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Diesel Generator Operation Manual GENERAL MAINTENANCE Part 1
Locking the Generator Set Out of Service
All maintenance tasks must be assessed for health and safety risks, the preventative measures identified must be actioned. Accompaniment is required for tasks where the presence of someone else will add significantly to the safety of the task.
Read, understand and comply with all Caution and Warning notes in this section, those contained within Section 1 - Preliminary and Safety, and those contained within the Health and Safety Manual (0908-0110-00). Refer also to the Operator’s engine specific manual supplied as part of the generator set documentation pack. This latter manual will contain further information regarding the running and care of the generator set and also specific equipment instructions that may differ from the standard generator set.
Ensure adequate lighting and staging (where required) are installed.
Caution:Maintenance. must only be carry out by authorised and qualified maintenance engineers, who are familiar with the equipment and its operation.
WARNING:DEPENDENT UPON THE CONTROL SYSTEM FITTED, THIS UNIT MAY OPERATE AUTOMATICALLY AND COULD START WITHOUT WARNING.
Caution:Before carrying out any maintenance work, become familiar with the Generator Plant Safety Code given in Section 1 of this manual, together with the Health and Safety Manual (0908-0110-00).
Caution:Always disconnect a battery charger from its AC source before disconnecting the battery leads. Failure to do so can result in voltage spikes high enough to damage the DC control circuits of the generator set.
WARNING: ACCIDENTAL STARTING OF THE GENERATOR SET WHILE WORKING ON IT CAN CAUSE SEVERE PERSONAL INJURY OR DEATH. PREVENT ACCIDENTAL STARTING BY DISCONNECTING THE STARTING BATTERY LEADS (NEGATIVE [-] FIRST).
ENSURE BATTERY AREA HAS BEEN WELL-VENTILATED BEFORE SERVICING THE BATTERY. SPARKS OR ARCING CAN IGNITE EXPLOSIVE HYDROGEN GAS GIVEN OFF BY BATTERIES, CAUSING SEVERE PERSONAL INJURY. ARCING CAN OCCUR WHEN LEADS ARE REMOVED OR REPLACED, OR WHEN THE NEGATIVE (-) BATTERY LEAD IS CONNECTED AND A TOOL USED TO CONNECT OR DISCONNECT THE POSITIVE (+) BATTERY LEAD TOUCHES THE FRAME OR OTHER GROUNDED METAL PART OF THE GENERATOR SET.
INSULATED TOOLS MUST BE USED WHEN WORKING IN THE VICINITY OF THE BATTERIES.
ALWAYS REMOVE THE NEGATIVE (-) LEAD FIRST AND RECONNECT LAST.
ENSURE HYDROGEN FROM THE BATTERY, ENGINE FUEL AND OTHER EXPLOSIVE FUMES ARE FULLY DISSIPATED. THIS IS ESPECIALLY IMPORTANT IF THE BATTERY HAS BEEN CONNECTED TO A BATTERY CHARGER.
WARNING: TO COMPLETE MAINTENANCE TASKS AT HEIGHT REFER TO LOCAL LEGISLATIVE REQUIREMENTS. SUITABLE EQUIPMENT FOR PERFORMING THESE TASKS MUST BE USED IN ACCORDANCE WITH THE LOCAL GUIDELINES AND LEGISLATION. FAILURE TO FOLLOW THESE INSTRUCTIONS CAN RESULT IN SEVERE PERSONAL INJURY OR DEATH.
WARNING: DO NOT USE THE SKID (BEDFRAME) OR ANY PART OF THE GENERATOR SET AS A MEANS OF ACCESS. USE OF THE GENERATOR SET AS ACCESS MAY RESULT IN SEVERE PERSONAL INJURY OR DEATH AND/OR PROPERTY AND EQUIPMENT DAMAGE.
WARNING:BEFORE CARRYING OUT ANY MAINTENANCE WORK, LOCK OFF FOR SAFE WORKING:
1.PRESS THE OFF MODE SWITCH ON THE GENERATOR SET CONTROL PANEL.
2.AS AN ADDITIONAL PRECAUTION, PRESS THE EMERGENCY STOP BUTTON, AND HOLD IN FOR 30 SECONDS.
3.ISOLATE ALL SUPPLIES TO THE GENERATOR SET.
4.ISOLATE THE BATTERY CHARGER.
5.DISCONNECT THE BATTERY.
6.REMOVE THE STARTER CONTROL WIRES.
7.A SUITABLE WARNING PLATE STATING ‘MAINTENANCE IN PROGRESS’ SHOULD BE DISPLAYED PROMINENTLY.
WARNING:SOME PANEL INTERNAL COMPONENTS MAY HAVE LIVE TERMINATIONS EVEN EXPOSED IF THE GENERATOR SET IS NOT RUNNING. ISOLATE (LOCK AND TAG) ALL EXTERNAL ELECTRICAL SUPPLIES PRIOR TO ACCESS OF THE CONTROL PANEL.
6.1 Locking the Generator Set Out of Service
Before any work is carried out for maintenance, etc., the plant must be immobilised. Even if the plant is put out of service by pressing the Off switch on the control panel, the plant cannot be considered safe to work on until the engine is properly immobilised as detailed in the following procedures.
Caution:Refer also to the Operator’s engine specific manual included in the documentation package supplied with the generator set. This manual will contain specific equipment instructions that may differ from the standard generator set.
WARNING: BEFORE CARRYING OUT ANY MAINTENANCE, ISOLATE ALL SUPPLIES TO THE GENERATOR SET AND ANY CONTROL PANELS. RENDER THE SET INOPERATIVE BY DISCONNECTING THE PLANT BATTERY.
Caution:If the engine has been running recently explosive gases (given off during battery charging) may be present in the vicinity of the batteries. Ensure the area is well ventilated before disconnecting batteries.
6.1.2 Immobilising the Generator Set for Safe Working
Note: Shutdown the engine first, as described in Section 5.7 - Stopping.
To immobilise the engine:
1.Press the Off Mode switch on the display panel.
2.Press the Emergency Stop Button, (and hold in for 30 seconds). This will prevent the starting of the generator set regardless of the Start signal source and will therefore provide an additional safety step for immobilising the generator set. (See also Section 5.7).
Note: When this Stop Button is pressed the display panel will indicate the Shutdown condition by illuminating the red Shutdown status LEDand displaying the following message on the graphical LCD display:
Fault Number: 1433
Fault Number: 1434
REMOTE EMERGENCY STOP
Note: This Fault will affect the Fault History memory bank.
3.As an additional precaution, thoroughly ventilate the plant room before disconnecting any leads.
4.Isolate and lock off the supply to the heater, where fitted.
5.Isolate and lock off the supply to the battery charger, where fitted.
6.Isolate the fuel supply to the engine.
7.Disconnect the starting batteries and control system batteries, (if separate). Disconnect the negative (-) lead first. Attach a padlock through one of the battery leads and tag for safe working.
8.Fit warning notices at each of the above points to indicate Maintenance in Progress - Plant Immobilised for Safe Working.