time Competent In Man Hrs
Entry
Core
Apply LOTO 20 min Gas Generators 1 0.33
Radiator fan removal 90 min Gas Generators 1 1 3
Replacing radiator fan motor bearings 300 min Gas Generators 1 1 10
Radiator fan refitting 90 min Gas Generators 1 1 3
Remove LOTO 20 min Gas Generators 1 0.33
Total Man Hrs 8.66 8 16.66
PERSONAL PROTECTION EQUIPMENT
Item Notes
Standard PPE If in doubt, refer to your local HSE representative.
Heat Resistant Gloves Part no. 20-0015061
Safety Harness Part no. 20-0020139
P06300493
Revision A, 22/02/2022
Page 1
EQUIPMENT
Item Qty Part No.

Tools:
Combination Spanner 24mm 1 20-0015527
3/8” Ratchet 1 20-0015537
3/8” Medium Extension x 6” 1 20-0020862
3/8” Socket 10mm 1 20-0020785
3/8” Socket 13mm 1 20-0020782
Flat Screwdriver 1 20-0015539
M16 Eye Bolt 1 07-0029938
Gland Pliers 1 20-0015555
Chain Block and Tackle 1 20-0015575
Pry Bar 1 20-0015535
Bearing Heater, SKF TWIM 15 1 SKFTWIM15
Dead-Blow Hammer 1 20-0015504
Bearing Puller 1 015180004
M6 Stud Threaded Rod – 600mm Length 3 07-0042408

Fan Motor Bearing & Seal Kit for 800mm Fan Motors:
1 x Drive End Bearing (PN 07-0025838)
1 x Non Drive End Bearing (PN 07-0025839) 1 801042A
2 x Oil Seals
Fan Motor Bearing & Seal Kit for 900mm Fan Motors:
1 x Drive End Bearing (PN 07-0025838)
1 x Non Drive End Bearing (PN 07-0025839) 1 801047A
2 x Oil Seals
Consumables:
Clean Rags 4 Local Purchase
Fine Emery Paper 2 20-0024128
Grease Bearing Molykote High Temperature 1 782252
WD40 1 20-0015376
Wooden Planks 2 Local Purchase
Wooden Pallet 1 Local Purchase
P06300493
Page 2
RISK CONTROL
Risk Risk Control Measures that can minimise Legal & Other Residual Risk
Hazards Risks
Rating Scoring the risk level to ALARP Requirements Risk Scoring
S L R L M H S L R H M L
LOTO applied as detailed in the Energy
Electrical/ Safety Rules (ESR). ESR
Electric shock/
Mechanical 5 3 15 High Employees training in LOTO procedures and ST-01 5 1 5 Low
burns.
Isolation authorised under Letter of Electrical ST-05
Authorisation (LEA).
Make sure working area/ground is kept free

Slips, Trips Sprains, strains, GSCS
3 2 6 Medium from tools and discarded waste. 3 1 3 Low
and Falls lacerations OPO
Be aware of trailing cables.
Make sure the engine/ equipment is left to

cool down, if practicable before task is
Hot Surface Burns and scalds 3 2 6 Medium carried out. SOP 04 3 1 3 Low
Appropriate hand gloves to be worn during
task if engine is hot.
Personnel trained in manual handling
Upper limp
techniques.
Manual disorder, strains
3 2 6 Medium Should equipment/ item be difficult to move, PCP 3 1 3 Low
Handling due to twisting
seek assistance or manual handling aids
and pulling
should be used if available, e.g. lift truck.
Trapped fingers,
Wear task specific PPE- hardhat, safety SOP 04
Hand Tools cuts, lacerations, 3 3 9 Medium 3 1 3 Low
glasses and gloves. ST-05
bruises
Damage to No accumulation of waste materials allowed
health through to build up.
Waste contact, damage 2 2 4 Low All waste materials and debris to be ST-12 2 1 2 Low
to environment, disposed of in appropriate waste receptacles
contamination in accordance with company policy.
Dust mask to be worn to prevent inhalation
Inhalation, skin of small particles of dust and debris
contact, eye Safety glasses to be worn to prevent dust SOP 04
Dust 2 3 6 Medium 2 2 4 Low
contact, particles from entering/ irritating the eyes ST-09
ingestion Gloves and coveralls to be worn to prevent
skin irritation.
Guards are permanent fixtures and should
not be removed unless task specifies. They
Friction/abrasion, are to prevent injury from the following:
cutting, shearing, SOP-04
stabbing, Moving/rotating machine parts.
Entrapment 4 3 12 Medium GSCS 4 1 4 Low
puncturing, Moving/rotating work pieces.
drawing in and OPO
Loose clothing, jewellery, including rings are
ejection not to be worn.
Long hair is required to be tied back.
Electrical shocks
or burns from
Safety checks of the electrical equipment
faulty electrical
and installations are carried out to ensure ST-01
Portable equipment or on
5 3 15 High that equipment continues to be safe. Where 5 1 5 Low
Appliances installation. ST-05
necessary this is done by a competent
Electrical faults
electrician.
can also lead to
fires
P06300493
Page 3
REFERENCES
Document No. Document Title

AGG-ALL-ALL-HS-00-ST-00 HSE ST 00 – Standard Zero
AGK-ALL-ALL-HS-01-ST-01 HSE Standard 01- Working with Energy
AGK-ALL-ALL-HS-05-ST-01 HSE Standard 05- Work Equipment
AGK-ALL-ALL-HS-09-ST-01 HSE Standard 09- Occupational Health & Welfare
AGK-ALL-ALL-HS-11-ST-01 HSE Standard 11- Pollution Prevention
AGK-ALL-ALL-HS-12-ST-01 HSE Standard 12- Waste Management
AGK-ALL-ALL-HS-13-ST-01 HSE Standard 13- Use of Natural Resources
GSCS General Service Centre Standards
OPO Optimised Project Operations
PCP Pristine Condition Program
HS-00-SOP-04 Personal Protective Equipment
AGK-ALL-ALL-HS-01-SOP-01 Energy Safety Rules
G41000123 Preventative Maintenance Plan QSK60 G5 Gas 800mm – Transactional
Business
G41000124 Preventative Maintenance Plan QSK60 G5 Gas 800mm – Project
Business
G41000142 Preventative Maintenance Plan QSK60 G5 Gas 900mm Fan – Project
Business
G41000143 Preventative Maintenance Plan QSK60 G5 Gas 900mm Fan –
Transactional Business
P06000942 Containerised Gas Generators LOTO Procedure
REVISION HISTORY
Prepared Reviewed Approved

Rev. Rev. Date Details of Change
By By By
A 22/02/2022 First Issue E. Cuco A. Khachaturov J. Pearson
P06300493
Page 4
DETAILED WORK INSTRUCTION
1 Preparation
1.1 Please make sure all Aggreko HSE Standards and Risk Assessments applicable with
the tasks in this document are followed.
IMPORTANT
All personnel that isolate energy sources must be competent and authorised in accordance
with the Aggreko Energy Safety Rules (minimum level of authorisation under ESR’s is LOTO
LV) and must have a valid individual Letter of Electrical Authorisation (LEA).
1.2 If the equipment is operating, shut it down. Refer to the genset operations manual for
the correct shut down procedure.
1.3 Isolate the genset from all energy sources and apply LOTO in accordance with the
Energy Safety Rules (AGK-ALL-ALL-HS-01-SOP-01) and SWI P06000942.
1.4 Use an approved test probe and proving unit to test the equipment for dead.
1.5 If unsure, please consult the line manager for more clarity.
IMPORTANT
At the radiator fan bearing replacement section, this document is divided in 2 different
sections, one for 800mm and the other for 900mm Fan motor version. Please check what is
the suitable version before beginning the service.
2 Radiator Fan Removal (for 800mm and 900mm Fans)

2.1 Remove motor fan electrical connections cover.
Figure 1
2.2 Disconnect fan cables.
Figure 2
P06300493
Page 5
2.3 Remove cabling and electro flex from fan junction box taking care to prevent damage
at electro flex and glands.
Figure 3 Figure 4
2.4 Remove 6 x M8 bolts of radiator fan grill fixings.
Figure 5
2.5 Remove fan grill to allow access to the fan.
Figure 6
P06300493
Page 6
2.6 Remove M16 impeller fixing bolt and replace with M16 eye bolt.
Figure 7 Figure 8
2.7 Using chain block, attach to lifting eye and make taught.
Figure 9
2.8 Remove 8 x M20 bolts of fixings fan motor support brackets.
Figure 10
P06300493
Page 7
2.9 Remove the fan motor from the GAM and place it on a pallet.
Figure 11
2.10 Remove M16 eye bolt and remove impeller using either a pry bar or pulley system.
Figure 12
2.11 Remove the keyway from the fan motor shaft using a screwdriver or similar tool and a
hammer.
Figure 13
P06300493
Page 8
CAUTION
Use a safety harness whilst work is carried out in the GAM.
NOTE
If the fan motor won’t fit through door aperture impeller, it will have to be removed inside the
GAM.
WARNING
For safety reasons, refit the radiator fan grill after each fan is removed.
3 Replacing Radiator Fan Motor Bearings

3.1 For 800mm Fan Motors only:
3.1.1 Remove 4 x M8 bolts of fixings securing drive end cover. Keep bolts for refitting the
housing.
Figure 14
3.1.2 Remove drive end cover from motor body using a pry bar or similar tool.
Figure 15
P06300493
Page 9
3.1.3 Once drive end cover has been loosened fit 2 x pieces of wood under the housing.
Figure 16
3.1.4 Hit the shaft with a mallet to loosen.
Figure 17
3.1.5 Remove drive end cover and keep in a safe place for bearing replacement.
Figure 18 Figure 19
P06300493
Page 10
3.1.6 Remove the rotor assembly from the main body. Be very careful not to damage the
stator assembly.
Figure 20 Figure 21
3.1.7 Remove the drive end bearing from the shaft by gently tapping with a hammer and
discard it properly.
Figure 22 Figure 23
3.1.8 Remove 4 x M8 bolts of fixings securing drive end cover, keep bolts for refitting
housing.
Figure 24
P06300493
Page 11
3.1.9 Remove the drive end cover from the motor body using a pry bar or similar tool.
Figure 25
3.1.10 Remove the washer from the bearing recess and make sure that the bearing recess
area and washer are clean and free from dirt.
Figure 26
3.1.11 Lightly lubricate with an appropriate Lithium based grease and refit the washer, then fit
new non drive end bearing by gently tapping with a hammer.
Figure 27 Figure 28
P06300493
Page 12
3.1.12 At this point if required clean stator assembly using the appropriate cleaning solution.
Figure 29
3.1.13 Refit non drive end cover and secure using the 4 x M8 bolts of fixing previously
removed.
Figure 30 Figure 31
3.1.14 Clean and grease non drive end motor shaft, then refit rotor assembly to fan motor
housing. If necessary, gently tap rotor shaft so shaft fits into new non drive end
bearing.
Figure 32 Figure 33
P06300493
Page 13
3.1.15 Remove 3 x M6 bolts of fixing securing for drive end cover. Keep bolts for refitting.
Figure 34
3.1.16 Remove bearing back plate.
Figure 35
3.1.17 Use a chisel or similar tool to remove drive end bearing from housing. Discard it
properly then clean and remove any dirt and grease from bearing recess.
Figure 36 Figure 37
P06300493
Page 14
3.1.18 Lightly lubricate new oil seal and new bearing with an appropriate Lithium based
grease, then fit new oil seal to drive end bearing recess.
Figure 38
3.1.19 Fit new drive end bearing by gently tapping with a hammer.
Figure 39
3.1.20 Ensure bearing back plate is clean and free from any dirt, then refit the plate to end
cover using the original 3 x M6 bolts, applying a Torque of 32Nm at each bolt.
Figure 40 Figure 41
P06300493
Page 15
3.1.21 Lubricate rotor shaft with the appropriate lithium based grease to allow for ease of
bearing fitting onto rotor shaft. (Figure 42).
Figure 42
3.1.22 Refit drive end cover plate onto rotor shaft. (Figure 43)
Figure 43
3.1.23 Gently tap cover plate with a mallet to ensure correct fitting.
Figure 44
P06300493
Page 16
3.1.24 Refit 4 x M8 bolts of fixings and secure end cover.
Figure 45
3.1.25 Clean drive shaft key using fine Emery paper before fitting then fit drive shaft key to
rotor shaft gently tapping until key is located correctly. (Figure 46)
Figure 46
3.2 For 900mm Fan Fan Motors only:

3.2.1 Take drive end bearing P/N 07-0025838 and place on heater or oil bath and set to 120°
maximum with induction bar.
Figure 47 Figure 48
P06300493
Page 17
3.2.2 Remove 3 x M6 bolts of fixings that secure the back plate within the fan motor. Keep
bolts for refitting.
Figure 49
3.2.3 Remove 4 x M8 bolts of fixings securing housing cover. Keep bolts for refitting.
Figure 50
3.2.4 Gently tap the housing with a hammer to loosen the cover.
Figure 51
P06300493
Page 18
3.2.5 If housing is still secure, use a screwdriver and hammer to loosen all 4 fixing locations.
Figure 52 Figure 53
3.2.6 Mark bearing position on drive shaft.
Figure 54
3.2.7 Set up hydraulic bearing puller and remove bearing.
Figure 55
P06300493
Page 19
3.2.8 Remove bearing back plate and O-ring seal.
Figure 56 Figure 57
3.2.9 Clean bearing back plate with fine Emery paper. (Figure 58)
Figure 58
3.2.10 Fit back onto drive shaft, ensure back plate O-ring is clean and free from debris.
(Figure 59)
Figure 59
P06300493
Page 20
3.2.11 Lubricate the O-ring slightly and fit to the drive shaft, locating the O-ring under the
bottom shoulder.
Figure 60 Figure 61
3.2.12 Clean drive end shaft with fine Emery paper to ensure ease of bearing replacement.
Figure 62
NOTE
Ensure that fan motor windings are fully covered before shaft to be cleaned.
3.2.13 Lubricate drive end shaft with an appropriate Lithium based grease.
Figure 63
P06300493
Page 21
3.2.14 Remove bearing from the heater using the appropriate heat resistant gloves.
Figure 64 Figure 65
CAUTION
Make sure that you are using the appropriate heat resistant gloves, as the bearing will be very
hot.
3.2.15 The bearing should be quickly slipped into place, ensuring that the bearing is in contact
with the shaft shoulder.
Figure 66
3.2.16 If bearing does not come in contact with the shaft shoulder, place a small length of
tubing with an ID of 50mm over the drive shaft making contact with the inner race only.
Figure 67
P06300493
Page 22
3.2.17 Gently tap till bearing comes in contact with the shaft shoulder.
Figure 68
3.2.18 Remove old oil seal from the fan motor housing.
Figure 69
3.2.19 Lubricate and fit the new oil seal.
Figure 70
P06300493
Page 23
3.2.20 Fit 2 x 600mm lengths of 6mm screwed rod into the bearing back plate.
Figure 71
3.2.21 Fit fan housing cover over the screwed rod.
Figure 72
3.2.22 Gently tap the housing cover till it fits into place.
Figure 73
P06300493
Page 24
3.2.23 Pull up screwed rod this will allow the back plate to be lifted and 3 x M6 bolts of fixings
to be located.
Figure 74
3.2.24 Remove threaded rods one by one and replace with original M6 bolts applying a
Torque of 32Nm at each bolt.
Figure 75 Figure 76
3.2.25 Locate 4 x M8 fixing screws for fan housing cover and refit.
Figure 77
P06300493
Page 25
3.2.26 Lubricate and replace the original O-ring seal.
Figure 78
3.2.27 Clean drive shaft key and refit gently tap into position.
Figure 79 Figure 80
3.2.28 Take drive end bearing P/N 07-0025839 and place on heater or oil bath and set to 120°
maximum with induction bar.
Figure 81 Figure 82
P06300493
Page 26
3.2.29 Rotate the fan motor ensuring drive shaft fits through the gap on the pallet.
Figure 83
3.2.30 Remove 3 x M6 bolts of fixings securing the bearing back plate.
Figure 84
NOTE
These fixings are not supplied on earlier versions of fan motors where back plate is not
available.
3.2.31 Remove 4 x M8 bolts of fixings securing the fan housing cover. Keep these fixings for
refitting.
Figure 85
P06300493
Page 27
3.2.32 Gently tap the housing with a hammer to loosen cover.
Figure 86
3.2.33 If housing still secure use a screwdriver and hammer to loosen all 4 fixing locations.
Figure 87
3.2.34 Remove and keep the washer located at the top of the bearing.
Figure 88
P06300493
Page 28
3.2.35 Mark the bearing position on the drive shaft.
Figure 89
3.2.36 Set up the hydraulic bearing puller and remove the bearing. (Figure 89)
3.2.37 Remove the O-ring seal and the bearing back plate for cleaning using fine emery
paper.
Figure 90
NOTE
Back plate is not applicable on earlier motors.
3.2.38 Fit the back plate onto the drive shaft.

3.2.39 Lubricate the O-ring slightly and fit to the drive shaft.
Figure 91
P06300493
Page 29
3.2.40 Locate the O-ring under the bottom shoulder of the drive shaft.
Figure 92
3.2.41 Lubricate the drive end shaft with an appropriate Lithium based grease.
Figure 93
3.2.42 Remove the bearing from the heater using appropriate heat resistant gloves.
Figure 94 Figure 95
CAUTION
Make sure that you are using appropriate heat resistant gloves, as the bearing will be very hot.
P06300493
Page 30
3.2.43 The bearing should be quickly slipped into place, ensuring that the bearing is in contact
with the shaft shoulder.
Figure 96
3.2.44 If the bearing does not come in contact with the shaft shoulder, place a small length of
tubing with an ID of 40mm over the drive shaft making contact with the inner race only.
Figure 97
3.2.45 Gently tap till bearing comes in contact with the shaft shoulder.
Figure 98
P06300493
Page 31
3.2.46 Lubricate and fit the new oil seal.
Figure 99 Figure 100
3.2.47 Refit the original washer into the bearing housing.
3.2.48 Fit 2 x 600mm lengths of 6mm screwed rod into the bearing back plate. This will not be
applicable to earlier fan motors as they do not have a bearing backplate.
Figure 103
P06300493
Page 32
3.2.49 Fit the fan housing cover over the screwed rod.
Figure 104
3.2.50 Gently tap the housing cover till it fits in place.
Figure 105
3.2.51 Pull up the screwed rod. This will allow the back plate to be lifted and the 3 x M6 bolts
of fixings to be located.
Figure 106
P06300493
Page 33
3.2.52 Remove the threaded rods one by one and replace with original M6 bolts applying a
torque of 32Nm at each bolt. (Figure 106)
3.2.53 Locate 4 x M8 fixing screws for fan housing cover and refit.
3.2.54 Rotate the motor fan at the pallet.
Figure 109
3.2.55 Make sure that the impeller is in the correct orientation to allow it to fit over the drive
shaft key.
Figure 110
P06300493
Page 34
3.2.56 Refit the impeller to the fan motor drive shaft.
Figure 111
3.2.57 Secure the M16 eye bolt to allow lifting.
Figure 112
4 Radiator Fan Refitting (For 800mm and 900mm Fans)

4.1 Remove 6 x M8 bolts of radiator fan grill fixings. (Figure 5)
4.2 Remove the fan grill to allow access to the fan place. (Figure 6)
4.3 Using chain block attached to the lifting eye, remove the fan motor from pallet and put
back on the GAM. (Figure 11)
4.4 Using chain block attached to the lifting eye, make taught. (Figure 9)
4.5 Refit 8 x M20 bolts of fixings fan motor support brackets with a torque of 120Nm.
(Figure 10)
4.6 Remove the chain block from the lifting eye. (Figure 8)
4.7 Remove the M16 eye bolt and replace with the original M16 impeller bolt. (Figure 7)
4.8 Refit the fan grill. (Figure 6)
4.9 Refit 6 x M8 bolts of radiator fan grill fixings. (Figure 5)
4.10 Refit the cabling and electro flex at the fan junction box taking care to prevent damage
to the electro flex and glands. (Figure 3 & Figure 4)
4.11 Reconnect the fan cables. (Figure 2)
4.12 Refit the motor fan electrical connections cover. (Figure 1)
P06300493
Page 35
CAUTION
Safety harness to be used whilst work is carried out in the GAM.
NOTE
If the fan motor won’t fit through door aperture impeller, it will have to be removed inside the
GAM.
5 Job Completion
5.1 Inspect the work.
5.2 Clean the area.
5.3 All tools to be removed and accounted for.
5.4 Remove all LOTO devices as per P06000942.
5.5 Start and run the engine.
5.6 Switch the engine to rated capacity and confirm that the engine runs normally.
5.7 Check if the rotation of the radiator fan motors is correct.
5.8 Shut down the engine. Refer to the genset operations manual for the correct shut down
procedure.
5.9 Release the unit back to the Site Operations Team.
- - - END OF DOCUMENT - - -
P06300493
Page 36

P06300493-A Mantenimiento Motores HT

Uploaded by

Document Information

Original Description:

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

P06300493-A Mantenimiento Motores HT

Uploaded by

Copyright:

Available Formats

QSK60 Gas – Replacement of Radiator Fan Bearings

Document ID: P06300493

Product QSK60 Gas Generators

PERSONAL PROTECTION EQUIPMENT

Item Qty Part No.

3/8” Medium Extension x 6” 1 20-0020862

3/8” Socket 10mm 1 20-0020785

3/8” Socket 13mm 1 20-0020782

Flat Screwdriver 1 20-0015539

M16 Eye Bolt 1 07-0029938

Gland Pliers 1 20-0015555

Chain Block and Tackle 1 20-0015575

Pry Bar 1 20-0015535

Bearing Heater, SKF TWIM 15 1 SKFTWIM15

Dead-Blow Hammer 1 20-0015504

Bearing Puller 1 015180004

M6 Stud Threaded Rod – 600mm Length 3 07-0042408

Fine Emery Paper 2 20-0024128

Grease Bearing Molykote High Temperature 1 782252

Wooden Planks 2 Local Purchase

Wooden Pallet 1 Local Purchase

Make sure working area/ground is kept free

Make sure the engine/ equipment is left to

Document No. Document Title

Prepared Reviewed Approved

2 Radiator Fan Removal (for 800mm and 900mm Fans)

2.2 Disconnect fan cables.

2.4 Remove 6 x M8 bolts of radiator fan grill fixings.

2.5 Remove fan grill to allow access to the fan.

2.8 Remove 8 x M20 bolts of fixings fan motor support brackets.

3 Replacing Radiator Fan Motor Bearings

3.1.4 Hit the shaft with a mallet to loosen.

3.1.16 Remove bearing back plate.

3.2 For 900mm Fan Fan Motors only:

3.2.6 Mark bearing position on drive shaft.

3.2.7 Set up hydraulic bearing puller and remove bearing.

3.2.19 Lubricate and fit the new oil seal.

3.2.21 Fit fan housing cover over the screwed rod.

3.2.30 Remove 3 x M6 bolts of fixings securing the bearing back plate.

3.2.38 Fit the back plate onto the drive shaft.

Figure 99 Figure 100

3.2.47 Refit the original washer into the bearing housing.

Figure 101 Figure 102

3.2.50 Gently tap the housing cover till it fits in place.

Figure 107 Figure 108

3.2.54 Rotate the motor fan at the pallet.

3.2.57 Secure the M16 eye bolt to allow lifting.

4 Radiator Fan Refitting (For 800mm and 900mm Fans)

You might also like