Doc.

Type: Work Instructions

Doc. Title: Standard Work Instruction - QSK60 Gas A Service Planned_Reactive Standard Time 5

This document is applicable to any 1375kVA (Aggreko manufacturing built) GAS Generator fitted with a QSK60G5 engine incorporating a GEMPAC control system (on operational
Scope: Doc. No. P04300012
sites).
This document describes the steps involved in performing a “60A” A Service on an Aggreko GAS generator. As this work instruction is based around a 3-man team, for clarity each step
Purpose: is broken down to Aggreko Mechanic 1 (AM1), Operator 1 (OP1) and Aggreko Electrician LV APS trained (AE1). Rev. No. D
NOTE: AM1 & OP1 MUST be trained in every step of this work instruction.

Related Docs. M05000313 (OAT Coolant) Issue Date: 31/05/2016

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

1 (AM1) Take the Job Card from control
room or if Service Mobility
(Handheld Device) has been
implemented follow all service
mobility instructions.
 Check details on Job Card or Handheld device. Wear appropriate PPE:
 Check the physical plant number matches the plant number on the job card.  Helmet or bump cap
 Open fully the LHS personnel door.  Safety glasses
 Check the service is due by checking the SMR meter hours match the service due sticker hours.  Safety Gloves
 Any discrepancies in the meter reading must be reported to the OS to reschedule the service.  Ear defender
 Close the Control Panel door.  Overalls
 Full face shield
NOTE: New GAS generators require an ‘Early Life Inspection’ at the first 250 hrs. Refer to SWI  Apron
P06300076.  Safety boots
 Bi-line stoppa kit
This Includes:  Goggles
1) Emissions check 2) Oil analysis 3) Valve height measurement 4) Overhead adjustment  Dust mask
5) Oil filters only change.

2 (AM1&OP1) 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 Service: Spares required to complete Service:
 Oil sample tube purging container.  4 x BD7176 Oil Filter.
 Oil sampling kit.  8 x PA3873 Door filters (If required).
 Filter-strap.  382 Litres Bulk Engine Oil.
 Spanner 12” Adjustable.  Alternator cloth (If required).
 ½” Ratchet.  Cleaning Cloths.
 Filter piercing tool.  Oil Sample bottle.
 CAT refractometer.  Cummins OAT Coolant (if required).
 pH tester  2 x B5088 (every 3000Hrs).
 Two-way radio set.  Service stickers.
 Drain tray for fuel and oil  Contact cleaner for battery terminals.
 Waste oil pump.  Molykote 44 Grease: Part No - 782252
 Oil removal pump skid with hoses.
 Locks and tags. NOTE: If Oil ring main is not available on
 Non-Contact Voltage Indicator. site, then waste oil drums will be required.
 2 x Buckets for waste filters.
 Step ladder.
 Wire brush for battery terminals.
 Torch or inspection lamp.
 Steam cleaner.
 Anti-corrosive spray for battery terminals.
 LV potential indicator
 1 x Grease Gun: Part No – 20- 0021180
 1 x Grease Meter: Part No – 20- 0015585

Equipment Position: Key Points: Page 1 of 13

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

3 (AM1&OP1) Visual check.  The engine must be left running until the instruction advises to shut the engine down. CAUTION: Surfaces will be
 Walk around the container and listen for any abnormal engine noises. hot, ensure full PPE is worn.
 Check the exhaust system located in the roof of generator for leaks.
 Check the exhaust emissions condition for signs of abnormal engine performance (Black/Blue/ White
Smoke).
 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 personnel door on the RHS of the container and open the 2 rear cargo doors.
 Carry out visual checks for signs of any fluid leaks, paying particular attention to fuel pipes and fittings.
 Check all AC /DC lighting, metering and switches are operational.

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

4 (OP1) Stop generator and allow the
engine to cool down.
 Prior to stopping the engine prepare oil sample bottle.
 Complete form and bottle label.
 Open the Control Panel door.
 To stop the engine when it’s running in “Auto” mode press the “stop” button.
 To stop the engine when it’s running in “Semi” mode press the “breaker open” button.
 The generator will de-load and open circuit breaker.
 Allow generator to go through engine cool down period of 300 seconds (5 minutes).
 Take an oil sample during the cool down period.

NOTE: When the engine ramps down in “Semi” mode it will not automatically go into cool down. To
make it go into cool down mode the stop button must be pressed but only after the load is removed
and the main breaker is open.
Stop Button Breaker Open

5 (AM1) Take oil sample.(As Required)  Engine running in cool down mode.
 Remove rubber sample point cover.
 Fit clean tube to sample valve operating nipple.
 Fit sample valve operating nipple to sample valve. (Picture 1)
 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. (Picture 2)
 Repeat steps above to get oil to flow.
 Fill ¾ of bottle.
 Remove sample tube.
 Clean sample point and refit rubber sample cover.
 Dispose the used oil used to flush the valve into the designated waste oil storage area. CAUTION: The engine oil Picture 1 Picture 2
will be very hot, ensure
gloves are worn.

6 (OP1) Inspect / Change Rear Container
door filters if required.
 Inspect the condition of the container door air filters, if they require to be changed:
 Remove wire mesh grill.
 Remove the used container door air filters. (Picture 1)
 Clean louver area of loose dirt/ dust
 Write SMR and date onto new filter.
 Fit clean filters ensure pleats are vertical and the direction arrow on the filter faces the direction of air
flow. If no arrow is present ensure the wire mesh side of the filter is facing towards your direction.
 Refit the wire mesh grill. (Picture 2)

Picture 1 Picture 2

Equipment Position: Key Points: Page 2 of 13

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

7 (AE1) 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. to operate. Ensure your
Lock off the switch and fit a “Do not operate” sign to the LV Isolator. (Picture 2) hands are as far down the
handle as possible so that
 Turn off the fuel supply valve by turning the handle 90° from the outlet. your hands do not get
Lock and fit a “Do not operate” sign to the handle. (Picture 3) jammed between the handle
and the container.
 Switch off battery isolator by turning handle anti clockwise.
Fit the lock off cover and “Do not operate” sign. (Picture 4)
Picture 2
Picture 1
 Prove the system being worked on is dead with a LV potential indicator.

NOTE: Apply LOTO in line with the Aggreko procedure.

Picture 3 Picture 4

8 (OP1) Check / Replace alternator filter
cloth (If required).
 Release the latch on each side of the main alternator to allow access to the filter cloth. (Picture 1)
 Remove the used filter cloth.
 Cut the new filter to the required size.
 Fit the new filter cloth. (Picture 2)
 Refit the mesh and secure in place with both latches.

Newage PE7 – 1 cloth

Leroy Somer LSA – 3 cloth

NOTE: If there is substantial dust / black carbon build up on any of these internal components this
issue MUST be reported to the OS.
Picture 1 Picture 2
CAUTION: In extreme dust
areas such as cement
plants, wear dust mask
when removing alternator
filter.

9 (AM1) Prepare oil filters for removal.  Fit oil drain trays below the oil filters.
 Puncture the bottom of the each filter using the filter piercing tool.
 Allow each filter to drain into the drain trays.

CAUTION: The engine oil

will be hot!
Ensure gloves are worn

Equipment Position: Key Points: Page 3 of 13

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

10 (OP1) Removing used engine oil.  Prepare the mobile oil pump for pumping out the used engine oil.
 Fix the oil drain hose to the oil ring main drain connection. (Picture 1)
 Fix the oil drain hose to the oil drain connection on the side of the engine bed plate. (Picture 2)
 Close the isolation valve on the Murphy Tank or the Murphy valve on the sump. (Picture 3)
 Open the sump drain valve. (Picture 4)
 Open the secondary drain valve at the rear of the engine. (Picture 5)

CAUTION: The engine oil

will be hot!
Ensure gloves are worn.
Picture 1 Picture 2

Picture 3 Picture 4

N/A

Picture 5

11 (OP1) Connecting the power supply to the  Plug in the three phase supply line to the site distribution board. (Picture 1)
mobile oil pump.  Start the pump until the engine sump is fully drained. (Picture 2)

-CONTINUED ON NEXT PAGE-

Picture 1 Picture 2

Equipment Position: Key Points: Page 4 of 13

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

 Re-coil all hoses that are associated with the mobile oil pump and return to storage area. (Picture 3)
 Clean up any oil drips or spills.

N/A

Picture 3

12 (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 by pouring oil into the outer holes of the filer. container by using a drip
 Apply a thin smear of oil to the each filter seal. tray.
 Cover filter to prevent any dust or dirt entering filter before fitting.

N/A

.
13 (OP1) Change the Oil Filters.  Loosen left hand filter using filter strap. (Picture 1)

 Remove oil filter by using both hands turning clockwise. (Picture 2)

 When removed place in a waste tray.

 Loosen 2nd filter using filter strap.

 Remove oil filter by using both hands turning clockwise.
 When removed place in a waste tray.
CAUTION: When changing
 Loosen 3rd filter using filter strap. the filter elements please
 Remove oil filter by using both hands turning clockwise. remember both the filter and
 When removed place in a waste tray. the oil drained from them will
be hot! Picture 1 Picture 2
 Loosen 4th filter using filter strap.
 Remove oil filter by using both hands turning clockwise. Minimize oil spillage when
 When removed place in a waste tray. removing from container by
using a drip tray.
 Clean area of any spilled oil.
 Check the filter seals are coated with oil prior to fitting.
 Fit all new oil filters (starting from right to left) and turn anticlockwise until touching filter head, rotate
the filter a further ¾ of a turn. Do not over tighten. (Picture 3) N/A

Picture 3

Equipment Position: Key Points: Page 5 of 13

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

14 (AM1) Inspect the crankcase breather  Visually check the restriction indicator gauge. (Picture 1)
filter restriction indicator.  If the indicator reads above 12 inches of H20 this issue must be reported to the OS to schedule the
filtration change. (Picture 2)

NOTE: The maintenance of this filtration unit is covered by SWI P04300019.

Picture 1 Picture 2

15 (AM1 & OP1) Fill the engine with new lube oil. NOTE: There are currently two configurations of oil fill pipe work. CAUTION: Filling of new
 If the generator does not have the permanently installed oil fill pipe work, connect the oil fill hose to the lube oil. Be sure to check
engine sump connection, mounted on the side of the bed plate. (Picture 1) the pipe for any leaks.
 Connect the oil fill hose to the oil ring main. (Picture 2)
 Start the pump by communicating to the pump operator using handheld intercom. (Picture 3)
 Check the sump drain valve is open.
 Check the secondary drain valve at the rear of the engine is open.
 Pump oil into sump.
 Stop filling the sump once the oil level reaches the Max level shown on the dipstick. (Picture 4)
(382Ltr Oil = Dipstick Max)
 Stop the pump by communicating to the pump operator using handheld intercom. (Picture 3)
 Close the sump drain valve. Picture 1 Picture 2
 Close the secondary drain valve at the rear of the engine.
 Remove the oil fill hose at the oil ring main connector.
 Remove the oil fill hose at the oil sump connection on the side of the engine bed plate.
 Cover the new and used oil connections at the ring main. (Picture 5)

Picture 3 Picture 4

N/A

Picture 5

Equipment Position: Key Points: Page 6 of 13

CP = Control Panel Safety
LH = Left Side Environmental
RH= Right Side
 Step No. /
Main Steps
(Responsibility)
16 (AM1 & OP1) Check the level of the coolant in
the radiator top tank.
M05000313 (Use of OAT Coolant
in Aggreko Generators)
17 (OP1) Check coolant concentrate.
Reference Documents:
M05000313 (Use of OAT Coolant
in Aggreko Generators)
M070057 (Valvoline Extended Life
Coolant)
M05000307 (Introduction of
Cummins ES Compleat)
M05000302 (Replacement of
Valvoline Extended Life Coolant on
QSK60 Gas)
M07000214 (Change from
Valvoline to ES Compleat OAT
Premix)
18 (OP2) Testing the coolant pH value.
M05000313
Equipment Position: Key Points:
CP = Control Panel Safety
LH = Left Side Environmental
RH= Right Side
Detailed Steps Key Points Photos / Comments
 Check the coolant level of the HT and LT cooling system using the sight glasses found at the left and
right hand side of the GAM unit. (Picture 1)
 If it is not possible to see the level using the sight glass double check by removing both expansion
tank caps and visually verify. Ensure the coolant temperature is below 50°C.
 The temperature can be found on the Gempac or manually verified. (Picture 2)
 Place a rag or the cap and slowly turn anti clockwise to allow the pressure to vent.
 Check the cap seal for any damage.
 Top up the system as required with the approved pre mix coolant.
 Replace each radiator cap to their respective tanks and tighten securely. Picture 1 Picture 2
Colour identification of coolant types:
Cummins OAT is red in colour CAUTION: Coolant will be
Valvoline OAT is yellow in colour hot and under pressure so
Valvoline HD Extended Life is blue in colour. Change to OAT as soon as possible. take extra precaution when
removing cap.
NOTE: The HT cap pressure rating is lower than the LT cap pressure rating. (HT Cap = 4psi)
Wear a Bi-line stoppa kit
when working at height.
Wear a full face shield to
check coolant levels. Picture 3 - LT header tank
Picture 4 - HT header tank
 Take coolant sample from bottom of radiator or water pump drain tap.
 Allow sample to cool to room temperature (20°C).
 Drop a small amount of the coolant mixture onto lens of the refractometer. (Picture 1)
 Close flap, view and take reading, where the dark line crosses bright.
 A healthy mixture will measure -32 °C to -50°C.
Picture 2
Healthy - From -32°C (-25°F) to -51°C (-59.8°F).
Dilution - Between -16°C (3.2°F) and -32°C (-34°F). Top up and monitor.
Change Coolant - If greater than -16°C (3.2°F) the coolant to be replaced.
Change Coolant - If lower than -52°C.
CAUTION: Wear goggles
and nitrile gloves.
Picture 1 Picture 2
 Insert the PH meter into mineral 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. (Picture 1)
 The reading will be shown on the digital display.
Picture 2
Healthy - Between 7 and 10.5
Change Coolant - Below 6.9 (Acidic and corrosive to Iron, steel & soft metals)
Change Coolant - Above 10.6 (High Alkaline and corrosive to Aluminium)
CAUTION: Wear goggles
and nitrile gloves.
Picture 1 Picture 2
Page 7 of 13
 Step No. /
Main Steps Detailed Steps Key Points Photos / Comments
(Responsibility)

19 (AM1) Coolant filters change.
Change every 3000 hours.
 Close isolation valves on the filter housing. (Picture 1) 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. (Picture 2)
 Open the isolation valve on the filter housing.

Picture 1 Picture 2

20 (OP1) Check and clean the radiator
compartment & radiator fan.
Grease fan motor bearings every
4500 hours.
 Remove the 6 side panel bolts with a 13mm socket and ratchet. (Picture 1) CAUTION: When entering
 Inspect all hoses for cracks and leaks, record any defects on the Job card, 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 both fans and feel for any sticking points also listen out for any squeaks or grinding sounds.
 Grease both fan motor bearings if applicable with Molykote 44 Grease. (Picture 3)
Drive End – 12 grams
Picture 1 Picture 2
Non Drive End – 8 grams
 Refit the side panel with the 13mm socket and ratchet.

N/A

Picture 3

21 (AE1) Check the electrolyte level in each Optima Batteries – Spiral wound CAUTION: In addition to
battery cell:  Remove any corrosion with wire brush and spray terminals with battery protect spray. (Picture 1) normal PPE when working
 Replace battery box lid. (Picture 2) with batteries wear full face
shield and rubber apron.
NOTE: Optima batteries are sealed and do not require topping up, cleaning is still required.

NOTE: Never mix local batteries with Optima batteries.

Picture 1 Picture 2

Equipment Position: Key Points: Page 8 of 13

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

22 (AE1) Check the fan circuit supply fuses
Ensure the fuses and holders are
the latest configuration as per
M01000119.
 Open the door surrounding to the ACB panel to access the fuses and holders. (Picture 1)
 Visually check for signs of damage or arcing. (Picture 2)
 Example of damaged cable due to bad crimping. (Picture 3)
 Check the cable connections are secure with a torque wrench and 5mm allen key:13 N/m. (Picture 4)
 Check the fuse holder are secure with a torque wrench and a 11mm socket: 7.9 N/m. (Picture 5)
 After all check are made close and lock the ACB panel door.
 Open the GCP panel and check the cables are secure at the terminal bock. (Picture 6)
 Close and lock the GCP panel door.
 Report any damage to the OS, complete a CFR and replace parts.

NOTE: Any damaged parts should be replaced, reported to OS and recorded with a CFR report.
Picture 1 Picture 2

CAUTION: Ensure the

person accessing the panel
is licensed or qualified to
local legislation.

During the inspection fuses

could be hot so gloves must Picture 3 Picture 4
be worn throughout the
checks.

Picture 5 Picture 6

23 (OP1) Pre Engine start checks: Replace all relevant filter service interval stickers on the following as applicable:
 Engine oil filters.
 Coolant test sticker on control panel.
 Alternator cloth. (As required)
 Container door filter. (As required) BLANK
 Air filter. (As required)
 Fan motor grease.
 ‘A’ service sticker on control panel door.

Equipment Position: Key Points: Page 9 of 13

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

24 (AE1) Removing Electrical / Mechanical  Review all tasks have been completed. CAUTION: LV isolator
Isolations. Check that all electrical panel doors are closed. The operation of this LV
Isolator requires some force
 Remove the “Do not operate” sign from the LV Isolator switch. 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. (Picture 1) handle as possible so that
your hands do not get
 Remove the battery isolator lock, cover and “Do not operate” sign. jammed between the handle
Switch ON the battery isolator by turning handle clockwise. (Picture 2) and the container.

 Remove the “Do not operate” sign from the key switch. Picture 1 Picture 2
Switch control key to the Local position. (Picture 3)

 Remove the lock and “Do not operate” sign from the fuel isolation valve handle.
Turn on the fuel supply valve by turning the handle in line with the outlet. (Picture 4)

NOTE: Remove LOTO in line with the Aggreko procedure.

Picture 3 Picture 4

25 (AM1) Priming the oil system.  Prime the lubrication system with the pre-lube pump on the control panel. (Picture 1)
 Check the oil pressure on the Gempac rises. (Picture 2)
 Switch the RATED/IDLE toggle switch to the IDLE position. (Picture 3)
 The engine needs to be ‘cranked’ over on the starter motors but you do not want start the engine at
this stage.
 Press the start button on the Gempac and the engine will crank once on the starter motor. Switch off
the ignition key before the second cranking starts.
 Switch the key switch to the LOCAL position.
 Carry out the same process now but leave the ignition switch on. Now the engine will crank again on
the starter but on the second attempt it will start at low idle.
 Allow the engine to run for 3 minutes at low idle.
 Check engine oil pressure.
 Remove the low idle on the Gempac and allow the engine to run at full idle with no load.
Picture 1 Picture 2

N/A

Picture 3

Equipment Position: Key Points: Page 10 of 13

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

26 (AE1) Check both Battery Charging circuit  Turn the control panel key switch to “local”.
voltages with multi-meter.  Set the multi-meter to VDC.

 Start Battery Circuit and carry out the following: (Picture 1)

a) Place red lead onto positive terminal on battery isolator.
b) Place black lead onto negative terminal on starter motor.
c) Voltage should read approximately 27 VDC +/- 1.5v.

 Control Battery Circuit – Generator Control Panel: (Picture 2)

a) Place red lead onto positive terminal on battery charger – Cable No 1 (+Ve)
b) Place black lead onto negative terminal on battery charger – Cable No2 (-Ve)
c) Voltage should read approximately 27 VDC +/- 1.5v.

Picture 1 Picture 2

27 (AM1) Start the engine.  Turn the key switch to “local”.

 Press the “Semi” mode button.
 Press the “Start” button. The pre lube oil pump will now pressurise the oil system including the oil
filters.
 Check the oil filters for oil leakage.

Picture 1 Picture 2

28 (AM1& OP1) Operate Emergency Stop.  With the engine running, OP1 push the “Emergency Stop” button on the left hand side of the
container.
 The Gempac should display an alarm and the machine should shut down.

Picture 1 Picture 2

29 (AM1 &OP1) Reset the alarm and restart  Pull out the Emergency Stop Button (OP1).
 Reset the alarm messages displayed on the GEMPAC unit by pushing the alarm reset button on the
control panel (AM1). (Picture 1)
 Press the “Start” button. (Picture 2)
 Allow engine to stabilise.

Picture 1 Picture 2

Equipment Position: Key Points: Page 11 of 13

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

30 (AM1 & OP1) Operate Emergency Stop.  With the engine running, (OP1) push the “Emergency Stop” button on right hand side of the container.
(Picture 1)
 The Gempac should display an alarm and the machine should shut down.

Picture 1 Picture 2

31 (AM1 &OP1) Reset the alarm.  Pull out the Emergency Stop Button (OP1).
 Reset the alarm messages displayed on the GEMPAC unit by pushing the Alarm reset button on the
control panel (AM1).
N/A

32 (AM1) Engine oil level check:  Remove the oil 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 to the H (high) 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.

33 (AM1 &OP1) Start Up preparation.  Turn the key switch to “local” position.
 Press the “Auto” Mode Button. (Picture 1)
 Press the “Start” button. (Picture 2)
 Run the engine and check for any fluid leaks.
 Once engine oil temperature reaches 46°c it will automatically ramp to rated speed.
 The machine will auto synchronise and automatically close the main circuit breaker.
 The machine will now ramp up to predefined site load.

NOTE: On Restart observe the engine for signs of leaks.

Picture 1 Picture 2

34 (AM1) Check the oil replenishment unit  Allow the engine to run at full load for 15 minute to allow the crankcase pressure to stabilise and the
set up. oil temperature to stabilise.
 Check the oil level within the Murphy oil top up device:
a) If this unit has been previously commissioned, the oil level should be within the green band.
(Picture 1)
b) If the oil level is found to be above or below the green band the unit needs to be adjusted to
maintain the sump at the correct oil level.
c) If the oil level is found to be within the green band, open the oil supply valve from the oil make up
tank. (Picture 2)

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

Picture 1 Picture 2

Equipment Position: Key Points: Page 12 of 13

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

35 (AM1, OP1, AE1) Complete the task  Complete job card with the job completion time or if using service mobility update the material All waste to be disposed of
consumed, accurate labour and lead technician signs off completed assignment. responsibly.
 Ensure all doors are closed.
 Clean and account for all tools. N/A
 Return all tools to the store or the shadow board.
 Ensure all documentation is updated.

Add Row Delete Row

REVISION HISTORY
Rev. No. Rev. Date Details of Changes Prepared By Reviewed By Approved By
A 02 February 12 New Document Issuance Ross Smith Allan Methven Ron Sams
B 28 August 12 Document Revision Turlough Breslin Allan Methven Ron Sams
[Step 1 - added PPE][Step 2 - added Valvoline test strips to tools][Step 3 - updated picture][Step 7 - updated
C 15 June 2014 Robert Philip John Winning Allan Methven
isolation][Step 17 – updated coolant testing][Step 21 updated fuse check][Step 25 to 29 – updated pictures]
D 17 December 2015 Step 17 – Updated coolant testing Robert Philip Andrew Wormald Allan Methven
E 28 March 2016 Step 16, 17 and 18 updated coolant test procedures. Added caution signs. Step 25 added start up procedure. Robert Philip Andrew Wormald Allan Methven

Equipment Position: Key Points: Page 13 of 13

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