Alternator Bearings Grease Service
Document ID: P06000840
Revision: D
Created: J. McEwan
Approved: A. Methven
Issue Date: 16/12/2022
APPLICABILITY
Product All Gensets fitted with the following alternators:
Leroy Somer LSA 52.3
Stamford PE734C
Stamford PE734H
Stamford PE734E
Part Number N/A
SCOPE
This document provides the detailed instructions required to grease the alternator bearings.
PLANNING
Competency
Intermediate
Advanced
Task Time Competent In Man Hrs
Entry
Core
Apply LOTO 20 Min 1 0.33
Diesel / Gas
Alternator Bearings Greasing 30 Min 1 0.5
Generators
Remove LOTO 20 Min 1 0.33
Total Man Hrs 1.16 1.16
EQUIPMENT
Item Qty Part No.
Grease Gun 1 20-0015585
3/8 x 13mm Socket 1 20-0020782
3/8 x 6” Extension 1 20-0020036
3/8 x Drive Ratchet 1 20-0015537
Flat Screwdriver 1 20-0020727
Rags 1 Local Purchase
Kluber Asonic Grease GHY72 (Stamford Alternators) 1 14-0027406
Kluber Quiet BQ 72-72 Grease (Leroy-Somer Alternator) 1 14-0016373
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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 ESR
Electrical/ Safety Rules (ESR).
Electric shock/ ST-01
Mechanical 5 3 15 High Employees training in LOTO procedures and 5 1 5 Low
burns. ST-05
Isolation authorised under Letter of Electrical
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.
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
Induced hearing
loss from long-
term noise
exposure,
Appropriate hearing protection to be worn
Noise temporary noise 4 2 8 Medium ST-09 4 1 2 Low
when engine/ equipment is running.
effects such as
tinnitus, noise
pollution and lack
of concentration
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.
Appropriate hand protection to be used when
Skin irritation, working with lubricants.
Fuel, Oil, ST-08
absorption,
Coolant & 3 3 9 Medium Refer to COSHH assessment for further 3 1 3 Low
dermatitis. ST-09
Grease guidance on first aid treatment and PPE if
Ingestion
required.
PERSONAL PROTECTION EQUIPMENT
Item Notes
Standard PPE If in doubt refer to your local HSE representative
Nitrile Gloves Nitrile gloves must be worn when greasing the bearings.
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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-03-ST-01 HSE Standard 03- Lifting Operations
AGK-ALL-ALL-HS-05-ST-01 HSE Standard 05- Work Equipment
AGK-ALL-ALL-HS-08-ST-01 HSE Standard 08- Working with Harmful Substances
AGK-ALL-ALL-HS-09-ST-01 HSE Standard 09- Occupational Health & Welfare
GSCS General Service Centre Standards
OPO Optimised Project Operations
HS-00-SOP-04 Personal Protective Equipment
AGK-ALL-ALL-HS-01-SOP-01 Energy Safety Rules
P06000944 Containerised Diesel Generators LOTO Procedure
P06000942 Containerised Gas Generators LOTO Procedure
M05000371 AGC4 - Help Guide (for common features)
REVISION HISTORY
Rev. Prepared Reviewed Approved
Rev. Details of Change
Date By By By
A 22/03/2019 First Issue J. McEwan A. McGeoch M. Bjorkman
Removed step 2.7.2, “waiting for the engine to
B 05/08/2019 reach operating temperature”. J. McEwan R. Davies C. Bythell
Time and Man hours added.
LOTO references added, procedure times
updated, and grease part removed. Planning
C 16/05/2020 J. McEwan R. Philip J. Pearson
section updated with competencies, timings
and table design. Grease amount added.
Genset Idle mode steps added & tool P/Ns
D 16/12/2022 J. McEwan R. Philip A. Methven
Kluber Quiet BQ 72-72 P/N added
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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 Isolate the genset from all energy sources in accordance with the Energy Safety Rules
and LOTO procedures. Refer to P06000942 for Gas Generators and P06000944 for
Diesel Generators.
1.3 If unsure, please consult technical support for more clarity.
2 Alternator Bearings Greasing
2.1 Locate the grease nipple for the Non-Drive End and Drive End bearings:
Stamford PE734C / PE734E / PE734H, Non-Drive End. See Figure 1.
Stamford PE734C / PE734E / PE734H, Drive End. See Figure 2.
Leroy Somer LSA52.3 L12 Non-Drive End. See Figure 3.
Leroy Somer LSA52.3 L12 Drive End. See Figure 4.
Figure 1 Figure 2
Figure 3 Figure 4
2.2 Clean the grease nipples with a lint-free cloth.
2.3 Switch off excitation.
2.4 Remove all starter battery isolations and control panel lockout tag. Refer to LOTO
procedure documents, P06000942 for Gas Generators and P06000944 for Diesel
Generators.
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2.5 Switch the key switch to the ON position.
2.6 Set the genset controller in idle mode. See the below steps for the different generators:
2.6.1 KTA50G3 Gempac and Analogue
2.6.1.1 On the stop solenoid there is a knurled screw, this will need screwed in to allow the
engine to run in idle. See Figure 5.
Figure 5
2.6.2 QSK45 Analogue
2.6.2.1 Inside the control panel at the top left corner there is a switch labelled RATED / IDLE.
Turn swich to the idle position. See Figure 6.
Figure 6
2.6.3 QSK45 Gempac
2.6.3.1 On the controller, select "SETUP", select "CONTROL", scroll to menu "2210" and press
"START".
2.6.3.2 Enter password "2000", you will see menu 2011, enter the time "600" secs” (10 mins).
2.6.3.3 Move the cursor under "SAVE" and press "SEL". The generator will now run for 10
mins on idle and then it will ramp to nominal frequency.
2.6.3.4 When the greasing has been completed, return menu 2011 to 0.0 seconds and save.
See Figure 7.
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Figure 7
2.6.4 QSK50G4 Gempac
2.6.4.1 Go to "SETUP", select "SYSTEM", scroll to menu "4770" and select "IDLE".
2.6.4.2 Enter password "2000" and press "SEL". You will now be in the menu 4773.
2.6.4.3 Press the top arrow and ON will appear.
2.6.4.4 Move the cursor under "SAVE" and press "SEL". The generator will now run in idle.
See Figure 8.
Figure 8
2.6.5 QSK60 Gas Deif AGC
2.6.5.1 On the front panel turn the RATED / IDLE switch to the IDLE position. See Figure 9.
Figure 9
2.6.6 Sets with AGC4 MKII controllers fitted
2.6.6.1 For sets fitted with AGC4 MKII controllers, refer to M05000371 on how to put the
machine into idle mode.
2.6.6.2 Press the start button and run the engine in idle mode.
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2.7 At the Non-Drive End grease nipple(s), slowly pump in the grease. Refer to Table 1 for
the correct amount of grease to use.
Table 1- Alternator Bearing Grease Amounts
Alternator Model Non-Drive End Drive End
Leroy Somer LSA 52.3 35g 70g
Stamford PE734H 85cm3 / 75g 136cm3 / 121g
Stamford PE734C / PE734E 85cm3 / 75g 100cm3 / 89g
IMPORTANT
Make sure not to over grease as this could lead to premature bearing failures.
2.8 Repeat step 2.7 for the Drive End grease nipple(s).
2.9 Once finished stop the generator and switch the key switch to the OFF position.
2.10 Reapply starter battery isolations and the control panel lockout tag. Refer to LOTO
procedure documents, P06000942 for Gas Generators and P06000944 for Diesel
Generators.
2.11 Clean any excess grease using the lint free cloth.
3 Job Completion
3.1 Remove all LOTO devices as per P06000942 for Gas Generators and P06000944 for
Diesel Generators.
3.2 Return the engine / controller back to normal operating mode.
3.3 Turn the excitation system.
3.4 Restart the engine and check the unit returns to the specified frequency and voltage.
3.5 All tools to be removed and accounted for.
3.6 Dispose of waste in an appropriate waste receptacle.
- - - END OF DOCUMENT - - -
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