TM 9-6115-484-14 Mep-Pu-810a/b Part 3

USAF TO 35C2-3-518-1
USA TM 9-6115-484-14
DRS RADIAN CTM 01646.1R0253/1R0254
5.5.3.3 DISTRIBUTION AND CONTROL CABLING
WARNING
DO NOT PERFORM THE FOLLOWING TASK WHEN THE GENERATOR SET IS

OPERATING. DO NOT TOUCH EXPOSED ELECTRICAL CONNECTION WHEN A
SOURCE OF POWER SUCH AS UTILITY POWER OR ANOTHER GENERATOR SET
IS CONNECTED TO THE LOAD TERMINALS. DEATH OR INJURY MAY RESULT
FROM FAILURE TO OBSERVE THIS WARNING.
WARNING
HIGH VOLTAGE MAY CAUSE SEVERE INJURY OR DEATH UPON CONTACT

DURING CHECKOUT OR MAINTENANCE OF THIS EQUIPMENT. USE CAUTION
AND AVOID CONTACT WITH ENERGIZED COMPONENTS. USE HOT STICK WHEN
LOAD CABLES ARE HANDLED.
WARNING
VERIFY THAT CONNECTION POINTS ARE DE-ENERGIZED BEFORE MAKING ANY

CONNECTIONS. FAILURE TO CHECK THAT CONNECTORS ARE DE-ENERGIZED
MAY RESULT IN INJURY OR DEATH.
a. Lay out and park the load cables for each phase (A, B, & C) between the PU Tie Output parking
stations and the Primary Switching Center (PSC).
b. Connect each phase cable to the appropriate phase connection on the Primary Switching Center
(PSC).
NOTE 1: For complete set-up of the Primary Switching Center (PSC), refer to Radian Inc. Commercial
Technical Manual CTM 01646.1R1260, Chapter 2.6.
NOTE 2: For Unit Isolation Procedure (any unit) - Plant with PSC, and Unit Re-Installation
Procedure – Plant with PSC, refer to Chapter 5.9, Sections 5.9.6.15 and 5.9.6.16.
c. Connect each load cables drain wire to the grounding grid.
d. Open the Tie Output connector loadbreak covers on the first PU.
e. Connect the Tie Output Cables to the appropriate phase connectors; ensure there are no cross-
phase connections.
f. Close and lock the Tie Output connector covers.
g. Repeat steps ‘a’ through ‘f’ on each remaining PU.
h. Connect the first (A) (B) communication cable to “B” receptacle on first PU.
i. Route the first (A) (B) communication cable to second PU.
j. Connect the first (A) (B) communication cable to “A” receptacle on second PU.
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k. Connect the second (A) (B) communication cable to “B” receptacle on second PU.
l. Route the second (A) (B) communication cable to second PU.
m. Connect the second (A) (B) communication cable to “A” receptacle on third PU.
n. Connect third (A) (B) communication cable to “B” receptacle on third PU.
o. Route the third (A) (B) communication cable to fourth PU.
p. Connect the third (A) (B) communication cable to “A” receptacle on fourth PU.
q. Connect the fourth (A) (B) communication cable to “B” receptacle on fourth PU.
r. Leave the loose end of the fourth cable loose and capped.
5.5.3.4 SETPOINT VERIFICATION
a. Turn on PU DC control power by pushing in on the DC Control Power breaker.
b. On each of the five overcurrent relays, verify the settings:
(1) Press the [▲] key to get to the top-level menu “1 REPORT STATUS”.
(2) Press the [►] key 5 times to display “6 GENERAL SETTINGS”.
(3) Press the [▼] key to display “6.1 COM SETTINGS”.
(4) Press the [►] key 2 times to display “6.3 POWER SYSTEM SETTINGS”.
(5) Press the [▼] key to display “6.3.1 CT RATIO”.
(6) Verify the “P” and “N” values match Chapter 5.1 Table 5.1.3.4-1 CT Ratio Settings.
(7) Press the [▲] key 2 times to display “6 GENERAL SETTINGS”.

(8) Press the [◄] key to display “5 PROTECTION LOGIC USER”.
(9) Press the [▼] key 3 times to display “5.1.1.1 50TP”.
(10) Verify the 50TP “PU” and “TD” settings in Chapter 5.1 Table 5.1.3.4-2 Instantaneous Trip
Settings. In order to edit values, Press the “Edit” key. Select correct value, and press
“Edit” again to save changes. Ensure light is off otherwise you can accidentally change
value again.
(11) Press the [►] key to display “5.1.1.2 50TN”.
(12) Verify the “50TN” settings.
(13) Press the [►] key to display “5.1.1.3”.
(14) Verify the “50TQ” settings.
(15) Press the [▲] key to display “5.1.1 50T SETTINGS”.
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(16) Press the [►] key to display “5.1.2 51 SETTINGS”.
(17) Press the [▼] key to display “5.1.2.1 51P”.
(18) Verify the 51P “PU”, “TD”, and “C” settings in Chapter 5.1 Table 5.1.3.4-3 Time
Overcurrent Settings.
19) Press the [►] key to display “5.1.2.2 51N”.
(20) Verify the 51N settings.
(21) Press the [▲] key 3 times to display “5 PROTECTION LOGIC USER”.
c. Use the following procedure to verify the Generator 1 and Generator 2 GSC+ settings:
NOTE: Refer to the “EMCPII+ Reference Chart”, located on the interior Generator Control Panel
Door (Look-up)
(1) Place ECS in the COOLDOWN/STOP position.
(2) Press SERVICE MODE key to enter service mode. OP1 is showing on the lower display.
(3) Press SCROLL UP key until “OP3” is showing.
(4) Press SELECT key. “PE -“ with the first dash flashing is showing.
(5) Press SCROLL RIGHT key. “PE 1 -“ with the second dash flashing is showing.
(6) Press SCROLL DOWN key. “PE 13 –“ with the third dash flashing is showing.
(7) Press SCROLL UP key. “PE 132 –“ with the fourth dash flashing is showing.
(8) Press SCROLL DOWN key. “PE 1323 –“ with the fifth dash flashing is showing.
(9) Press SCROLL RIGHT key. “PE13231” with all digits not flashing is showing.
(10) Press ENTER key. “PE PASS” is showing.
(11) Press EXIT key. “OP4” is showing.
(12) Press SCROLL UP key until “OP5-0” is showing on the lower display.
(13) Press SELECT key. “POO1” followed with the value of the setpoint is showing.
(14) Press SCROLL UP or SCROLL DOWN key. The next setpoint with its value is showing.
Use Chapter 5.1 Table 5.1.3.4-4 OP5 Settings for the parameter values to be verified.
Repeat until the desired setpoints are verified.
(15) Press EXIT key. “OP5-0” is showing on the lower display.
(16) Press SCROLL UP key until “OP5-1” is showing.
(17) Press SELECT key.
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Use Chapter 5.1 Table 5.1.3.4-5 OP5-1 Settings for the parameter values to be verified.
(19) Press EXIT key. “OP5-1” is showing.
(20) Press SCROLL UP key. “OP6” is showing.
(23) Press EXIT key twice. The display returns to normal.
NOTE: If an incorrect setpoint value is displayed, the value must be changed to match the DPGDS
setpoint value as follows:
(a) With the setpoint with the incorrect value showing on the display, press the
SELECT key. The incorrect value flashes on the display.
(b) Press SCROLL UP or SCROLL DOWN key until the correct value appears
flashing on the display.
(c) Press ENTER. The correct value stops flashing on the display.
(d)Press SCROLL UP or SCROLL DOWN key to continue to verify the remaining

parameter values.
d. Return ECS1 and ECS2 to the OFF/RESET position.
NOTE: Use up or down keys to change values.
e. At the AVR verify the operation settings using Chapter 5.1 Table 5.1.3.4-7 AVR
Parameter/Setpoints:
(1) Open the GCPG1 cabinet door.
(2) Press the [▼] key to display parameter “90”.
(3) Press the [◄►] key to display the current value.
(4) Press the [▲] key to change the value to “0015”. Enables parameter editing.
(5) Press the [◄►] key to accept change and display the parameter number.
(6) Press the [▲] key to the next parameter needed to change.
(8) Press the [▲] or [▼] key to change the value.
(10) Repeat steps ‘5’ through ‘9’ for the each parameter needing to be changed.
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(11) When complete, press the [▼] to display parameter “01”.
NOTE: Parameters 20, 21, 22, 36, 37, and 38 are displayed but not used.
NOTE: Parameters 23 to 29, 39 to 49, 59 and 61 to 89 are not displayed and not used.
(14) Press the [▼] key to change the value to “0009”. Disables DVR parameter editing.
(16) Press the [▲] key to change to display parameter “01”.
(17) Close the GCPG1 cabinet door.
(18) Repeat steps ‘1 ‘through ‘16’ for Generator 2.
5.5.3.5 PRE-OPERATION CHECKS
Starting from the left rear of the PU and working around the PU in a clockwise direction, perform the
checks identified in Chapter 5.1 Table 5.1.3.5-1 Pre-Operation Checklist. (Gen. 1 is on the left and Gen. 2
is on the right):
5.5.3.6 PRE-OPERATION RUN
WARNING
ENSURE ALL PERSONNEL ARE CLEAR AND THE PU DOORS ARE CLOSED
PRIOR TO STARTING A GENERATOR.
WARNING
HEARING LOSS WILL OCCUR IF THIS WARNING IS NOT OBSERVED AND

ENFORCED.
NOISE LEVELS IN EXCESS OF 85 DB EXIST WITHIN AN 88-FOOT RADIUS OF AN
OPERATING DPGDS. PERSONNEL MUST WEAR SINGLE HEARING PROTECTION
WITHIN 88 FEET OF AN OPERATING DPGDS.
WARNING

ENFORCED.
DURING MAINTENANCE ACTIVITIES WITH THE SIDEDOORS OPEN, NOISE
LEVELS IN EXCESS OF 113 DB EXIST WITHIN A 12-FOOT RADIUS OF AN
OPERATING DPGDS. PERSONNEL MUST WEAR DOUBLE HEARING PROTECTION
WITHIN 12 FEET OF AN OPERATING DPGDS. EXPOSURE MUST BE LIMITED TO
UNDER 2.5 HOURS.
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WARNING
BY CLOSING THE FEEDER OR TIE BREAKER, HIGH VOLTAGE WILL BE PRESENT

ON THE LOAD CABLES. ENSURE ALL PERSONNEL ARE CLEAR OF ALL LOAD
CABLES PRIOR TO CLOSING FEEDER OR TIE BREAKERS.
TABLE 5.5.3.6-1 PRE-OPERATION RUN INSTRUCTION SEQUENCE

(Perform on each PU in the power plant)
STEP -- 60HZ OPERATIONS -- -- 50HZ OPERATIONS --
1 Verify System Mode Switch (SMS) is in MANUAL
2 Verify DC Control Power is on
3 Verify Emergency Stop is pulled out
4① Verify the 60Hz light is on ① Verify the 50Hz light is on①
5 Start engine 1 by placing ECS1 in MANUAL
6 Verify the engine accelerates to 1800RPM Verify the engine accelerates to 1500RPM
7 Adjust the generator frequency to 60Hz Adjust the generator frequency to 50Hz using
using the Frequency Adjust Rheostat (FAR) the Frequency Adjust Rheostat (FAR)
8 Adjust the generator voltage to 4295VAC Adjust the generator voltage to 3915VAC
using the Voltage Adjust Rheostat (VAR) using the Voltage Adjust Rheostat (VAR)
9 Close BCS-G1, toggle the Phase Rotation Test Light switch, verify that light ABC lights,
open BCSG1
10 Shutdown engine 1 by placing ECS1 in OFF/RESET
open BCSG2
① If the wrong frequency light is on, open the Master Control Door and change the Frequency
Selector Switch (FSS) to the desired frequency.
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5.5.3.7 ORT SETUP
a. Remove the ORT from its case and set it up on a flat and level surface.
b. Remove the mouse from the case and plug it into the mouse (PS2) port on the back of the ORT.
c. If 120VAC power is available, connect the ORT power supply cord to the 120VAC power. The
ORT can operate up to three hours on its batteries.
d. Connect one end of the 150-foot patch cable to the ORT networking port on the PU.
e. Route the cable from the ORT to the PU and connect the cable to the ORT port.
f. Turn on the ORT.
g. Observe that the ORT boots to the operator’s Overview screen.
h. Select the EquipID pop-up screen and enter the necessary information for the units. This
includes the Trailer ID number, the Engine ID number, and the Generator ID number for each
PU.
i. Select the Oneline pop-up screen and enter the descriptor for the main load connected to the
feeders.
h. Return to the Overview pop-up screen.
5.5.3.8 CONTROLS SETUP
Complete the switch arrangements according to the following Table, and verify the lamp
indicators:
NOTE: Ignore settings for Power Units not being used.
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TABLE 5.5.3.8-1 CONTROL SWITCH SETUP

PANEL SWITCH 1ST PU 2ND PU 3RD PU 4TH PU
Pushed In Pushed In Pushed In Pushed In
DC Power
(ON) (ON) (ON) (ON)
SMS OFF OFF OFF OFF
PRIME PRIME PRIME PRIME
GMS
POWER POWER POWER POWER
MASTER PRIME PRIME PRIME PRIME
CONTROL PANEL AVRS
MCP 60Hz Light ON① ON① ON① ON①
USS A② B② C② D②
BSS NORMAL NORMAL NORMAL NORMAL
SSS OFF OFF OFF OFF
SSL All OFF All OFF All OFF All OFF
INSIDE MCP FSS 50/60 Hertz① 50/60 Hertz① 50/60 Hertz① 50/60 Hertz①
GENERATOR Emergency
Pulled-Out Pulled-Out Pulled-Out Pulled-Out
CONTROL PANEL Stop
GCPG1 ECS OFF OFF OFF OFF
GENERATOR Emergency
CONTROL PANEL Stop
① With the SMS in the OFF position, the 50/60Hz lights indicate the position of the Frequency
Selector Switch (FSS). If the wrong light is on, open the door and change the switch position.
② No more than one switch can be in the same position in any multi-PU line-up. With the SMS in
OFF, none of the USI lights will be on and any previously set address on the PU is cleared.
5.5.3.9 PSC RELAY SETTING VERIFICATION
a. Turn on the ORT and log in as administrator using the procedures of PSC Manual (Table 3.3.2-1
DPGDS ORT ADMINISTRATOR LOG-IN PROCEDURE).
b. Click on Windows Start button.
c. Select Programs then Accessories then HyperTerminal.
d. Double Click on “Vista.ht”
NOTE: if “vista.ht” does not appear on the menu, refer to the windows 98 procedure contained in
APPENDIX C of S&C instruction sheet 681-515 to create it.
NOTE: Use Com 1 communications port on the ORT.
e. Click on “Connect”.
NOTE: Do Not Connect the communication cable before completing step “e”. Otherwise Windows NT
will search for a new device on the ORT COM port.
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f. Connect the communication cable between the ORT to the left (Ways 3 and 4) Overcurrent
Relay (OCR).
g. Press “Enter” on the ORT.
NOTE: The overcurrent relay main menu should appear.
h. Select View Menu 1, WAY 3.
i. Select View relay settings.
j. Verify relay settings according to Table 5.5.3.9-1
NOTE: Refer to S&C Instruction Sheet 681-515 page 14, PROGRAMMING to change settings.
k. Repeat steps g through I for WAY 4.
l. Return to the main menu and test the “Trip Function” of each interrupter using the Test Trip
Menu.
m. Return to the Main Menu and “Disconnect” using Windows HyperTerminal when desired
programming action is complete.
n. Disconnect the OCR end of the communication cable.
o. Repeat steps e. through l, for the right OCR (Ways 5 and 6).
p. Repeat steps e. though m. for each PSC in use.
q. Exit Windows HyperTerminal.
r. Shut-down the ORT.
TABLE 5.5.3.9-1 PSC RELAY SETTINGS

MIN. INST. TIME
PSC CABLE
FUNCTION CURVE PICKUP PICKUP DELAY
WAY SIZE
(AMPS) (KAMPS) (SEC.)
3,4, or 5 Feeder 1/0 TAP 200 1 Off
3,4, or 5 Feeder Ground 1/0 TAP 50 0 Off
3,4, or 5 Single Output 500 KCM MAIN 600 1 Off
3,4, or 5 Single Output Ground 500 KCM MAIN 100 0 Off
6 PSC Interconnect 4/0 TAP 400 0 C (64ms)
PSC Interconnect
6 4/0 TAP 80 0 C (64ms)
Ground
5.5.4 PLANT STARTUP
WARNING
ALWAYS PAD LOCK THE PSC INTERCONNECT SWITCHES. FAILURE TO DO SO

COULD RESULT IN PERSONAL INJURY. OR DAMAGE TO EQUIPMENT. IF
ATTEMPTING TO RECLOSE WAY, REFER TO SECTION 5.9.5.3.
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Starting up a Multi-PU Prime Power Plant in Manual Mode
a. At the external switchgear, close the associated connection for each PU supplying power to the
switchgear and close and pad lock the PSC interconnect switches when using more than one
primary switch.
b. At the external switchgear, close the connections between the external switchgears.
c. At the external switchgear, open all connections of loads to the switchgear.
NOTE: 1: For complete set-up of the Primary Switching Center (PSC), refer to USAF TO 35F14-1-1
and USA TM9-6115-725-14&P.
NOTE: 2: For Unit Isolation Procedure (any unit) - Plant with PSC, and Unit Re-Installation
Procedure – Plant with PSC, refer to Section 5.9, Section 5.9.6.15, and Section 5.9.6.16.
d. Complete the switch arrangements according to the following Table, and verify the lamp
indicators:
TABLE 5.5.4-1 SWITCH SETUP – MANUAL MODE

BCS-T Green Target Green Target Green Target Green Target
MASTER CONTROL SMS MANUAL MANUAL MANUAL MANUAL
PANEL MCP MSES Enable① Enable① Enable① Enable①
USI A①, ② B①, ② C① , ② D① , ②
GENERATOR BCS-G1 Green Target Green Target Green Target Green Target
CONTROL PANEL 1 BCS-F1 Green Target Green Target Green Target Green Target
GCPG1 ECS-1 OFF OFF OFF OFF
① Hold the MSES in an ENABLE position until the selected USI indicator energizes. The switch
returns to the center position when released. This sets the PU networking address and enables
the control and monitoring.
② No more than one of each indicator can be on for multi-PU operations. The light on should match
USS position. The USI light will de-energize after the SMS has been in OFF for 3 seconds.
e. At A-unit GCPG1 place the Engine Control Switch (ECS) in MANUAL.
f. Observe the generator starts and accelerates to operating voltage and frequency.
g. At the A-unit MCP, place the Sync Source Switch (SSS) in the GEN 1 position.
h. Close Generator 1 breaker by cycling BCS-G1 to the CLOSE position.
i. Observe that BCSG1 breaker closes.
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j. Place the SSS in the TIE position
k. Close the BCST by cycling BCST to the CLOSE position.
l. Return the SSS to the OFF position.
m. At A-unit GCPG2 place the Engine Control Switch (ECS) in MANUAL.
n. Observe the engine starts and accelerates to operating voltage and frequency.
o. At the A-unit MCP, place the Sync Source Switch (SSS) in the GEN 2 position.
p. Close BCSG2 when the two green triangular LEDs at 12 o’clock on the Synchroscope are
energized by cycling BCSG2 to the CLOSE position. For detailed instructions on manual
synchronizing refer to Chapter 5.9 Section 5.9.6.14.
q. Observe that the BCSG2 closes.
r. Return the SSS to the OFF position.
s. At B-unit MCP, place the SSS in the TIE position.
t. Close the BCST by cycling BCST to the CLOSE position.
u. Return the SSS to the OFF position.
v. At B-unit GCPG1, place the Engine Control Switch (ECS) in MANUAL.
w. Observe the generator starts and accelerates to operating voltage and frequency.
x. At the B-unit MCP, place the Sync Source Switch (SSS) in the GEN 1 position.
y. Close BCSG1 when the two green triangular LEDs at 12 o’clock on the Synchroscope are
z. At B-unit GCPG2, place the Engine Control Switch (ECS) in MANUAL.
aa. Observe the generator starts and accelerates to operating voltage and frequency.
bb. At the B-unit MCP, place the Sync Source Switch (SSS) in the GEN 2 position.
cc. Close BCSG2 when the two green triangular LEDs at 12 o’clock on the Synchroscope are
dd. Return the SSS to the OFF position.
ee. At the C-unit, if installed, repeat steps ‘s’ through ‘dd’.
ff. At the D-unit, if installed, repeat steps ‘s’ through ‘dd’.
gg. At the external switchgear, close the connections of loads to the switchgear.
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hh. Ensure generators have assumed load.

ii. Observe the KW, PF and KVAR of each generator at the LCP.
Note: If adjustment is needed for KVAR balance, start with the generator that is the furthest from the average
KVAR (either too low or too high). Make minor adjustments of the Voltage Adjust Rheostat (VAR) until the
KVAR sharing between generators are within +/– 10% of the average plant KVAR load. This adjustment will
typically be required only once during initial power plant setup and is intended to compensate for meter
variations among generators.
CAUTION
Improper adjustment of the VAR can cause a reverse KVAR shutdown of a generator.
5.5.5 PLANT OPERATIONS
Refer to Chapter 5.9 for specific operating procedures.
In this mode of operation the ORT provides no remote operation capability. It will provide monitoring of
the generator parameters.
5.5.6 POWER PLANT TEARDOWN
5.5.6.1 SHUTDOWN GENERATORS
a. Unload all generators by opening all feeder breakers. This must be done locally from the LCP or
ORT.
b. Open each BCST locally at the respective MCP.
c. Place all generators in cooldown by placing all SMS switches in OFF.
d. Observe all generator breakers open.
e. Open all the switchgear generator supply disconnect switches.
f. Allow all engines to completely cooldown and shutdown (5 minutes).
g. Place all ECS switches in OFF/RESET.
h. Pull out the DC Control Power breaker on all PUs.
5.5.6.2 DISCONNECT CABLES
WARNING
NEVER REMOVE POWER CABLES BY HAND, USE HOT STICK AND HIGH
VOLTAGE GLOVES. NEVER TOUCH A HIGH VOLTAGE LEAD OR TERMINAL UNTIL
IT HAS BEEN DISCHARGED TO GROUND. FAILURE TO OBSERVE THE WARNING
MAY RESULT IN DEATH BY ELECTROCUTION.
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CAUTION
ALLOW ALL OPERATING ENGINES TO SHUT DOWN AND COOL DOWN

COMPLETELY.
a. Disconnect the (A)(B) communication cables from between the PUs, Reinstall the
communication cable receptacle covers, and store inside the PUs (one per unit).
b. Disconnect the ORT cable and store it in the ORT case.
c. Close and latch the ORT port on the PU.
d. Disconnect all load cables used in operation of the PUs.
5.5.6.3 DISCONNECT FUEL LINES
a. Turn all fuel system valves to the off position.
b. Disconnect the fuel hose from the PU fuel connection and the fuel supply.
c. Drain any fuel from the hoses into an auxiliary fuel supply and store the hoses.
5.5.6.4 DISCONNECT GROUNDING
a. Remove ground connections from the PU and store with the ground rod.
b. Disconnect the parking stations from the ground grid.
c. Remove the parking stations from their operating positions and reinstall them in their
transportation locations on the inside of the PU rear side access doors.
5.5.6.5 PREPARE PU FOR TRANSPORTATION
a. Reinstall the four radiator splashguards (PU-810B only).
b. Verify DC Control power is off.
c. Close and lock the LCP access doors.
d. Close and lock all PU side doors.
5.5.6.6 FUEL, OIL, AND COOLANT DRAINAGE
The Power Unit may be safely shipped with oil, fuel, and coolant at maximum capacities or less. Draining
fluids is not required unless federal, state, or local regulations prohibit shipment with fluids present. Refer
to Section 14.3.1.1, Section 13.4.5.5 and Section 6.5.3 for procedures for draining the oil, coolant and fuel
liquids respectively.
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CHAPTER 5.6
OPERATING INSTRUCTIONS
SINGLE OR MULTIPLE PU, PRIME POWER, EXTERNAL SWITCH,

AUTOMATIC MODE
TABLE OF CONTENTS
SECTION TITLE PAGE
5.6 SINGLE/ MULTIPLE PU, PRIME POWER, EXTERNAL
SWITCH, AUTOMATIC MODE ................................................................................111
5.6.1 SAFETY PROCEDURES .........................................................................................111
5.6.2 POSITIONING THE PU ............................................................................................111
5.6.3 INITIAL PLANT SETUP ...........................................................................................112
5.6.3.1 GROUNDING............................................................................................................112
5.6.3.2 FUEL MANIFOLD.....................................................................................................113
5.6.3.3 DISTRIBUTION AND CONTROL CABLING ...........................................................114
5.6.3.4 SETPOINT VERIFICATION......................................................................................115
5.6.3.5 PRE-OPERATION CHECKS....................................................................................119
5.6.3.6 PRE-OPERATION RUN ...........................................................................................119
5.6.3.7 ORT SETUP..............................................................................................................121
5.6.3.8 CONTROLS SETUP .................................................................................................122
5.6.3.9 PSC RELAY SETTING VERIFICATION ..................................................................122
5.6.4 PLANT STARTUP ....................................................................................................124
5.6.5 PLANT OPERATIONS (AUTOMATIC MODE) ........................................................126
5.6.5.1 PRECAUTIONS AND WARNINGS ..........................................................................126
5.6.5.2 DESCRIPTION..........................................................................................................127
5.6.5.3 DEFAULT OPERATING SEQUENCE......................................................................127
5.6.6 POWER PLANT TEARDOWN .................................................................................128
5.6.6.1 SHUT DOWN GENERATORS .................................................................................128
5.6.6.2 DISCONNECT CABLES ..........................................................................................128
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5.6.6.3 DISCONNECT FUEL LINES ....................................................................................129
5.6.6.4 DISCONNECT GROUNDING...................................................................................129
5.6.6.5 PREPARE PU FOR TRANSPORTATION ...............................................................129
5.6.6.6 FUEL, OIL, AND COOLANT DRAINAGE................................................................129
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LIST OF FIGURES
FIGURE TITLE PAGE
FIGURE 5.6.3.1-1 MEP-PU-810A GROUND POINTS 112
FIGURE 5.6.3.1-2 MEP-PU-810B GROUND POINTS 113
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LIST OF TABLES
TABLE TITLE PAGE
TABLE 5.6.3.6-1 PRE-OPERATION RUN INSTRUCTION SEQUENCE 120
TABLE 5.6.3.8-1 PDC CONTROL SWITCH SETUP 122
TABLE 5.6.3.9-1 PSC RELAY SETTINGS 124
TABLE 5.6.4-1 SWITCH SETUP – AUTOMATIC MODE 125
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5.6 SINGLE/ MULTIPLE PU, PRIME POWER, EXTERNAL SWITCH, AUTOMATIC MODE
5.6.1 SAFETY PROCEDURES
a. Safety precautions must be observed while operating or maintaining the PU. Safety
precautions must be observed to ensure that the operator/technician cannot have contact with the
following:
• Hot engine parts

• Hot engine fluids
• Medium Voltage AC electricity
• Low Voltage AC electricity
• Low Voltage DC electricity
• Rotating Parts
• High noise levels
b. Minor Troubleshooting can be performed while both engines are running as long as safety
precautions are taken. Refer to the appropriate troubleshooting section for recommendations.
5.6.2 POSITIONING THE PU
a. Position the PU in such a way as to allow the plant operator to have full vision of the operator
control panels on the unit.
b. Level the MEP-PU-810B front to rear with the trailer leveling hand crank.
c. Position the PU to provide a minimum of 10 feet of clearance for maintenance access on all
sides of each unit. Ensure that there are no overhead obstructions around the exhaust outlets.
WARNING
FUEL SPILLAGE CAN OCCUR IF THE POWER UNIT LEVEL IS GREATER THAN + 5
DEGREES.
d. Ensure that the ground is capable of supporting the weight of the PU. The site surface should be
as level as possible (+ 5 degrees).
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5.6.3 INITIAL PLANT SETUP
5.6.3.1 GROUNDING
WARNING
THERE CAN ONLY BE ONE GROUNDING POINT FOR THE PU.
a. Drive an 8-foot ground rod into the earth and should be within 6 feet of the PU and at a location
that minimizes the tripping hazard, until only 6 inches (15 cm) protrudes above the surface.
b. Repeat step “a” for each PU being used.
c. Connect all of the grounding rods together with a #2 AWG copper conductor creating a central
ground grid.
d. Using a #2 AWG copper conductor, secure one end of a ground cable to one of the slotted
ground studs on the PU, see Figure 5.6.3.1-1 or Figure 5.6.3.1-3. Secure the other end of the
ground cable to the ground rod.
e. Repeat step “d” for every PU.
f. Test Ground Resistance using Ground Resistance Test Equipment. Resistance must be 25Ω or
less. Refer to Annex H for special equipment required for this task.
g. Remove parking stand plates from their transportation positions inside each rear, side PU door
and slide them into their respective operating positions on the sides of the PDC.
h. Connect the parking stand ground wires to either of the two chassis ground lugs on the PU.
GROUND POINT
GROUND POINT
FIGURE 5.6.3.1-1 MEP-PU-810A GROUND POINTS
NOTE: Connect only one ground point to the ground grid.
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GROUND POINT GROUND POINT
FIGURE 5.6.3.1-2 MEP-PU-810B GROUND POINTS
5.6.3.2 FUEL MANIFOLD
WARNING
ENSURE THAT THE FUEL LINES ARE PROTECTED FROM ALL ELECTRICAL
CABLES AND ARE ROUTED TO MINIMIZE THE POTENTIAL FOR PHYSICAL
DAMAGE OR CAUSING A TRIPPING HAZARD.
a. Lay out the fuel hoses between the PU, the fuel manifold, and the fuel bladders to establish the
fuel supply system. See Chapter 5.1 Figure 5.1.3.2-1 External Fuel Supply.
b. Install the external fuel hose for the PU to the Fuel Transfer Pump at the Tow end of the PU.
c. Connect the other end of the fuel hose to the fuel manifold outlets.
d. Connect the 3” hose, with quick-disconnect hose ends, from the fuel manifold to the fuel
bladders.
e. Connect the fuel manifold ground wire to the ground grid.
f. Open only the appropriate fuel manifold valves (once connected to the PU) to supply fuel to the
power units and check for leaks.
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WARNING

WARNING

WARNING

stations and the Primary Switching Center (PSC).
(PSC).
and USA TM9-6115-725-14&P.
phase connections.
g. Repeat steps ‘a’ through ‘f’ on each remaining PU.
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l. Route the second (A) (B) communication cable to third PU.
n. Connect the third (A) (B) communication cable to “B” receptacle on third PU.
r. Leave the loose end of fourth cable loose and capped.
(6) Verify the “P” and “N” values match Chapter 5.1 Table 5.1.3.4-1 CT Ratio Settings.

(10) Verify the 50TP “PU” and “TD” settings in Chapter 5.1 Table 5.1.3.4-2 Instantaneous Trip
Settings. In order to edit values, Press the “Edit” key. Select correct value, and press
“Edit” again to save changes. Ensure light is off otherwise you can accidentally change
value again.
(14) Verify the “50TQ” settings.
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19) Press the [►] key to display “5.1.2.2 51N”.
Door (Look-up)
Use Chapter 5.1 Table 5.1.3.4-5 OP5-1 Settings for the parameter values to be verified.
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(20) Press SCROLL UP key. “OP6” is showing.
(23) Press EXIT key twice. The display returns to normal.
Press SCROLL UP or SCROLL DOWN key to continue to verify the remaining

(d)
parameter values.
Parameter/Setpoints:
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checks identified in Chapter 5.1 Table 5.1.3.5-1 Pre-Operation Checklist. (Gen. 1 is on the left and Gen. 2
is on the right):
WARNING
WARNING

ENFORCED.
WARNING

ENFORCED.
UNDER 2.5 HOURS.
WARNING

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open BCSG1
open BCSG2
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5.6.3.7 ORT SETUP
f. Turn on the ORT.
PU.
feeders.
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indicators:
NOTE: Ignore settings for Power Units not being used:
TABLE 5.6.3.8-1 PDC CONTROL SWITCH SETUP

DC Power
(ON) (ON) (ON) (ON)
SMS OFF OFF OFF OFF
GMS
MASTER CONTROL PRIME PRIME PRIME PRIME
AVRS
PANEL MCP POWER POWER POWER POWER
60Hz Light ON① ON① ON① ON①
SSS OFF OFF OFF OFF
50/60 50/60 50/60 50/60
INSIDE MCP FSS
Hertz① Hertz① Hertz① Hertz①
GENERATOR Emergency
CONTROL PANEL Stop
GENERATOR Emergency
CONTROL PANEL Stop
c. Select Programs then Accessories then HyperTerminal.
NOTE: If “vista.ht” does not appear on the menu, refer to the Windows 98 procedure contained in
APPENDIX C of S&C instruction sheet 681-515 to create it.
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e. Click on “Connect”.
NOTE: Do Not Connect the communication cable before completing step “e”. Otherwise Windows NT
will search for a new device on the ORT COM port.
f. Connect the communication cable between the ORT to the left (Ways 3 and 4) Overcurrent
Relay (OCR).
g. Press “Enter” on the ORT.
h. Select View Menu 1, WAY 3.
i. Select View relay settings.
j. Verify relay settings according to Table 5.6.3.9-1
NOTE: Refer to S&C Instruction Sheet 681-515 page 14, PROGRAMMING to change settings.
k. Repeat steps g through I for WAY 4.
l. Return to the main menu and test the “Trip Function” of each interrupter using the Test Trip
Menu.
m. Return to the Main Menu and “Disconnect” using Windows HyperTerminal when desired
n. Disconnect the OCR end of the communication cable.
o. Repeat steps e. through l. for the right OCR (Ways 5 and 6).
p. Repeat steps e. though m. for each PSC in use.
q. Exit Windows HyperTerminal.
r. Shut-down the ORT.
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MIN. INST. TIME
CABLE
PSC WAY FUNCTION CURVE PICKUP PICKUP DELAY
SIZE
Feeder
3,4, or 5 1/0 TAP 50 0 Off
Ground
Single
3,4, or 5 500 KCM MAIN 600 1 Off
Output
Single
3,4, or 5 Output 500 KCM MAIN 100 0 Off
Ground
PSC
6 4/0 TAP 400 0 C (64ms)
Interconnect
PSC
6 Interconnect 4/0 TAP 80 0 C (64ms)
Ground
5.6.4 PLANT STARTUP
WARNING
ONCE THE SYSTEM STATUS LIGHTS TURN GREEN AND THE MSES IS ENABLED,
THE PU WILL START. ENSURE PERSONNEL ARE CLEAR OF THE PU.
WARNING
ONLY ONE PU MAY BE SELECTED TO ANY ONE USS POSITION DURING MULTIPLE
PU OPERATIONS. OPERATING WITH MORE THAN ONE UNIT AT THE SAME ID
CAUSE UNSAFE AND ERRATIC OPERATIONAL CONDITIONS.
WARNING

COULD RESULT IN PERSONAL INJURY OR DAMAGE TO EQUIPMENT
Starting up a Multi-PU Prime Power Plant in Automatic Mode
a. At the Primary Switching Center (PSC), close the associated connection for each PU supplying
power to the switchgear and close and pad lock the PSC interconnect switches when using more
than one primary switch.
b. At the PSC, close the connections between the external switchgears.
c. At the PSC, open all the connections of loads to the PSC.
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and USA TM9-6115-725-14&P.
indicators:
TABLE 5.6.4-1 SWITCH SETUP – AUTOMATIC MODE

BCS-T Red Target Red Target Red Target Red Target
MASTER CONTROL
PANEL MCP
SMS AUTO③ AUTO③ AUTO③ AUTO③
USS A B C D
GENERATOR BCS-G1 Red Target Red Target Red Target Red Target
CONTROL PANEL 1 BCS-F1 Red Target Red Target Red Target Red Target
GCPG1 ECS-1 AUTO AUTO AUTO AUTO
MASTER CONTROL MSES Enable① Enable① Enable① Enable①
PANEL MCP USI A①, ② B①, ② C① , ② D① , ②
③ With the SMS in AUTO any generator started, manually or automatically, will automatically
parallel to the bus. To prevent the generator from paralleling to the bus put the generator’s
breaker in the Pull-To-Lock position.
NOTE: The automatic economizing feature will shutdown one generator every 3 minutes until the
system load is at or below the 360KW/450KVA per generator threshold.
e. At A-unit, observe Generator 1 automatically starts and accelerates to operating voltage and
frequency.
f. At A-unit, observe Generator 1 automatically closes to the system bus.
g. At A-unit, observe the Tie breaker automatically closes.
h. At B-unit, observe the Tie breaker automatically closes.
i. At C-unit, observe the Tie breaker automatically closes.
j. At D-unit, observe the Tie breaker automatically closes.
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k. At A-unit, observe Generator 2 automatically starts and accelerates to operating voltage and
frequency.
l. At A-unit, observe Generator 2 automatically parallels to the system bus.
m. At B-unit, observe Generator 1 automatically starts and accelerates to operating voltage and
frequency.
n. At B-unit, observe Generator 1 automatically parallels to the system bus.
o. At B-unit, observe Generator 2 automatically starts and accelerates to operating voltage and
frequency.
p. At B-unit, observe Generator 2 automatically parallels to the system bus.
q. At C-unit, observe Generator 1 automatically starts and accelerates to operating voltage and
frequency.
r. At C-unit, observe Generator 1 automatically parallels to the system bus.
s. At C-unit, observe Generator 2 automatically starts and accelerates to operating voltage and
frequency.
t. At C-unit, observe Generator 2 automatically parallels to the system bus.
u. At D-unit, observe Generator 1 automatically starts and accelerates to operating voltage and
frequency.
v. At D-unit, observe Generator 1 automatically parallels to the system bus.
w. At D-unit, observe Generator 2 automatically starts and accelerates to operating voltage and
frequency.
x. At D-unit, observe Generator 2 automatically parallels to the system bus.
y. At the external switchgear, close all switches/breakers connecting the external switchgear to the
load (s).
z. Ensure generators have assumed load.

aa. Observe the KW, PF and KVAR of each generator at the LCP.
CAUTION
5.6.5 PLANT OPERATIONS (AUTOMATIC MODE)
5.6.5.1 PRECAUTIONS AND WARNINGS
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This mode of operation places control of all generator starting, stopping, synchronizing, and load
management under the auspices of the Programmable Logic Controller (PLC) system. As long as the
SMS is in AUTO, any generator started, manually or automatically, is automatically synchronized to the
system bus. Care must be taken when starting a generator manually when the SMS is in AUTO. Either
place the associated BCS in Pull-To-Lock (prevent closing to the bus) or ensure it has the red target
visible (allow paralleling to the bus) before starting the engine. The only exception is automatic operation
of the feeder breakers. Auto Mode does not automatically close feeder breakers; it only enables remote
operation of the feeder breakers from the ORT.
5.6.5.2 DESCRIPTION
The master controller (the designated “A” unit) will control all connected generators based on the total
system KW/KVA load. The controller shuts down one of the generators after 3 minutes should the system
load drop below a level where the remaining generator load would not exceed 85% (360kW) if a
generator is shutdown. If the load of the remaining generator exceeds 85% (360kW) for one minute, a
standby generator is started and paralleled to the bus. A change of system load is recognized by the
control system and appropriate action is taken to maintain generator load in the 85% (360 KW/450 KVA)
range. The system never automatically shuts down the final generator under normal operating conditions.
The shutdown of the final generator must be done following manual operating procedures. The default
configuration is Economizing Mode on. The economizing mode can be turned off from the ORT. Through
the ORT, the AUTO shut down is disabled but the AUTO start-up remains active to prevent overloading
the online generator(s).
5.6.5.3 DEFAULT OPERATING SEQUENCE
Start-Up Sequence: The automatic controls will continuously monitor the system load. As load on the
system increases, the controls automatically start and place additional units on line in the following
sequence at 1-minute intervals:
a. One generator from PU “B” based on lower engine runtime.

b. One generator from PU “C” based on lower engine runtime.
c. One generator from PU “D” based on lower engine runtime.
d. Remaining generator from PU “A”.
e. Remaining generator from PU “B”.
f. Remaining generator from PU “C”.
g. Remaining generator from PU “D”.
Shutdown Sequence: Based on the loading experienced, the controller shuts down generator sets that
are not needed. For the purpose of explanation, we will assume that all generator sets are on line
following an initial startup. Based on load, the controls shut down generator sets in the following
a. One generator from PU “D” based on higher engine runtime.

b. One generator from PU “C” based on higher engine runtime.
c. One generator from PU “B” based on higher engine runtime.
d. One generator from PU “A” based on higher engine runtime.
e. Remaining generator from PU “D”.
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g. Remaining generator from PU “B”.
5.6.6.1 SHUT DOWN GENERATORS
a. Unload all generators by opening all feeder breakers. This must be done locally from the LCP or
ORT.
b. Open each BCST locally at the respective MCP.
c. Place all generators in cooldown by placing all SMS switches in OFF.
d. Observe all generator breakers open.
e. Open all the switchgear generator supply disconnect switches.
f. Allow all engines to completely cooldown and shutdown (5 minutes).
g. Place all ECS switches in OFF/RESET.
h. Pull out the DC Control Power breaker on all PUs.
WARNING
NEVER REMOVE POWER CABLES BY HAND, USE HOT STICK AND HIGH VOLTAGE
GLOVES. NEVER TOUCH A HIGH VOLTAGE LEAD OR TERMINAL UNTIL IT HAS BEEN
DISCHARGED TO GROUND. FAILURE TO OBSERVE THE WARNING MAY RESULT IN
DEATH BY ELECTROCUTION.
CAUTION
ALLOW ALL OPERATING ENGINES TO SHUT DOWN AND COOL DOWN COMPLETELY.
communication receptacle covers, and store inside the PUs (one per unit).
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THIS PAGE INTENTIONALLY BLANK
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CHAPTER 5.7
MEP-PU-810 AND MEP-012 PARALLEL OPERATIONS, MANUAL AND

AUTOMATIC MODE
TABLE OF CONTENTS
SECTION TITLE PAGE

5.7 MEP-PU-810 & MEP-012 PARALLEL OPERATIONS, MANUAL AND
AUTOMATIC MODE 135
5.7.1 SAFETY PROCEDURES 135
5.7.2 MEP-PU-810 AND MEP-012 PARALLEL OPERATION DESCRIPTION 135
5.7.3 POSITIONING THE PU 136
5.7.4 INITIAL PLANT SETUP 137
5.7.4.1 GROUNDING 137
5.7.4.2 FUEL MANIFOLD 139
5.7.4.3 DISTRIBUTION AND CONTROL CABLING 140
5.7.4.4 SETPOINT VERIFICATION 142
5.7.4.5 PRE-OPERATION CHECKS 155
5.7.4.6 PRE-OPERATION RUN 157
5.7.4.7 ORT SETUP 159
5.7.4.8 CONTROLS SETUP 160
5.7.5 PLANT STARTUP 161
5.7.5.1 MANUAL MODE 161
5.7.5.1.1 STARTING UP SINGLE OR MULTIPLE PU’S IN MANUAL MODE WITH A

MEP-012 POWER PLANT 161
5.7.5.1.2 STARTING UP SINGLE OR MULTIPLE MEP-012’S WITH A MEP-PU-810

POWER PLANT IN MANUAL MODE 164
5.7.5.2 AUTOMATIC MODE 165
5.7.5.2.1 STARTING UP SINGLE OR MULTIPLE PU’S IN AUTOMATIC MODE WITH A

MEP-012 POWER PLANT 165
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5.7.5.2.2 STARTING UP SINGLE OR MULTIPLE MEP-012’S WITH A PU POWER

PLANT IN AUTOMATIC MODE 167
5.7.6 PLANT OPERATIONS 168
5.7.7 POWER PLANT TEARDOWN 168
5.7.7.1 SHUT DOWN GENERATORS 168
5.7.7.2 DISCONNECT CABLES 168
5.7.7.3 DISCONNECT FUEL LINES 169
5.7.7.4 DISCONNECT GROUNDING 169
5.7.7.5 PREPARE PU FOR TRANSPORTATION 169
5.7.7.6 FUEL, OIL, AND COOLANT DRAINAGE 169
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LIST OF FIGURES
FIGURE TITLE PAGE

FIGURE 5.7.4.2-1 EXTERNAL FUEL SUPPLY 139
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LIST OF TABLES
TABLE TITLE PAGE

TABLE 5.7.4.4-1 CT RATIO SETTINGS 142
TABLE 5.7.4.4-2 INSTANTANEOUS TRIP SETTINGS 142
TABLE 5.7.4.4-3 TIME OVERCURRENT TRIP SETTINGS 143
TABLE 5.7.4.4-4 OP5-0 SETPOINTS 145
TABLE 5.7.4.4-4 OP5-0 SETPOINTS (CONTINUED) 146
TABLE 5.7.4.4-6 OP6 SETPOINTS 151
TABLE 5.7.4.4-6 OP6 SETPOINTS (CONTINUED) 152
TABLE 5.7.4.4-7 AVR PARAMETERS/SETPOINTS 153
TABLE 5.7.4.4-7 AVR PARAMETERS/SETPOINTS (CONTINUED) 154
TABLE 5.1.3.5-1 PRE-OPERATION CHECKLIST 155
TABLE 5.1.3.5-1 PRE-OPERATION CHECKLIST (CONTINUED) 156
TABLE 5.7.4.8-1 CONTROL SWITCH SETUP 160
TABLE 5.7.5.1-1 SWITCH SETUP – MANUAL MODE 162
TABLE 5.7.5.1-2 GENERATOR CAPACITIES 163
TABLE 5.7.5.2.1-1 SWITCH SETUP – AUTOMATIC MODE 166
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5.7 MEP-PU-810 & MEP-012 PARALLEL OPERATIONS, MANUAL AND AUTOMATIC

MODE
following:

• Rotating Parts
5.7.2 MEP-PU-810 AND MEP-012 PARALLEL OPERATION DESCRIPTION
The MEP-PU-810 generator is an isochronous generator. It operates at 50 or 60 Hertz for its

complete load range of 0-420KW. By design, a single isochronous generator will assume the
load on the bus up to its full capacity. To allow multiple isochronous generators to work in parallel
Load Share Modules (LSM) are used. Each generator has its own LSM and these are
interconnected by load share lines. The LSMs of online generators put a voltage on the load
share lines that is sensed by all other LSMs. Each LSM then compares the load share line
voltage to its internal load voltage and develops an error signal. This error is then used to raise
or lower the KW load carried by that generator until all online generators are sharing the load
equally (no error signal). With this type of operation no adjustment to the generator frequency is
required to distribute load equally among the generators. This also allows multiple generators,
even ones of different capacity, to operate in parallel under all conditions from no-load to full-load.
The MEP-012 will be operated as a droop generator. As it is loaded from 0-750KW, its frequency
droops by a set ratio. The generator’s frequency adjust potentiometer is then raised to maintain
the desired frequency. Operating multiple droop generators together requires the operator to
adjust generator frequency potentiometers to distribute the load proportionally among generators.
Additionally, the operator must constantly adjust generator frequencies to maintain the required
frequency whenever loads are added or shed.
Both kinds of generators may be operated together; however, close attention must be paid to the
system load and the droop unit’s frequency. The isochronous generator will set system
frequency and try to assume its full capacity. This requires the operator to lower the droop unit
frequency to transfer the load to the isochronous generator. That unit carries load increases up
to the capacity of the droop unit. Additional load above the total capacity of both generators will
obviously require an additional generator. Load decreases below the full capacity rating of just
the isochronous unit will require the operator to shutdown the droop unit.
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The recommended method of operating MEP-PU-810s and MEP-012s together is to place the
MEP-PU-810 generators on the bus and allow them to carry the normal load. When the system
load approaches the rated capacity of the MEP-PU-810 generator(s), add MEP-012 generators
as required to provide the necessary capacity. As the load drops off, shutdown the MEP-012
generator(s).
CAUTION
THE MEP-PU-810 WILL TRY TO ASSUME ITS RATED LOAD WHEN PARALLELED
WITH ANOTHER GENERATOR THAT IS OPERATING IN DROOP. VOLTAGE AND
FREQUENCY ADJUSTMENTS ON THE DROOP PLANT MUST BE USED TO
CONTROL THE LOAD SHARING BETWEEN THE PLANT AND THE MEP-PU-810.
There may be situations where the recommended method of operation is not ideal. In these
situations, understanding the way isochronous and droop generators work and operational
experience are useful in achieving a line-up that is best for the application.
WARNING
DEGREES.
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5.7.4.1 GROUNDING
WARNING
THERE CAN ONLY BE ONE GROUNDING POINT FOR THE PU. WHEN USING A
NEUTRAL GROUND RESISTER (NGR), IT MUST USE THE PU GROUND ROD TO
AVOID CREATING A GROUND LOOP.
ground grid.
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WARNING
fuel supply system see Figure 5.7.4.2-1.
bladders.
FIGURE 5.7.4.2-1 EXTERNAL FUEL SUPPLY
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WARNING

WARNING

WARNING

CONNECTIONS. FAILURE TO CHECK CONNECTORS DE-ENERGIZED MAY
RESULT IN INJURY OR DEATH.
stations and the load.
(PSC).
and USA TM9-6115-725-14&P.
phase connections.
g. Repeat steps ‘b’ through ‘f’ on each remaining PU.
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r. Leave the loose end of fourth cable loose and capped.
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a. Turn on the control power by pushing in the DC Control Power breaker.
(6) Verify the “P” and “N” values match the following table:
TABLE 5.7.4.4-1 CT RATIO SETTINGS

BREAKER RELAY CT RATIO “P” VALUE “N” VALUE
GENERATOR 100:5 20 20
FEEDER 200:5 40 40
TIE 200:5 40 40

(10) Verify the 50TP “PU” and “TD” settings in Table 5.7.4.4-2. In order to edit values, Press
the “Edit” key. Select correct value, and press “Edit” again to save changes. Ensure
light is off otherwise you can accidentally change value again.
TABLE 5.7.4.4-2 INSTANTANEOUS TRIP SETTINGS

PHASE NEUTRAL NEGATIVE SEQUENCE
INSTANTANEOUS INSTANTANEOUS TRIP
BREAKER RELAY
TRIP 50TP TRIP 50TN 50 TQ
PU TD PU TD PU TD
GENERATOR 0.0 0m 3.0 0m 3.0 0m
FEEDER 7.5 84m 1.25 84m 0 0m
TIE 0.0 0m 0 0m 0.0 0m
(12) Verify the 50TN settings in Table 5.7.4.4-2.
(14) Verify the “50TQ” settings
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(18) Verify the 51P “PU”, “TD”, and “C” settings in Table 5.7.4.4-3.
TABLE 5.7.4.4-3 TIME OVERCURRENT TRIP SETTINGS

PHASE TIME OVERCURRENT NEUTRAL TIME OVERCURRENT
BREAKER RELAY TRIP 51P TRIP 51N
PU TD C PU TD C
GENERATOR 4.50 0.5 VV2 1.25 0.5 VV2
FEEDER 2.50 1.0 VV2 1.00 1.0 VV2
TIE 5.00 2.0 VV2 1.50 2.0 VV2
(19) Press the [►] key to display “5.1.2.2 51N”.
(20) Verify the 51N settings in Table 5.7.4.4-3.
c. Use the following procedure to verify the Generator 1 and Generator 2 GSC+ settings in step “d”:
Door (Look-up)
Use Table 5.7.4.4-4 for the parameter values to be verified. Repeat until the desired
setpoints are verified.
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Use Table 5.7.4.4-6 OP6 Setpoints for the parameter values to be verified. Repeat until the
desired setpoints are verified.
(23) Press EXIT Key twice. The display returns to normal.
Press SCROLL UP or SCROLL DOWN key to continue to verify the remaining

(d)
parameter values.
d. At GSCG1 and GSCG2, verify the operation settings using the following table:
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TABLE 5.7.4.4-4 OP5-0 SETPOINTS
SETPOINTS OP5-0 ENGINE/GENERATOR PROGRAMMING①
FACTORY DPGDS
SETPOINT-NAME-DESCRIPTIONS RANGE OF VALUES
DEFAULT SETPOINT
P001 - Fuel Solenoid Type: type of fuel system solenoid 0- ETR fuel solenoid
0 0
used on the genset. 1- ETS fuel solenoid
P002 - Units Shown: type of measurement units shown 0-for English units (PSI, ºF)
0 0
on the GSC+ display. 1-for metric units (kPa, ºC).
P003 - Shutdown Override For Engine Fault: GSC+ 0-for engine shutdown
response to a low engine oil pressure or high coolant 1-for alarm only (shutdown override, no 0 0
temperature fault. engine shutdown).
P004 - Shutdown Override For Sensor Fault: GSC+ 0-for alarm only shutdown override, no
response to a diagnostic fault with the engine oil pressure engine shutdown). 0 0
sensor, coolant temperature sensor, oil temperature
sensor, sensor power supply or coolant loss sensor. 1-for engine shutdown.
P005 - Coolant Loss Sensor Installed: tells whether or 0-for gensets without a coolant loss sensor
not the optional engine coolant loss sensor is installed on 0 1
the genset. 1-for gensets with coolant loss sensor
0-for engine shutdown.

P006 - Shutdown Override For Coolant Loss Fault:
1-for alarm only (shutdown override, no 0 0
GSC+ response to an engine coolant loss fault.
engine shutdown).
P007 - System Voltage, 24 Or 32 Volts: system voltage
24 or 32. 24 24
(battery voltage) of the genset.
P008 - This setpoint is not currently being used by the
N/A N/A N/A
GSC+ and cannot be programmed.
P009 - Number Of Ring Gear Teeth: number of teeth on
the ring gear of the engine. Used by the GSC+ to 95 to 350 teeth in increments of one tooth. 136 teeth 136 teeth
determine engine speed.
P010 - Engine Overspeed: engine speed used by the
GSC+ to declare that an engine overspeed fault exists.
500 to 4330 rpm in increments of 10 rpm. 2120 rpm 2120 rpm
The engine overspeed setpoint (for all 60 Hz applications)
is 1.18 times the rated speed.
P011 - Crank Terminate Speed: engine speed used by
the GSC+ to disengage the starting motor during engine 100 to 1000 rpm in increments of 10 rpm. 400 rpm 400 rpm
cranking.
P012 - Oil Step Speed: engine speed used by the GSC+
for distinguishing between rated speed and idle speed 400 to 1800 rpm in increments of 10 rpm. 1350 rpm 1350 rpm
when a low oil pressure fault exists.
P013② - Low Oil Pressure Shutdown At Rated Speed:

oil pressure used by the GSC+ to declare that a low oil 30 PSI 30 PSI
pressure shutdown fault exists with engine at rated speed 5 to 61PSI (34 to 420kPa) in increments of 1
(205 kPa) (205 kPa)
(the engine speed must have exceeded the oil step speed
for nine seconds).
P014② - Low Oil Pressure Shutdown At Idle Speed:

oil pressure used by the GSC+ to declare that a low oil
10 PSI 10 PSI
pressure shutdown fault exists with the engine at idle 20 to 336kPa (3 to 49PSI) in increments of 1
speed (the engine must have been running for at least 9 (70 kPa) (70 kPa)
seconds and the engine speed must be less than oil step
speed).
P015③ - High Water Temperature Shutdown: coolant

185 to 253ºF (85 to 123ºC) in increments of 225ºF 225ºF
temperature used by the GSC+ to declare a high coolant
temperature shutdown fault exists (after a 10 second 1 (107ºC) (107ºC)
delay).
P016 - Low Water Temperature Alarm: coolant
temperature used by the GSC+ to declare that a low 70ºF 70ºF
32 to 97ºF (0 to 36ºC) in increments of 1
coolant temperature alarm fault exists (after a 2 second (21ºC) (21ºC)
delay).
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TABLE 5.7.4.4-4 OP5-0 SETPOINTS (CONTINUED)

FACTORY DPGDS
DEFAULT SETPOINT
P017 - Total Cycle Crank Time: cycle crank time used by the 5 to 120 seconds in increments of 1
90 seconds 90 seconds
GSC+ to declare that an overcrank fault exists. second.
P018 - Cycle Crank Time: amount of time the GSC+ cranks 5 to 60 seconds in increments of 1
and then rests the starting motor during a single crank cycle. second.
P019 - Cooldown Time: amount of time the GSC+ allows the 0 to 30 minutes in increments of 1
5 minutes 5 minutes
engine to run after a normal shutdown is initiated. minute.
P020④ - AC Voltage: nominal AC voltage of the generator. 700, 150, 300, 500, 600, 750, 3.0k,
The GSC+ measures the AC voltage and shows it on the 4.5k, 5.20k, 5.25k, 9.0k, 15.0k, 18.0k, 700 5.20k
display. 30.0k
P021 - AC Current Full Scale: nominal full scale AC current 75, 100, 150, 200, 300, 400, 600, 800,
of the generator. AC current full scale is equal to the ratio of 1000, 1200, 1500, 2000, 2500, 3000, 600A 100A
the external current transformers in the generator housing. and 4000A
P022⑤ - GSC+ Engine Number: informs other devices on

01 (Gen 1)
01 through 08 01
the CAT Data Link of the engine number for the GSC+. 02 (Gen 2)
SETPOINTS - OP5-0-ENGINE/GENERATOR PROGRAMMING①

RANGE OF FACTORY 60HZ 50HZ
SETPOINT-NAME-DESCRIPTIONS
VALUES DEFAULT SETPOINT SETPOINT
P023 - Engine Type: identifies the engine as a 0 - MUI diesel
mechanical unit injector (MUI) diesel, spark
1 - Gas 0 2 2
ignited (gas), or electronic unit injector (EUI)
diesel engine. 2 - EUI diesel
P024 - Crank Time Delay: amount of time the
GSC+ delays activation of the fuel control relay
(FCR) during a crank cycle. This setpoint is for 0 to 20 seconds in increments of 1
5 Seconds 5 Seconds 5 Seconds
Gas engines only. The P024 setpoint only second.
functions when the P023 setpoint is set to 1 (gas
engine).
0 - for gensets without an oil
P025 - Oil Temperature Sensor Installed: tells temperature sensor
whether or not the optional engine oil temperature 0 0 0
sensor is installed on the genset. 1 - for gensets with an oil
temperature sensor
P026 - High Oil Temperature Shutdown: oil
temperature used by the GSC+ to declare a high 185 to 253ºF (85 to 123ºC) in
225ºF (107ºC) 225ºF (107ºC) 225ºF (107ºC)
oil temperature shutdown fault exists (after a 10 increments of 1
second delay). Refer to the panel model number.
P027 - Shutdown Override For High Oil 0 - for alarm only (shutdown override,
Temperature Fault: GSC+ response to an engine no engine shutdown). 0 0 0
high oil temperature fault. 1 - for engine shutdown.
P028 - Nameplate Voltage: rated voltage of the
generator. This setpoint is used for protective 100 to 25kV in increments of 1 480V 4160V 3800V
relaying functions.
P029 - Nameplate Current: rated current output
0 to 4000 A in increments of 1 600A 80A 73A
of the generator.
P030 - Nameplate Power: rated power capability 0 through 10MW in increments of
400kW 420kW 350kW
of the generator. 1kW.
P031 - Rated Frequency: nominal frequency
50 or 60Hz 60Hz 60Hz 50Hz
rating of genset.
P032 - Connection Configuration Of Generator: 0 - wye
0 0 0
wye or delta configuration of generator. 1 - delta
P033 - Number Of Generator Poles. 0 through 254 in increments of 2. 4 4 4
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① The setpoints (stored or being programmed) must match the specified DPGDS setpoints.
② When oil pressure drops to within 5PSI (34kPa) of the P013 or P014 setpoint, a low oil pressure alarm
is issued by the GSC+.
③ When coolant temperature rises to within 11ºF (6ºC) of the P015 setpoint, a high coolant temperature
alarm is issued by the GSC+.
④ The values other than the default (700V) are for switchgear applications and require the use of external
potential transformers and the removal of the AC voltage range jumper located in the relay module.
The DPGDS unit is factory configured for the 5.20 K value. See the Caterpillar Electronic Modular
Control Panel II+ manual topic AC Voltage Range Selection in the Testing and Adjusting section.
⑤ After setpoint P022 is reprogrammed, the GSC+ must be power cycled (powered down and then
powered up)
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SETPOINTS OP5-1 PROTECTIVE RELAYING PROGRAMMING①
FACTORY 60HZ 50HZ
SETPOINT-NAME-DESCRIPTION RANGE OF VALUES
DEFAULT SETPOINT SETPOINT
P101 - Generator Overvoltage Alarm Enable: the 0 - disabled
GSC+ enables or disables the generator 1 1 1
overvoltage alarm function. 1 - enabled
P102 - Generator Overvoltage Alarm Threshold:
100 to 125% of nameplate voltage in
voltage the GSC+ uses to issue an overvoltage 105% 105% 105%
increments of 1%.
alarm.
P103 - Generator Overvoltage Alarm Time Delay:
amount of time the GSC+ waits before issuing an 0 through 120 seconds② in increments 10 seconds 10 seconds 10 seconds
overvoltage alarm. of 1
P104 - Generator Overvoltage Shutdown Enable: 0 - disabled
the GSC+ enables or disables the generator 1 1 1
overvoltage shutdown function. 1 - enabled
P105 - Generator Overvoltage Shutdown
Threshold: voltage the GSC+ uses to issue an 110% 110% 110%
increments of 1%.
overvoltage shutdown.
P106 - Generator Overvoltage Shutdown Time
Delay: amount of time the GSC+ waits before 0 through 120 seconds② in increments 10 seconds 10 seconds 10 seconds
issuing an overvoltage shutdown. of 1
P107 - Generator Undervoltage Alarm Enable: 0 - disabled
undervoltage alarm function. 1 - enabled
P108 - Generator Undervoltage Alarm
increments of 1%.
undervoltage alarm.
P109 - Generator Undervoltage Alarm Time
issuing an undervoltage alarm. of 1
P110 - Generator Undervoltage Shutdown 0 - disabled
Enable: the GSC+ enables or disables the 1 1 1
generator undervoltage shutdown function. 1 - enabled
P111 - Generator Undervoltage Shutdown
60 through 100% of rated voltage in
increments of 1%.
undervoltage shutdown.
P112 - Generator Undervoltage Shutdown Time
issuing an undervoltage shutdown. of 1
P113 - Generator Overfrequency Alarm Enable: 0 - disabled
overfrequency alarm function. 1 - enabled
P114 - Generator Overfrequency Alarm 50-60Hz, for 50Hz Gen 53Hz

Threshold: frequency the GSC+ uses to issue an 60-70Hz, for 60Hz Gen 63Hz 63 Hz 53 Hz
overfrequency alarm. 400-480, for 400Hz Gen 422Hz
P115 - Generator Overfrequency Alarm Time
issuing an overfrequency alarm. of 1
P116 - Generator Overfrequency Shutdown 0 - disabled
generator overfrequency shutdown function. 1 - enabled
P117 - Generator Overfrequency Shutdown 50-60Hz, for 50Hz Gen 55Hz

Threshold: frequency the GSC+ uses to issue an 60-70Hz, for 60Hz Gen 66Hz 66Hz 55Hz
overfrequency shutdown. 400-480, for 400Hz Gen 440Hz
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FACTORY 60HZ 50HZ
P118 - Generator Overfrequency Shutdown Time
issuing an overfrequency shutdown. of 1
P119 - Generator Underfrequency Alarm Enable: 0 - disabled
underfrequency alarm function. 1 - enabled
P120 - Generator Underfrequency Alarm 30-50Hz, for 50Hz Gen 48Hz

underfrequency alarm. 240-400, for 400Hz Gen 378Hz
P121 - Generator Underfrequency Alarm Time
issuing an underfrequency alarm. of 1
P122 - Generator Underfrequency Shutdown 0 - disabled
Enable: the GSC+ enables or disables the generator 1 1 1
underfrequency shutdown function. 1 - enabled
P123 - Generator Underfrequency Shutdown 30-50Hz, for 50Hz Gen 45Hz

underfrequency shutdown. 240-400, for 400Hz Gen 360Hz
P124 - Generator Underfrequency Shutdown
Time Delay: amount of time the GSC+ waits before 0 through 120 seconds② in increments 15 seconds 03 seconds 03 seconds
issuing an underfrequency shutdown. of 1
P125 - Generator Reverse Power Shutdown 0 - disabled
reverse power shutdown function. 1 - enabled
P126 - Generator Reverse Power Shutdown
0 through 20% of rated power in
Threshold: level of reverse power the GSC+ uses to 15% 4% 4%
increments of 1%.
issue a reverse power shutdown.
P127 - Generator Reverse Power Shutdown Time
issuing a reverse power shutdown. of 1
P128 - Generator Overcurrent Alarm Enable: the 0 - disabled
1 1 1
GSC+ enables or disables the overcurrent alarm. 1 - enabled
P129 - Generator Phase Overcurrent Alarm
100 through 160% of nameplate current
Threshold: level of current the GSC+ uses to issue a 105% 150% 150%
in increments of 5%
phase overcurrent alarm.
P130 - Generator Phase Overcurrent Alarm Time
issuing a phase overcurrent alarm. of 1
P131 - Generator Total Overcurrent Alarm
100 through 160% of three times
Threshold: level of current the GSC+ uses to issue a 105% 150%. 150%
nameplate current in increments of 5%
total overcurrent alarm.
P132 - Generator Total Overcurrent Alarm Time
issuing a total overcurrent alarm. of 1
P133 – Generator Overcurrent Shutdown Enable: 0 – disabled
the GSC+ enables or disables the overcurrent 1 1 1
shutdown. 1 – enabled
P134 – Generator Phase Overcurrent Shutdown
100 through 160% in increments of 5%
Threshold: level of current the 110% 150% 150%
GSC+ uses to issue a phase overcurrent shutdown.
issuing a phase overcurrent shutdown. of 1
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FACTORY 60HZ 50HZ
P136 - Generator Total Overcurrent Shutdown
Threshold: level of current the GSC+ uses to 110% 150%. 150%
issue a total overcurrent shutdown.
P137 - Generator Total Overcurrent Shutdown
Time Delay: amount of time the GSC+ waits 0 through 250 seconds② in 0 seconds 10 seconds 10 seconds
before issuing a total overcurrent shutdown. increments of 1
P138 - KW Level Relay Enable : the GSC+ 0 - disabled
1 1 1
enables or disables the kW level relay function. 1 - enabled
P139 - KW Level Relay Threshold: level of
0 through 110% of nameplate power in
power the GSC+ uses to activate the kW level 105% 105% 105%
increments of 1%
relay function.
P140 - KW Level Relay Time Delay: amount of
time the GSC+ waits before activating the kW level 0 through 120 seconds② in 0 seconds 0 seconds 0 seconds
relay function. increments of 1
P141 - KW Level Relay Disengage Threshold:
level of power the GSC+ uses to deactivate the 100% 100% 100%
increments of 1%.
kW level relay function.
P142 - KW Level Relay Disengage Time Delay:
amount of time the GSC+ waits before 0 through 120 seconds② in 10 seconds 10 seconds 10 seconds
deactivating the kW level relay function. increments of 1
① The setpoints are programmed at the factory to the default value.

② When programmed to 0 seconds, the actual time is from 0.5 to 1.0 seconds.
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TABLE 5.7.4.4-6 OP6 SETPOINTS

SETPOINTS OP6 SPARE INPUT/OUTPUT PROGRAMMING
FACTORY DPGDS
DEFAULT SETPOINT
SP01 - Spare Input 1 Active State. Input state used by the 0-active low
0 0
GSC+ to declare a SP1 fault exists. 1-active high
SP02 - Spare Input 1 Response: GSC+ response to a SP1 0-shutdown
0 0
fault. 1-alarm
SP03 - Spare Input 1 Time Delay: Amount of time the GSC+
0 - 250 seconds in increments of 1 0 seconds 1 second
waits before responding to a SP1 fault.
0 1
0 0
fault. 1-alarm
0 - 250 seconds in increments of 1 0 seconds 0 seconds
0 0
0 0
fault. 1-alarm
0 0
0 0
fault. 1-alarm
SP13 - Spare Output Response: GSC+ response to the spare 0-active low
0 0
output trigger condition. 1-active high
0-unused
1-active SP1 fault②

SP14 - Spare Output Trigger Condition: The condition used
5-any combination of active SP faults②
8 8
by the GSC+ to trigger the spare output response
6-any active shutdown
7-any active alarm or shutdown
8-cooldown mode
9-coolant loss mode②
10-high oil temp fault②

11-CCM control
SP15 – Spare Relay Output Response: GSC+ response to the 0-relay inactive when triggered
spare relay trigger condition. 1-relay active when triggered
1 1
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TABLE 5.7.4.4-6 OP6 SETPOINTS (CONTINUED)

FACTORY DPGDS
DEFAULT SETPOINT
0-unused

SP16 - Spare Relay Output Trigger Condition: The condition
8 1
used by the GSC+ to trigger the spare relay.
8-cooldown mode

11-CCM control
0-unused

SP17 - Spare Indicator 1 Trigger Condition: The condition
4-active SP4 fault② 0 6
used by the GSC+ to trigger spare indicator①.
5-any combination of active SP1, SP2,
SP3 or SP4 faults②
6-Coolant loss fault②
7-high oil temperature fault②

Battle Short mode. 0 0 Battleshort③
used by the GSC+ to trigger spare indicator②.
SP19 - Spare Indicator 3 Trigger Condition: The condition 0 In 50Hz
Not in 60 Hz mode. 0
used by the GSC+ to trigger spare indicator③. Mode③
② Either alarm or shutdown faults are valid trigger conditions
③ Battleshort and 50Hz Mode are unique features to DPGDS for spare indicators 2 and 3.
e. Return ECS1 and ECS2 to the OFF/RESET position.
f. At the AVR verify the operation settings using Table 5.7.4.4-7:
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TABLE 5.7.4.4-7 AVR PARAMETERS/SETPOINTS

DPGDS
DPGDS AVR PARAMETERS
SETPOINTS
RANGE OF DEFAULT 60HZ 50HZ
PARAMETER TITLE TYPE UNITS
VALUES VALUE OPS OPS
01 Generator Output Voltage Program Volts 0080-9999 480① 4160 3800

Ratio of Output Voltage To
02 Program 001.0-100.0 001.0 17.3 17.3
Sensing Voltage
03 Generator Type Program 0000-0004 0004 4 4
04 Rated Generator Output Current Program Amps 0000-9999 0600 80 73
CT Voltage At Rated Generator
05② Current
Program Volts 01.00-05.00 05.00 4.00 3.66
06 Knee Frequency Program Hz 045.0-065.0 050.0 59.8 49.8

07 Decreasing Volts/Hz Slope I Program Volts/Hz 001.0-010.0 002.0 2.0 2.0
08 Decreasing Volts/Hz Slope 2 Program Volts/Hz 001.0-010.0 002.0 2.0 2.0
09 Minimum Voltage Program % 050.0-100.0 050.0 50.0 50.0
10 Under Frequency Point Program Hz 020.0-040.0 025.0 25.0 25.0
11 Overvoltage Trip Point Program % 0105-0140 014.0 125.0 125.0
12 Overvoltage Trip Time Program Seconds 0002-0030 0002 5 5
13 Under Voltage Trip Point Program % 0060-0095 0060 75 75
14 Under Voltage Trip Time Program Seconds 0030-0120 0030 30 30
000.0-0
15 Voltage Gain (IR Compensation) Program % 0000 0 0
10.0
16⑤ Integral Gain Program 001.0-020.0 006.0 6.0 6.0
17⑥ Proportional Gain Program 001.0-020.0 005.0 5.0 5.0

Single Phase Sensing Select
18 Program 0000,0001 0000 0000 0000
(0=three phase, 1=single phase)
19 Diode Monitor Trip Point Program Amps 001.0-010.0 002.0 2.0 2.0
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TABLE 5.7.4.4-7 AVR PARAMETERS/SETPOINTS (CONTINUED)

DPGDS
SETPOINTS
30 Droop Percentage Program % 000.0-010.0 0000 3 3
31③ pf/Kvar Select (0=pf, 1=Kvar) Program 0000, 0001 0000 0 0
32③ Pf Reference Program 00.60-01.10 01.00 0.8 0.8
33③ KVAR Reference Program Per Unit 00.00-01.00 0000 0.10 0.10
34③ Reverse Power Trip Point Program % 000.0-020.0 010.0 15 15
35③ Reverse Power Trip Time Program Seconds 000.0-020.0 010.0 5 5

50 Generator Output Frequency View Hz
51 Generator Output Voltage View Volts
52 Generator Output Current View Amps
Generator Reactive Output
53 View Amps
Current
54 Generator Real Current View Amps
55 Exciter Field Current View Amps
Three Phase Kilowatts
56③ (KB and later)
View KW
57③ Power Factor View

Three Phase Kvar (KE and
58③, ④ later)
View
60 Hours View Hours 0000-9999

90 Password Program 0009 0009
91 Software ID View
92 Latest Fault View 0000 0000 0000
93 Previous Fault View 0000 0000 0000
94 Fault Clear View
96 Shutdown Fault Reset Switch
①- Default value for output voltage is different depending on regulator sensing voltage. If the regulator is
designed for 120 volts sensing, then the default output voltage is 4160 volts. All other sensing types
have the default output voltage set to 480 volts.
②- Digital Voltage Regulators with earlier software (KD and earlier) have 1 less digit to the right of the
decimal point.
③- Optional feature.
④- New parameter on serial number prefix KE and later Digital Voltage Regulators.
⑤- Previous range of 0001-099.9 and default value of 002.0
⑥-Previous range of 0001-099.9 and default value of 002.0
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following checks (Gen. 1 is on the left and Gen. 2 is on the right):
TABLE 5.1.3.5-1 PRE-OPERATION CHECKLIST

ITEM CHECK
ACTION REQUIRED
NUMBER COMPLETED
1 Ensure the parking brake is set. Rotate the crank in a clockwise rotation
(PU-810 A) to set.
1 Ensure that the wheels are properly chocked or the Spring Brakes are
(PU-810-B) set by opening the petcock on the air tank and evacuating all the air.
2 Check the ground connection.
3 Check that the ORT communication cable is connected properly.
Ensure the feeder output cables, if used, are properly connected and
4
that the concentric neutrals are connected to ground.
5 Ensure that the feeder output cover is secured. (Locked)
6 Check Parking Stands for proper mounting and connection.
Check the two 120-Volt auxiliary duplex receptacles and the 60 amp 3
7 phase receptacle cables are securely connected or the covers are
properly installed / closed.
Open the left rear PU side access door and inspect the area for
cleanliness, loose electrical connections, loose hardware, and leaks
8
around the oil filter and lines. Check for signs of heat damage or other
abnormalities. Check all high voltage panels for security
Ensure that the battery charger voltmeter displays (24 VDC), is plugged
into the battery charger receptacle, and that all circuit breakers are
9
turned on. Return to this step after a generator breaker is closed to
ensure charger is supplying current to the batteries.
10 Visually inspect the air intake duct for obstructions or foreign objects.
11 Close the left rear PU door.
Open the left front PU side access door and inspect the area for
12 cleanliness, loose electrical connections, loose hardware, leaks around
oil and fuel lines, signs of heat damage or other abnormalities.
13 Drain the crankcase vent reservoir (fumes box) into a proper container.
If necessary, open the Primary Fuel Filter Drain Valve and drain any
14
accumulated water into an appropriate container.
15 Check oil level for Generator 1.
Ensure fuel shutoff valve is in the open position (valve handle is parallel
16
to the fuel hose).
17 Close the left front PU side access door.
18 Remove the Gen. 1 splashguard (PU-810 B).
Check the fuel tank, hydraulic tank, and radiator fill tank for signs of
19
damage or leaks.
Check fuel level with the built-in dipstick, coolant levels through the
20
coolant sightglass and hydraulic fluid levels with the sightglass.
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TABLE 5.1.3.5-1 PRE-OPERATION CHECKLIST (CONTINUED)

ITEM CHECK
ACTION REQUIRED
NUMBER COMPLETED
Check the fuel transfer pump assembly for mounting security and leaks.
21 Place the fuel transfer mode switch in “A” (automatic mode) position.
Place the fuel transfer pump power switch in the G1 position.
Check the condition of the batteries for cleanliness and signs of
22 damage. Check the battery electrical connections for tightness and
signs of corrosion.
Check to ensure that the battery isolation switch is in the OFF
23
position.①
24 Remove the Gen. 2 splashguard (PU-810B only).
Open the PU right side front access door and inspect the area for
If necessary open the Primary Fuel Filter Drain Valve and drain any
28
water accumulated into an appropriate container
Ensure manual fuel cutoff valve is in the open position; valve handle is
29
parallel to the fuel hose.
30 Close the right front PU side access door.
Open the right rear PU side access door and inspect the area for
cleanliness, loose electrical connections, loose hardware, leaks, around
31
the oil filter, and for signs of heat damage or other abnormalities.
Check all high voltage access panels for security.
32 Visually inspect the air intake for obstructions or foreign objects.
33
Check with a flashlight between generator sets G1 and G2 for leaks,
35
loose hardware, and any other potential problem.
36 Close the right rear PU side access door.
Ensure the tie output cables are properly connected and that the
37
concentric neutrals are connected to ground.
38 Ensure that the tie-output cover is secured. (Locked)
39 Check PU equipment grounds for proper connection.
Check that the PU interconnect control cable is properly connected to
40
the “B” connector.
Inspect the exterior fuel system for proper connection, leaks, and
41
availability of fuel.
Open all three PDC doors. Check for damage, loose connections, and
42
foreign objects.
43 Position the 50/60 Hz selector switch in the proper mode.
44 Close all PDC doors.
① The Battery Parallel Switch should be left in the OFF position except in extreme conditions where
the additional DC power is required to crank an engine. Once started, return the switch to the OFF
position.
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WARNING
WARNING

ENFORCED. NOISE LEVELS IN EXCESS OF 85 DB EXIST WITHIN AN 88-FOOT
RADIUS OF AN OPERATING DPGDS. PERSONNEL MUST WEAR SINGLE HEARING
PROTECTION WITHIN 88 FEET OF AN OPERATING DPGDS.
WARNING

ENFORCED. DURING MAINTENANCE ACTIVITIES WITH THE SIDEDOORS OPEN,
NOISE LEVELS IN EXCESS OF 113 DB EXIST WITHIN A 12-FOOT RADIUS OF AN
UNDER 2.5 HOURS.
WARNING

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open BCSG1
open BCSG2
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5.7.4.7 ORT SETUP
c. If 120VAC power is available, connect the ORT power supply cord to the 120 VAC power. The
f. Turn on the ORT.
h. Select the Equip ID pop-up screen and enter the necessary information for the units. This
PU.
feeders.
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indicators:
TABLE 5.7.4.8-1 CONTROL SWITCH SETUP

PANEL SWITCH SETUP
DC Control Breaker Pushed In (ON)
SMS OFF
GMS PRIME POWER
AVRS PRIME POWER
MASTER CONTROL PANEL 60Hz Light ON①
MCP
USS A②
BSS NORMAL
SSS OFF
SSL lights All OFF
INSIDE MCP FSS 50/60 Hertz①
GENERATOR CONTROL Emergency Stop Pulled-Out
PANEL GCPG1 ECS OFF
GENERATOR CONTROL Emergency Stop Pulled-Out
PANEL GCPG2 ECS OFF
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5.7.5 PLANT STARTUP
CAUTION
ENSURE THERE IS SUFFICIENT KW LOAD FOR BOTH GENERATOR UNITS ON

THE BUS BEFORE PARALLELING A MEP-PU-810 POWER UNIT INTO AN
OPERATING MEP-012 PLANT OR MEP-012 GENERATOR INTO AN OPERATING
MEP-PU-810 PLANT.
5.7.5.1 MANUAL MODE
5.7.5.1.1 STARTING UP SINGLE OR MULTIPLE PU’S IN MANUAL MODE WITH A MEP-012

POWER PLANT
WARNING

ENFORCED.
WARNING

ENFORCED.
UNDER 2.5 HOURS.
CAUTION
THIS PROCEDURE IS FOR OPERATION OF A MEP-PU-810 WITH AN EXISTING

POWER PLANT THAT IS OPERATING IN DROOP (PARALLELING A MEP-PU-810 TO
A MEP-012 PLANT). THE PROCEDURE ASSUMES THAT THE DROOP PLANT IS
ON-LINE CARRYING THE LOAD AND THE PU IS PROPERLY CONNECTED TO THE
EXISTING PLANT.
NOTE: The MEP-PU-810 must be connected to the MEP-012A common bus (PDC or PSC).
a. Complete the switch arrangements according to the following Table, and verify the lamp
indicators:
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TABLE 5.7.5.1-1 SWITCH SETUP – MANUAL MODE

BCS-T Green Target Green Target Green Target Green Target
MASTER CONTROL SMS MANUAL MANUAL MANUAL MANUAL
PANEL MCP MSES Enable① Enable① Enable① Enable①
USI A①, ② B①, ② C①, ② D① , ②
a. At A-unit GCPG1, place the Engine Control Switch (ECS) in MANUAL.
b. Observe the generator starts and accelerates to operating voltage and frequency.
c. At the A-unit MCP, place the Sync Source Switch (SSS) in the GEN 1 position.
d. Close BCSG1 by cycling BCSG1 to the CLOSE position.
e. Observe that the BCSG1 breaker closes.
f. Place the SSS in the TIE position
g. Close BCST breaker when the two green triangular LEDs at 12 o’clock on the Synchroscope are
energized by cycling BCST to the CLOSE position. For detailed instructions on manual
synchronizing, refer to Section 5.9.6.14.
h. Observe that the BCST breaker closes.
i. Return the SSS to the OFF position.
j. At the MEP-012 control panel, slowly reduce the generator frequency to transfer up to a
maximum of 420KW to the Unit-A Generator 1.
k. Shutdown a MEP-012 generator if necessary to maintain load up to a maximum of 420KW on

Unit-A PU.
l. At A-unit GCPG2 place the Engine Control Switch (ECS) in MANUAL.
m. Observe the engine starts and accelerates to operating voltage and frequency.
n. At the A-unit MCP, place the Sync Source Switch (SSS) in the GEN 2 position.
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o. Close BCSG2 breaker when the two green triangular LEDs at 12 o’clock on the Synchroscope
are energized by cycling BCSG2 to the CLOSE position. For detailed instructions on manual
synchronizing, refer to Section 5.9.6.14.
p. Observe that the BCSG2 breaker closes.
q. Return the SSS to the OFF position.
r. At the MEP-012 control panel, slowly reduce the generator frequency to transfer an additional
load up to a maximum of 420KW to the Unit-A Generator 2.
s. Shutdown a MEP-012 generator if necessary to maintain load up to a maximum of 840KW on

Unit-A PU.
t. Repeat steps ‘b’ through ‘s’ for each PU (B – D) put into the plant lineup, increasing the maximum
capacity by 420KW for each PU generator added to the bus see Table 5.7.5.1-2.
u. Ensure generators have assumed load. After the MEP-PU-810 have stabilized proceed with the
following if necessary:
v. Observe the KW, PF and KVAR of each MEP-PU-810 generator at the LCP.
CAUTION
TABLE 5.7.5.1-2 GENERATOR CAPACITIES
QUANTITY ONLINE 1 2 3 4 5 6 7 8
KW 420 840 1260 1680 2100 2520 2940 3360
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5.7.5.1.2 STARTING UP SINGLE OR MULTIPLE MEP-012’S WITH A MEP-PU-810 POWER

PLANT IN MANUAL MODE
WARNING

ENFORCED.
WARNING

ENFORCED.
UNDER 2.5 HOURS.
This procedure is for operation of a MEP-012 with an existing MEP-PU-810 power plant that is operating
in Prime Power mode (paralleling a MEP-012 to a MEP-PU-810 plant). The procedure assumes that the
Prime Power plant is on-line carrying the load and the MEP-012 is properly connected to the existing
plant.
a. Complete the setup of each MEP-012 generator per the MEP-012 Instruction Manual.
b. At the external switchgear, close the disconnect switch (multiple PU lineup). At the PU MCP
close the Tie Breaker (single PU lineup only).
c. At the MEP-012 control panel, start the generator.
d. Match the MEP-012 voltage to the bus voltage.
e. Manually synchronize the MEP-012 into the PU plant.
f. At the MEP-012 control panel, slowly increase the generator frequency control to transfer load,
up to the maximum capacity of the MEP-012 generator.
g. Repeat steps b through f for each additional MEP-012 being paralleled into the PU plant (multiple
PU lineups only).
h. Maintain only the number of MEP-012 generators on the bus necessary to carry the system load.
Extra MEP-012 generators should be unloaded and shutdown until required.
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5.7.5.2 AUTOMATIC MODE
CAUTION
LOAD CHANGES WILL INITIALLY BE APPLIED TO THE MEP-012 UNIT(S) AND

WILL THEN AUTOMATICALLY TRANSFER TO THE MEP-PU-810 UNIT(S) AFTER A
10 TO 15 SECOND DELAY. THE MEP-012 OPERATOR MUST MAINTAIN AN
ADEQUATE RESERVE CAPACITY TO ABSORB THE APPLIED LOAD CHANGE.
EXCEEDING THE MEP-012 CAPACITY WILL CAUSE THE MEP-012 UNIT(S) TO GO
INTO OVERLOAD AND DROP OFFLINE, RESULTING IN A COMPLETE SHUTDOWN.
CAUTION
LOAD CHANGES WILL BE ABSORBED OR SHED BY THE MEP-PU-810 UNIT(S).

THE MEP-012 UNIT(S) FREQUENCY CONTROL MUST BE ADJUSTED TO ACHIEVE
THE DESIRED LOAD BALANCE AND TO PREVENT OVERLOADING.
5.7.5.2.1 STARTING UP SINGLE OR MULTIPLE PU’S IN AUTOMATIC MODE WITH A MEP-012

POWER PLANT
WARNING

WARNING

UNDER 2.5 HOURS.
WARNING
WARNING
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This procedure is for operation of a MEP-PU-810 with an existing power plant that is operating in Droop
(paralleling a MEP-PU-810 to a MEP-012 plant). The procedure assumes that the Droop plant is on-line
carrying the load and the PU is properly connected to the existing plant.
a. Complete the plant startup following the Automatic Mode start up procedures described in
Section 5.7.5.2, then proceed as follows:
b. Complete the switch arrangements according to the following Table, and verify the lamp
indicators:
TABLE 5.7.5.2.1-1 SWITCH SETUP – AUTOMATIC MODE

MASTER CONTROL
PANEL MCP
USS A B C D
PANEL MCP USI A①, ② B①, ② C① , ② D① , ②
c. At A-unit GCPG1, place the Engine Control Switch (ECS) to the AUTO position.
d. Ensure that the ECS on all other units is in the OFF position.
e. Move the Master Start Enable Switch (MSES) the ENABLE position and hold until the engine
starts to crank.
f. Observe that the Tie Breaker closes, Engine/Generator 1 starts, synchronizes and closes to the
bus.
g. At the PU system ORT, disable the PU plant Economizing feature. This will prevent the plant
from dropping PU generators offline during light loading conditions.
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h. Adjust the voltage and frequency on the MEP-012A to achieve and stabilize the desired load
share.
i. Repeat steps c. through h. for each MEP-PU-810 Engine/Generator to be brought on-line.
j. Ensure generators have assumed load. After the load has stabilized on the MEP-PU-810,
proceed with the following if necessary:
k. Observe the KW, PF and KVAR of each generator at the LCP of each MEP-PU-810.
CAUTION
5.7.5.2.2 STARTING UP SINGLE OR MULTIPLE MEP-012’S WITH A PU POWER PLANT IN

AUTOMATIC MODE
This procedure is for operation of a MEP-012 with an existing MEP-PU-810 power plant that is operating
in Prime Power mode (paralleling a MEP-012 to a MEP-PU-810 plant). The procedure assumes that the
Prime Power plant is on-line carrying the load and the MEP-012 is properly connected to the existing
plant.
a. At the MEP-PU-810 system ORT, disable the PU plant Economizing feature. This will prevent
the plant from dropping PU generators offline under light loading conditions due to the MEP-012
generator(s) being online.
b. Complete the setup of each MEP-012 generator per the MEP-012 Instruction Manual.
c. At the external switchgear, close the disconnect switch (multiple PU lineup). At the PU MCP
close the Tie Breaker (single PU lineup only).
d. At the MEP-012 control panel, start the generator.
e. Match the MEP-012 voltage to the bus voltage.
f. Manually synchronize the MEP-012 into the PU system.
g. At the MEP-012 control panel, slowly increase the generator frequency control to transfer load
up to the desired capacity of the MEP-012 generator.
h. Repeat steps c through g for each additional MEP-012 being paralleled into the PU system
(multiple PU lineups only).
j. Maintain only the number of MEP-012 generators on the bus necessary to carry the system load.
Extra MEP-012 generators should be unloaded and shutdown until required.
NOTE: If the PUs exceed their nominal 85% loading setpoint, an idle PU generator will start and
parallel to the bus. This oncoming generator will affect the load on all online generators
including the MEP-012(s). Manual load correction by the operator will be required. This
feature is embedded in the automatic operation of the MEP-PU-810 and cannot be disabled.
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Refer to Chapter 5.9 for specific procedures
In this manual mode of operation, the ORT provides no remote operation capability. It will provide
monitoring of the generator parameters.
a. Reduce the load on the MEP-PU-810 plant to zero by adjusting voltage and frequency of the
Droop Plant.
b. Open all load connections. If the PU is in Manual Mode, this must be done locally using the Local
Control Panels (LCPs). If the PU is in Automatic, this can be done remotely using the ORT or
locally using the Local Control Panels (LCPs).
c. Open both generator breakers using the respective BCS switches.
d. Place both generators in cooldown by placing both ECS switches in STOP/COOLDOWN.
e. Allow all engines to complete cooldown and shut down (5 minutes).
f. Place all ECS switches in OFF/RESET.
g. Pull out the DC Control Power breaker on the PU.
WARNING
CAUTION

COMPLETELY.
communincation cable receptacle covers, and store inside the PUs (one per unit).
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CHAPTER 5.8
UTILITY PARALLEL CONFIGURATION
TABLE OF CONTENTS
SECTION TITLE PAGE

5.8 UTILITY PARALLEL CONFIGURATION 175
5.8.2 POSITIONING THE PU 175
5.8.3 INITIAL PLANT SETUP 176
5.8.3.1 GROUNDING 176
5.8.3.2 FUEL MANIFOLD 178
5.8.3.3 DISTRIBUTION AND CONTROL CABLING 178
5.8.3.4 SETPOINT VERIFICATION 179
5.8.3.5 PRE-OPERATION CHECKS 182
5.8.3.6 PRE-OPERATION RUN 183
5.8.3.7 ORT SETUP 185
5.8.3.8 CONTROLS SETUP 186
5.8.4 PLANT STARTUP 187
5.8.4.1 GENERAL 187
5.8.4.2 MANUAL MODE 187
5.8.4.3 AUTOMATIC MODE 187
5.8.5 PLANT OPERATIONS 190
5.8.6 POWER PLANT TEARDOWN 190
5.8.6.1 SHUT DOWN GENERATORS 190
5.8.6.2 DISCONNECT CABLES 190
5.8.6.3 DISCONNECT FUEL LINES 191
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TABLE OF CONTENTS
SECTION TITLE PAGE

5.8.6.4 DISCONNECT GROUNDING 191
5.8.6.5 PREPARE PU FOR TRANSPORTATION 191
5.8.6.6 FUEL, OIL, AND COOLANT DRAINAGE 191
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LIST OF FIGURES
FIGURE TITLE PAGE

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LIST OF TABLES
TABLE TITLE PAGE

TABLE 5.8.3.8-1 PDC CONTROL SWITCHES SETUP 186
TABLE 5.8.4-1 SWITCH SETUP – AUTOMATIC MODE 188
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5.8 UTILITY PARALLEL CONFIGURATION
following:

• Rotating Parts
WARNING
DEGREES.
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5.8.3.1 GROUNDING
WARNING
THERE CAN ONLY BE ONE GROUNDING POINT FOR THE PU.
ground grid.
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WARNING
fuel supply system. See Chapter 5.1 Figure 5.1.3.2-1 External Fuel Supply.
bladders.
WARNING

CONNECTIONS. FAILURE TO CHECK CONNECTORS DE-ENERGIZED MAY
b. Connect each load cable to the appropriate phase connection on the utility bus. Ensure there
are no cross-phase connections.
phase connections.
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(6) Verify the “P” and “N” values match Chapter 5.1 Table 5.1.3.4-1, CT Ratio Settings.

(10) Verify the 50TP “PU” and “TD” settings match Chapter 5.1 Table 5.1.3.4-2, Instantaneous
Trip Settings. In order to edit values, Press the “Edit” key. Select correct value, and
press “Edit” again to save changes. Ensure light is off otherwise you can accidentally
change value again.
(12) Verify the 50TN settings.
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Door (Look-up)
Use Chapter 5.1 Table 5.1.3.4-4 OP5-0 Setpoints for the parameter values to be verified.
Repeat until all OP5-0 setpoints are verified.
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Use Chapter 5.1 Table 5.1.3.4-5 OP5-1 Setpoints for the parameter values to be verified.
Repeat until all OP5-1 Setpoints are verified.
(22) Press SCROLL UP or SCROLL DWON key. The next setpoint with its value is showing.
Using Chapter 5.1 Table 5.1.3.4-6 OP6 Setpoints for the parameter values to be verified.
Repeat until all OP6 Setpoints are verified.
(d) Press SCROLL UP or SCROLL DOWN key to continue to verify the remaining
parameter values.
Parameter/Sepoints:
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checks indentified in Chapter 5.1 Table 5.1.3.5-1 Pre-Operation Checklist. (Gen. 1 is on the left and Gen.
2 is on the right):
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WARNING
WARNING

WARNING

UNDER 2.5 HOURS.
WARNING

WARNING
IF PHASE ROTATION IS DIFFERENT, PRIOR TO CORRECTING PHASE ROTATION,

ENSURE THE LOAD CABLES ARE DE-ENERGIZED. ISOLATE THE LOAD CABLES
FROM THE UTILITY AND CORRECT THE PHASE ROTATION PROBLEM.
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9 Close BCSG1, toggle the Phase Rotation Test Light switch, verify that light ABC lights,
open BCSG1
15 Close BCST, toggle the Phase Rotation Test Light switch, verify that light ABC lights, open
BCST
16 Close BCSG2, toggle the Phase Rotation Test Switch, verify that light ABC lights, open
BCSG2
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5.8.3.7 ORT SETUP
f. Turn on the ORT.
PU.
feeders.
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indicators:
TABLE 5.8.3.8-1 PDC CONTROL SWITCHES SETUP

DC Power
(ON) (ON) (ON) (ON)
SMS OFF OFF OFF OFF
UTILITY UTILITY UTILITY UTILITY
GMS
PARALLEL PARALLEL PARALLEL PARALLEL
Master Control AVRS
Panel MCP
SSS OFF OFF OFF OFF
Inside MCP FSS 50/60 Hertz① 50/60 Hertz① 50/60 Hertz① 50/60 Hertz①
Emergency
Generator Control Pulled-Out Pulled-Out Pulled-Out Pulled-Out
Stop
Panel GCPG1
ECS OFF OFF OFF OFF
Emergency
Generator Control Pulled-Out Pulled-Out Pulled-Out Pulled-Out
Stop
Panel GCPG2
ECS OFF OFF OFF OFF
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5.8.4 PLANT STARTUP
5.8.4.1 GENERAL
CAUTION
DO NOT SET THE DESIRED LOAD ON THE ORT SLIDEBAR FOR A UTILITY
PARALLEL PU OR PLANT TO A VALUE THAT EXCEEDS THE TOTAL AVAILABLE
LOAD. PARALLELED PRIME POWER GENERATORS MAY BE REVERSE
POWERED AND TRIP OFFLINE. PLANT OPERATORS MUST MONITOR THE TOTAL
PLANT LOAD TO PREVENT THE UTILITY PARALLEL PU OR PLANT FROM OVER-
POWERING THE SYSTEM. SET THE DESIRED LOAD ON THE ORT SLIDEBAR FOR
A UTILITY PARALLEL PU OR PLANT TO A VALUE THAT PREVENTS OVERLOAD
OF THE PRIME POWER GENERATORS. FAILURE TO FOLLOW THIS CAUTION
MAY RESULT IN POWER FAILURE .
Operating PUs in parallel with a utility source should be done with the PUs operating in Automatic
mode. This provides the operator with control over the amount of load the generators will carry.
Operating PUs in Manual mode with a utility source limits the units to carrying only 25KW per
generator. The PUs can be started and put online manually, but should be operated automatically
using an ORT.
5.8.4.2 MANUAL MODE
Use Section 5.5.4 (Multi-PU Prime Power Manual Startup) to start a plant manually. Use Section
5.9.6.12 to change the units to Auto mode to allow changing the load.
5.8.4.3 AUTOMATIC MODE
WARNING

ENFORCED.
WARNING

ENFORCED.
UNDER 2.5 HOURS.
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WARNING
WARNING
Starting up PUs in Utility Parallel in Automatic Mode
a. At the utility connection, close the associated connection for each PU supplying power to the
utility.
b. Complete the switch arrangements according to the following Table, and verify the lamp
indicators:
TABLE 5.8.4-1 SWITCH SETUP – AUTOMATIC MODE

Master Control
Panel MCP
Generator BCS-G1 Red Target Red Target Red Target Red Target
Control Panel 1
Generator BCS-G2 Red Target Red Target Red Target Red Target
Control Panel 2

Master Control
Panel MCP
MSES Enable① Enable① Enable① Enable①
USI A①, ② B①, ② C① , ② D① , ②
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c. At A-unit, observe the Tie breaker automatically closes.
d. At A-unit, observe Generator 1 automatically starts and accelerates to operating voltage and
frequency.
frequency.
f. At B-unit, observe the Tie breaker automatically closes.
g. At B-unit, observe Generator 1 automatically starts and accelerates to operating voltage and
frequency.
h. At B-unit, observe Generator 2 automatically starts and accelerates to operating voltage and
frequency.
j. At C-unit, observe Generator 1 automatically starts and accelerates to operating voltage and
frequency.
k. At C-unit, observe Generator 2 automatically starts and accelerates to operating voltage and
frequency.
l. At D-unit, observe the Tie breaker automatically closes.
m. At D-unit, observe Generator 1 automatically starts and accelerates to operating voltage and
frequency.
n. At D-unit, observe Generator 2 automatically starts and accelerates to operating voltage and
frequency.
o. At A-unit, observe Generator 1 automatically parallels to the system bus.
p. At A-unit, observe Generator 2 automatically parallels to the system bus.
q. At B-unit, observe Generator 1 automatically parallels to the system bus.
r. At B-unit, observe Generator 2 automatically parallels to the system bus.
s. At C-unit, observe Generator 1 automatically parallels to the system bus.
u. At D-unit, observe Generator 1 automatically parallels to the system bus.
w. Observe that each generator assumes 25KW when it parallels to the system bus.
x. From the ORT, set the desired load for all generators running. The load is set on a per generator
basis.
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y. Ensure generators have assumed load. After the desired load has been stabilized, proceed with
the following if necessary:
z. Observe the KW, PF and KVAR of each generator at the LCP.
CAUTION
NOTE: The automatic economizing feature is disabled while a generator is operating in Utility
Parallel mode.
Refer to Chapter 5.9 for specific operating procedures.
The power plant must be in Auto Mode to be operated remotely or to adjust the load on the generators.
a. Unload all generators by opening all Tie breakers. This must be done locally from the LCP or
ORT.
b. Open both generator breakers using the respective BCS switches.
c. Place both generators in cooldown by placing both ECS switches in STOP/COOLDOWN.
d. Allow all engines to complete cooldown and shut down (5 minutes).
e. Place all ECS switches in OFF/RESET.
f. Pull out the DC Control Power breaker on the PU.
WARNING
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CAUTION

COMPLETELY.
communications cable receptacle covers, and store inside the PUs (one per unit).
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CHAPTER 5.9
SPECIFIC OPERATING PROCEDURES

TABLE OF CONTENTS
SECTION TITLE PAGE

5.9 SPECIFIC OPERATING PROCEDURES 196
5.9.2 CHANGE OPERATING FREQUENCY FROM 50HZ TO 60HZ 197
5.9.2.1 MASTER CONTROL PANEL 197
5.9.2.2 DIGITAL VOLTAGE REGULATOR (AVR) 197
5.9.2.3 GENERATOR SET CONTROLLER (GSC+) 199
5.9.3 CHANGE OPERATING FREQUENCY FROM 60HZ TO 50HZ 209
5.9.3.1 MASTER CONTROL PANEL 209
5.9.3.2 DIGITAL VOLTAGE REGULATOR (AVR) 209
5.9.3.3 GENERATOR SET CONTROLLER (GSC+) 210
5.9.4 RE-DESIGNATE A PU WITHOUT PLANT SHUTDOWN 211
5.9.5 FAULT RESETTING 212
5.9.5.1 OVERCURRENT RELAY TRIP AND BREAKER LOCKOUT 212
5.9.5.2 ENGINE OR GENERATOR FAULT 212
5.9.5.3 RE-CLOSING PSC INTERCONNECT AFTER A FAULT 213
5.9.6 GENERATOR PROCEDURES 214
5.9.6.1 ADD A GENERATOR TO THE BUS – MANUAL MODE 214
5.9.6.2 ADD A GENERATOR TO THE BUS - AUTO MODE 215
5.9.6.3 ADD A GENERATOR TO THE BUS – ORT 215
5.9.6.4 TAKE A GENERATOR OFFLINE – MANUAL MODE 215
5.9.6.5 TAKE A GENERATOR OFFLINE – AUTO MODE – WITHOUT ORT 216
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TABLE OF CONTENTS
SECTION TITLE PAGE

5.9.6.6 TAKE A GENERATOR OFFLINE – AUTO MODE - WITH ORT 216
5.9.6.7 ACKNOWLEDGE AN ALARM OR FAULT – MANUAL MODE 217
5.9.6.8 ACKNOWLEDGE AN ALARM OR FAULT – AUTO MODE 217
5.9.6.9 ACKNOWLEDGE AN ALARM OR FAULT – ORT 217
5.9.6.10 ADD AND REMOVE GENERATOR FROM PLANT LINE-UP WITH ORT 217
5.9.6.11 ECONOMIZING ON/OFF – ORT 218
5.9.6.12 CHANGE FROM MANUAL MODE TO AUTOMATIC MODE 218
5.9.6.13 CHANGE FROM AUTOMATIC MODE TO MANUAL MODE 219
5.9.6.14 UNIT ISOLATION PROCEDURE (ANY UNIT) – PLANT WITH PSC 219
5.9.6.15 UNIT RE-INSTALLATION PROCEDURE – PLANT WITH PSC 220
5.9.6.16 ISOLATING A PU IN A TWO PLANT, NO PSC, LINEUP 221
5.9.6.17 RE-INSTALLING THE SECOND PU INTO A TWO-PLANT-NO-PSC LINEUP 222
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LIST OF TABLES
TABLE TITLE PAGE

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5.9 SPECIFIC OPERATING PROCEDURES
a. Safety precautions must be observed while operating and or maintaining the power unit. Refer
to the appropriate troubleshooting section for recommendations Safety precautions must be
observed to ensure that the operator/technician cannot have contact with the following:

• Rotating Parts
WARNING

WARNING

UNDER 2.5 HOURS.
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5.9.2 CHANGE OPERATING FREQUENCY FROM 50HZ TO 60HZ
5.9.2.1 MASTER CONTROL PANEL
a. Push-in DC Control Power Circuit Breaker.
b. Open the MCP cabinet door.
c. Place the Frequency Selector Switch (FSS) in the 60 Hz position.
d. Close the MCP cabinet door.
5.9.2.2 DIGITAL VOLTAGE REGULATOR (AVR)
a. Open GCPG1 cabinet door.
b. At the AVR verify/change the operation settings for 60 Hz using Table 5.9.2.2-1:
c. Press the [▼] key to display parameter “90”.
d. Press the [◄►] key to display the current value.
e. Press the [▲] key to change the value to “0015”. Enables parameter editing.
f. Press the [◄►] key to accept change and display the parameter number.
g. Press the [▲] key to the next parameter needed to change.
h. Press the [◄►] key to display the current value.
i. Press the [▲] or [▼] key to change the value.
j. Press the [◄►] key to accept change and display the parameter number.
k. Repeat steps ‘g’ through ‘j’ for each parameter needing to be changed.
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DPGDS
SETPOINTS
02 Ratio of Output Voltage To Program 001.0-100.0 001.0 17.3 17.3

Sensing Voltage
05② CT Voltage At Rated Generator Program Volts 01.00-05.00 05.00 4.00 3.66
Current
15 Voltage Gain (IR Compensation) Program % 000.0-0 0000 0 0
10.0
18 Single Phase Sensing Select Program 0000,0001 0000 0000 0000

(0=three_phase,_1=single
phase)
31③ pf/kVAR Select (0=pf, 1=kVAR) Program 0000, 0001 0000 0 0
33③ KVAR Reference Program Per Unit 00.00-01.00 0000 .10 .10

53 Generator Reactive Output View Amps
Current
56③ Three Phase Kilowatts (KB and View KW
later)
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DPGDS
SETPOINTS
58③,④ Three Phase kVAR (KE and View
later)
91 Software ID View
94 Fault Clear View
decimal point.
l. When complete, press the [▼] to display parameter “90”.
m. Press the [◄►] key to display the current value.
n. Press the [▼] key to change the value to “0009”. Disables parameter editing.
o. Press the [◄►] key to accept change and display the parameter number.
p. Press the [▲] key to change to display parameter “01”.
q. Close GCPG1 cabinet door.
r. Repeat steps ‘a ‘through ‘q’ for Generator 2.
5.9.2.3 GENERATOR SET CONTROLLER (GSC+)
At GSCG1, verify/change the operation settings for 60 Hz using Table 5.9.2.3-1 and Table 5.9.2.3-2:
a. Place ECS in the COOLDOWN/STOP position.
b. Press SERVICE MODE key to enter service mode. “OP1” is showing on the lower display.
c. Press SCROLL UP key until “OP3” is showing.
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d. Press SELECT key. “PE - -“ is showing.
e. Press SELECT key. “PE -“ with the first dash flashing is showing.
f. Press SCROLL RIGHT key. “PE 1 -“ with the second dash flashing is showing.
g. Press SCROLL DOWN key. “PE 13 –“ with the third dash flashing is showing.
h. Press SCROLL UP key. “PE 132 –“ with the fourth dash flashing is showing.
i. Press SCROLL DOWN key. “PE 1323 –“ with the fifth dash flashing is showing.
j. Press SCROLL RIGHT key. “PE13231” with all digits not flashing is showing.
k. Press ENTER key. “PE PASS” is showing.
l. Press EXIT key. “OP4” is showing.
m. Press SCROLL UP key until “OP5-0” is showing on the lower display.
n. Press SELECT key, the value of the setpoint is showing.
o. Press SCROLL UP or SCROLL DOWN key. The next setpoint with its value is showing.
p. Press SELECT key. The value of the setpoint is flashing. Use the GSC Setpoints Table 5.9.2.3-1
for the values to verify/change in each parameter.
q. Press SCROLL UP or SCROLL DOWN key to adjust the value of the setpoint.
NOTE: To adjust the value of some setpoints, it is necessary to press and release the scroll key
several times in order for the value to change. To rapidly scroll through a large range of
values, press and hold the appropriate scroll key.
r. Press ENTER key. The value of the setpoint stops flashing.
s. Repeat steps ‘o’ through ‘r’ until all the desired setpoints are adjusted.
t. Press EXIT key. “OP5-0” is showing on the lower display.
u. Repeat steps ‘m’ through ‘s’ for “OP5-1” using Table 5.9.2.3-2.
v. Press EXIT key twice. The display returns to normal.
w. Return ECS to the OFF/RESET position.
x. Repeat steps ‘a’ through ‘w’ for GSC G2.
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FACTORY DPGDS
DEFAULT SETPOINT
0 0
0 0

engine shutdown).
24 or 32. 24 24
N/A N/A N/A
cranking.

(205 kPa) (205 kPa)
for nine seconds).

10 PSI 10 PSI
speed).

delay).
delay).
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FACTORY DPGDS
DEFAULT SETPOINT
5 minutes 5 minutes
display. 30.0k

01 (Gen 1)
01 through 08 01

1 - Gas 0 2 2
engine).
temperature sensor
225ºF (107ºC) 225ºF (107ºC) 225ºF (107ºC)
relaying functions.
of the generator.
400kW 420kW 350kW
rating of genset.
0 0 0
wye or delta configuration of generator. 1 – delta
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powered up)
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FACTORY 60HZ 50HZ
overvoltage alarm function. 1 – enabled
increments of 1%.
alarm.
overvoltage shutdown function. 1 – enabled
increments of 1%.
undervoltage alarm function. 1 – enabled
increments of 1%.
undervoltage alarm.
generator undervoltage shutdown function. 1 – enabled
increments of 1%.
overfrequency alarm function. 1 – enabled

generator overfrequency shutdown function. 1 – enabled

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FACTORY 60HZ 50HZ
underfrequency alarm function. 1 – enabled

underfrequency shutdown function. 1 – enabled

reverse power shutdown function. 1 – enabled
increments of 1%.
1 1 1
GSC+ enables or disables the overcurrent alarm. 1 – enabled
in increments of 5%
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FACTORY 60HZ 50HZ
P136 - Generator Total Overcurrent
Shutdown Threshold: level of current the 100 through 160% of three times
110% 150%. 150%
GSC+ uses to issue a total overcurrent nameplate current in increments of 5%
shutdown.
Shutdown Time Delay: amount of time the 0 through 250 seconds② in increments 0 seconds 10 seconds 10 seconds
GSC+ waits before issuing a total overcurrent of 1
shutdown.
enables or disables the kW level relay 1 1 1
function. 1 – enabled
increments of 1%
relay function.
P140 - KW Level Relay Time Delay: amount
of time the GSC+ waits before activating the 0 through 120 seconds② in increments 0 seconds 0 seconds 0 seconds
kW level relay function. of 1
P141 - KW Level Relay Disengage
Threshold: level of power the GSC+ uses to 100% 100% 100%
increments of 1%.
deactivate the kW level relay function.
P142 - KW Level Relay Disengage Time
deactivating the kW level relay function. of 1

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FACTORY DPGDS
DEFAULT SETPOINT
0 0
0 0
fault. 1-alarm
0 1
0 0
fault. 1-alarm
0 0
0 0
fault. 1-alarm
0 0
0 0
fault. 1-alarm
0 0
0-unused

8 8
8-cooldown mode

11-CCM control
1 1
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FACTORY DPGDS
DEFAULT SETPOINT
0-unused

8 1
8-cooldown mode

11-CCM control
0-unused


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5.9.3 CHANGE OPERATING FREQUENCY FROM 60HZ TO 50HZ
5.9.3.1 MASTER CONTROL PANEL
a. Turn on DC power.
b. Open the MCP cabinet door.
c. Place the Frequency Selector Switch (FSS) in the 50 Hz position.
d. Close the MCP cabinet door.
5.9.3.2 DIGITAL VOLTAGE REGULATOR (AVR)
a. Open the GCPG1 cabinet door.
b. At the AVR verify/change the operation settings for 50Hz using Table 5.9.2.2-1:
c. Press the [▼] key to display parameter “90”.
d. Press the [◄►] key to display the current value.
e. Press the [▲] key to change the value to “0015”. Enables parameter editing.
f. Press the [◄►] key to accept change and display the parameter number.
g. Press the [▲] key to the next parameter needed to change.
h. Press the [◄►] key to display the current value.
i. Press the [▲] or [▼] key to change the value.
j. Press the [◄►] key to accept change and display the parameter number.
k. Repeat steps ‘g’ through ‘j’ for the each parameter needing to be changed.
l. When complete, press the [▼] to display parameter “90”.
m. Press the [◄►] key to display the current value.
n. Press the [▼] key to change the value to “0009”. Disables parameter editing.
o. Press the [◄►] key to accept change and display the parameter number.
p. Press the [▲] key to change to display parameter “01”.
q. Close the GCPG1 cabinet door.
r. Repeat steps ‘a ‘through ‘q’ for Generator 2.
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5.9.3.3 GENERATOR SET CONTROLLER (GSC+)
At GSC G1, verify/change the operation settings for 50 Hz using Table 5.9.2.3-1 and Table 5.9.2.3-2.
a. Place ECS in the STOP/COOLDOWN position.
b. Press SERVICE MODE key to enter service mode. “OP1” is showing on the lower display.
c. Press SCROLL UP key until “OP3” is showing.
d. Press SELECT key. “PE - -“ is showing.
e. Press SELECT key. “PE -“ with the first dash flashing is showing.
f. Press SCROLL RIGHT key. “PE 1 -“ with the second dash flashing is showing.
g. Press SCROLL DOWN key. “PE 13 –“ with the third dash flashing is showing.
h. Press SCROLL UP key. “PE 132 –“ with the fourth dash flashing is showing.
i. Press SCROLL DOWN key. “PE 1323 –“ with the fifth dash flashing is showing.
j. Press SCROLL RIGHT key. “PE13231” with all digits not flashing is showing.
k. Press ENTER key. “PE PASS” is showing.
l. Press EXIT key. “OP4” is showing.
m. Press SCROLL UP key until “OP5-0” is showing on the lower display.
n. Press SELECT key. The value of the setpoint is showing.
o. Press SCROLL UP or SCROLL DOWN key. The next setpoint with its value is showing.
p. Press SELECT key. The value of the setpoint is flashing. Use the GSC+ Setpoints Table for the
values to verify/change in each parameter.
q. Press SCROLL UP or SCROLL DOWN key to adjust the value of the setpoint.
NOTE: To adjust the value of some setpoints, it is necessary to press and release the scroll key
several times in order for the value to change. To rapidly scroll through a large range of
values, press and hold the appropriate scroll key.
r. Press ENTER key. The value of the setpoint stops flashing.
s. Repeat steps ‘o’ through ‘r’ until all the desired setpoints are adjusted.
t. Press EXIT key. “OP5-0” is showing on the lower display.
u. Repeat steps ‘m’ through ‘s’ for “OP5-1”..
v. Press EXIT key twice. The display returns to normal.
w. Return ECS to the OFF/RESET position.
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x. Repeat steps ‘a’ through ‘w’ for GSC G2.
5.9.4 RE-DESIGNATE A PU WITHOUT PLANT SHUTDOWN
In a multi-PU plant operating in the automatic mode, the PU designated as the “A” unit (PU-A) controls
the Economizing function of the plant. There must always be one, and only one, PU designated as PU-A
for the plant to operate properly. Each of the other PUs in the plant must also be uniquely designated
(PU-B, PU-C, etc.). If it becomes necessary to shutdown PU-A, another unit must be designated as PU-
A. It may be applied to any unit that is connected to the system network. However, there can be only one
(1) PU per plant configured with an individual address.
a. Turn off the economizer on the ORT.
b. Place the SMS in the MANUAL position for all units in the plant.
c. Place the ECS in the MANUAL/START position for all units in the plant.
NOTE: Wait five (5) seconds.
d. Place the SMS in the OFF position on all units in the plant—wait for the USI light to go out.
e. Place the USS in the desired position (A, B, C, or D). Note the general procedure in the Section
above.
NOTE: If necessary, reroute Communication Cables.
f. Place the SMS in the MANUAL position for all units in the plant.
g. Place the MSES in the ENABLE position and hold until the USI energizes.
h. Verify that the correct unit selector indicator is lit for each unit.
i. Place the ECS in the AUTO position on each unit in the plant.
NOTE: Wait five (5) seconds.
j. Place the SMS in the AUTO position on each unit in the plant.
NOTE: After re-designation of any PU, the system defaults to ECONOMIZER MODE.
j. Enter equipment ID for re-designated units on the ORT.
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5.9.5 FAULT RESETTING
5.9.5.1 OVERCURRENT RELAY TRIP AND BREAKER LOCKOUT
WARNING
DO NOT RESET A FAULT BEFORE DETERMINING AND CORRECTING THE CAUSE

OF A FAULT. RECORD ALL FAULTS/ALARMS BEFORE CLEARING. FAILURE TO
CORRECT A FAULT BEFORE RESETTING CAN RESULT IN DEATH, PERSONAL
INJURY, OR EQUIPMENT DAMAGE
a. At the overcurrent relay with the “TRIP” LED on:
(1) Press the UP arrow twice to get to “1.1 RECLOSER OFF” display.
(2) Press the DOWN arrow key once to get to “1.2 TARGETS YES” display.
(3) Press RIGHT arrow key twice to get to “1.3 ALARMS YES” display.
(4) Press and Hold “RESET” key to clear the trip.
(5) Observe the “TRIP” LED de-energizes.
b. At the MCP:
(1) Cycle the MSES to ENABLE to reset the control lockout.
(2) Observe the red SSL de-energizes and the generator will sync and close to the bus if the
engine is still running.
5.9.5.2 ENGINE OR GENERATOR FAULT
WARNING

OF A FAULT. RECORD ALL FAULTS/ALARMS BEFORE CLEARING. FAILURE TO
CORRECT A FAULT BEFORE RESETTING CAN RESULT IN DEATH, PERSONAL
INJURY, OR EQUIPMENT DAMAGE
a. At the respective GCP, place the ECS in OFF/RESET.
b. Observe the fault LED(s) de-energize.
c. At the MCP, cycle the MSES to reset the engine lockout.
d. Observe the red SSL de-energizes.
e. Place the ECS in COOLDOWN/STOP.
f. Observe the fault LED(s) and red SSL remain de-energized.
g. Return respective Generator to manual or automatic mode of operation as appropriate.
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5.9.5.3 RE-CLOSING PSC INTERCONNECT AFTER A FAULT
WARNING

OF A FAULT. FAILURE TO CORRECT A FAULT BEFORE RESETTING CAN
RESULT IN DEATH, PERSONAL INJURY, OR EQUIPMENT DAMAGE
WARNING
DO NOT RE-CLOSE THE PSC INTERCONNECT SWITCHES UNLESS ONE SIDE OF

THE SWITCH IS NOT ENERGIZED. FAILURE TO CORRECT A FAULT BEFORE
RESETTING CAN RESULT IN DEATH, PERSONAL INJURY, OR EQUIPMENT
DAMAGE
NOTE: This procedure assumes the PUs in the plant are operating in Automatic and that PSC1 is
chosen to power down prior to re-closing the interconnect. The procedure may also be used
for isolation of PSC2 by substituting “PSC2” for “PSC1” and “PSC1” for “PSC2”.
a. At the ORT, open the GCGG1 and GCGG2 breakers for all Power Units connected to PSC 1.
b. At PSC 1, open and reset all ways connected to loads.
c. Unlock, open and reset the interconnecting switches on PSC 1 and PSC 2.
d. Close and lock PSC 2 interconnect Switch.
e. Close and lock PSC 1 interconnect switch.
f. At the ORT, close all generator breakers on all Power Units connected to PSC 1.
g. At PSC 1, close all ways connected to loads.
NOTE: For Interconnection and Operating Procedures of the Primary Switching Center (PSC), refer
to USAF TO 35F14-1-1/USA TM9-6115-725-14&P.
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5.9.6 GENERATOR PROCEDURES
5.9.6.1 ADD A GENERATOR TO THE BUS – MANUAL MODE
WARNING

WARNING

UNDER 2.5 HOURS.
At the GCP for the generator to be added to the bus, perform the following:
NOTE: This procedure assumes that the DC Power is on, and the Generator Pre-Operation inspection has
been performed.
a. Place the ECS in MANUAL.
b. Observe the idle generator starts and accelerates to operating voltage and frequency.
c. Check Voltage and Frequency (3915 VAC, 50 hz or 4295 VAC, 60 hz). Adjust as necessary
using FAR and VAR.
d. Check the following engine parameters:

i Coolant Water Temperature (nominally 180°F)
i Oil Pressure (nominally 40 psi)
e. Place the Sync Source Switch in the oncoming GEN position
f. Observe that the BVFM energizes and shows the bus voltage.
g. Observe that the green rectangular LEDs at 3 and 9 on the synchroscope are on. This indicates
that the synchroscope sees both running and incoming buses as being energized.
h. Observe that the synchroscope appears to be rotating slowly in the clockwise direction. The
LEDs composing the circular pattern on the sync scope sequentially illuminate in a clockwise
rotation pattern.
i. When the triangular green LED at 12 o-clock energizes, close the BCSG breaker switch.
NOTE: You will have to wait until the triangular green LED to reach 12 0-clock.
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j. Observe that the breaker closed LED energizes and the open LED de-energizes.
k. Verify the syncscope LEDs stop rotating.
l. Place the Sync Source Switch back in the OFF position.
m. Verify that the generator takes load from the bus.
5.9.6.2 ADD A GENERATOR TO THE BUS - AUTO MODE
At the PU for the generator to be added, perform the following:
a. At the MCP, cycle the MSES switch.
b. Observe idle generator starts and automatically parallels to the bus.
5.9.6.3 ADD A GENERATOR TO THE BUS – ORT
a. Select the PU Control Screen for the generator to be added to the bus.
b. Press on the START button.
c. Observe the button now says STOP.
d. Observe the generator’s color changes to red.
e. Observe the status text says RUNNING.
f. Observe the generator breaker closes and the generator assumes load.
g. Return to the OVERVIEW screen and verify the generators are sharing load equally.
NOTE: If the added generator reduces the individual generator load below the economizing
threshold, then the control system will automatically shutdown a generator after three
minutes.
5.9.6.4 TAKE A GENERATOR OFFLINE – MANUAL MODE
CAUTION
ENSURE THERE WILL BE SUFFICIENT GENERATING CAPACITY AVAILABLE

BEFORE TAKING A GENERATOR OFF LINE.
At the GCP for the generator you want to shutdown, perform the following:
a. Open the generator’s breaker by turning the BCS to TRIP and releasing when the green indicator
light energizes.
b. Place the ECS in STOP/COOLDOWN.
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c. Observe the generator continues to run for 5 minutes then shuts down.
d. Place the ECS in OFF/RESET.
5.9.6.5 TAKE A GENERATOR OFFLINE – AUTO MODE – WITHOUT ORT
CAUTION

At the PU for the generator to be shutdown, perform the following:
a. At the MCP, place SMS in MANUAL without stopping in OFF.
b. At the GCP for the off going generator, open the generator’s breaker by turning the BCS to TRIP
and releasing when the green indicator light energizes.
c. At the GCP for the off going generator, place the ECS in STOP/COOLDOWN.
d. At the MCP, place the SMS in AUTO.
e. Observe the generator continues to run for 5 minutes then shuts down.
f. At the GCP for the off going generator, place the ECS in OFF/RESET.
5.9.6.6 TAKE A GENERATOR OFFLINE – AUTO MODE - WITH ORT
CAUTION

a. Select the PU Control Screen for the generator to be shutdown.
b. Click on the STOP button.
c. Observe the button now says START.
d. Observe the generator’s color changes to green.
e. Observe the status text says COOLDOWN.
f. Observe the generator breaker opens.
g. Return to the OVERVIEW screen and verify the remaining generators are sharing load equally.
h. Observe the generator continues to run for 5 minutes then shuts down.
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5.9.6.7 ACKNOWLEDGE AN ALARM OR FAULT – MANUAL MODE
At the PU with the active alarm or fault, perform the following:
a. Press the Silence pushbutton and hold for 1 second.
b. Repeat ‘a.’ until the horn silences.
NOTE: The repeated pressing of the Silence button is required for multiple alarms or faults. The
Silence button will silence only one alarm/fault per action.
5.9.6.8 ACKNOWLEDGE AN ALARM OR FAULT – AUTO MODE
At the PU with the active alarm or fault, perform the following:
a. Press the Silence pushbutton and hold for 1 second.
b. Repeat ‘a.’ until the horn silences.
NOTE: The repeated pressing of the BSPB is required for multiple alarms or faults. The BSPB will
silence only one alarm/fault per action.
5.9.6.9 ACKNOWLEDGE AN ALARM OR FAULT – ORT
On the Critical Alarm Screen Pop-up:
a. Select the top alarm.
b. Repeat this for each active alarm.
NOTE: This screen cannot be exited until all alarms are acknowledged. Acknowledging alarms on
the ORT also silences the buzzer(s) on the PU(s).
NOTE: All Alarms should be acknowledged individually.
5.9.6.10 ADD AND REMOVE GENERATOR FROM PLANT LINE-UP WITH ORT
a. Select the PU Control Screen for the generator to be added to the bus.
b. Click on the START button.
c. Observe the button now says STOP.
d. Observe the generator’s color changes to red.
e. Observe the status text says RUNNING.
f. Observe the generator breaker closes and the generator assumes load.
h. Select the PU Control Screen for the generator desiring to take offline.
i. Click on the STOP button.
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j. Observe the button now says START.
k. Observe the engine’s color changes to green.
l. Observe the status text says COOLDOWN.
m. Observe the generator breaker opens.
n. Return to the OVERVIEW screen and verify the generators are sharing load equally.
o. Observe the generator continues to run for 5 minutes then shuts down.
5.9.6.11 ECONOMIZING ON/OFF – ORT
From any PU Control Screen, perform the following:
a. Press the “Economize OFF” button to disable economizing.
b. Press the “Economize ON” button to enable economizing.
NOTE: Disabling economizing only stops the control system from shutting down generators during
light load conditions. To prevent overloading generators the “add” feature remains active and
cannot be disabled.
5.9.6.12 CHANGE FROM MANUAL MODE TO AUTOMATIC MODE
WARNING
ONLY ONE PU MAY BE SELECTED TO ANY ONE USS POSITION DURING

MULTIPLE PU OPERATIONS. OPERATING WITH MORE THAN ONE UNIT AT THE
SAME ID CAUSE UNSAFE AND ERRATIC OPERATIONAL CONDITIONS.
At each PU to be put in Automatic mode, perform the following:
a. At the MCP, place the SMS in AUTO without stopping in OFF.
b. At GCPG1, place ECSA in AUTO.
c. At GCPG2, place ECSB in AUTO.
d. At the MCP, place the MSES in ENABLE and release.
e. Observe that either generator, if online, remains online.
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5.9.6.13 CHANGE FROM AUTOMATIC MODE TO MANUAL MODE
WARNING

SAME ID CAUSE UNSAFE AND ERRATIC OPERATIONAL CONDITIONS.
At each PU to be put into Manual Mode, perform the following:
a. At the MCP, place the SMS in MANUAL without stopping in OFF.
b. At GCPG1, place ECSA in MANUAL.
c. At GCPG2, place ECSB in MANUAL.
d. Observe that either generator, if online, remains online.
5.9.6.14 UNIT ISOLATION PROCEDURE (ANY UNIT) – PLANT WITH PSC
a. Place the System Mode Switch (SMS) in “Manual” on all units in the plant.
OBSERVE:
• System Status Light (SSL) green LEDs on all units are not illuminated indicating that the units
are operating in Manual Mode and that there are no faults or alarms.
b. Start all off-line Engine/Generator sets on the units NOT being isolated.
c. Sync and close to the bus all off-line Engine/Generator sets.
OBSERVE:
• All Engine/Generator sets share the load equally.
d. Place the SMS to “OFF” on the unit being isolated.
e. Connect (A) (B) Communication cables as required to maintain the load share bus.
• If the unit being isolated is an end unit on the communication bus (Unit A or Unit D), no
additional (A) (B) Communication cable connections are required.
• If the unit being isolated is an inner unit on the communication bus (Unit B or Unit C),
connect an (A) (B) Communication cable between the output connector (B) on Unit D to the
input connector (A) on Unit A.
f. Disconnect the (A) (B) Communication cable(s) on the unit being isolated.
g. Ensure that there is an (A) (B) Communication cable connected to the output connector (B) on
unit that is now the right end unit on the communication bus and that the input connector end of
that (A) (B) Communication cable is capped.
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h. If the ORT cable is connected to the unit being isolated, move the cable to another unit.
OBSERVE:
• Both Engine/Generator breakers on the unit being isolated open
• Remaining on-line Engine/Generator sets in the plant share the load equally
i. Place the ECS for both Engine/Generator sets in the “Cool down” position on the unit being
isolated.
OBSERVE:
• Both Engines shut-down after 5 minutes.
j. Open the Tie breaker on the unit being isolated.
k. Turn off the DC Control Power Circuit Breaker on the unit being isolated.
l. Open the ESG input switch for the unit being isolated.
m. Place the ESG input switch for the unit being isolated in the “Grounded” position if so equipped.
n. Place the BCST on the unit being isolated in the “Pull-to-Lock” position.
o. On the external switchgear, visually confirm, through the viewing windows, that the ESG switch is
in the grounded position.
NOTE: At this point the Tie Power cables are completely de-energized. However, safe working
practice requires the use of personal protective equipment until a circuit is grounded. If the
ESG is equipped with internal circuit grounding, then step “n” can be accomplished without
the use of Hot Stick or lineman’s gloves. If the ESG is not equipped with internal circuit
grounding, then personal protective equipment should be used.
p. Using a Hot Stick and lineman’s gloves, disconnect and Park the Tie load cables.
NOTE: The unit is now electrically isolated.
q. Re-designate the MEP-PU-810s to ensure that one and only one unit is designated A, B, C or D.
There must be a unit designated as “A”.
r. Place the System Mode Switch (SMS) on all units in the plant to the “Automatic” position. DO
NOT pause in the “OFF” position when transitioning the SMS from “Manual” to “Automatic".
s. Cycle the Master Start Enable Switch (MSES) on all units in the plant to the “Enable” position
and hold for 3 seconds.
NOTE: The plant is now operating in automatic.
5.9.6.15 UNIT RE-INSTALLATION PROCEDURE – PLANT WITH PSC
a. Ensure the switch for the PSC input to be used is open (“Grounded” if so equipped)
b. Connect the load power cables between the MEP-PU-810 Tie output and the PSC input.
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c. Connect unit equipment ground.
d. Connect the (A) (B) Communication cable(s) with other units in the plant.
NOTE: If the unit being installed is an end unit, ensure a (A) (B) Communication cable is connected
to the output side connector.
NOTE: If the unit being installed is replacing center unit, disconnect the (A) (B) Communication cable
that is connecting the two end units at the input side of the left most unit.
e. Perform initial plant setup. Refer to Section 5.7.4.4.
f. Setup the unit to operate in the same mode as the unit(s) that the (A) (B) Communication
cable(s) are connected to (either Automatic / Prime Power or Automatic / Utility Parallel)
g. Enter equipment ID for replacement unit on the ORT.
OBSERVE:
• System Status Light (SSC) on all Units: both green lights are on steady indicating the
Engine/Generator sets are available in Automatic mode; the amber and red lights are off
indicating no active alarms or faults.
h. Close the PSC input switch.
OBSERVE:
• The Tie breaker closes as soon as power is received from the PSC.
• The MEP-PU-810 internal bus is energized and common with the power plant bus.
i. Designate the unit according to the plant setup, ensure one and only one unit is designated “A”,
“B”, “C”, or “D”.
j. One unit must be designated “A”
k. Cycle the MSS to the “ENABLE” position and hold until an engine cranks.
OBSERVE:
• Both Engine/Generator sets start, sync and close to the bus
NOTE: The unit is now integrated with the power plant.
5.9.6.16 ISOLATING A PU IN A TWO PLANT, NO PSC, LINEUP
a. At each PU, change to the Manual Mode per Section 5.9.5.13.
b. Start any idle generators on the PU that are to remain operating per Section 5.9.5.1.
c. Open both feeders breakers on the PU to be isolated.
d. Open the “B” plant Tie breaker from its MCP.
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e. Place the BCST to the Pull-To-Lock position.
f. Open the “A” plant Tie breaker from its MCP.
g. Place the BCST to the Pull-To-Lock position.
h. Verify the generators on the remaining PU are carrying the load properly.
i. Take the generators on the PU being isolated offline per Section 5.9.5.4.
j. Using a Hot Stick and lineman’s gloves, disconnect and park the Tie Load Cables on the
operating PU.
k. Verify that the isolated PU feeders are not looped to any operating feeders.
l. Using a Hot Stick and lineman’s gloves, disconnect and park the Feeder Load Cables on the
isolated PU.
m. If either of the feeders on the operating PU is unused, the disconnected feeder cables from the
isolated PU may be relocated to that feeder.
n. Disconnect the (A) (B) Communication cable (s) between PUs.
o. On the isolated PU, place its SMS in OFF.
p. Observe the isolated generators shutdown after 5 minutes of cooldown.
q. De-energize the isolated PU by pulling out on its DC Power breaker.
r. If the remaining PU is designated as “B”, follow the procedure in Section 5.9.3 for re-designating
that unit as “A”.
5.9.6.17 RE-INSTALLING THE SECOND PU INTO A TWO-PLANT-NO-PSC LINEUP
This procedure assumes that the operating PU is operating as Unit “A” in AUTOMATIC.
a. Place the operating PU in MANUAL by putting its SMS in MANUAL without stopping in OFF.
b. Observe no operating generators drop off line.
c. Position and Ground the incoming PU and perform the startup checks for the unit per Chapter
5.3.
d. Turn on the PU’s DC power by pushing in on the DC Control Power Circuit Breaker.
e. Verify the PU’s SMS is in OFF.
f. Connect the Tie Load Cables between the PUs.
g. Connect the (A) (B) Communication cable between the PUs; ‘B-plug’ on operating unit to ‘A-plug’
on incoming unit.
h. Connect the other (A) (B) Communication cable into the incoming PU’s ‘B-plug’, leaving the
loose end capped.
i. Place the USS on the incoming unit in the “B” position.
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j. Cycle the incoming tie breaker switch to display the red target.
k. Place the operating PU’s SMS in AUTOMATIC without stopping in OFF.
l. Observe the operating PU’s tie breaker automatically closes.
m. Place the incoming PU SMS in AUTOMATIC.
n. Observe incoming PU’s tie breaker automatically closes.
o. Cycle both generator and feeder breaker switches to display red targets.
p. Place both ECSA and ECSB in AUTOMATIC.
q. Observe that the generator ready lights on the SSL energize.
r. Cycle the incoming unit MSES and observe the “B” USI energizes.
s. Observe both generators start and parallel to the bus.
t. At 3-minute intervals, depending on the load, the automatic system shuts down unnecessary
generators.
u. On the ORT, enter equipment ID for the new unit installed.
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DRS RADIAN CTM: 01646.1R0253/1R0254
CHAPTER 5.10
PARALLELING MULTIPLE PU PLANTS, EXTERNAL SWITCH,

AUTOMATIC MODE
TABLE OF CONTENTS
SECTION TITLE PAGE

5.10 PARALLELING MULTIPLE PU PLANTS, EXTERNAL SWITCH, AUTOMATIC
MODE 229
5.10.1 PLANT 1 (PRIME POWER CONFIGURATION) 229
5.10.1.1 SAFETY PROCEDURES 229
5.10.1.2 POSITIONING THE PU 229
5.10.1.3 INITIAL PLANT SETUP 230
5.10.1.3.1 GROUNDING 230
5.10.1.3.2 FUEL MANIFOLD 232
5.10.1.3.3 DISTRIBUTION AND CONTROL CABLING 233
5.10.1.3.4 SETPOINT VERIFICATION 235
5.10.1.3.5 PRE-OPERATION CHECKS 248
5.10.1.3.6 PRE-OPERATION RUN 250
5.10.1.3.7 ORT SETUP 252
5.10.1.3.8 CONTROLS SETUP 253
5.10.1.4 PLANT STARTUP 254
5.10.1.5 PLANT OPERATIONS 257
5.10.1.5.1 PRECAUTIONS AND WARNINGS 257
5.10.1.5.2 DESCRIPTION 257
5.10.1.5.3 DEFAULT OPERATING SEQUENCE 257
5.10.2 PLANT 2 (UTILITY PARALLEL CONFIGURATION) 258
5.10.2.1 SAFETY PROCEDURES 258
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TABLE OF CONTENTS
SECTION TITLE PAGE

5.10.2.2 POSITIONING THE PU 258
5.10.2.3 INITIAL PLANT SETUP 259
5.10.2.3.1 GROUNDING 259
5.10.2.3.2 FUEL MANIFOLD 261
5.10.2.3.3 DISTRIBUTION AND CONTROL CABLING 262
5.10 2.3.4 SETPOINT VERIFICATION 263
5.10.2.3.5 PRE-OPERATION CHECKS 276
5.10.2.3.6 PRE-OPERATION RUN 278
5.10.2.3.7 ORT SETUP 280
5.10.2.3.8 CONTROLS SETUP 281
5.10.2.4 PLANT STARTUP 282
5.10.2.4.1 GENERAL 282
5.10.2.4.2 MANUAL MODE 283
5.10.2.4.3 AUTOMATIC MODE 283
5.10.2.4 PLANT OPERATIONS 285
5.10.2.5 POWER PLANT TEARDOWN (PLANT 1 & PLANT 2) 285
5.10.2.5.1 SHUT DOWN GENERATORS 285
5.10.2.5.2 DISCONNECT CABLES 286
5.10.2.5.3 DISCONNECT FUEL LINES 286
5.10.2.5.4 DISCONNECT GROUNDING 286
5.10.2.5.5 PREPARE PU FOR TRANSPORTATION 287
5.10.2.5.6 FUEL, OIL, AND COOLANT DRAINAGE 287
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LIST OF FIGURES
FIGURE TITLE PAGE

FIGURE 5.10.1.3.1-1 MEP-PU-810A GROUND POINTS 231
FIGURE 5.10.1.3.1-2 MEP-PU-810B GROUND POINTS 231
FIGURE 5.10.1.3.2-1 EXTERNAL FUEL SUPPLY 232
FIGURE 5.10.2.3.1-1 MEP-PU-810A GROUND POINTS 260
FIGURE 5.10.2.3.1-3 MEP-PU-810B GROUND POINTS 260
FIGURE 5.10.2.3.2-1 EXTERNAL FUEL SUPPLY 261
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LIST OF TABLES
TABLE TITLE PAGE

TABLE 5.10.1.3.4-1 CT RATIO SETTINGS 235
TABLE 5.10.1.3.4-2 INSTANTANEOUS TRIP SETTINGS 235
TABLE 5.10.1.3.4-3 TIME OVERCURRENT TRIP SETTINGS 236
TABLE 5.10.1.3.4-4 OP5-0 SETPOINTS 238
TABLE 5.10.1.3.4-4 OP5-0 SETPOINTS (CONTINUED) 239
TABLE 5.10.1.3.4-6 OP6 SETPOINTS 244
TABLE 5.10.1.3.4-6 OP6 SETPOINTS (CONTINUED) 245
TABLE 5.10.1.3.4-7 AVR PARAMETERS/SETPOINTS 246
TABLE 5.10.1.3.4-7 AVR PARAMETERS/SETPOINTS (CONTINUED) 247
TABLE 5.10.1.3.5-1 PRE-OPERATION CHECKLIST 248
TABLE 5.10.1.3.5-1 PRE-OPERATION CHECKLIST (CONTINUED) 249
TABLE 5.10.1.3.6-1 PRE-OPERATION RUN INSTRUCTION SEQUENCE 251
TABLE 5.10.1.3.8-1 PDC CONTROL SWITCH SETUP 253
TABLE 5.10.1.4-1 SWITCH SETUP – AUTOMATIC MODE 255
TABLE 5.10.2.3.4-1 CT RATIO SETTINGS 263
TABLE 5.10.2.3.4-2 INSTANTANEOUS TRIP SETTINGS 264
TABLE 5.10.2.3.4-3 TIME OVERCURRENT TRIP SETTINGS 264
TABLE 5.10.2.3.4-6 OP6 SETPOINTS 272
TABLE 5.10.2.3.4-6 OP6 SETPOINTS (CONTINUED) 273
TABLE 5.10.2.3.4-7 AVR PARAMETERS/SETPOINTS 274
TABLE 5.10.2.3.4-7 AVR PARAMETERS/SETPOINTS (CONTINUED) 275
TABLE 5.10.2.3.5-1 PRE-OPERATION CHECKLIST 276
TABLE 5.10.2.3.5-1 PRE-OPERATION CHECKLIST (CONTINUED) 277
TABLE 5.10.2.3.6-1 PRE-OPERATION RUN INSTRUCTION SEQUENCE 279
TABLE 5.10.2.3.8-1 PDC CONTROL SWITCH SETUP 281
TABLE 5.10.2.4.3-1 SWITCH SETUP – AUTOMATIC MODE 283
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5.10 PARALLELING MULTIPLE PU PLANTS, EXTERNAL SWITCH, AUTOMATIC MODE
This procedure is for parallel operation of two MEP-PU-810 power plants. One plant must be operated in
Prime Power Mode (Plant 1) and the second plant must be operated in Utility Parallel Mode (Plant 2).
The procedure assumes that both plants will be connected to external switchgear (PSC or US Army
CCV). Once the two plants are setup and operating in parallel, the Utility Parallel plant will produce a
fixed power that is specified by the operator and the Prime Power plant will provide power to make up the
difference between the total load requirement and the power being produced by the Utility Parallel plant.
Each plant is remotely controlled by its own ORT.
5.10.1 PLANT 1 (PRIME POWER CONFIGURATION)
5.10.1.1 SAFETY PROCEDURES
following:

• Rotating Parts
5.10.1.2 POSITIONING THE PU
WARNING
DEGREES.
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5.10.1.3 INITIAL PLANT SETUP
5.10.1.3.1 GROUNDING
WARNING
ground grid.
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FIGURE 5.10.1.3.1-1 MEP-PU-810A GROUND POINTS
FIGURE 5.10.1.3.1-2 MEP-PU-810B GROUND POINTS
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5.10.1.3.2 FUEL MANIFOLD
WARNING
fuel supply system see Figure 5.10.3.2-1.
bladders.
FIGURE 5.10.1.3.2-1 EXTERNAL FUEL SUPPLY
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5.10.1.3.3 DISTRIBUTION AND CONTROL CABLING
WARNING

WARNING

WARNING

(PSC).
NOTE 1: For complete set-up of the Primary Switching Center (PSC), refer to Radian Inc. Commercial
Technical Manual CTM 01646.1R1260, Chapter 2.6.
NOTE 2: For Unit Isolation Procedure (any unit) - Plant with PSC, and Unit Re-Installation
Procedure – Plant with PSC, refer to Chapter 5.9, Sections 5.9.6.15 and 5.9.6.16.
phase connections.
h. Connect “B” end of the first (A) (B) communication cable to “B” receptacle on first PU.
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m. Route the second (A) (B) communication cable to second PU.
n. Connect the second (A) (B) communication cable to “A” receptacle on third PU.
o. Connect the third (A) (B) communication cable to “B” receptacle on third PU.
p. Route the third (A) (B) communication cable to fourth PU.
q. Connect the third (A) (B) communication cable to “A” receptacle on fourth PU.
r. Connect the fourth (A) (B) communication cable to “B” receptacle on fourth PU.
s. Leave the loose end of fourth cable loose and capped.
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5.10.1.3.4 SETPOINT VERIFICATION
TABLE 5.10.1.3.4-1 CT RATIO SETTINGS

FEEDER 200:5 40 40
TIE 200:5 40 40

(10) Verify the 50TP “PU” and “TD” settings in Table 5.10.1.3.4-2. In order to edit values,
Press the “Edit” key. Select correct value, and press “Edit” again to save changes.
Ensure light is off otherwise you can accidentally change value again.
TABLE 5.10.1.3.4-2 INSTANTANEOUS TRIP SETTINGS

BREAKER RELAY
PU TD PU TD PU TD
FEEDER 7.5 84m 1.25 84m 0 0m
TIE 0.0 0m 0 0m 0.0 0m
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(18) Verify the 51P “PU”, “TD”, and “C” settings in Table 5.10.1.3.4-3.
TABLE 5.10.1.3.4-3 TIME OVERCURRENT TRIP SETTINGS

PU TD C PU TD C
GENERATOR 4.50 0.5 VV2 1.25 0.5 VV2
FEEDER 2.50 1.0 VV2 1.00 1.0 VV2
TIE 5.00 2.0 VV2 1.50 2.0 VV2
(20) Verify the “51N” settings.
Door (Look-up)
Use table 5.10.3.4-4 for the parameter values to be verified.
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(15) Repeat step “15” until the desired setpoints are verified.
(19) Repeat steps 15 and 16 for “OP5-1” using Table 5.10.3.4-5.
(20) Repeat steps 17, 18, and 19 for OP6.
(21) Repeat steps 15 and 16 for “OP6” using Table 5.10.3.4-6.
parameter values.
d. At GSC G1 and GSC G2, verify the operation settings using the following table:
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TABLE 5.10.1.3.4-4 OP5-0 SETPOINTS
FACTORY DPGDS
DEFAULT SETPOINT
0 0
0 0

engine shutdown).
24 or 32. 24 24
N/A N/A N/A
cranking.

(205 kPa) (205 kPa)
for nine seconds).

10 PSI 10 PSI
speed).

delay).
delay).
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TABLE 5.10.1.3.4-4 OP5-0 SETPOINTS (CONTINUED)

FACTORY DPGDS
DEFAULT SETPOINT
5 minutes 5 minutes
display. 30.0k

01 (Gen 1)
01 through 08 01

1 - Gas 0 2 2
engine).
temperature sensor
225ºF (107ºC) 225ºF (107ºC) 225ºF (107ºC)
relaying functions.
of the generator.
400kW 420kW 350kW
rating of genset.
0 0 0
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powered up)
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FACTORY 60HZ 50HZ
increments of 1%.
alarm.
increments of 1%.
increments of 1%.
undervoltage alarm.
increments of 1%.


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FACTORY 60HZ 50HZ


increments of 1%.
1 1 1
in increments of 5%
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FACTORY 60HZ 50HZ
110% 150%. 150%
shutdown.
shutdown.
function. 1 - enabled
increments of 1%
relay function.
increments of 1%.

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TABLE 5.10.1.3.4-6 OP6 SETPOINTS

FACTORY DPGDS
DEFAULT SETPOINT
0 0
0 0
fault. 1-alarm
0 1
0 0
fault. 1-alarm
0 0
0 0
fault. 1-alarm
0 0
0 0
fault. 1-alarm
0 0
0-unused

8 8
8-cooldown mode

11-CCM control
1 1
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TABLE 5.10.1.3.4-6 OP6 SETPOINTS (CONTINUED)

FACTORY DPGDS
DEFAULT SETPOINT
0-unused

8 1
8-cooldown mode

11-CCM control
0-unused


f. At the AVR verify the operation settings using Table 5.10.1.3.4-7:
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TABLE 5.10.1.3.4-7 AVR PARAMETERS/SETPOINTS

DPGDS
SETPOINTS

02 Program 001.0-100.0 001.0 17.3 17.3
Sensing Voltage
05② Current
Program Volts 01.00-05.00 05.00 4.00 3.66

000.0-0
10.0

18 Program 0000,0001 0000 0000 0000
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TABLE 5.10.1.3.4-7 AVR PARAMETERS/SETPOINTS (CONTINUED)

DPGDS
SETPOINTS

53 Generator Reactive Output Current View Amps
View KW
58③, ④ Three Phase Kvar (KE and later) View

91 Software ID View
94 Fault Clear View
decimal point.
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5.10.1.3.5 PRE-OPERATION CHECKS
TABLE 5.10.1.3.5-1 PRE-OPERATION CHECKLIST

ITEM CHECK
ACTION REQUIRED
NUMBER COMPLETED
(PU-810 A) to set.
4
8
9
14
16
to the fuel hose).
19
damage or leaks.
20
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TABLE 5.10.1.3.5-1 PRE-OPERATION CHECKLIST (CONTINUED)

ITEM CHECK
ACTION REQUIRED
NUMBER COMPLETED
signs of corrosion.
23
position.①
28
29
31
33
35
37
40
41
42
foreign objects.
position.
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5.10.1.3.6 PRE-OPERATION RUN
WARNING
WARNING

ENFORCED.
WARNING

ENFORCED.
UNDER 2.5 HOURS.
WARNING

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TABLE 5.10.1.3.6-1 PRE-OPERATION RUN INSTRUCTION SEQUENCE

open BCSG1
open BCSG2
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5.10.1.3.7 ORT SETUP
f. Turn on the ORT.
PU.
feeders.
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5.10.1.3.8 CONTROLS SETUP
indicators:
NOTE: Ignore settings for Power Units not being used.
TABLE 5.10.1.3.8-1
PDC CONTROL SWITCH SETUP
DC Power
(ON) (ON) (ON) (ON)
SMS OFF OFF OFF OFF
GMS
MASTER CONTROL PANEL PRIME PRIME PRIME PRIME
AVRS
MCP POWER POWER POWER POWER
SSS OFF OFF OFF OFF
50/60 50/60 50/60 50/60
INSIDE MCP FSS
Emergency
GENERATOR CONTROL Pulled-Out Pulled-Out Pulled-Out Pulled-Out
Stop
PANEL GCPG1
ECS OFF OFF OFF OFF
Emergency
Stop
PANEL GCPG2
ECS OFF OFF OFF OFF
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5.10.1.4 PLANT STARTUP
WARNING

WARNING

UNDER 2.5 HOURS.
WARNING
WARNING
a. At the external switchgear, close the associated connection for each PU supplying power to the
switchgear.
b. At the external switchgear, close the connections between the external switchgears.
c. At the external switchgear, open all the connections of loads to the external switchgear.
/USA TM9-6115-725-14&P.
indicators:
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TABLE 5.10.1.4-1 SWITCH SETUP – AUTOMATIC MODE

Red Red Red Red
BCS-T
Target Target Target Target
MASTER CONTROL PANEL MCP
USS A B C D
Red Red Red Red
BCS-G1
GENERATOR CONTROL PANEL 1
Red Red Red Red
GCPG1 BCS-F1
ECS-1 AUTO AUTO AUTO AUTO
Red Red Red Red
BCS-G2
GENERATOR CONTROL PANEL 2
Red Red Red Red
GCPG2 BCS-F2
ECS-2 AUTO AUTO AUTO AUTO
MSES Enable① Enable① Enable① Enable①
MASTER CONTROL PANEL MCP
USI A①, ② B①, ② C① , ② D① , ②
frequency.
frequency.
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frequency.
frequency.
frequency.
frequency.
frequency.
frequency.
y. At the external switchgear, close load connections to supply power to the loads.
z. Ensure generators have assumed load. After the load has stabilized, proceed with the following if
necessary:
CAUTION
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5.10.1.5 PLANT OPERATIONS
5.10.1.5.1 PRECAUTIONS AND WARNINGS
5.10.1.5.2 DESCRIPTION
The master controller (the designated “A” unit) will control all connected generators based on the total
system KW/KVA load. The controller shuts down one of the generators after 3 minutes should the system
load drop below a level where the remaining generator load would not exceed 85% (360kW) if a
generator is shutdown. If the load of the remaining generator exceeds 85% (360kW) for one minute, a
standby generator is started and paralleled to the bus. A change of system load is recognized by the
control system and appropriate action is taken to maintain generator load in the 85% (360 KW/450 KVA)
range. The system never automatically shuts down the final generator under normal operating conditions.
The shutdown of the final generator must be done following manual operating procedures. The default
configuration is Economizing Mode on. The economizing mode can be turned off from the ORT. Through
the ORT, the AUTO shut down is disabled but the AUTO start-up remains active to prevent overloading
the online generator(s).
5.10.1.5.3 DEFAULT OPERATING SEQUENCE
Start-Up Sequence: The automatic controls will continuously monitor the system load. As load on the
system increases, the controls automatically start and place additional units on line in the following
a. One generator from PU “B” based on lower engine runtime.

b. One generator from PU “C” based on lower engine runtime.
c. One generator from PU “D” based on lower engine runtime.
d. Remaining generator from PU “A”.
e. Remaining generator from PU “B”.
g. Remaining generator from PU “D”.
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Shutdown Sequence: Based on the loading experienced, the controller shuts down generator sets that
are not needed. For the purpose of explanation, we will assume that all generator sets are on line
following an initial startup. Based on load, the controls shut down generator sets in the following
a. One generator from PU “D” based on higher engine runtime.

b. One generator from PU “C” based on higher engine runtime.
c. One generator from PU “B” based on higher engine runtime.
d. One generator from PU “A” based on higher engine runtime.
e. Remaining generator from PU “D”.
g. Remaining generator from PU “B”.
5.10.2 PLANT 2 (UTILITY PARALLEL CONFIGURATION)
5.10.2.1 SAFETY PROCEDURES
following:

• Rotating Parts
b. Minor troubleshooting can be performed while both engines are running as long as safety
precautions are taken. Refer to the appropriate troubleshooting section for Recommendations.
5.10.2.2 POSITIONING THE PU
WARNING
DEGREES.
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5.10.2.3 INITIAL PLANT SETUP
5.10.2.3.1 GROUNDING
WARNING
ground grid.
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FIGURE 5.10.2.3.1-1 MEP-PU-810A GROUND POINTS
GROUND POINT
GROUND POINT
FIGURE 5.10.2.3.1-2 MEP-PU-810B GROUND POINTS
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5.10.2.3.2 FUEL MANIFOLD
WARNING
fuel supply system see Figure 5.10.2.3.2-1.
bladders.
FIGURE 5.10.2.3.2-1 EXTERNAL FUEL SUPPLY
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5.10.2.3.3 DISTRIBUTION AND CONTROL CABLING
WARNING

SOURCE OF POWER SUCH AS UTILITY POWER OR ANOTHER GENERATOR SET IS
CONNECTED TO THE LOAD TERMINALS. DEATH OR INJURY MAY RESULT FROM
FAILURE TO OBSERVE THIS WARNING.
WARNING
HIGH VOLTAGE MAY CAUSE SEVERE INJURY OR DEATH UPON CONTACT DURING
CHECKOUT OR MAINTENANCE OF THIS EQUIPMENT. USE CAUTION AND AVOID
CONTACT WITH ENERGIZED COMPONENTS. USE HOT STICK WHEN LOAD CABLES
ARE HANDLED.
WARNING

CONNECTIONS. FAILURE TO CHECK THAT CONNECTORS ARE DE-ENERGIZED MAY
(PSC).
and USA TM9-6115-725-14&P.
phase connections.
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p. Connect third (A) (B) communication cable to “A” receptacle on fourth PU.
5.10 2.3.4 SETPOINT VERIFICATION
TABLE 5.10.2.3.4-1 CT RATIO SETTINGS

FEEDER 200:5 40 40
TIE 200:5 40 40

(10) Verify the 50TP “PU” and “TD” settings in Table 5.10.2.3.4-2. In order to edit values,
Press the “Edit” key. Select correct value, and press “Edit” again when correct. Ensure
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TABLE 5.10.2.3.4-2 INSTANTANEOUS TRIP SETTINGS

BREAKER RELAY
PU TD PU TD PU TD
FEEDER 7.5 84m 1.25 84m 0 0m
TIE 0.0 0m 0 0m 0.0 0m
(12) Verify the 50TN “PU” and “TD” settings in Table 5.10.2.3.4-2.
(18) Verify the 51P “PU”, “TD”, and “C” settings in Table 5.10.2.3.4-3.
TABLE 5.10.2.3.4-3 TIME OVERCURRENT TRIP SETTINGS

PU TD C PU TD C
GENERATOR 4.50 0.5 VV2 1.25 0.5 VV2
FEEDER 2.50 1.0 VV2 1.00 1.0 VV2
TIE 5.00 2.0 VV2 1.50 2.0 VV2
(20) Verify the 51N “PU”, “TD”, and “C” settings in Table 5.10.2.3.4-3.
c. Use the following procedure to verify the Generator 1 GSC+ settings in step “d”:
Door (Look-up)
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Use Table 5.10.2.3.4-4 for the parameter values to be verified.
(15) Repeat step “15” until the desired setpoints are verified.
(19) Repeat steps 15 and 16 for “OP5-1” using Table 5.10.2.3.4-5.
(20) Repeat steps 17, 18, and 19 for OP6.
(21) Repeat steps 15 and 16 for “OP6” using Table 5.10.2.3.4-6.
parameter values.
d. At GSC G1, verify the operation settings using the following table:
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FACTORY DPGDS
DEFAULT SETPOINT
0 0
0 0

engine shutdown).
24 or 32. 24 24
N/A N/A N/A
cranking.

(205 kPa) (205 kPa)
for nine seconds).

10 PSI 10 PSI
speed).

delay).
delay).
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FACTORY DPGDS
DEFAULT SETPOINT
5 minutes 5 minutes
display. 30.0k

01 (Gen 1)
01 through 08 01

1 - Gas 0 2 2
engine).
temperature sensor
225ºF (107ºC) 225ºF (107ºC) 225ºF (107ºC)
relaying functions.
of the generator.
400kW 420kW 350kW
rating of genset.
0 0 0
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powered up)
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FACTORY 60HZ 50HZ
increments of 1%.
alarm.
increments of 1%.
increments of 1%.
undervoltage alarm.
increments of 1%.


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FACTORY 60HZ 50HZ


increments of 1%.
1 1 1
in increments of 5%
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FACTORY 60HZ 50HZ
110% 150%. 150%
shutdown.
shutdown.
function. 1 - enabled
increments of 1%
relay function.
increments of 1%.

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TABLE 5.10.2.3.4-6 OP6 SETPOINTS

FACTORY DPGDS
DEFAULT SETPOINT
0 0
0 0
fault. 1-alarm
0 1
0 0
fault. 1-alarm
0 0
0 0
fault. 1-alarm
0 0
0 0
fault. 1-alarm
0 0
0-unused

8 8
8-cooldown mode

11-CCM control
1 1
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TABLE 5.10.2.3.4-6 OP6 SETPOINTS (CONTINUED)

FACTORY DPGDS
DEFAULT SETPOINT
0-unused

8 1
8-cooldown mode

11-CCM control
0-unused


e. Return ECS1 to the OFF/RESET position.
f. At the AVR verify the operation settings using Table 5.10.2.3.4-7:
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TABLE 5.10.2.3.4-7 AVR PARAMETERS/SETPOINTS

DPGDS
SETPOINTS

02 Program 001.0-100.0 001.0 17.3 17.3
Sensing Voltage
05② Current
Program Volts 01.00-05.00 05.00 4.00 3.66

000.0-0
10.0

18 Program 0000,0001 0000 0000 0000
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TABLE 5.10.2.3.4-7 AVR PARAMETERS/SETPOINTS (CONTINUED)

DPGDS
SETPOINTS

Generator Reactive Output
53 View Amps
Current
View KW

91 Software ID View
94 Fault Clear View
decimal point.
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5.10.2.3.5 PRE-OPERATION CHECKS
TABLE 5.10.2.3.5-1 PRE-OPERATION CHECKLIST

ITEM CHECK
ACTION REQUIRED
NUMBER COMPLETED
(PU-810 A) to set.
4
8
9
14
16
to the fuel hose).
19
damage or leaks.
20
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TABLE 5.10.2.3.5-1 PRE-OPERATION CHECKLIST (CONTINUED)

ITEM CHECK
ACTION REQUIRED
NUMBER COMPLETED
signs of corrosion.
23
position.①
28
29
31
33
35
37
40
41
42
foreign objects.
position.
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5.10.2.3.6 PRE-OPERATION RUN
WARNING
WARNING

WARNING

UNDER 2.5 HOURS.
WARNING

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TABLE 5.10.2.3.6-1 PRE-OPERATION RUN INSTRUCTION SEQUENCE

open BCSG1
open BCSG2
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5.10.2.3.7 ORT SETUP
f. Turn on the ORT.
PU.
feeders.
i. Return to the Overview pop-up screen.
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5.10.2.3.8 CONTROLS SETUP
indicators:
NOTE: Ignore settings for PUs not being used.
TABLE 5.10.2.3.8-1
PDC CONTROL SWITCH SETUP
DC Power
(ON) (ON) (ON) (ON)
SMS OFF OFF OFF OFF
GMS
MASTER CONTROL PANEL AVRS
MCP
SSS OFF OFF OFF OFF
50/60 50/60 50/60 50/60
INSIDE MCP FSS
Emergency
Stop
PANEL GCPG1
ECS OFF OFF OFF OFF
Emergency
Stop
PANEL GCPG2
ECS OFF OFF OFF OFF
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5.10.2.4 PLANT STARTUP
5.10.2.4.1 GENERAL
WARNING

ENFORCED.
WARNING

ENFORCED.
UNDER 2.5 HOURS.
CAUTION
DO NOT SET THE DESIRED LOAD ON THE ORT SLIDEBAR FOR A UTILITY
PARALLEL PU OR PLANT TO A VALUE THAT EXCEEDS THE TOTAL AVAILABLE
LOAD. PARALLELED PRIME POWER GENERATORS MAY BE REVERSE
POWERED AND TRIP OFFLINE. PLANT OPERATORS MUST MONITOR THE TOTAL
PLANT LOAD TO PREVENT THE UTILITY PARALLEL PU OR PLANT FROM OVER-
POWERING THE SYSTEM. SET THE DESIRED LOAD ON THE ORT SLIDEBAR FOR
A UTILITY PARALLEL PU OR PLANT TO A VALUE THAT PREVENTS OVERLOAD
OF THE PRIME POWER GENERATORS. FAILURE TO FOLLOW THIS CAUTION
MAY RESULT IN DESTRUCTION OF CONNECTED EQUIPMENT.
CAUTION
SETTING THE DESIRED LOAD ON THE ORT FOR A UTILITY PARALLEL PLANT TO
A VALUE THAT CAUSES THE PLANT OUTPUT TO REDUCE THE LOAD ON A
PARALLELED PRIME POWER PLANT BELOW ECONOMIZER SETTINGS WILL
CAUSE PRIME POWER PLANT GENERATORS TO SHUT DOWN.
Operating one PU utility parallel power plant with another PU power plant should be done with the PUs
operating in automatic mode. This provides the operator with control over the amount of load the
generators will carry. Operating PUs in manual in the Utility Parallel Mode limits the units to carrying only
25KW per generator. The PUs can be started and put online manually, but should be operated
automatically using an ORT.
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5.10.2.4.2 MANUAL MODE
Use Section 5.5.4 (Starting up a Multi-PU Prime Power Plant in Manual Mode) procedure 2.5 to start the
plant manually. Use Section 5.9.6.12 to change the units to Auto Mode to allow changing the load.
5.10.2.4.3 AUTOMATIC MODE
WARNING
WARNING
Starting up a Multi-PU in Utility Parallel Plant in Automatic Mode
indicators:
TABLE 5.10.2.4.3-1
SWITCH SETUP – AUTOMATIC MODE
MASTER CONTROL PANEL
MCP
USS A B C D
GENERATOR CONTROL BCS-G1 Red Target Red Target Red Target Red Target
PANEL 1 GCPG1 ECS-1 AUTO AUTO AUTO AUTO
GENERATOR CONTROL BCS-G2 Red Target Red Target Red Target Red Target
PANEL 2 GCPG2 ECS-2 AUTO AUTO AUTO AUTO
MASTER CONTROL PANEL MSES Enable① Enable① Enable① Enable①
MCP USI A①, ② B①, ② C① , ② D① , ②
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a. At A-unit, observe Generator 1 automatically starts and accelerates to operating voltage and
frequency.
b. At A-unit, observe Generator 1 automatically closes to the system bus.
c. At A-unit, observe the Tie breaker automatically closes.
d. At B-unit, observe the Tie breaker automatically closes.
e. At C-unit, observe the Tie breaker automatically closes.
f. At D-unit, observe the Tie breaker automatically closes.
g. At A-unit, observe Generator 2 automatically starts and accelerates to operating voltage and
frequency.
h. At A-unit, observe Generator 2 automatically parallels to the system bus.
i. At B-unit, observe Generator 1 automatically starts and accelerates to operating voltage and
frequency.
j. At B-unit, observe Generator 1 automatically parallels to the system bus.
k. At B-unit, observe Generator 2 automatically starts and accelerates to operating voltage and
frequency.
l. At B-unit, observe Generator 2 automatically parallels to the system bus.
m. At C-unit, observe Generator 1 automatically starts and accelerates to operating voltage and
frequency.
n. At C-unit, observe Generator 1 automatically parallels to the system bus.
o. At C-unit, observe Generator 2 automatically starts and accelerates to operating voltage and
frequency.
p. At C-unit, observe Generator 2 automatically parallels to the system bus.
q. At D-unit, observe Generator 1 automatically starts and accelerates to operating voltage and
frequency.
r. At D-unit, observe Generator 1 automatically parallels to the system bus.
s. At D-unit, observe Generator 2 automatically starts and accelerates to operating voltage and
frequency.
t. At D-unit, observe Generator 2 automatically parallels to the system bus.
u. Observe that each generator assumes 25KW when it parallels to the bus.
v. From the ORT, set the desired load for each generator to carry. The load value shown on the
ORT is on a per generator basis.
w. At the external switchgear, close load connections to supply power to the loads.
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x. Ensure generators have assumed load. After the load has stabilized, proceed with the following if
necessary:
y. Observe the KW, PF and KVAR of each generator at the LCP.
CAUTION
NOTE: The automatic economizing feature is disabled while a generator is operating in Utility
Parallel mode.
5.10.2.4 PLANT OPERATIONS
The power plant must be in Auto Mode to be operated remotely or adjust the load on the generators.
5.10.2.5 POWER PLANT TEARDOWN (PLANT 1 & PLANT 2)
5.10.2.5.1 SHUT DOWN GENERATORS
a. Ensure there is sufficient Plant 1 generator capacity online to carry the combined Plant 1 and
Plant 2 load.
b. Unload all Plant 2 generators using the Plant 2 ORT.
c. Open each Plant 2 generator breaker from the ORT or locally from its respective LCP.
d. Place each Plant 2 PU in manual by placing its respective SMS in MANUAL without stopping in
OFF.
e. Open each Plant 2 tie breaker locally at the respective MCP.
f. Place all Plant 2 generators in cooldown by placing all Plant 2 SMS switches in OFF.
g. Allow all Plant 2 engines to complete cooldown and shutdown (5 minutes).
h. Place all Plant 2 ECS switches in OFF/RESET.
i. Pull out the DC Control Power breaker on all Plant 2 PUs.
j. Unload all Plant 1 generators by opening all load breakers, either at the external switchgear or at
the PU if the PU feeder breakers are used.
k. Place each Plant 1 PU in manual by placing its respective SMS in MANUAL without stopping in
OFF.
l. Open each Plant 1 tie breaker locally at the respective MCP.
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m. Place all Plant 1 generators in cooldown by placing all SMS switches to OFF.
n. Observe all generator breakers open.
o. Allow all engines to complete cooldown and shutdown (5 minutes).
p. Place all ECS switches in OFF/RESET.
q. Pull out the DC Control Power breaker on all PUs.
r. Open all the external switchgear generator disconnect switches for Plant 1 and Plant 2.
5.10.2.5.2 DISCONNECT CABLES
WARNING
CAUTION

COMPLETELY.
communication cable receptacle covers, and store inside the PUs (one per unit).
5.10.2.5.3 DISCONNECT FUEL LINES
5.10.2.5.4 DISCONNECT GROUNDING
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5.10.2.5.5 PREPARE PU FOR TRANSPORTATION
5.10.2.5.6 FUEL, OIL, AND COOLANT DRAINAGE
liquids respectively
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5-288
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CHAPTER 5.11
TWO-PLANT, MULTIPLE PU, PRIME POWER, EXTERNAL SWITCH,

AUTOMATIC MODE
TABLE OF CONTENTS
SECTION TITLE PAGE
5.11 TWO-PLANT, MULTIPLE PU, PRIME POWER, EXTERNAL SWITCH,
AUTOMATIC MODE ..................................................................................................293
5.11.1 SAFETY PROCEDURES ...........................................................................................293
5.11.2 POSITIONING THE PU ..............................................................................................293
5.11.3 INITIAL PLANT SETUP .............................................................................................294
5.11.3.1 GROUNDING .............................................................................................................294
5.11.3.2 FUEL MANIFOLD ......................................................................................................296
5.11.3.3 DISTRIBUTION AND CONTROL CABLING .............................................................297
5.11.3.4 SETPOINT VERIFICATION .......................................................................................290
5.11.3.5 PRE-OPERATION CHECKS .....................................................................................304
5.11.3.6 PSC RELAY SETTING VERIFICATION ....................................................................306
5.11.3.7 PRE-OPERATION RUN .............................................................................................308
5.11.3.8 CONTROLS SETUP...................................................................................................310
5.11.3.8.1 PLANT ONE ...............................................................................................................310
5.11.3.8.2 PLANT TWO ..............................................................................................................310
5.11.3.9 ORT SETUP ...............................................................................................................311
5.11.3.9.1 PLANT ONE ...............................................................................................................311
5.11.3.9.2 PLANT TWO ..............................................................................................................312
5.11.4 PLANT STARTUP......................................................................................................312
5.11.5 PLANT OPERATIONS (AUTOMATIC MODE) ..........................................................315
5.11.5.1 PRECAUTIONS AND WARNINGS............................................................................315
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5.11.5.2 DESCRIPTION ...........................................................................................................315
5.11.6 POWER PLANT TEARDOWN...................................................................................315
5.11.6.1 SHUT DOWN GENERATORS ...................................................................................315
5.11.6.2 DISCONNECT CABLES ............................................................................................316
5.11.6.3 DISCONNECT FUEL LINES......................................................................................316
5.11.6.4 DISCONNECT GROUNDING ....................................................................................316
5.11.6.5 PREPARE PU FOR TRANSPORTATION .................................................................317
5.11.6.6 FUEL, OIL, AND COOLANT DRAINAGE .................................................................317
5-290
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LIST OF FIGURES
FIGURE TITLE PAGE
FIGURE 5.11.3.2-1 EXTERNAL FUEL SUPPLY, TYPICAL FOR EACH 4 PU PLANT 296
FIGURE 5.11.3.3-1 TWO-PLANT LAYOUT DIAGRAM 298
FIGURE 5.11.3.3-2 PLANT EXPANSION ADAPTER 299
5-291
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LIST OF TABLES
TABLE TITLE PAGE
TABLE 5.11.3.4-1 CT RATIO SETTINGS 290
TABLE 5.11.3.4-2 INSTANTANEOUS TRIP SETTINGS 290
TABLE 5.11.3.4-3 TIME OVERCURRENT TRIP SETTINGS 291
TABLE 5.11.3.4-6 OP6 SETPOINTS (CONTINUED) 300
TABLE 5.11.3.4-7 AVR PARAMETERS/SETPOINTS (CONTINUED) 302
TABLE 5.11.3.5-1 PRE-OPERATION CHECKLIST 304
TABLE 5.11.3.5-1 PRE-OPERATION CHECKLIST (CONTINUED) 305
TABLE 5.11.3.6-1 PSC RELAY SETTINGS 307
TABLE 5.11.4-1 SWITCH SETUP (EACH PLANT) – AUTOMATIC MODE 313
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5.11 TWO-PLANT, MULTIPLE PU, PRIME POWER, EXTERNAL SWITCH,

AUTOMATIC MODE
following:

• Rotating Parts
b. Minor Troubleshooting can be performed while both engines are running as long as
safety precautions are taken. Refer to the appropriate troubleshooting section for
recommendations.
WARNING
DEGREES.
5-293
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5.11.3.1 GROUNDING
a. Drive an 8-foot ground rod into the earth. It should be within 6 feet of the PU and at a location
ground grid.
5-294
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5-295
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WARNING
fuel supply system see. Figure 5.11.3.2-1. This is a typical set-up for each 4 PU plant.
bladders.
FIGURE 5.11.3.2-1 EXTERNAL FUEL SUPPLY, TYPICAL FOR EACH 4 PU PLANT
5-296
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WARNING

WARNING

WARNING

a. Lay out and park the load cables for each phase (A, B, & C) on the PU Tie Output parking
stations on all PUs.
(PSC). Refer to Figure 5.11.3.3-1 for Two-Plant and PSC layout diagram
phase connections.
h. Connect communication cables to each PU
i. Install the Multi-Plant Expansion Adapter between plant 1 D unit and plant 2 A unit (See figure
5.11.3.3-2). The Adapter is stored inside the PDC of the PU behind the door rails. Ensure that D
unit on plant two has the second communication cable installed and the loose end is capped.
5-297
FIGURE 5.11.3.3-1
ORT ORT
PLANT 1 PLANT 2
Plant Expansion
A B C D Adapter A B C D
G1 G2 G1 G2 G1 G2 G1 G2 G1 G2 G1 G2 G1 G2 G1 G2
52G1 52G2 52G1 52G2 52G1 52G2 52G1 52G2 52G1 52G2 52G1 52G2 52G1 52G2 52G1 52G2
52F1 52F1 52F1 52F1 52F1 52F1 52F1 52F1
52F2 52T 52F2 52T 52F2 52T 52F2 52T 52F2 52T 52F2 52T 52F2 52T 52F2 52T
TWO-PLANT LAYOUT DIAGRAM
5-298
PSC 1 PSC 2
PSC 3 PSC 4

6 5 4 3 2 1
6 5 4 3 2 1
6 5 4 3 2 6 5 4 3 2 1
1
LOAD
LOAD LOAD
LOAD
USAF TO 35C2-3-518-1
USA TM 9-6115-484-14
USAF TO 35C2-3-518-1
USA TM 9-6115-484-14
Multi-Plant Multi-Plant Adapter

Expansion Storage Location
Adapter Installed (Behind Door)
FIGURE 5.11.3.3-2 PLANT EXPANSION ADAPTER
5-299
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TABLE 5.11.3.4-1 CT RATIO SETTINGS

FEEDER 200:5 40 40
TIE 200:5 40 40

(10) Verify the 50TP “PU” and “TD” settings in Table 5.11.3.4-2. In order to edit values, Press
the “Edit” key. Select correct value, and press “Edit” again to save changes. Ensure
TABLE 5.11.3.4-2 INSTANTANEOUS TRIP SETTINGS

BREAKER RELAY
PU TD PU TD PU TD
FEEDER 7.5 84m 1.25 84m 0 0m
TIE 0.0 0m 0 0m 0.0 0m
(12) Verify the “50TN” settings in Table 5.11.3.4-2.
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(18) Verify the 51P “PU”, “TD”, and “C” settings in Table 5.11.3.4-3.
TABLE 5.11.3.4-3 TIME OVERCURRENT TRIP SETTINGS

PU TD C PU TD C
GENERATOR 4.50 0.5 VV2 1.25 0.5 VV2
FEEDER 2.50 1.0 VV2 1.00 1.0 VV2
TIE 5.00 2.0 VV2 1.50 2.0 VV2
(20) Verify the “51N” settings in Table 5.11.3.4-3.
c. Use the following procedure to verify the Generator 1 and Generator 2 GSC+ settings in step “d”:
Door (Look-up)
5-291
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Use Table 5.11.3.4-5 OP5-1 Setpoints for the parameter values to be verified. Repeat until
all the desired setpoints are verified.
Use “OP6” Setpoints, Table 5.11.3.4-6 for the parameter values to be verified. Repeat until
all the desired setpoints are verified.
parameter values.
d. At GSC G1 and GSC G2, verify the operation settings using the following table:
5-292
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FACTORY DPGDS
DEFAULT SETPOINT
0 0
0 0

engine shutdown).
24 or 32. 24 24
N/A N/A N/A
cranking.

(205 kPa) (205 kPa)
for nine seconds).

10 PSI 10 PSI
speed).

delay).
delay).
5-293
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USA TM 9-6115-484-14

FACTORY DPGDS
DEFAULT SETPOINT
5 minutes 5 minutes
display. 30.0k

01 (Gen 1)
01 through 08 01

1 - Gas 0 2 2
engine).
temperature sensor
225ºF (107ºC) 225ºF (107ºC) 225ºF (107ºC)
relaying functions.
of the generator.
400kW 420kW 350kW
rating of genset.
0 0 0
5-294
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USA TM 9-6115-484-14
powered up)
5-295
USAF TO 35C2-3-518-1
USA TM 9-6115-484-14

FACTORY 60HZ 50HZ
increments of 1%.
alarm.
increments of 1%.
increments of 1%.
undervoltage alarm.
increments of 1%.


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FACTORY 60HZ 50HZ


increments of 1%.
1 1 1
in increments of 5%
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FACTORY 60HZ 50HZ
110% 150%. 150%
shutdown.
shutdown.
1 1 1
enables or disables the kW level relay function. 1 - enabled
increments of 1%
relay function.
P140 - KW Level Relay Time Delay: amount of
time the GSC+ waits before activating the kW 0 through 120 seconds② in increments 0 seconds 0 seconds 0 seconds
level relay function. of 1
increments of 1%.

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FACTORY DPGDS
DEFAULT SETPOINT
0 0
0 0
fault. 1-alarm
0 1
0 0
fault. 1-alarm
0 0
0 0
fault. 1-alarm
0 0
0 0
fault. 1-alarm
0 0
0-unused

8 8
8-cooldown mode

11-CCM control
1 1
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FACTORY DPGDS
DEFAULT SETPOINT
0-unused

8 1
8-cooldown mode

11-CCM control
0-unused


f. At the AVR verify the operation settings using Table 5.6.3.4-7:
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DPGDS
SETPOINTS

Ratio of Output Voltage To Sensing
02 Program 001.0-100.0 001.0 17.3 17.3
Voltage
05② Current
Program Volts 01.00-05.00 05.00 4.00 3.66

15 Voltage Gain (IR Compensation) Program % 000.0-0 10.0 0000 0 0

18 Program 0000,0001 0000 0000 0000
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TABLE 5.11.3.4-7 AVR PARAMETERS/SETPOINTS (CONTINUED)

DPGDS
SETPOINTS

53 Generator Reactive Output Current View Amps
View KW

91 Software ID View
94 Fault Clear View
①- Default value for output voltage is different depending on regulator sensing voltage. If the regulator is designed for 120
volts sensing, then the default output voltage is 4160 volts. All other sensing types have the default output voltage set to 480 volts.
②- Digital Voltage Regulators with earlier software (KD and earlier) have 1 less digit to the right of the decimal point.
⑥- Previous range of 0001-099.9 and default value of 002.0
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(17) Close the GCPG cabinet door.
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TABLE 5.11.3.5-1 PRE-OPERATION CHECKLIST

ITEM CHECK
ACTION REQUIRED
NUMBER COMPLETED
(PU-810 A) to set.
4
8
9
14
16
to the fuel hose).
19
damage or leaks.
20
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TABLE 5.11.3.5-1 PRE-OPERATION CHECKLIST (CONTINUED)

ITEM CHECK
ACTION REQUIRED
NUMBER COMPLETED
signs of corrosion.
23
position.①
28
29
31
33
35
37
40
41
42
foreign objects.
position. If the battery parallel switch is left in the “ON” position, it could cause one of the generators in
the PU to shut down when the other generator is tyring to start.
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c. Select Programs then “Accessories” then “Communication” then “HyperTerminal”.
e. Connect the communication cable between the ORT to the left (Ways 3 and 4) Overcurrent
Relay (OCR).
f. Click on “PSC”, press “Enter” on the ORT.
g. Select View Menu 1, WAY 3. Then press “enter”
h. Select View relay settings. Then press “enter”
i. Verify relay settings according to Table 5.11.3.6-1
NOTE: Refer to S&C Instruction Sheet 681-515 page 14, PROGRAMMING to change
settings.
The User Password “6601” must be entered to change control settings and test trip the
solenoids.
j. To change relay settings, press “enter”
k. Select “Switch to Main Menu”
l. Select Configuration Menu 1 or 2
m. Type in Password-6601
n. Select “Change relay Settings” Press “enter”
o. Set relay settings according to Table 5.11.3.6-1
p. Ensure new settings are saved by pressing “Y” then “enter”
q. Repeat steps g through p for WAY 4.
r. Return to the main menu and test the “Trip Function” of each interrupter using the Test Trip
Menu.
s. Return to the Main Menu and “Disconnect” using Windows HyperTerminal when desired
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t. Disconnect the OCR end of the communication cable.
CAUTION
WAY 5 TRIP SETTINGS ARE DIFFERENT DEPENDING ON WHETHER IT IS DESIGNATED AS A

TIE-IN POINT FOR ANOTHER PSC OR A FEEDER OUTPUT. ALWAYS ENSURE THAT THE
TRIP SETTINGS ARE PROPERLY SET FOR THE APPLICATION. FAILURE TO DO SO MAY
CAUSE WAY 5 TO TRIP OFF LINE
u. Repeat steps e. through t. for the right OCR (Ways 5 and 6).
v. Repeat steps e. though u. for each PSC in use.
x. Exit Windows HyperTerminal.
y. Shut-down the ORT.

MIN. INST. TIME
CABLE TCC
PSC WAY FUNCTION PICKUP PICKUP DELAY
SIZE CURVE
Feeder
3,4, or 5 1/0 TAP 50 Off Off
Ground
3,4, or 5 Single Output 500 KCM MAIN 600 1 Off
Single Output
3,4, or 5 500 KCM MAIN 100 0 Off
Ground
PSC
5 or 6 4/0 TAP 400 0 C (64ms)
Interconnect
PSC
6 Interconnect 4/0 TAP 80 0 C (64ms)
Ground
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WARNING
WARNING

ENFORCED.
WARNING

ENFORCED.
UNDER 2.5 HOURS.
WARNING

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(Perform on each PU in the power plant(s))
5 Start engine 1 by placing ECS1 in MANUAL (START)
open BCS-G1
11 Start engine 2 by placing ECS2 in MANUAL (START)
15 Close BCS-G2, toggle the Phase Rotation Test Light switch, verify that light ABC lights
16 Close all BCS-T on all PUs in the plant lineup(s)
17 At each PDC toggle the Phase Rotation Test Light switch, verify that light ABC lights②
18 Open all BCS-T to isolate the PU
19 Open BCS-G2 on the PU
Selector Switch (FSS) to the desired frequency with the SMS in OFF.
② If wrong phase rotation lights (CBA), shutdown plant and check for proper cable connections
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5.11.3.8.1 PLANT ONE
indicators:

DC Power
(ON) (ON) (ON) (ON)
SMS OFF OFF OFF OFF
GMS
MASTER CONTROL AVRS
PANEL MCP
SSS OFF OFF OFF OFF
50/60 50/60 50/60 50/60
INSIDE MCP FSS
GENERATOR Emergency
CONTROL PANEL Stop
GENERATOR Emergency
CONTROL PANEL Stop
② No more than one switch can be in the same position in any multi-PU line-up Per 4 PU plant.
With the SMS in OFF, none of the USI lights will be on and any previously set address on the PU
is cleared.
5.11.3.8.2 Plant Two
indicators:
CAUTION
ENSURE THAT THE PLANT EXPANSION ADAPTER IS INSTALLED BETWEEN PLANT 1 D UNIT
AND PLANT 2 A UNIT. DAMAGE TO THE PLANT OR IMPROPER OPERATION MAY OCCUR IF
THE DEVICE IS NOT INSTALLED
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DC Power
(ON) (ON) (ON) (ON)
SMS OFF OFF OFF OFF
GMS
MASTER CONTROL AVRS
PANEL MCP
SSS OFF OFF OFF OFF
50/60 50/60 50/60 50/60
INSIDE MCP FSS
GENERATOR Emergency
CONTROL PANEL Stop
GENERATOR Emergency
CONTROL PANEL Stop
② No more than one switch can be in the same position in any multi-PU line-up per 4 PU plant.
With the SMS in OFF, none of the USI lights will be on and any previously set address on the PU
is cleared.
5.11.3.9 ORT SETUP
5.11.3.9.1 PLANT ONE
b. Remove the mouse from the case and plug it into the mouse (PS2) port on the back of the ORT
(if needed).
d. Connect one end of the 150-foot patch cable to the ORT networking port on the back of ORT.
e. Route the cable from the ORT to the PU and connect the cable to the ORT port on the bottom of
PDC on Gen 1 side.
f. Turn on the ORT by pressing the power switch forward.
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g. Observe that the ORT boots to the Login screen.
h. Login as Operator, no password
i.. Select the EquipID pop-up screen and enter the necessary information for the units. This
PU.
j. Select the Oneline pop-up screen and enter the descriptor for the main load connected to the
feeders.
NOTE: Unit must be designated (A,B,C,D light) must be on.
k. Return to the Overview pop-up screen (Home)
5.11.3.9.2 PLANT TWO
Repeat steps a. through k above.
5.11.4 PLANT STARTUP
WARNING
WARNING
ONLY ONE PU MAY BE SELECTED TO ANY ONE USS POSITION IN PLANT 1 OR

PLANT 2 DURING TWO PLANT OPERATIONS. OPERATING WITH MORE THAN ONE
UNIT AT THE SAME ID MAY CAUSE UNSAFE AND ERRATIC OPERATIONAL
CONDITIONS.
WARNING

COULD RESULT IN PERSONAL INJURY OR DAMAGE TO EQUIPMENT
CAUTION
THE TIE BREAKER MUST REMAIN CLOSED AT ALL TIMES WHILE A PU IS IN AN

OPERATING PLANT LINEUP. OPENING THE TIE BREAKER WILL CAUSE LOAD
SHARING TO BE AFFECTED AND THE PLANT TO OPERATE IMPROPERLY
CAUTION
THE DC POWER MUST REMAIN ON AT ALL TIMES WHILE A PU IN AN OPERATING

LINEUP, EVEN WITH NO ENGINES OPERATING ON THAT PU. TURNING OFF DC
POWER WILL AFFECT NETWORK COMMUNICATIONS BETWEEN UNITS AND THE
ORT
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a. At the Primary Switching Center (PSC), close the associated connection for each PU supplying
power to the switchgear and close and pad lock the PSC interconnect switches when using more
than one primary switch.
b. At the PSC, close the connections between the external switchgears.
c. At the PSC, open all the connections of loads to the PSC.
indicators. Set all units up before enabling the MSES at Master Control Panel.
TABLE 5.11.4-1SWITCH SETUP (EACH PLANT) – AUTOMATIC MODE

MASTER CONTROL
PANEL MCP
USS A B C D
MASTER CONTROL Gen 1 Green Gen 1 Green Gen 1 Green Gen 1 Green
SSL
PANEL Gen 2 Green Gen 2 Green Gen 2 Green Gen 2 Green
PANEL MCP USI A①, ② B①, ② C①, ② D①, ②
① Hold the MSES in the ENABLE position until the selected USI indicator energizes. The switch
the control and monitoring. NOTE: both generators will start and BCS-G1, BCS-G2, and
BCS-T close as indicated by the red breaker status lights.
NOTE: Enable all units MSES and observe the following:
PLANT 1
frequency.
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frequency.
frequency.
frequency.
frequency.
frequency.
frequency.
frequency.
Plant 2
Observe steps e through x above.
y. At the external switchgear, close all switches/breakers connecting the external switchgear to the
load (s).
z. Ensure generators have assumed load. After the load has stabilized for both power
plants, proceed with the following if necessary:
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Note: If adjustment is needed for KVAR balance, start with the generator that is the furthest
from the average KVAR (either too low or too high). Make minor adjustments of the
Voltage Adjust Rheostat (VAR) until the KVAR sharing between generators are within +/–
10% of the average plant KVAR load. This adjustment will typically be required only once
during initial power plant setup and is intended to compensate for meter variations among
generators.
CAUTION
5.11.5 PLANT OPERATIONS (AUTOMATIC MODE)
5.11.5.1 PRECAUTIONS AND WARNINGS
5.11.5.2 DESCRIPTION
The master controller (the designated “A” unit in each plant) will control all connected generators, in their
respective plant based on the total system KW/KVA load. The controller shuts down one of the
generators after 3 minutes should the system load drop below a level where the remaining generator load
would not exceed 85% (350kW) if a generator is shutdown. If the load of the remaining generator
exceeds 85% (350kW) for one minute, a standby generator is started and paralleled to the bus. A change
of system load is recognized by the control system and appropriate action is taken to maintain generator
load in the 85% (350 KW/470 KVA) range. The system never automatically shuts down the final generator
under normal operating conditions. The shutdown of the final generator must be done following manual
operating procedures. The default configuration is Economizing Mode on. The economizing mode can be
turned off from the ORT. Through the ORT, the AUTO shut down is disabled but the AUTO start-up
remains active to prevent overloading the online generator(s).
a. Place SMS in Manual.
b. Unload all generators by opening all feeder breakers. This must be done locally from the LCP or
ORT.
c. Open each BCST locally at the respective MCP.
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d. Place all generators in cooldown by placing all SMS switches in OFF.
e. Observe all generator breakers open.
f. Open all the switchgear generator supply disconnect switches.
g. Allow all engines to completely cooldown and shutdown (5 minutes).
h. Place all ECS switches in OFF/RESET.
i. Pull out the DC Control Power breaker on all PUs.
WARNING
NEVER REMOVE POWER CABLES BY HAND, USE HOT STICK AND HIGH VOLTAGE
GLOVES. NEVER TOUCH A HIGH VOLTAGE LEAD OR TERMINAL UNTIL IT HAS BEEN
DISCHARGED TO GROUND. FAILURE TO OBSERVE THE WARNING MAY RESULT IN
DEATH BY ELECTROCUTION.
CAUTION
ALLOW ALL OPERATING ENGINES TO SHUT DOWN AND COOL DOWN COMPLETELY.
a. Disconnect the communication cables from between the PUs and store inside the PUs (one per
unit).
b. Reinstall the communication cable receptacle covers.
c. Disconnect the ORT cable and store it in the ORT case.
d. Close and latch the ORT port on the PU.
e. Disconnect all load cables used in operation of the PUs.
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Refer to Section 4.3 “MOVEMENT” to complete preparation for transportation.

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CHAPTER 6
SCHEDULED MAINTENANCE
TABLE OF CONTENTS
SECTION TITLE PAGE

6.0 SCHEDULED MAINTENANCE 4
6.1 SAFETY PROCEDURES 4
6.2 DAILY PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS) 15
6.3 PREVENTIVE MAINTENANCE CHECKS AND SERVICES
(SCHEDULED) (PMCS) 18
6.3.2 RUNNING GEAR SCHEDULED MAINTENANCE 21
6.3.2.1 MEP-PU 810A RUNNING GEAR SCHEDULED MAINTENANCE 21
6.3.2.2 MEP-PU 810B RUNNING GEAR SCHEDULED MAINTENANCE 23
6.3.3 SR4B ALTERNATOR SCHEDULED MAINTENANCE 25
6.3.4 PRIMARY DISTRIBUTION CENTER (PDC) SCHEDULED MAINTENANCE 26
6.4 REQUIRED INSPECTIONS NOT COVERED IN OTHER CHAPTERS 28
6.4.1 INSPECT THE EXTERNAL FUEL MANIFOLD 28
6.4.2 INSPECT FRONT, MIDDLE, REAR ENGINE / ALTERNATOR SUPPORT
ASSEMBLY 29
6.4.3 INSPECT THE OIL PAN ASSEMBLY 29
6.4.4 INSPECT THE FRONT AND REAR CRANKSHAFT AND ACCESSORY DRIVE
SEALS 30
6.4.5 INSPECT THE CRANKSHAFT VIBRATION DAMPER 31
6.4.6 INSPECT THE CYLINDER HEAD GROUNDING STUD 31
6.4.7 INSPECT THE ENGINE MOUNTS 32
6.4.8 INSPECT THE SWITCHGEAR 32
6.5 SERVICE REQUIREMENTS NOT COVERED IN OTHER CHAPTERS 33
6.5.1 ENGINE CRANKCASE BREATHER SERVICE REQUIREMENTS 34
6.5.1.1 FUME COLLECTOR BOX VENT STACK 34
6.5.2 CYLINDER HEAD GROUNDING STUD SERVICE REQUIREMENTS 35
6.5.3 FUEL TANK SEDIMENT SERVICE REQUIREMENTS 37
6.5.4 REMOTE TERMINAL UNIT (RTU) 37
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LIST OF TABLES
TABLE TITLE PAGE

TABLE 6.2-1 DAILY MAINTENANCE CHECKS AND SERVICES 15
TABLE 6.2-1 DAILY MAINTENANCE CHECKS AND SERVICES (CONTINUED) 16
TABLE 6.3-1 PREVENTIVE MAINTENANCE CHECKS AND SERVICES
(SCHEDULED PMCS) 18
(SCHEDULED PMCS) (CONTINUED) 19
(SCHEDULED PMCS) (CONTINUED) 20
TABLE 6.3.2.1-1 MEP-PU-810A MAINTENANCE SCHEDULE 21
TABLE 6.3.2.1-1 MEP-PU-810A MAINTENANCE SCHEDULE (CONTINUED) 22
TABLE 6.3.2.2-1 MEP-PU-810B MAINTENANCE SCHEDULE 23
TABLE 6.3.2.2-1 MEP-PU-810B MAINTENANCE SCHEDULE (CONTINUED) 24
TABLE 6.3.3-1 SR4B ALTERNATOR SCHEDULED MAINTENANCE 25
TABLE 6.3.4-1 PRIMARY DISTRIBUTION CENTER (PDC) SCHEDULED
MAINTENANCE 26
TABLE 6.3.4-1 PRIMARY DISTRIBUTION CENTER (PDC) SCHEDULED
MAINTENANCE (CONTINUED) 27
6-2
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LIST OF FIGURES
FIGURE TITLE PAGE

6.5.2-1 CYLINDER HEAD GROUNDING STUD 36
6-3
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6.0 SCHEDULED MAINTENANCE
Scheduled Maintenance procedures covered in this section are:
• Daily Preventive Maintenance Checks And Services (PMCS)

• Preventive Maintenance Checks And Services (Scheduled)(PMCS)
• Required Inspections Not Covered In Other Chapters
• Service Requirements Not Covered In Other Chapters
6.1 SAFETY PROCEDURES
WARNING
IMPORTANT: SAFETY WARNINGS ARE APPROPRIATE FOR ALL MAINTENANCE

ACTIVITIES. READ THIS SECTION, PRIOR TO PERFORMING ANY MAINTENANCE
WARNING
THE EQUIPMENT COVERED IN THIS MANUAL MUST BE INSTALLED, OPERATED,

AND MAINTAINED BY QUALIFIED PERSONS WHO ARE KNOWLEDGEABLE IN THE
INSTALLATION, OPERATION, AND MAINTENANCE OF MEDIUM VOLTAGE
ELECTRICAL POWER GENERATION EQUIPMENT ALONG WITH ASSOCIATED
HAZARDS. A QUALIFIED PERSON IS ONE WHO IS TRAINED AND COMPETENT IN:
• THE SKILLS AND TECHNIQUES NECESSARY TO DISTINGUISH

ENERGIZED PARTS FROM NON-ENERGIZED PARTS OF ELECTRICAL
EQUIPMENT.
• THE SKILLS AND TECHNIQUES NECESSARY TO DETERMINE THE

PROPER APPROACH DISTANCES CORRESPONDING TO THE VOLTAGES
TO WHICH THE QUALIFIED PERSON WILL BE EXPOSED.
• THE PROPER USE OF SPECIAL PRECAUTIONARY TECHNIQUES,

PERSONAL PROTECTIVE EQUIPMENT, INSULATING AND SHIELDING
MATERIALS, AND INSULATED TOOLS FOR WORKING ON OR NEAR
ENERGIZED PARTS OF ELECTRICAL EQUIPMENT AND ROTATING
MACHINERY.

EXPOSED HOT SURFACES OF ENGINE AND EXHAUST SYSTEM
COMPONENTS.
THESE INSTRUCTIONS ARE INTENDED ONLY FOR SUCH QUALIFIED PERSONS.

THEY ARE NOT A SUBSTITUTE FOR ADEQUATE TRAINING AND EXPERIENCE IN
SAFETY PROCEDURES FOR THIS TYPE OF EQUIPMENT.
6-4
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WARNING
BATTERY ELECTROLYTE CONTAINS SULFURIC ACID, WHICH CAN CAUSE

SEVERE CHEMICAL BURNS. AVOID ALL CONTACT. SKIN AND EYE PROTECTION
IS REQUIRED. IN CASE OF CONTACT, IMMEDIATELY FLUSH WITH LARGE
AMOUNTS OF CLEAN WATER AND OBTAIN MEDICAL AID.
WARNING
WHEN DISCONNECTING BATTERY CABLES, ALWAYS DISCONNECT NEGATIVE

TERMINAL FIRST. WHEN RECONNECTING, CONNECT NEGITIVE TERMINAL LAST.
FAILURE TO COMPLY MAY CAUSE SPARKING AND CONSEQUENT BATTERY
EXPLOSION.
WARNING

WARNING

WARNING
REMOVE ALL RINGS, NECKLACES, JEWELERY AND LOOSE CLOTHING.

FAILURE TO DO SO COULD CAUSE SEVERE INJURY OR DEATH.
WARNING
SIDE PANELS ARE HEAVY. USE EXTREME CAUTION WHEN UNBOLTING AND
REMOVING.
WARNING
TOP PANELS ARE HEAVY. USE EXTREME CAUTION WHEN UNBOLTING AND
REMOVING.
6-5
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WARNING
MUFFLER ASSEMBLIES ARE HEAVY. USE EXTREME CAUTION WHEN UNBOLTING

AND REMOVING.
WARNING
ENSURE THAT HEATER STRIP COVERS ARE ON WHEN GENERATOR IS

RUNNING. LOW VOLTAGE IS PRESENT AT THE HEATER STRIP TERMINALS
WARNING
THE INSULATION TESTER PRODUCES HIGH VOLTAGE. TO AVOID PERSONAL

INJURY DURING THE TEST, DO NOT TOUCH THE WINDING BEING TESTED OR
THE TEST LEADS.
WARNING
DO NOT COME IN CONTACT WITH LOAD TERMINAL DURING TEST. DEATH BY

ELECTROCUTION MAY RESULT
WARNING
FOLLOW MANUFACTURER'S TEST PROCEDURES INCLUDED WITH THE TEST

EQUIPMENT
WARNING
ALWAYS CONSIDER AN ARRESTER TO BE ENERGIZED UNTIL THE LINE AND

GROUND LEADS HAVE BEEN DISCONNECTED FROM THE CIRCUIT.
WARNING
NEVER INSTALL A DAMAGED ARRESTER. A DAMAGED ARRESTER MAY

MALFUNCTION VIOLENTLY, CAUSING SEVERE PERSONAL INJURY.
WARNING
USE OF A LIFTING DEVICE IS RECOMMENDED FOR REMOVING THE STATION

POWER TRANSFORMER. EXTREMELY HEAVY OVER 100 LBS
6-6
USAF TO 35C2-3-518-1
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WARNING
PRIOR TO TROUBLESHOOTING THE POWER UNIT (PU), ENSURE THE TIE AND
FEEDER CABLES ARE ALL INSTALLED ON PARKING STANDS, TO PREVENT THE
POSSIBILITY OF UTILITY POWER BEING FED BACK INTO GENERATOR SET.
ENSURE EQUIPMENT IS PROPERLY TAGGED AND NOT ENERGIZED. RESIDUAL
VOLTAGE IS PRESENT AT THE GENERATOR LEADS WITH THE REGULATOR
TURNED OFF, REACHING SEVERAL HUNDRED VOLTS ON THE GENERATOR SET.
PROPER INSULATION AND ISOLATION OF METERING EQUIPMENT MUST BE
OBSERVED WHEN TESTING GENERATOR. USE PROPER TEST EQUIPMENT TO
CHECK FOR VOLTAGE BEFORE PROCEEDING. FAILURE TO COMPLY MAY
RESULT IN DEATH BY ELECTROCUTION.
WARNING
BEFORE WORKING ON THE BATTERY CHARGER, ENSURE THAT AC POWER IS

OFF AND DISCONNECTED. ALSO, DISCONNECT THE NEGATIVE BATTERY LEAD
WARNING
ETHER IS HIGHLY FLAMMABLE AND TOXIC TO SKIN, EYES, AND RESPIRATORY

TRACT. USE ONLY IN AN ADEQUATELY VENTILATED AREA. SKIN, EYE. AND
RESPIRATORY PROTECTION IS REQUIRED. FAILURE TO COMPLY MAY RESULT
IN SERIOUS INJURY OR ILLNESS.
WARNING
DIESEL FUEL IS FLAMMABLE AND MODERATELY TOXIC TO EYES, SKIN, AND

RESPIRATORY TRACT. SKIN AND EYE PROTECTION REQUIRED. AVOID
REPEATED OR PROLONGED CONTACT. USE IN WELL-VENTILATED AREA.
FAILURE TO COMPLY MAY RESULT IN SERIOUS INJURY OR ILLNESS.
WARNING
WHEN POWER GENERATION EQUIPMENT MUST BE IN OPERATION TO MAKE

TESTS AND/OR ADJUSTMENTS, HIGH VOLTAGE AND CURRENT ARE PRESENT.
MAKE SURE THE TESTING EQUIPMENT IS DESIGNED FOR AND CORRECTLY
OPERATED FOR THE HIGH VOLTAGE AND CURRENT TESTS. IMPROPER TEST
EQUIPMENT MAY FAIL AND PRESENT A HIGH VOLTAGE SHOCK HAZARD TO ITS
USER.
WARNING

SAME ID MAY CAUSE UNSAFE AND ERRATIC OPERATIONAL CONDITIONS.
6-7
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WARNING
EXPLOSION HAZARD – WHEN IN HAZARDOUS LOCATIONS, DISCONNECT

POWER BEFORE REPLACING OR WIRING MODULES.
WARNING
ALWAYS WEAR EYE PROTECTION WHEN YOU PERFORM ANY SERVICE WORK
ON A COOLING SYSTEM
WARNING
RELEASE THE PRESSURE IN THE COOLING SYSTEM BEFORE PERFORMING ANY

SERVICE WORK. IF THE PRESSURE IN THE COOLING SYSTEM IS NOT
RELEASED OR THE TEMPERATURE OF THE SYSTEM IS NOT PERMITTED TO
COOL, STEAM OR HOT WATER MAY BE RELEASED WHEN YOU REMOVE THE
FILLER CAP. THIS MAY CAUSE PERSONAL INJURY.
WARNING
TO RELEASE THE PRESSURE IN A COOLING SYSTEM, LET THE SYSTEM COOL,

PUT A HEAVY CLOTH OVER THE CAP AND LOOSEN IT SLOWLY.
WARNING
DO NOT ALLOW UNDILUTED CORROSION INHIBITORS OR DILUTED/UNDILUTED

RADIATOR CLEANERS TO COME IN CONTACT WITH THE SKIN OR EYES.
WARNING
DO NOT USE CHROMATE CORROSION INHIBITORS IN A COOLING SYSTEM.
WARNING
ALWAYS FOLLOW THE MANUFACTURER’S INSTRUCTIONS WHEN HANDLING

CORROSION INHIBITORS, RADIATOR CLEANERS OR ANTIFREEZE. BE
ESPECIALLY SURE TO FOLLOW THE MANUFACTURER’S RECOMMENDATIONS
CONCERNING TOXICITY.
WARNING
ETHYLENE GLYCOL MAY CATCH FIRE WHEN IT IS HOT OR EXPOSED TO AN

OPEN FLAME. DO NOT WELD, CUT OR USE AN OPEN FLAME NEAR LEAKING
COOLANT THAT CONTAINS ANTIFREEZE.
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WARNING
DO NOT USE ALCOHOL IN PLACE OF ANTIFREEZE. ALCOHOL HAS A LOWER

BOILING TEMPERATURE AND FLASH POINT.
WARNING
DO NOT ATTEMPT TO TIGHTEN ANY HOSE CLAMPS WHILE THE COOLING

SYSTEM IS HOT OR UNDER PRESSURE. IF THERE IS A FAILURE OF THE HOSE
CLAMP WHEN IT IS TIGHTENED, A SUDDEN LOSS OF HOT COOLANT OR STEAM
COULD RESULT.
WARNING
DO NOT REMOVE FILLER CAP AFTER OPERATION UNTIL SYSTEM HAS COOLED
DOWN. FAILURE TO ALLOW ENGINE COOLANT TO COOL DOWN COULD RESULT
IN SECOND AND THIRD DEGREE BURNS. CAP MAY BE HALF-TURNED TO
RELIEVE PRESSURE AND THEN REMOVED TO INSPECT COOLANT LEVEL.
WARNING
PERSONAL INJURY CAN RESULT FROM HOT COOLANT, STEAM AND ALKALI.
WARNING
AT OPERATING TEMPERATURE, ENGINE COOLANT IS HOT AND UNDER

PRESSURE. THE RADIATOR AND ALL LINES TO THE ENGINE CONTAIN HOT
COOLANT OR STEAM. ANY CONTACT CAN CAUSE SEVERE BURNS.
WARNING
REMOVE FILLER CAP SLOWLY TO RELIEVE PRESSURE ONLY WHEN THE

ENGINE IS STOPPED AND THE FILLER CAP IS COOL ENOUGH TO TOUCH WITH
YOUR BARE HAND.
WARNING
COOLING SYSTEM CONDITIONER CONTAINS ALKALI. AVOID CONTACT WITH

SKIN AND EYES.
6-9
USAF TO 35C2-3-518-1
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WARNING
HOT OIL AND HOT COMPONENTS CAN CAUSE PERSONAL INJURY. DO NOT
ALLOW HOT OIL OR HOT COMPONENTS TO CONTACT THE SKIN. DO NOT DRAIN
THE OIL WHEN THE ENGINE IS COLD. AS THE OIL COOLS, SUSPENDED WASTE
PARTICLES SETTLE ON THE BOTTOM OF THE OIL PAN. THE WASTE PARTICLES
ARE NOT REMOVED WHEN DRAINING COLD OIL. DRAIN THE CRANKCASE WITH
THE ENGINE STOPPED. DRAIN THE CRANKCASE WITH THE OIL WARM. THIS
DRAINING METHOD ALLOWS THE WASTE PARTICLES THAT ARE SUSPENDED IN
THE OIL TO BE DRAINED PROPERLY.
WARNING
HYDRAULIC FLUID IS HOT AND UNDER HIGH PRESSURE. DO NOT PLACE ANY
PART OF YOUR BODY OVER ANY LEAK. SEVERE INJURY CAN OCCUR IF THIS
HAPPENS.
WARNING
DO NOT MIX PETROLEUM BASED OIL WITH BRAKE FLUID. THIS WILL CAUSE
SEAL SWELLING AND NON-FUNCTIONING BRAKES.
WARNING
THE HYDRAULIC PRESSURE HELD IN THE BREAKAWAY LEVER MAY CAUSE THE
LEVER TO SNAP QUICKLY. KEEP HANDS AND FINGERS CLEAR, AS YOU RESET
THE BREAKAWAY MECHANISM. WHEN TOWING, AVOID SHARP TURNS THAT
CAN CAUSE THE ACTUATOR TO BIND AGAINST THE TOW VEHICLE. THIS CAN
DAMAGE THE ACTUATOR AND TRAILER, CAUSING BRAKE FAILURE.
WARNING
DO NOT GET GREASE OR OIL ON BRAKE LININGS. BRAKES WILL NOT

FUNCTION PROPERLY
WARNING
DO NOT MIX LITHIUM, CALCIUM, SODIUM OR BARIUM COMPLEX GREASES DUE

TO POSSIBLE COMPATIBILITY PROBLEMS. WHEN CHANGING FROM ONE TYPE
OF GREASE TO ANOTHER, IT IS NECESSARY TO ENSURE ALL THE OLD GREASE
HAS BEEN REMOVED.
6-10
USAF TO 35C2-3-518-1
USA TM 9-6115-484-14
WARNING
DO NOT DISASSEMBLE THE SPRING BRAKE. IT CONTAINS A COMPRESSED

SPRING THAT MAY CAUSE INJURY IF REMOVED. THE SPRING BRAKE MUST BE
CAGED BEFORE SERVICING AND SHOULD ONLY BE PERFORMED BY QUALIFIED
PERSONNEL.
WARNING
FAILURE TO CORRECTLY LUBRICATE BEARINGS AND MAINTAIN PROPER

LUBRICATION COULD CAUSE BEARING AND AXLE SPINDLE DAMAGE, WHICH
COULD RESULT IN THE WHEEL LOCKING UP OR COMING OFF DURING VEHICLE
OPERATION.
WARNING
APPLYING HIGH VOLTAGES ACROSS THE CONTACTS OF THE VACUUM

INTERRUPTERS MAY PRODUCE X-RAYS. THE RADIATION MAY INCREASE WITH
AN INCREASE IN THE VOLTAGE OR A DECREASE IN THE DISTANCE BETWEEN
THE OPEN CONTACTS. THE LEVELS OF RADIATION GENERATED AT THE
RECOMMENDED TEST VOLTAGES AND NORMAL BREAKER OPEN GAP SPACING
ARE EXTREMELY LOW. HOWEVER, AS A PRECAUTIONARY MEASURE IT IS
RECOMMENDED THAT ALL PERSONNEL STAND AT LEAST THREE FEET AWAY
FROM THE BREAKER WHILE TESTING.
CAUTION
SIGNIFICANT DIFFERENCES BETWEEN THE MEP-PU-810A AND MEP-PU-810B

REQUIRE SPECIFIC INSTRUCTIONS FOR EACH VERSION.
CAUTION
DO NOT ALLOW THE STARTER MOTOR TO OPERATE MORE THAN 30 SECONDS.

ALLOW IT TO COOL AT LEAST 2 MINUTES BEFORE RE-ENERGIZING THE
MOTOR. OVERHEATING WILL DAMAGE THE MOTOR.
CAUTION
ALWAYS HANDLE SURGE ARRESTERS PACKED OR UNPACKED VERY

CAREFULLY. DO NOT DROP, JAR, OR HANDLE AN ARRESTER ROUGHLY.
DROPPING, JARRING, AND/OR ROUGH HANDLING MAY DAMAGE THE
ARRESTER INTERNALLY OR EXTERNALLY. THIS COULD MAKE THE ARRESTER
INCAPABLE OF PROTECTING THE CIRCUIT AND COULD SHORTEN THE SERVICE
LIFE OF THE ARRESTER SIGNIFICANTLY.
6-11
USAF TO 35C2-3-518-1
USA TM 9-6115-484-14
CAUTION
DO NOT USE A COMMERCIAL COOLANT/ANTIFREEZE THAT ONLY MEETS THE

ASTM D3306 OR D4656 SPECIFICATION. THIS TYPE OF COOLANT/ANTIFREEZE IS
MADE FOR LIGHT DUTY AUTOMOTIVE APPLICATIONS.
CAUTION
TURBOCHARGER BEARING FAILURES CAN CAUSE LARGE QUANTITIES OF OIL

TO ENTER THE AIR INLET AND EXHAUST SYSTEMS AND AIR TO AIR AFTER
COOLER. LOSS OF ENGINE LUBRICANT CAN RESULT IN SERIOUS ENGINE
DAMAGE. TURBOCHARGER COMPONENTS REQUIRE PRECISION CLEARANCES.
THE TURBOCHARGER CARTRIDGE MUST BE BALANCED DUE TO HIGH RPM.
SEVERE SERVICE APPLICATIONS CAN ACCELERATE COMPONENT WEAR.
SEVERE SERVICE APPLICATIONS REQUIRE MORE FREQUENT INSPECTIONS OF
THE CARTRIDGE.
CAUTION
WHEEL NUT OR BOLTS MUST BE APPLIED AND MAINTAINED AT THE PROPER

TORQUE LEVELS TO PREVENT LOOSE WHEELS, BROKEN STUDS, AND
POSSIBLE DANGEROUS SEPARATION OF WHEELS FROM YOUR AXLE.
CAUTION
THE MAXIMUM TOWING SPEED IS 20 MPH FOR THE MEP-PU-810A.
6-12
USAF TO 35C2-3-518-1
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a. Safety precautions must be observed while any maintenance is being performed. Safety
following:

• Rotating Parts
c. Minor Maintenance can be performed while one generator is running and the other generator
set has been shutdown. Some examples of this maintenance are:
• Lubrication System – Oil and Filter Change.

• Hydraulic System – Oil and Filter Change.
• Fuel System – Primary and Secondary Filter Change.
• Coolant System – Coolant Change.
• Minor Troubleshooting.
• Check Fluid levels and add required fluids.
(1) The generator set that has been shut down must be rendered unable to start, and cool
enough for the maintenance to be performed. Procedures to render a generator set
unable to start are:
(a) Shutdown the PU in accordance with Section 5.1.6.1 Shutdown Generators.

(b) Push to OPEN the Emergency Stop Switch.
(c) Place the Engine Control Switch (ECS) in the OFF position.
(d) Place a DO NOT OPERATE tag on the generator control panel.
(e) Turn the Battery Bank Parallel Switch to the OFF position.
(f) De-energize the Battery Charger.
(g) Disconnect the negative and positive cables from the Battery Bank for the engine
due maintenance.
(h) Place a DO NOT OPERATE tag on the Battery Bank.
(i) Place the generator Circuit Breaker in the LOCK OUT position.
(j) Disconnect the 7P1 and 7P2 Connectors located on the inside panel of the PDC.
(k) Close and Lock the generator set control panel.
NOTE: The fuel transfer pump electrical power is normally fed directly from the G1 generator set
battery bank. If you disconnect the G1 battery bank, the external fuel transfer pump will not
function. Place the Fuel Pump Source Switch (S2) into the (G1 or G2 position) for the
generator set not receiving maintenance.
d. Major maintenance or service requires that the PU MUST be shutdown, isolated from any
power plant electrical bus or utility connection, isolated from any power plant control
system, and rendered unable to start. This is accomplished by performing the following:
6-13
USAF TO 35C2-3-518-1
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(1) Shutdown the PU in accordance with Section 5.1.6.1 Shutdown Generators.

(2) Isolate the PU from any power plant or utility connection in accordance with Section
5.9.6.15, Unit Isolation Procedure with PSC. Note 1 and 2.
(3) Isolate the PU from any power plant control system in accordance with Note 3.
(4) Pull to open the PU DC Power Control Breaker.
(5) Push to open both Emergency Stop Switches.
(6) Place both Engine Control Switches (ECS) in the OFF position.
(7) Place a DO NOT OPERATE tag on both generator control panels.
(8) Turn the Battery Bank Parallel Switch to the OFF position.
(9) De-energize both Battery Chargers.
(10) Disconnect the negative and positive cables from both Battery Banks.
(11) Place a DO NOT OPERATE tag on both Battery Banks.
(12) Place all Circuit Breakers in the LOCK OUT position.
(13) Disconnect both 7P1 and 7P2 Connectors located on the inside panel of the PDC.
(14) Close and Lock both generator set control panels.
NOTE 1: Also the PU must be completely electrically isolated from the power distribution bus and
any other electrical source that can back feed into the PU. All medium voltage cables need to
be placed on the standoff insulators by use of hot sticks and other safety gear.
NOTE 2: Ensure cables are not energized by opening the circuit breaker of the Primary Switching
Center (PSC), then disconnect Load Cables (Using the proper safety gear) on the PU and
place them on the Parking Stands.
NOTE 3: When the DC Control Power Circuit Breaker is in the (OFF) position (Pulled – Out), all control
power is turned off to the PU. This will cause the HUB to stop functioning. This causes the
network to not see the equipment shutdown and all PU’s after it. When pulling major
maintenance the Communication Cable must be routed to the next PU in order to reestablish
the communication network. In Automatic Mode of operation, if the PU being isolated is
designated as “A” unit then you must redesignate another PU as “A” in accordance with
Section 5.9.4. Re-desgnate a PU Without Plant Shutdown.
6-14
USAF TO 35C2-3-518-1
USA TM 9-6115-484-14
6.2 DAILY PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS)
a. The required daily Before (B), During (D) and After (A) Preventive Maintenance Checks and
Services (PMCS) are identified in Table 6.2-1.
b. All Safety Warnings and Cautions in Section 6.1 apply to this Table.
TABLE 6.2-1 DAILY MAINTENANCE CHECKS AND SERVICES

OPERATOR DAILY TIME
ITEMS TO BE INSPECTED/INSPECTION PROCEDURES
B D A (MHrs)
GROUND TERMINALS:
X Ensure the Power Unit, Ground Grid and Load Cable Drain Lines are properly connected to 0.1
Ground.
EXHAUST:
• Check Muffler Flex Connector pipe between engine and roof for condition, leakage and
X X X security. 0.1
• During operation, be alert for development of excessively black, white, or blue exhaust
smoke.
COOLING SYSTEM:
X X X Check radiator for proper coolant level before starting. During operation, check radiator and 0.1
all cooling lines for leakage and security.
LUBE OIL SYSTEM:

• Check Dip Stick for proper oil level.
X X X • During operation, check for leakage. 0.1
• Change Oil at intervals specified in Table 6.3-1, Preventive Maintenance Checks and
Services.
BATTERY CHARGER:
X X X During operation verify voltmeter measures approximately 26 – 29 VDC and ampmeter 0.1
measures > 2 amps DC.
BATTERIES AND CABLES:

X 0.1
Service Batteries and check Battery Cables for security. See Section 9.4.1.5 for reference.
AIR FILTER DIFFERENTIAL PRESSURE GAUGE:

Check condition of Air Filter by checking the Air Filter Differential Pressure gauge located on
the Filter Monitoring Panel. If the Air Filter High Differential Pressure Alarm is activated on
X the (GCP), or the Air Filter Differential Pressure Gauge reads 25 inches of water, the Air Filter 0.1
needs to be changed. Replace the Air Filter at intervals specified in Section 16.3.1, Air Filter.
Change the Air Filter at intervals specified in Table 6.3-1, Preventive Maintenance Checks
and Services.
PRIMARY FUEL FILTER DIFFERENTIAL PRESSURE GAUGE:
Check condition of the Primary Fuel Filter by checking the Primary Fuel Filter Differential
X gauge located on the Filter Monitoring Panel. If the Primary Fuel Filter Differential Pressure 0.1
Alarm is activated on the (GCP), or the Primary Fuel Filter Differential Pressure Gauge reads
5 PSID, the Primary Fuel Filter needs to be changed. Change the Primary Fuel Filter at
intervals specified in Table 6.3-1, Preventive Maintenance Checks and Services.
SECONDARY FUEL FILTER DIFFERENTIAL PRESSURE GAUGE:
Check condition of the Secondary Fuel Filter by checking the Secondary Fuel Filter
Differential gauge located on the Filter Monitoring Panel. If the Secondary Fuel Filter
X Differential Pressure Alarm is activated on the (GCP), or the Secondary Fuel Filter Differential 0.1
Pressure Gauge reads 30 PSID, the Secondary Fuel Filter needs to be changed. Change
the Secondary Fuel Filter at intervals specified in Table 6.3-1, Preventive Maintenance
Checks and Services.
6-15
USAF TO 35C2-3-518-1
USA TM 9-6115-484-14
TABLE 6.2-1 DAILY MAINTENANCE CHECKS AND SERVICES (CONTINUED)

OPERATOR
DAILY TIME
ITEMS TO BE INSPECTED/INSPECTION PROCEDURES
(MHrs)
B D A
OIL FILTER DIFFERENTIAL PRESSURE GAUGE:
Check condition of the Oil Filter by checking the Oil Filter Differential gauge located on the
X Filter Monitoring Panel. If the Oil Filter Differential Pressure Alarm is activated on the (GCP), 0.1
or the Oil Filter Differential Pressure Gauge reads 30 PSID, the Oil Filter needs to be
changed. Change the Oil Filter at intervals specified in Table 6.3-1, Preventive Maintenance
Checks and Services.
FUMES DISPOSAL COLLECTOR:
X X X Ensure that the Fumes Disposal Collector is drained and wipe down any oil residue in and 0.1
around fumes box vent pipe.
EXTERNAL FUEL SUPPLY:

X X X Check that external fuel supply is adequate for the mission and is properly connected to the 0.1
Power Unit External Fuel Transfer System.
FUEL SYSTEM:
• During operation, check all Fuel lines for leakage and security.
X X X 0.2
• Clean fuel strainer at interval specified in Table 6.3-1, Preventive Maintenance Checks
and Services.
FUEL/SEPERATOR:
X X 0.1
Drain Water from Cup.
HYDRAULIC SYSTEM:
• During operation, check all hydraulic lines for leakage and security.
X X X • Replace the 3 Micron (Absolute), Filter at intervals specified in Table 6.3-1, Preventive 0.1
Maintenance Checks and Services.
• Check fluid level. Fluid level should be approximately ¾ full on the tank mounted fluid
level gauge. Look for leaks.
CABLING:
X X • Check for Proper Mechanical Connections and Phase Color Coding. 0.1
• Check for Cable Damage and proper Medium Voltage Cable Terminations.
EXTERNAL FUEL TRANSFER PUMP CONTROLS:
• During Operation, check all fuel lines, valves and pumps for leaks and security.
X X X • Ensure that the position of the External Fuel Transfer Pump Control switches, are in the 0.1
proper position.
• Inspect Fuel Solenoid Valve for leaks, damage.
MEP-PU-810B, DC LIGHTS:
X X 0.1
Check for proper operation.
MEP-PU-810A & MEP-PU-810B, AC LIGHTS:

X X 0.1
Check for proper operation.
6-16
USAF TO 35C2-3-518-1
USA TM 9-6115-484-14
THIS PAGE IS INTENTIONALLY BLANK
6-17
USAF TO 35C2-3-518-1
USA TM 9-6115-484-14
6.3 PREVENTIVE MAINTENANCE CHECKS AND SERVICES (SCHEDULED) (PMCS)
a. Table 6.3-1 identifies the scheduled preventive maintenance requirements for the MEP-PU-810. The Preventive Maintenance Checks and
Services (PMCS) are to be performed at the intervals identified. All Safety Warnings and Cautions in Section 6.1 apply to this Table.
b. Problems encountered during the MEP-PU-810 operations that do not present safety hazards or do not degrade operations must be identified for
correction during scheduled maintenance periods or at the end of operations, as appropriate.
CAUTION
PROBLEMS WHICH PRESENT SAFETY HAZARDS AND WHICH SIGNIFICANTLY DEGRADE OPERATIONS
REQUIRE THE STOPPING OF ALL OPERATIONS IMMEDIATELY. RECORD ALL DEFICIENCIES AND
SHORTCOMINGS, TOGETHER WITH THE CORRECTIVE ACTION TAKEN, ON THE APPLICABLE FORMS.
TABLE 6.3-1 PREVENTIVE MAINTENANCE CHECKS AND SERVICES (SCHEDULED PMCS)

INTERVAL (HOURS/GALLONS/YEARS)
3,000 HOURS 6,000 HOURS
40 250 HOURS
ITEMS TO BE INSPECTED ACTION REQUIRED 30,000 (GAL), 60,000 (GAL), FOR INSTRUCTIONS REFER TO:
HOURS OR ANNUALLY
OR 3 YEARS OR 6 YEARS
See Section 13.4.5 and NOTE 1.
AFTERCOOLER CORE Inspect, Clean ●
Test annually
Evaluate for possible overhaul
ENGINE ● ● Caterpillar Dealer and NOTE 1.
needs
CYLINDER HEAD GROUNDING STUD Inspect, Service ● See Section 6.5.2 and NOTE 1.
ENGINE LUBE OIL/ FILTER Replace ● See Section 14.3 and NOTE 1.
ENGINE AIR FILTER Replace ● See Section 16.3.2 and NOTE 1.
ENGINE CRANKCASE BREATHERS Service ● See Section 6.5.1 and NOTE 1.
FUME COLLECTOR BOX VENT
● See Section 6.5.1.1
STACK
FUEL SYSTEM PRIMARY FILTER Replace ● See Section 11.3.1 and NOTE 1.
FUEL SYSTEM SECONDARY FUEL
Replace ● See Section 11.3.2 and NOTE 1.
FILTER
FUEL TANK Inspect ● See Section 6.5.3 and NOTE 1.
FUEL SYSTEM STRAINER Service ● See Section 11.3.3 and NOTE 1.
6-18
USAF TO 35C2-3-518-1
USA TM 9-6115-484-14
TABLE 6.3-1 PREVENTIVE MAINTENANCE CHECKS AND SERVICES (SCHEDULED PMCS) (CONTINUED)
INITIAL 250
3,000
(HOURS)
250 HOURS, 1,000 HOURS
(INCLUDE 8,000 16,000 6,000 HOURS
ITEMS TO BE ACTION 2,500 (GAL) HOURS OR 30,000
THE – HOURS OR HOURS OR 60,000 (GAL), COMMENTS
INSPECTED REQUIRED OR SEMI – (GAL),
STANDARD ANNUALLY 3 YEARS OR 6 YEARS
ANNUALLY ANNUALLY OR 3
250 H
YEARS
SERVICE)
See Section 15.4.5,
Section 15.4.6 and
HOSES AND CLAMPS Inspect, Replace ● Section 15.4.7 and
NOTE 1.
See Section 13.4.5
RADIATOR Inspect (Exterior) ● and NOTE 1.
ENGINE VALVE LASH See Section 15.4.8,
AND INJECTOR Inspect, Adjust ● ● and Section 15.4.9
TIMING and NOTE 1.
ENGINE SPEED
SENSOR, (FLYWHEEL Clean, Inspect, See Section 12.4.1.4
HOUSING MOUNTED - Adjust ● ● ● and NOTE 1.
MPU)
ENGINE PROTECTIVE See Section 12.4.1
DEVICES
Inspect ● and NOTE 1.
INSPECT RADIATOR See Section 13.4.3
CAP GASKET
WATER
See Section 13.4.1
TEMPERATURE Replace ● and NOTE 1.
REGULATORS
CRANKSHAFT See Section 6.4.5 and
VIBRATION DAMPER
Inspect ● NOTE 1.
See Section 6.4.7 and
ENGINE MOUNTS Inspect ● NOTE 1.
ENGINE SPEED / Check, Clean, See Section 12.4.1.7
TIMING SENSORS Calibrate ● ● and NOTE 1.
See Section 15.4.2
TURBOCHARGER Inspect ● and NOTE 1.
6-19
USAF TO 35C2-3-518-1
USA TM 9-6115-484-14
TABLE 6.3-1 PREVENTIVE MAINTENANCE CHECKS AND SERVICES (SCHEDULED PMCS) (CONTINUED)
INITIAL 250
3,000
(HOURS)
250 HOURS, 1,000 HOURS
(INCLUDE 8,000 16,000 6,000 HOURS
ITEMS TO BE ACTION 2,500 (GAL) HOURS OR 30,000
THE – HOURS OR HOURS OR 60,000 (GAL), COMMENTS
INSPECTED REQUIRED OR SEMI – (GAL),
STANDARD ANNUALLY 3 YEARS OR 6 YEARS
ANNUALLY ANNUALLY OR 3
250 H
YEARS
SERVICE)
JACKET WATER See Section 13.4.2
PUMP
See Section 9.4.6 and
STARTING MOTOR Inspect ● NOTE 1.
Test: ●
COOLING SYSTEM
Level 1 Test ● See Section 13.3 and
ELC NOTE 1.
Level 2 Test ●
Change
(At 6000 hours) ●
COOLING SYSTEM
Add See Section 13.3 and
ELC EXTENDER
(At 3000 hours) ● NOTE 1.
PACKAGE
HOUSING ACCESS
DOORS, RAIN CAPS
Inspect ● See Section 8.3.1
HYDRAULIC SYSTEM
STRAINER
Clean ● ● See Section 19.3.1
HYDRAULIC SYSTEM See Section 19.3.1 and

FLUID
Replace ● NOTE 2
HYDRAULIC SYSTEM
FLUID FILTER AND Replace ● ● See Section 19.3.1
O-RING
STATION POWER
TRANSFORMER
Inspect ● See Section 10.4.1.1
NOTE 1: For Additional information see SMCS Code: 1000;7500, in SEBU6959-01, or later version and SMCS Code: 1000;7500, in SEBU7163-01, or
later version.
NOTE 2: An annual fluid sample should be taken and analyzed. The fluid change schedule may be adjusted accordingly.
6-20
USAF TO 35C2-3-518-1
USA TM 9-6115-484-14
6.3.2 RUNNING GEAR SCHEDULED MAINTENANCE
6.3.2.1 MEP-PU 810A RUNNING GEAR SCHEDULED MAINTENANCE
a. Table 6.3.2.1-1 identifies the MEP-PU-810A Running Gear Scheduled Maintenance. The MEP-PU-810A Running Gear Scheduled Maintenance
is to be performed at the intervals identified. All Safety Warnings and Cautions in Section 6.1 apply to this Table.
b. Problems encountered during the MEP-PU-810A operations that do not present safety hazards or do not degrade operations must be identified
for correction during scheduled maintenance periods or at the end of operations, as appropriate.
CAUTION
TABLE 6.3.2.1-1 MEP-PU-810A MAINTENANCE SCHEDULE

ITEM FUNCTION REQUIRED WEEKLY 3 MONTHS 6 MONTHS 12 MONTHS COMMENTS
Must be serviced by a qualified mechanic familiar with

BRAKES Test that they are operational At Every Use
this type of axle. See NOTE 1.
Adjust to proper operating Must be serviced by a qualified mechanic familiar with
BRAKE ADJUSTMENT ● this type of axle. See NOTE 1.
clearance
Inspect for wear & Must be serviced by a qualified mechanic familiar with
BRAKE LININGS ● this type of axle. See NOTE 1.
contamination
BRAKE CYLINDERS Check for leaks & sticking ● this type of axle. See NOTE 1.
BRAKE LINES Inspect for cracks, leaks, kinks ● this type of axle. See NOTE 1.
BRAKE ACTUATOR Check oil level ● this type of axle. See NOTE 1.
6-21
USAF TO 35C2-3-518-1
USA TM 9-6115-484-14
TABLE 6.3.2.1-1 MEP-PU-810A MAINTENANCE SCHEDULE (CONTINUED)

ITEM FUNCTION REQUIRED WEEKLY 3 MONTHS 6 MONTHS 12 MONTHS COMMENTS
Check breakaway chain and Must be serviced by a qualified mechanic familiar with
BREAKAWAY SYSTEM At Every Use this type of axle. See NOTE 1.
lever
Inspect for abnormal wear or Must be serviced by a qualified mechanic familiar with
HUB/DRUM ● this type of axle. See NOTE 1.
scoring
WHEEL BEARINGS & Inspect for corrosion or wear. Must be serviced by a qualified mechanic familiar with
● this type of axle. See NOTE 1.
CUPS Clean & repack
Inspect for leakage. Replace if Must be serviced by a qualified mechanic familiar with
SEALS ● this type of axle. See NOTE 1.
removed.
Tighten to specified torque Must be serviced by a qualified mechanic familiar with
WHEEL NUTS & BOLTS ● this type of axle. See NOTE 1.
values
Inspect for cracks, dents or Must be serviced by a qualified mechanic familiar with
WHEELS ● this type of axle. See NOTE 1.
distortion
TIRE INFLATION Inflate tires to manufacturer’s Must be serviced by a qualified mechanic familiar with
● this type of axle. See NOTE 1.
PRESSURE specification
Inspect for cuts, wear, bulging, Must be serviced by a qualified mechanic familiar with
TIRE CONDITION ● this type of axle. See NOTE 1.
etc.
NOTE 1: For Additional information refer to Section 18.3.1.
6-22
USAF TO 35C2-3-518-1
USA TM 9-6115-484-14
6.3.2.2 MEP-PU 810B RUNNING GEAR SCHEDULED MAINTENANCE
a. Table 6.3.2.2-1 identifies the MEP-PU-810B Running Gear Scheduled Maintenance. The MEP-PU-810B Running Gear Scheduled Maintenance
is to be performed at the intervals identified. All Safety Warnings and Cautions in Section 6.1 apply to this Table.
b. Problems encountered during the MEP-PU-810B operations that do not present safety hazards or do not degrade operations must be identified
CAUTION
TABLE 6.3.2.2-1 MEP-PU-810B MAINTENANCE SCHEDULE

EVERY EVERY
EVERY
EVERY 1,000 25,000 TO 100,000
ITEM FUNCTION REQUIRED WEEKLY 12,000 COMMENTS
MILES 30,000 MILES OR
MILES
MILES ANNUALLY
BRAKES Test that they are operational At Every Use
AIR TANK Drain condensation ●

Must be serviced by a qualified
BRAKE
Adjust to proper operating clearance ● mechanic familiar with this type of
ADJUSTMENT axle. See NOTE 1.
BRAKE LININGS Inspect for wear & contamination ● mechanic familiar with this type of
axle. See NOTE 1.
BRAKE LINES Inspect for cracks, leaks, kinks ● ● ● ● mechanic familiar with this type of
axle. See NOTE 1.
HUB/DRUM Inspect for abnormal wear or scoring ● ● ● ● mechanic familiar with this type of
axle. See NOTE 1.
WHEEL Must be serviced by a qualified
Inspect for corrosion or wear. Clean &
BEARINGS & ● mechanic familiar with this type of
repack axle. See NOTE 1.
CUPS
6-23
USAF TO 35C2-3-518-1
USA TM 9-6115-484-14
TABLE 6.3.2.2-1 MEP-PU-810B MAINTENANCE SCHEDULE (CONTINUED)

EVERY EVERY
EVERY
EVERY 1,000 25,000 TO 100,000
ITEM FUNCTION REQUIRED WEEKLY 12,000 COMMENTS
MILES 30,000 MILES OR
MILES
MILES ANNUALLY
Inspect for leakage. Replace if
SEALS ● ● ● ● ● mechanic familiar with this type of
removed. axle. See NOTE 1.
WHEEL NUTS &
Tighten to specified torque values At Every Use mechanic familiar with this type of
BOLTS axle. See NOTE 1.
WHEELS Inspect for cracks, dents or distortion ● ● ● ● ● mechanic familiar with this type of
axle. See NOTE 1.
TIRE INFLATION Inflate tires to manufacturer’s
● mechanic familiar with this type of
PRESSURE specification axle. See NOTE 1.
TIRE CONDITION Inspect for cuts, wear, bulging, etc. ● mechanic familiar with this type of
axle. See NOTE 1.
Check oil level in wheel hub and inspect
WHEEL HUB ● ● ● ● ● mechanic familiar with this type of
wheel for leaks. axle. See NOTE 1.
CAMSHAFT Inspect for any signs of wear ● mechanic familiar with this type of
axle. See NOTE 1.
CAMSHAFT Must be serviced by a qualified
SPIDER Inspect for any signs of wear ● mechanic familiar with this type of
axle. See NOTE 1.
BUSHING
CAMSHAFT
SUPPORT
Inspect for any signs of wear ● mechanic familiar with this type of
BRACKET axle. See NOTE 1.
BUSHING
BRAKE Must be serviced by a qualified
ACTUATING Lubricate ● mechanic familiar with this type of
axle. See NOTE 1.
COMPONENTS
Check brake air chambers and slack
BRAKE adjusters Inspect brake rollers, roller
● ● ● ● mechanic familiar with this type of
COMPONENTS shafts, anchor pins and bushings and axle. See NOTE 1.
replace it necessary.
NOTE 1: For Additional information refer to Section 18.3.2.
6-24
USAF TO 35C2-3-518-1
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6.3.3 SR4B ALTERNATOR SCHEDULED MAINTENANCE
a. Table 6.3.3-1 identifies the SR4B Alternator Scheduled Maintenance. The SR4B Alternator Scheduled Maintenance is to be performed at the
intervals identified. All Safety Warnings and Cautions in Section 6.1 apply to this Table.
b. Problems encountered during the SR4B Alternator operations that do not present safety hazards or do not degrade operations must be identified
CAUTION
TABLE 6.3.3-1 SR4B ALTERNATOR SCHEDULED MAINTENANCE

MAINTENANCE SCHEDULE TOPICS LIMITS / COMMENTS
Visual Inspection:
• Cleaning Check operation, moisture, dust, oils, grease, debris, bolts, exciter, flex plates, electrical
Before placing unit in operation
• Looseness connections, debris, cleanliness, looseness. See NOTE 1 and NOTE 2 for additional information.
• Walk around
• Generator - Dry
• Generator – Set - Test
• Insulation – Test
When Required See NOTE 1 and NOTE 2 for additional information.
• Rotating Rectifier – Test
• Varistor - Test
• Winding – Test
• Electrical Connections - Check
Every Week • Generator - Clean See NOTE 1 and NOTE 2 for additional information.
• Walk – Around Inspection
Use 28.3 grams (1 ounce) of grease. Inspect bearing and bracket every major engine overhaul.
Every 1000 HOURS Lubrication, Spherical Roller Bearings
See NOTE 1 and NOTE 2 for additional information.
Every 2000 Hours Lubrication, Ball Bearings Do not over grease. Use only one ounce. See NOTE 1 and NOTE 2 for additional information.
• Rotating Rectifier - Check
Minimum 1 megohm + rated V / 1000 (Typically much higher)
Every 7500 Hours or Annually • Generator – Clean
See NOTE 1 and NOTE 2 for additional information.
• Insulation Check
NOTE 1: For Additional information refer to Section 10.4.5.2.1.
NOTE 2: For Additional information see SMCS Code: 4450, in SEBU6918-02, or later version and SMCS Code: 4450, in SENR5359-01, or later
version.
6-25
USAF TO 35C2-3-518-1
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6.3.4 PRIMARY DISTRIBUTION CENTER (PDC) SCHEDULED MAINTENANCE
a. Table 6.3.4-1 identifies the Primary Distribution Center (PDC) Scheduled Maintenance. The Primary Distribution Center (PDC) Scheduled
Maintenance is to be performed at the intervals identified. All Safety Warnings and Cautions in Section 6.1 apply to this Table.
b. Problems encountered during the Primary Distribution Center (PDC) operations that do not present safety hazards or do not degrade operations
must be identified for correction during scheduled maintenance periods or at the end of operations, as appropriate.
CAUTION
TABLE 6.3.4-1 PRIMARY DISTRIBUTION CENTER (PDC) SCHEDULED MAINTENANCE

INTERVAL
ITEMS TO BE 250 HOURS OF PRIOR TO USE AS
ACTION REQUIRED ANNUALLY COMMENTS
INSPECTED OPERATION REQUIRED
Inspect for: ● ● See NOTE 1
LOAD TERMINALS
• Damage ● ● See NOTE 1
• Cleanliness ● ● See NOTE 1
• Missing components ● ● See NOTE 1
Inspect for: ● ● See Section 6.4.8
• Damage ● ● See Section 6.4.8
SWITCHGEAR • Cleanliness ● ● See Section 6.4.8
• Missing components ● ● See Section 6.4.8
Perform: Re-torque BUS ● ● See Section 6.4.8
ELECTRICAL COMPONENT Inspect all wire terminal screws for tightness.

TERMINAL SCREWS Tighten if loose. ● ● ● All
NOTE 1: For Additional information refer to Section 10.4.7.1.
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USAF TO 35C2-3-518-1
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WARNING
APPLYING HIGH VOLTAGES ACROSS THE CONTACTS OF THE VACUUM INTERRUPTERS MAY PRODUCE X-
RAYS. THE RADIATION MAY INCREASE WITH AN INCREASE IN THE VOLTAGE OR A DECREASE IN THE
DISTANCE BETWEEN THE OPEN CONTACTS. THE LEVELS OF RADIATION GENERATED AT THE
RECOMMENDED TEST VOLTAGES AND NORMAL BREAKER OPEN GAP SPACING ARE EXTREMELY LOW.
HOWEVER, AS A PRECAUTIONARY MEASURE IT IS RECOMMENDED THAT ALL PERSONNEL STAND AT LEAST
THREE FEET AWAY FROM THE BREAKER WHILE TESTING.
TABLE 6.3.4-1 PRIMARY DISTRIBUTION CENTER (PDC) SCHEDULED MAINTENANCE (CONTINUED)

INTERVAL
ITEMS TO BE
ACTION REQUIRED PRIOR TO USE AS REQUIRED ANNUALLY COMMENTS
INSPECTED
Inspect for: ● ● See Note 2
• Damage ● ● See Note 2
• Cleanliness ● ● See Note 2
CIRCUIT BREAKER • Missing components ● ● See Note 2
(MEDIUM VOLTAGE) Test: ● ● See Note 3
• Insulation Resistance ● ● See Note 3
• AC High Voltage Potential (HYPOT) ● ● See Note 3
• Digital Low Resistance Ohm (DLRO) reading ● ● See Note 3
6-27
USAF TO 35C2-3-518-1
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6.4 REQUIRED INSPECTIONS NOT COVERED IN OTHER CHAPTERS
The following Inspections are covered in this section:
• Inspect the External Fuel Manifold

• Inspect the Front, Middle, Rear Engine / Alternator Support Assembly
• Inspect the Oil Pan Assembly
• Inspect the Front and Rear Crankshaft and Accessory Drive Seals
• Inspect the Vibration Damper
• Inspect the Cylinder Head Grounding Stud
• Inspect the Engine Mounts
• Inspect the Switch Gear
6.4.1 INSPECT THE EXTERNAL FUEL MANIFOLD
WARNING

CAUTION
CARE MUST BE TAKEN TO ENSURE THAT FLUIDS ARE CONTAINED DURING

PERFORMANCE OF INSPECTION, MAINTENANCE, TESTING, ADJUSTING AND
REPAIR OF THE PU. BE PREPARED TO COLLECT THE FLUID WITH SUITABLE
CONTAINERS BEFORE OPENING ANY COMPARTMENT OR DISASSEMBLY ANY
COMPONENT CONTAINING FLUIDS. DISPOSE OF FLUIDS ACCORDING TO
LOCAL REGULATIONS AND MANDATES.
Inspect the Fuel Manifold for the following conditions:
a. Inspect the Fuel Manifold for leaks.
b. Inspect the Fuel Manifold for loose or missing hardware.
c. Inspect the Fuel Manifold for damage.
6.4.1.2. SERVICE
If leaks or damage are found at the fuel manifold requiring the fuel supply to be interrupted to the
PU the fuel transfer pump shall be shut-off prior to closing the fuel line.
a. Shutdown and Isolate PU in accordance with Section 5.1.6.1.

b. Turn off fuel transfer pumps on PU by setting fuel pump control switch to the center (OFF)
position.
c. Repair/replace fuel manifold as required.
d. Open fuel supply valve to PU.
e. Turn-on fuel transfer pump by setting pump control switch to “A” (Automatic) position.
f. Return PU to operation in accordance with Section 5 as appropriate for mode of operation.
6-28
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6.4.2 INSPECT FRONT, MIDDLE, REAR ENGINE / ALTERNATOR SUPPORT ASSEMBLY
WARNING

CAUTION

The Front, Middle, Rear Engine / Alternator Support Assembly provides a means of attaching the
Engine/Alternator to the PU Frame Assembly.
Inspect the Front, Middle, Rear Engine / Alternator Support Assembly for the following conditions:
a. This maintenance requires that the PU MUST be shutdown, rendered unable to start, cool
enough for the maintenance to be performed, and Communication Cable (A) and (B)
rerouted to the next PU. See Section 6.1.d. for procedures.
b. Inspect the Front, Middle, Rear Engine / Alternator Support Assembly for improper mounting of
the Engine/Alternator.
c. Inspect the Front, Middle, Rear Engine / Alternator Support Assembly for deterioration of the
rubber mounts. Replace defective rubber mounts as necessary.
d. Inspect the Front, Middle, Rear Engine / Alternator Support Assembly for any crack weldments
on the frame.
6.4.3 INSPECT THE OIL PAN ASSEMBLY
WARNING

CAUTION

The oil pan assembly, being the lowest point of the engine assembly, provides a means for housing the
oil pump assembly and attachment of oil drain lines.
6-29
USAF TO 35C2-3-518-1
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Inspect the Oil Pan Assembly for the following conditions:
b. Inspect the Oil Pan Assembly for cracks, nicks, dents or other damage that could cause leakage.
Make repairs as necessary.
c. Inspect the Oil Pan Assembly for evidence of leakage around gasket areas. Make repairs as
necessary.
d. Inspect the Oil Pan Assembly for evidence of leakage around threaded holes. Make repairs as
necessary.
e. Inspect the Oil Pan Assembly for evidence of leakage around the drain plug. Make repairs as
necessary.
6.4.4 INSPECT THE FRONT AND REAR CRANKSHAFT AND ACCESSORY DRIVE SEALS
WARNING

CAUTION

The front and rear crankshaft and accessory drive seals are provided to prevent engine oil from leaking
out of engine block where crankshaft and accessory drive shaft exit engine assembly.
Inspect the Front and Rear Crankshaft and Accessory Drive Seals for the following conditions:
b. Inspect the Front and Rear Crankshaft and Accessory Drive Seals for evidence of leakage on the
floor or below the flywheel area and on the front end of the engine (Vibration Damper).
NOTE: Slight seepage around seal area is considered normal.
6-30
USAF TO 35C2-3-518-1
USA TM 9-6115-484-14
6.4.5 INSPECT THE CRANKSHAFT VIBRATION DAMPER
WARNING

CAUTION

The Crankshaft Vibration Damper is a fluid filled case.
Inspect the Crankshaft Vibration Damper for the following conditions:
b. Inspect the Crankshaft Vibration Damper for evidence of dents.
c. Inspect the Crankshaft Vibration Damper for evidence of cracks.
d. Inspect the Crankshaft Vibration Damper for evidence of leaking of fluid.
e. Replace the damper if it has any of the above damage.
6.4.6 INSPECT THE CYLINDER HEAD GROUNDING STUD
WARNING

The Cylinder Head Grounding Stud must have a wire ground to the battery.
Inspect the Cylinder Head Grounding Stud for the following conditions:
b. Inspect the Cylinder Head Grounding Studs wiring harness for damage.
c. Inspect the Cylinder Head Grounding Stud for corrosion on the stud.
d. Correct any faults found.
6-31
USAF TO 35C2-3-518-1
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6.4.7 INSPECT THE ENGINE MOUNTS
WARNING

CAUTION

Inspect the Engine Mounts for the following conditions:
b. Inspect the Engine Mounts for signs of deterioration, if deterioration is found the mount should be
replaced.
c. Inspect the Engine Mounts for proper bolt torque, 150 Ft-Lbs.
d. Engine vibration can be caused by the following conditions:
• Improper mounting of the engine.

• Deterioration of the engine mounts.
6.4.8 INSPECT THE SWITCHGEAR
WARNING

WARNING
DO NOT TOUCH EXPOSED ELECTRICAL CONNECTION WHEN A SOURCE OF

POWER SUCH AS UTILITY POWER OR ANOTHER GENERATOR SET IS
CONNECTED TO THE LOAD TERMINALS. DEATH OR INJURY MAY RESULT FROM
FAILURE TO OBSERVE THIS WARNING.
6-32
USAF TO 35C2-3-518-1
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WARNING

WARNING
HIGH VOLTAGE, USE PROPER PROTECTIVE EQUIPMENT AND PROPER TEST

EQUIPMENT.
WARNING
DISCHARGE CAPACITIVE CHARGE FROM ALL EXPOSED CONDUCTORS
Inspect the Switchgear for the following:
a. This maintenance requires that the PU MUST be shutdown, isolated from any power plant
electrical bus or utility connection, isolated from any power plant control system, and rendered
unable to start. See Section 6.1.d. for procedures.
b. Remove the PDC from the PU. See Chapter 22 for reference.
c. Inspect the Internal AC Electrical System Bus for proper mounting.
d. Inspect the Internal AC Electrical System Bus for loose connections, physical damage and heat
damage.
e. Inspect the Internal AC Electrical System Bus and associated wiring for signs of insulation
breakdown such as cracked sleeves and burned insulation.
f. Inspect the Internal AC Electrical System Bus Mounting Bolts for proper torque. The torque
should be checked using the following guidelines:
• Annually or other time period required by USAF AFJMAN 32-1082, USA TM 5-684 and
current NETA Standards to verify tightness of accessible bolted electrical connections.
• The proper torque for the Bus mounting bolts is 20 ft. lbs.
6.5 SERVICE REQUIREMENTS NOT COVERED IN OTHER CHAPTERS
The following Service Requirements are covered in this section:
• Engine Crankcase Breather Service Requirements

• Cylinder Head Grounding Stud Service Requirements
• Fuel Tank Sediment Service Requirements
• Remote Terminal Unit (RTU)
6-33
USAF TO 35C2-3-518-1
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6.5.1 ENGINE CRANKCASE BREATHER SERVICE REQUIREMENTS
WARNING

CAUTION

If the crankcase breather is not maintained on a regular basis, the crankcase breather will become
plugged. A plugged crankcase breather will cause excessive crankcase pressure that may cause
crankcase seal leakage.
To service the Engine Crankcase Breather, proceed with the following:
rerouted to the next PU. See Section 6.1.c. for procedures.
b. To service the Engine Crankcase Breather, loosen the Engine Crankcase Breather Hose Clamp
and remove the hose from the Engine Crankcase Breather.
c. Loosen and remove the Cover Clamp and Engine Crankcase Breather Cover.
d. Wash the Engine Crankcase Breather Element, in solvent that is clean and non-flammable.
Allow the Engine Crankcase Breather Element to dry before reinstalling it.
e. Install a new seal.
f. If the Engine Crankcase Breather cannot be cleaned, install a clean and dry element.
g. Reinstall the Engine Crankcase Breather Clamp and Cover.
h. Reinstall the Engine Crankcase Breather Hose Clamp on the hose, connect the hose to the
Engine Crankcase Breather Cover and tighten the hose clamp.
NOTE: Refer to Caterpillar Manual SEBU 7163.
6.5.1.1 FUME COLLECTOR BOX VENT STACK
The Fume Collector Box Vent Stack contains a rough grade of steel wool that must be cleaned
periodically to keep the vent stack from clogging.
To service the Fume Collector Box Vent Stack, proceed with the following:
6-34
USAF TO 35C2-3-518-1
USA TM 9-6115-484-14
enough for the maintenance to be performed
b. Unscrew the top of the vent stack.
c. Flush the vent stack with one gallon of hot soapy water.
d. Drain the Fume Collector Box of all soapy water.
e. Screw on the top of the vent stack
6.5.2 CYLINDER HEAD GROUNDING STUD SERVICE REQUIREMENTS
WARNING

The Cylinder Head Grounding Stud must have a wire ground to the battery.
To Service the Cylinder Head Grounding Stud, proceed with the following:
b. To Service the Cylinder Head Grounding Stud, re-torque the Cylinder Head Grounding Stud to
35 ± 7 ft-lbs at every oil change. Ground wires and straps should be combined at engine
grounds. All grounds should be tight and free of corrosion.
c. To Service the Cylinder Head Grounding Stud, clean the Cylinder Head Grounding Stud and the
terminals for the cylinder head ground strap with a clean cloth.
d. If the connections are corroded, clean the connections with a solution of baking soda and water.
e. Keep the cylinder head grounding stud and the strap clean and coated with MPGM grease or
petroleum jelly.
6-35
USAF TO 35C2-3-518-1
USA TM 9-6115-484-14
CYLINDER HEAD
GROUNDING
STUD
FIGURE 6.5.2-1 CYLINDER HEAD GROUNDING STUD
6-36
USAF TO 35C2-3-518-1
USA TM 9-6115-484-14
6.5.3 FUEL TANK SEDIMENT SERVICE REQUIREMENTS
WARNING

CAUTION

Fuel quality is critical to the performance and to the service life of the engine. Water in the fuel tank can
cause excessive fuel system wear. Condensation occurs during the heating and cooling of fuel. The
condensation occurs as the fuel passes through the system fuel system and the fuel returns to the fuel
tank. Draining the fuel tank regularly and obtaining fuel from reliable sources can help to eliminate water
in the fuel.
To Service the Fuel Tank, proceed with the following:
enough for the maintenance to be performed, and Communication Cable rerouted to the
next PU. See Section 6.1.d. for procedures.
b. Inspect the Fuel Tank using a flashlight to view through the filler cap for sediment or water. The
fuel drain is located directly below the filler cap and any sediment or water should be visible. If
detected, Service.
c. To Service the Fuel Tank, empty the Fuel Tank with an external pump.
d. After the Fuel Tank is empty, remove the Fuel Tank Drain Plug and drain the sediment into a
suitable container.
e. Reinstall the Fuel Tank Drain Plug.
6.5.4 REMOTE TERMINAL UNIT (RTU)
To Service the RTU, proceed with the following:
CAUTION
THIS SERVICE MUST BE PERFORMED EVERY 6-MONTHS IF THE PU IS IN STORAGE. IT IS
CRITICAL THAT THE RTU BATTERY BE RECHARGED TO MAINTAIN PROGRAMMED VARIABLES
IN THE RTU MEMORY. IF THE RTU BATTERY IS ALLOWED TO DISCHARGE COMPLETELY, THE
RTU SOFTWARE WILL HAVE TO BE RELOADED BEFORE OPERATION.
a. If the PU is in storage and the batteries have been disconnected, reconnect the batteries.
6-37
USAF TO 35C2-3-518-1
USA TM 9-6115-484-14
b. Connect an external 120 VAC power source to the battery chargers and ensure the chargers are
supplying current to the batteries.
c. Open the MCP flip up door.
d. Turn on the DC Power Circuit Breaker (CB1). The PDC will be powered up and the RTU battery
will recharge through internal circuitry.
e. Leave the 120 VAC power source connected to the battery chargers and the CB1 on for a
minimum of 8 hours to recharge the RTU battery.
f. After 8 hours, Turn off CB1, disconnect the 120 VAC power source to the battery chargers, and
disconnect the PU batteries for continued storage.
NOTE: This service can be performed in conjunction with other service of the PU, has long as the
DC Power remains turned on for 8 continuous hours every 6-months.
6-38
USAF TO 35C2-3-518-1
USA TM 9-6115-484-14
CHAPTER 7
UNSCHEDULED MAINTENANCE/TROUBLESHOOTING
TABLE OF CONTENTS
SECTION TITLE PAGE

7.0 UNSCHEDULED MAINTENANCE / TROUBLESHOOTING PROCEDURES 5
7.2 UNSCHEDULED MAINTENANCE PROCEDURES 17
7.2.1 HOUSING ASSEMBLY UNSCHEDULED MAINTENANCE PROCEDURES 17
7.2.2 DC SYSTEM COMPONENTS UNSCHEDULED MAINTENANCE

PROCEDURES 17
7.2.3 AC SYSTEM COMPONENTS UNSCHEDULED MAINTENANCE

PROCEDURES 18
7.2.4 FUEL SYSTEM COMPONENTS UNSCHEDULED MAINTENANCE

PROCEDURES 18
7.2.5 CONTROL AND INSTRUMENT COMPONENTS UNSCHEDULED

MAINTENANCE PROCEDURES 18
7.2.6 COOLING SYSTEM COMPONENTS UNSCHEDULED MAINTENANCE

PROCEDURES 19
7.2.7 LUBRICATION SYSTEM COMPONENTS UNSCHEDULED MAINTENANCE

PROCEDURES 19
7.2.8 ENGINE COMPONENTS UNSCHEDULED MAINTENANCE PROCEDURES 19
7.2.9 AIR INTAKE AND EXHAUST SYSTEM COMPONENTS UNSCHEDULED

7.2.10 REMOTE OPERATOR TERMINAL (ORT) UNSCHEDULED MAINTENANCE

PROCEDURES 20
7.2.11 RUNNING GEAR/TRAILER ASSEMBLY COMPONENTS UNSCHEDULED

7.2.12 HYDRAULIC SYSTEM COMPONENTS UNSCHEDULED MAINTENANCE

PROCEDURES 20
7.2.13 ENGINE/ALTERNATOR UNSCHEDULED MAINTENANCE PROCEDURES 20
7.2.14 PDC UNSCHEDULED MAINTENANCE PROCEDURES 20
7.3 TROUBLESHOOTING PROCEDURES 21
7-1
USAF TO 35C2-3-518-1
USA TM 9-6115-484-14
TABLE OF CONTENTS
SECTION TITLE PAGE

7.3.1 BASIC ENGINE TROUBLESHOOTING PROCEEDURES 23
7.3.2 BASIC EMCP+ TROUBLESHOOTING PROCEDURES 34
7.3.3 BASIC GENERATOR OPERATIONS TROUBLESHOOTING PROCEDURES 35
7.3.4 TROUBLESHOOTING THE FUEL PRIMER PUMP 47
7.3.5 COOLING SYSTEM TROUBLE SHOOTING PROCEDURES 48
7.3.6 RUNNING GEAR/TRAILER TROUBLESHOOTING PROCEDURES 51
7.3.6.1 MEP-PU-810A RUNNING GEAR/TRAILER TROUBLESHOOTING

PROCEDURES 51
7.3.6.2 MEP-PU-810B RUNNING GEAR/TRAILER TROUBLESHOOTING

PROCEDURES 53
7.3.6.2.1 TROUBLESHOOTING THE ABS SYSTEM 53
7.3.6.2.2 MEP-PU-810A RUNNING GEAR/TRAILER TROUBLESHOOTING

PROCEDURES 58
7.3.7 HYDRAULIC SYSTEM TROUBLESHOOTING PROCEDURES 60
7-2
USAF TO 35C2-3-518-1
USA TM 9-6115-484-14
LIST OF TABLES
TABLE TITLE PAGE

TABLE 7.3.1-1 BASIC ENGINE TROUBLESHOOTING PROCEDURES 23
TABLE 7.3.1-1 BASIC ENGINE TROUBLESHOOTING PROCEDURES

(CONTINUED) 24

(CONTINUED) 25

(CONTINUED) 26

(CONTINUED) 27

(CONTINUED) 28

(CONTINUED) 29

(CONTINUED) 30

(CONTINUED) 31

(CONTINUED) 32

(CONTINUED) 33
TABLE 7.3.2-1 BASIC EMCP + TROUBLESHOOTING PROCEDURES 34
TABLE 7.3.3-1 BASIC GENERATOR OPERATIONS TROUBLESHOOTING

PROCEDURES 36

PROCEDURES (CONTINUED) 37



7-3
USAF TO 35C2-3-518-1
USA TM 9-6115-484-14
LIST OF TABLES
TABLE TITLE PAGE






TABLE 7.3.5-1 COOLANT SYSTEM TROUBLESHOOTING PROCEDURES 48
TABLE 7.3.5-1 COOLANT SYSTEM TROUBLESHOOTING PROCEDURES

(CONTINUED) 49

(CONTINUED) 50
TABLE 7.3.6.1-1 MEP-PU-810A RUNNING GEAR/TRAILER TROUBLESHOOTING

PROCEDURES 51
TABLE 7.3.6.1-1 MEP-PU-810A RUNNING GEAR/TRAILER TROUBLESHOOTING

TABLE 7.3.6.2.1-1 TROUBLESHOOTING THE ABS SYSTEM 54
TABLE 7.3.6.2.1-1 TROUBLESHOOTING THE ABS SYSTEM (CONTINUED) 55
TABLE 7.3.6.2.2-1 MEP-PU-810B RUNNING GEAR/TRAILER TROUBLESHOOTING

PROCEDURES 58
TABLE 7.3.6.2.2-1 MEP-PU-810B RUNNING GEAR/TRAILER TROUBLESHOOTING

TABLE 7.3.7-1 HYDRAULIC SYSTEM TROUBLESHOOTING PROCEDURES 60
7-4
USAF TO 35C2-3-518-1
USA TM 9-6115-484-14
7.0 UNSCHEDULED MAINTENANCE / TROUBLESHOOTING PROCEDURES
Unscheduled Maintenance / Troubleshooting procedures covered in this section are:
• Unscheduled Maintenance Procedures

• For In-Depth Troubleshooting Procedures see USAF TO 35C2-3-518-21 and CTM
01646.1R0253/1R0254 TR
WARNING
IMPORTANT: SAFETY WARNINGS ARE APPROPRIATE FOR ALL MAINTENANCE

ACTIVITIES. READ THIS SECTION, PRIOR TO PERFORMING ANY MAINTENANCE
WARNING
THE EQUIPMENT COVERED IN THIS MANUAL MUST BE INSTALLED, OPERATED,

AND MAINTAINED BY QUALIFIED PERSONS WHO ARE KNOWLEDGEABLE IN THE
INSTALLATION, OPERATION, AND MAINTENANCE OF MEDIUM VOLTAGE
ELECTRICAL POWER GENERATION EQUIPMENT ALONG WITH ASSOCIATED
HAZARDS. A QUALIFIED PERSON IS ONE WHO IS TRAINED AND COMPETENT IN:
• THE SKILLS AND TECHNIQUES NECESSARY TO DISTINGUISH

ENERGIZED PARTS FROM NON-ENERGIZED PARTS OF ELECTRICAL
EQUIPMENT.
• THE SKILLS AND TECHNIQUES NECESSARY TO DETERMINE THE

PROPER APPROACH DISTANCES CORRESPONDING TO THE VOLTAGES
TO WHICH THE QUALIFIED PERSON WILL BE EXPOSED.

ENERGIZED PARTS OF ELECTRICAL EQUIPMENT AND ROTATING
MACHINERY.

EXPOSED HOT SURFACES OF ENGINE AND EXHAUST SYSTEM
COMPONENTS.
THESE INSTRUCTIONS ARE INTENDED ONLY FOR SUCH QUALIFIED PERSONS.

THEY ARE NOT A SUBSTITUTE FOR ADEQUATE TRAINING AND EXPERIENCE IN
SAFETY PROCEDURES FOR THIS TYPE OF EQUIPMENT.
7-5
USAF TO 35C2-3-518-1
USA TM 9-6115-484-14
WARNING

WARNING

TERMINAL FIRST. WHEN RECONNECTING, CONNECT NEGITIVE TERMINAL LAST.
FAILURE TO COMPLY MAY CAUSE SPARKING AND CONSEQUENT BATTERY
EXPLOSION.
WARNING

WARNING

WARNING

WARNING
REMOVING.
WARNING
TOP PANELS ARE HEAVY. USE EXTREME CAUTION WHEN UNBOLTING AND
REMOVING.
7-6
USAF TO 35C2-3-518-1
USA TM 9-6115-484-14
WARNING
MUFFLER ASSEMBLIES ARE HEAVY. USE EXTREME CAUTION WHEN

UNBOLTING AND REMOVING.
WARNING

WARNING

THE TEST LEADS.
WARNING

WARNING

EQUIPMENT
WARNING

WARNING

MISSOPERATE VIOLENTLY, CAUSING SEVERE PERSONAL INJURY.
WARNING

7-7
USAF TO 35C2-3-518-1
USA TM 9-6115-484-14
WARNING
WARNING
BEFORE WORKING ON THE BATTERY CHARGER, ENSURE THAT AC POWER IS

OFF AND DISCONNECTED. ALSO, DISCONNECT THE NEGATIVE BATTERY LEAD
WARNING
ETHER IS HIGHLY FLAMMABLE AND TOXIC TO SKIN, EYES, AND RESPIRATORY

TRACT. USE ONLY IN AN ADEQUATELY VENTILATED AREA. SKIN, EYE. AND
RESPIRATORY PROTECTION ARE REQUIRED. FAILURE TO COMPLY MAY
RESULT IN SERIOUS INJURY OR ILLNESS.
WARNING
DIESEL FUEL IS FLAMMABLE AND MODERATELY TOXIC TO EYES, SKIN, AND

RESPIRATORY TRACT. SKIN AND EYE PROTECTION REQUIRED. AVOID
REPEATED OR PROLONGED CONTACT. USE IN WELL-VENTILATED AREA.
FAILURE TO COMPLY MAY RESULT IN SERIOUS INJURY OR ILLNESS.
WARNING
WHEN POWER GENERATION EQUIPMENT MUST BE IN OPERATION TO MAKE

TESTS AND/OR ADJUSTMENTS, HIGH VOLTAGE AND CURRENT ARE PRESENT.
MAKE SURE THE TESTING EQUIPMENT IS DESIGNED FOR AND CORRECTLY
OPERATED FOR THE HIGH VOLTAGE AND CURRENT TESTS. IMPROPER TEST
EQUIPMENT MAY FAIL AND PRESENT A HIGH VOLTAGE SHOCK HAZARD TO ITS
USER.
WARNING

SAME ID MAY CAUSE UNSAFE AND ERRATIC OPERATIONAL CONDITIONS.
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WARNING
EXPLOSION HAZARD – WHEN IN HAZARDOUS LOCATIONS, DISCONNECT

POWER BEFORE REPLACING OR WIRING MODULES.
WARNING
ALWAYS WEAR EYE PROTECTION WHEN YOU PERFORM ANY SERVICE WORK
ON A COOLING SYSTEM
WARNING
RELEASE THE PRESSURE IN THE COOLING SYSTEM BEFORE PERFORMING ANY

SERVICE WORK. IF THE PRESSURE IN THE COOLING SYSTEM IS NOT
RELEASED OR THE TEMPERATURE OF THE SYSTEM IS NOT PERMITTED TO
COOL, STEAM OR HOT WATER MAY BE RELEASED WHEN YOU REMOVE THE
FILLER CAP. THIS MAY CAUSE PERSONAL INJURY.
WARNING
TO RELEASE THE PRESSURE IN A COOLING SYSTEM, LET THE SYSTEM COOL,

PUT A HEAVY CLOTH OVER THE CAP AND LOOSEN IT SLOWLY.
WARNING
DO NOT ALLOW UNDILUTED CORROSION INHIBITORS OR DILUTED/UNDILUTED

RADIATOR CLEANERS TO COME IN CONTACT WITH THE SKIN OR EYES.
WARNING
DO NOT USE CHROMATE CORROSION INHIBITORS IN A COOLING SYSTEM.
WARNING
ALWAYS FOLLOW THE MANUFACTURER’S INSTRUCTIONS WHEN HANDLING

CORROSION INHIBITORS, RADIATOR CLEANERS OR ANTIFREEZE BE
ESPECIALLY SURE TO FOLLOW THE MANUFACTURER’S RECOMMENDATIONS
CONCERNING TOXICITY.
WARNING
ETHYLENE GLYCOL MAY CATCH FIRE WHEN IT IS HOT OR EXPOSED TO AN

OPEN FLAME. DO NOT WELD, CUT OR USE AN OPEN FLAME NEAR LEAKING
COOLANT THAT CONTAINS ANTIFREEZE.
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WARNING
DO NOT USE ALCOHOL IN PLACE OF ANTIFREEZE. ALCOHOL HAS A LOWER

BOILING TEMPERATURE AND FLASH POINT.
WARNING
DO NOT ATTEMPT TO TIGHTEN ANY HOSE CLAMPS WHILE THE COOLING

SYSTEM IS HOT OR UNDER PRESSURE. IF THERE IS A FAILURE OF THE HOSE
CLAMP WHEN IT IS TIGHTENED, A SUDDEN LOSS OF HOT COOLANT OR STEAM
COULD RESULT.
WARNING
DO NOT REMOVE FILLER CAP AFTER OPERATION UNTIL SYSTEM HAS COOLED
DOWN. FAILURE TO ALLOW ENGINE COOLANT TO COOL DOWN COULD RESULT
IN SECOND AND THIRD DEGREE BURNS. CAP MAY BE HALF-TURNED TO
RELIEVE PRESSURE AND THEN REMOVED TO INSPECT COOLANT LEVEL.
WARNING
PERSONAL INJURY CAN RESULT FROM HOT COOLANT, STEAM AND ALKALI.
WARNING
AT OPERATING TEMPERATURE, ENGINE COOLANT IS HOT AND UNDER

PRESSURE. THE RADIATOR AND ALL LINES TO THE ENGINE CONTAIN HOT
COOLANT OR STEAM. ANY CONTACT CAN CAUSE SEVERE BURNS.
WARNING
REMOVE FILLER CAP SLOWLY TO RELIEVE PRESSURE ONLY WHEN THE

ENGINE IS STOPPED AND THE FILLER CAP IS COOL ENOUGH TO TOUCH WITH
YOUR BARE HAND.
WARNING
COOLING SYSTEM CONDITIONER CONTAINS ALKALI. AVOID CONTACT WITH

SKIN AND EYES.
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WARNING
HOT OIL AND HOT COMPONENTS CAN CAUSE PERSONAL INJURY. DO NOT
ALLOW HOT OIL OR HOT COMPONENTS TO CONTACT THE SKIN. DO NOT DRAIN
THE OIL WHEN THE ENGINE IS COLD. AS THE OIL COOLS, SUSPENDED WASTE
PARTICLES SETTLE ON THE BOTTOM OF THE OIL PAN. THE WASTE PARTICLES
ARE NOT REMOVED WHEN DRAINING COLD OIL. DRAIN THE CRANKCASE WITH
THE ENGINE STOPPED. DRAIN THE CRANKCASE WITH THE OIL WARM. THIS
DRAINING METHOD ALLOWS THE WASTE PARTICLES THAT ARE SUSPENDED IN
THE OIL TO BE DRAINED PROPERLY.
WARNING
DO NOT ALLOW GASKET MATERIAL TO FALL INSIDE ROCKER LEVER HOUSING.

FAILURE TO COMPLY MAY RESULT IN DAMAGE TO ENGINE.
WARNING
DO NOT RESET A FAULT BEFORE DETERMINING AND CORRECTING THE CAUSE OF A

FAULT. FAILURE TO CORRECT A FAULT BEFORE RESETTING CAN RESULT IN DEATH,
PERSONAL INJURY, OR EQUIPMENT DAMAGE
WARNING
HYDRAULIC FLUID IS HOT AND UNDER HIGH PRESSURE. DO NOT PLACE ANY
PART OF YOUR BODY OVER ANY LEAK. SEVERE INJURY CAN OCCUR IF THIS
HAPPENS.
WARNING
THE HYDRAULIC PRESSURE HELD IN THE SYSTEM MAY CAUSE THE LEVER TO
SNAP QUICKLY. KEEP HANDS AND FINGERS CLEAR, AS YOU RESET THE
BREAKAWAY MECHANISM. WHEN TOWING, AVOID SHARP TURNS THAT CAN
CAUSE THE ACTUATOR TO BIND AGAINST THE TOW VEHICLE. THIS CAN
WARNING
DO NOT MIX PETROLEUM BASED OIL WITH BRAKE FLUID. THIS WILL CAUSE
SEAL SWELLING AND NON-FUNCTIONING BRAKES.
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WARNING
ASBESTOS DUST HAZARD
SINCE SOME BRAKE SHOE FRICTION MATERIALS CONTAIN ASBESTOS.

CERTAIN PRECAUTIONS MUST BE TAKEN WHEN SERVICING BRAKES:
AVOID CREATING OR BREATHING DUST. AVOID MACHINING, FILING, OR

GRINDING THE BRAKE LININGS. DO NOT USE COMPRESSED AIR OR DRY
BRUSHING FOR CLEANING. DUST CAN BE REMOVED WITH A DAMP BRUSH.
WARNING
THE HYDRAULIC PRESSURE HELD IN THE SYSTEM MAY CAUSE THE LEVER TO
SNAP QUICKLY. KEEP HANDS AND FINGERS CLEAR, AS YOU RESET THE
BREAKAWAY MECHANISM. WHEN TOWING, AVOID SHARP TURNS THAT CAN
CAUSE THE ACTUATOR TO BIND AGAINST THE TOW VEHICLE. THIS CAN
WARNING
SALTWATER, GRANULAR FERTILIZERS AND OTHER CORROSIVE MATERIALS

ARE DESTRUCTIVE TO METAL. TO PROLONG THE LIFE OF A BRAKING SYSTEM
USED UNDER CORROSIVE CONDITIONS, WE RECOMMEND THAT THE
ACTUATOR BE FLUSHED AFTER USE WITH A HIGH PRESSURE WATER HOSE.
BE SURE TO RE-GREASE BEARINGS AND OIL ALL MOVING PARTS AFTER THE
UNIT HAS DRIED. AT THE END OF THE SEASON, WHEN UNIT IS TO BE STORED,
REMOVE THE BRAKE DRUMS AND CLEAN INSIDE THE BRAKES. PACK WHEEL
BEARINGS BEFORE DRUM IS INSTALLED. FAILURE TO PROPERLY AND
ADEQUATELY GREASE AND MAINTAIN THE ACTUATOR COULD WEAKEN IT
AND/OR CAUSE IT TO FAIL AND RESULT IN SERIOUS INJURY AND/OR
PROPERTY DAMAGE.
WARNING
PROPER MATCHING OF THE TIRE/WHEEL COMBINATION IS ESSENTIAL TO

PROPER FUNCTION OF YOUR TRAILER RUNNING GEAR. SOME TIRES MAY CALL
FOR A MAXIMUM INFLATION PRESSURE ABOVE THE RIM OR WHEEL CAPACITY.
DO NOT EXCEED MAXIMUM INFLATION PRESSURES FOR RIMS OR WHEELS.
CATASTROPHIC FAILURE MAY RESULT.
WARNING
DO NOT GET GREASE OR OIL ON BRAKE LININGS. BRAKES WILL NOT

FUNCTION PROPERLY
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WARNING
DO NOT MIX LITHIUM, CALCIUM, SODIUM OR BARIUM COMPLEX GREASES DUE

TO POSSIBLE COMPATIBILITY PROBLEMS. WHEN CHANGING FROM ONE TYPE
OF GREASE TO ANOTHER, IT IS NECESSARY TO ENSURE ALL THE OLD GREASE
HAS BEEN REMOVED.
WARNING
DO NOT DISASSEMBLE THE SPRING BRAKE. IT CONTAINS A COMPRESSED

SPRING THAT MAY CAUSE INJURY IF REMOVED. THE SPRING BRAKE MUST BE
CAGED BEFORE SERVICING AND SHOULD ONLY BE PERFORMED BY QUALIFIED
PERSONNEL.
WARNING
FAILURE TO CORRECTLY LUBRICATE BEARINGS AND MAINTAIN PROPER

LUBRICATION COULD CAUSE BEARING AND AXLE SPINDLE DAMAGE, WHICH
COULD RESULT IN THE WHEEL LOCKING UP OR COMING OFF DURING VEHICLE
OPERATION.
CAUTION
SIGNIFICANT DIFFERENCES BETWEEN THE MEP-PU-810A AND MEP-PU-810B

REQUIRE SPECIFIC INSTRUCTIONS FOR EACH VERSION.
CAUTION

ALLOW IT TO COOL AT LEAST 2 MINUTES BEFORE RE-ENERGIZING THE
MOTOR. OVERHEATING WILL DAMAGE THE MOTOR.
CAUTION
ALWAYS HANDLE SURGE ARRESTERS PACKED OR UNPACKED VERY

CAUTION

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CAUTION
THE WATER TEMPERATURE REGULATORS (2 EA) ARE AN IMPORTANT PART OF

THE COOLING SYSTEM. THE WATER TEMPERATURE REGULATORS DIVIDE THE
COOLANT FLOW BETWEEN THE RADIATOR AND THE BYPASS ELBOW. THIS WILL
MAINTAIN THE CORRECT ENGINE TEMPERATURE. IF THE WATER TEMPERATURE
REGULATORS ARE NOT INSTALLED IN THE SYSTEM, THERE IS NO MECHANICAL
TEMPERATURE CONTROL. MOST OF THE COOLANT WILL GO THROUGH THE
BYPASS. THIS WILL CAUSE THE ENGINE TO OVERHEAT IN HOT WEATHER. IF A
HIGHER VOLUME OF COOLANT GOES THROUGH THE RADIATOR, THE ENGINE
WILL NOT REACH NORMAL OPERATING TEMPERATURES. THIS OCCURS DURING
COLD WEATHER.
CAUTION
DO NOT USE A COMMERCIAL COOLANT/ANTIFREEZE THAT ONLY MEETS THE

ASTM D3306 OR D4656 SPECIFICATION. THIS TYPE OF COOLANT/ANTIFREEZE IS
MADE FOR LIGHT DUTY AUTOMOTIVE APPLICATIONS.
CAUTION
IF NON ELC COOLANTS HAVE BEEN USED, IMPROPER OR INCOMPLETE

RINSING OF THE COOLING SYSTEM CAN RESULT IN DAMAGE TO COPPER AND
OTHER METAL COMPONENTS. TO AVOID DAMAGE TO THE COOLING SYSTEM,
MAKE SURE TO COMPLETELY FLUSH THE COOLING SYSTEM WITH CLEAN
WATER. CONTINUE TO FLUSH THE SYSTEM UNTIL ALL SIGNS OF THE
CLEANING AGENT ARE GONE.
CAUTION
TURBOCHARGER BEARING FAILURES CAN CAUSE LARGE QUANTITIES OF OIL

TO ENTER THE AIR INLET AND EXHAUST SYSTEMS AND AIR TO AIR AFTER
COOLER. LOSS OF ENGINE LUBRICANT CAN RESULT IN SERIOUS ENGINE
DAMAGE. TURBOCHARGER COMPONENTS REQUIRE PRECISION CLEARANCES.
THE TURBOCHARGER CARTRIDGE MUST BE BALANCED DUE TO HIGH RPM.
SEVERE SERVICE APPLICATIONS CAN ACCELERATE COMPONENT WEAR.
SEVERE SERVICE APPLICATIONS REQUIRE MORE FREQUENT INSPECTIONS OF
THE CARTRIDGE.
CAUTION
IF A TURBOCHARGER FAILURE OCCURS, REMOVE THE AIR TO AIR AFTER

COOLER CORE. FLUSH THE AIR TO AIR AFTER COOLER CORE INTERNALLY
WITH A SOLVENT THAT REMOVES OIL AND OTHER FORIEN SUBSTANCES.
SHAKE THE AFTER COOLER CORE ASSEMBLY IN ORDER TO REMOVE ANY
TRAPPED DEBRIS. WASH THE AFTER COOLER CORE ASSEMBLY WITH HOT
SOAPY WATER. THOROUGHLY RINCE THIS ASSEMBLY WITH CLEAN WATER,
AND THEN BLOW DRY THE ASSEMBLY IN THE REVERSE DIRECTION OF NORMAL
AIR FLOW. TO MAKE SURE THAT THE WHOLE SYSTEM IS CLEAN, CAREFULLY
INSPECT THE SYSTEM.
CAUTION
BE EXTREMELY CAREFUL - WEIGHT HAZARD - THE TURBOCHARGER WEIGHS

75 LBS.
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CAUTION
WHEEL NUT OR BOLTS MUST BE APPLIED AND MAINTAINED AT THE PROPER

TORQUE LEVELS TO PREVENT LOOSE WHEELS, BROKEN STUDS, AND
POSSIBLE DANGEROUS SEPARATION OF WHEELS FROM YOUR AXLE.
CAUTION
THE MAXIMUM TOWING SPEED IS 20 MPH FOR THE MEP-PU-810A.
following:

• Rotating Parts
precautions are taken.
c. Minor maintenance can be performed while one generator set is running and the other
generator set has been shutdown. Some examples of this maintenance are:


due maintenance.
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function. Place the Fuel Pump Source Switch (S2) into the (G1 or G2 position). Place the S2
in the (G1 or G2) position, for the generator set not receiving maintenance.

5.9.6.15, Unit Isolation Procedure with PSC. See Note 1 and 2.
(3) Isolate the PU from any power plant control system in accordance with NOTE 3.
maintenance the (A) (B) Communication Cable must be routed to the next PU in order to
reestablish the communication network.
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7.2 UNSCHEDULED MAINTENANCE PROCEDURES
All Safety Warnings and Cautions in Section 7.1 apply to this section.
7.2.1 HOUSING ASSEMBLY UNSCHEDULED MAINTENANCE PROCEDURES
The following Unscheduled Maintenance Procedures are located in Chapter 8 of this manual:
a. Remove and install Access Doors and Front Side Panels.
b. Remove and install Plenum Assembly Screens.
c. Remove and install Side Panels.
d. Remove and install Top Panel Assembly
e. Remove and install Battery Bank Tray Assembly
f. Remove and install Fuel Tank and Hydraulic Reservoir Assemblies
g. Remove and install Muffler Assembly
7.2.2 DC SYSTEM COMPONENTS UNSCHEDULED MAINTENANCE PROCEDURES
a. Remove and install Batteries.
b. Remove and install Battery Cables.
c. Remove and install Battery Charger.
d. Remove and install Wiring Harness.
e. Remove and install Battery Bank DC Tie Switch.
f. Remove and install Starter Motor/Solenoid.
g. Remove and install DC Control Power Circuit Breaker.
h. Remove and install DC Panel Lights and Indicators.
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7.2.3 AC SYSTEM COMPONENTS UNSCHEDULED MAINTENANCE PROCEDURES
a. Remove and install Station Power Transformer.
b. Remove and install Wiring Harness.
c. Remove and install Power Panel Board.
d. Remove and install Alternator.
e. Remove and install Varistor and Rectifier Block Assembly.
f. Remove and install High Voltage Output Terminals.
g. Remove and install Surge Arrestors.
h. Remove and install Instrument Potential Transformers.
i. Remove and install Instrument Current Transformers.
j. Remove and install Generator Feeder Breakers.
7.2.4 FUEL SYSTEM COMPONENTS UNSCHEDULED MAINTENANCE PROCEDURES
a. Remove and install Fuel Solenoid Valve (L3).
b. Remove and install External Fuel Transfer Pump Assembly.
c. Remove and install Fuel Primer Pump.
d. Remove and install Engine Mounted Fuel Transfer Pump.
e. Remove and install Fuel Float Switch Assembly.
7.2.5 CONTROL AND INSTRUMENT COMPONENTS UNSCHEDULED MAINTENANCE

PROCEDURES
a. Remove and install Engine Control Devices.
b. Remove and install PDC Controls and Instruments.
(1) Remove and install Generator Control Panel.
(2) Remove and install Master Control Panel.
(3) Remove and install Controls and Instruments within the interior of PDC.
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7.2.6 COOLING SYSTEM COMPONENTS UNSCHEDULED MAINTENANCE PROCEDURES
a. Remove and install Water Temperature Regulator & Manifold.
b. Remove and install Water Pump.
c. Remove and install Filler Cap.
d. Remove and install Engine Oil Cooler.
e. Remove and install Radiator/Aftercooler Assembly.
7.2.7 LUBRICATION SYSTEM COMPONENTS UNSCHEDULED MAINTENANCE

PROCEDURES
There are no Unscheduled Maintenance Procedures for Chapter 14, Lubrication System.
7.2.8 ENGINE COMPONENTS UNSCHEDULED MAINTENANCE PROCEDURES
a. Remove and install Valve Covers.
b. Remove and install Turbocharger.
c. Remove and install Air Intake Manifold.
d. Remove and install Exhaust Manifold.
e. Remove and install Air Transfer Tubes.
f. Remove and install Coolant Transfer Tubes.
g. Remove and install Hydraulic Fluid Transfer Hoses.
7.2.9 AIR INTAKE AND EXHAUST SYSTEM COMPONENTS UNSCHEDULED

MAINTENANCE PROCEDURES
There are no Unscheduled Maintenance Procedures for Chapter 16, Air Intake and Exhaust System.
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7.2.10 REMOTE OPERATOR TERMINAL (ORT) UNSCHEDULED MAINTENANCE

PROCEDURES
There are no Unscheduled Maintenance Procedures for Chapter 17, Remote Operator Terminal (ORT).
7.2.11 RUNNING GEAR/TRAILER ASSEMBLY COMPONENTS UNSCHEDULED

MAINTENANCE PROCEDURES
There are no Unscheduled Maintenance Procedures for Chapter 18, Running Gear/Trailer Assembly.
7.2.12 HYDRAULIC SYSTEM COMPONENTS UNSCHEDULED MAINTENANCE

PROCEDURES
a. Remove and install Hydraulic Pump.
b. Remove and install Radiator Motor.
c. Remove and install Air-to-Air Aftercooler (ATAAC) Motor.
d. Remove and install Engine Compartment Vent Motor.
e. Remove and install Radiator Fan Assembly.
f. Remove and install Aftercooler Fan Assembly.
g. Remove and install Engine Compartment Vent Fan Assembly.
h. Remove and install Radiator Motor Fan Blades.
i. Remove and install Aftercooler Motor Fan Blades.
j. Remove and install Engine Compartment Vent Fan Motor Fan Blades.
k. Remove and install Hydraulic Tank Low Level Shutdown Switch (HTLL).
7.2.13 ENGINE/ALTERNATOR UNSCHEDULED MAINTENANCE PROCEDURES
a. Remove and install Engine/Alternator.
7.2.14 PDC UNSCHEDULED MAINTENANCE PROCEDURES
a. Remove and install PDC.
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7.3 TROUBLESHOOTING PROCEDURES
Troubleshooting procedures covered in this section are:
• Basic Engine Troubleshooting Procedures

• Basic EMCP + Troubleshooting Procedures
• Basic Generator Operations Troubleshooting Procedures
• Troubleshooting the Fuel Primer Pump
• Cooling System Troubleshooting Procedures
• Running Gear / Trailer Troubleshooting Procedures
• Hydraulic System Troubleshooting Procedures
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7.3.1 BASIC ENGINE TROUBLESHOOTING PROCEEDURES
Table 7.3.1-1 contains Basic Engine Troubleshooting Procedures for locating and correcting operating troubles that may develop in the generator
set. Each malfunction, for either an individual component or entire system, is followed by a series of tests or inspections that will help determine
the probable cause and corrective actions to take.
Troubleshoot in accordance with Table 7.3.1-1. All Safety Warnings and Cautions in Section 7.1 apply to this table.
This manual cannot list all malfunctions that may occur, nor all tests or inspections and corrective actions. If a malfunction cannot be corrected by
listed corrective actions, notify supervisor and or contact Radian Inc.
NOTE: Although troubleshooting can be a daunting task. Troubleshooting can be made much easier if you start by isolating the fault first.
The first task is to determine if the system or device is getting the proper inputs AC voltage, AC current, DC voltage and DC current.
Check for loose wires and blown fuses. By isolating the fault by eliminating obvious problems will make the technicians job much
easier. When Caterpillar manuals are referenced, go to the SMCS CODE found in that manual.

MALFUNCTION PROBABLE CAUSE CORRECTIVE ACTION
1. PU Setup 1. Check PU setup. Refer to Section 5.1.3, make corrections as necessary.

PROBLEM 1:
2. DC Control Power Circuit Breaker (CBCP) 2. Place CBCP to the ON (Push-in) position.
ENGINE FAILS TO
3. Starter and Starter Solenoid 3. Test the Starter and Starter Solenoid refer to Section 9.4.6.2
CRANK
4. Engine Fault. 4. Check the GSC+ for a shutdown fault, refer to RENR2227-02 for troubleshooting procedures.
1. Open Fuel Shutoff Valve; refer to Figure 11.3.1-1 for reference.

• Prime Fuel System; refer to Section 11.3.5 for procedures.
1. Fuel • Check Fuel Filters, refer to Section 11.3 for reference.
• Check Fuel Quality (Have Fuel Sample Checked), refer to SENR1067-02 or later
PROBLEM 2: version, SMCS CODE: 1280-081 for procedures.
2. Check Engine Timing; refer to Section 15.4.8, Section 15.4.9, Section 15.4.10 and Section
ENGINE CRANKS BUT 2. Incorrect Engine Timing
15.4.11 for reference.
WILL NOT START
3. Check for obstructions in the Air Plenum Assembly, refer to Section 16.3.2 for reference.
3. Intake Air • Check Air Filter for obstructions, replace Air Filter as necessary, refer to Section 16.3.2
for reference.
4. Engine Mounted Fuel Pump 4. Check Engine Mounted Fuel Pump; refer to Section 11.4.4 for reference.
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TABLE 7.3.1-1 BASIC ENGINE TROUBLESHOOTING PROCEDURES (CONTINUED)


• Check Fuel Level in Fuel Tank.
1. Fuel System • Check Fuel Filters, refer to Section 11.3 for reference.
PROBLEM 3: version, SMCS CODE: 1280-081 for procedures.
• Perform Fuel System Test and Adjusting; refer to SENR1067-02 or later version, SMCS
ENGINE SHUTS DOWN CODE: 1250-040 for procedures.
SOON AFTER 2. Check Engine Timing; refer to Section 15.4.8, Section 15.4.9, Section 15.4.10 and Section
2. Incorrect Engine Timing
STARTING. 15.4.11 for reference.
for reference.
4. Engine Mounted Fuel Pump 4. Check Engine Mounted Fuel Pump, refer to Section 11.4.4 for reference.
1. Check Turbocharger, refer to SENR1068-01 or later version, SMCS CODE: 1052-040.

1. Turbocharger
Replace if turbocharger does not spin freely or damaged.
2. Engine Fault 2. Check the GSC+ for a shutdown fault, refer to RENR2227-02 for troubleshooting procedures.
for reference.
PROBLEM 4:
4. Incorrect Engine Timing
ENGINE RUNS 5. Open Fuel Shutoff Valve; refer to Figure 11.3.1-1 for reference.
ERRATICALLY OR • Check Fuel Level in Fuel Tank.
MISFIRES.
version, SMCS CODE: 1280-081 for procedures.
CODE: 1250-040 for procedures.
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1. Check Turbocharger; refer to SENR1068-01 or later version, SMCS CODE: 1052-040.

1. Turbocharger
Replace if turbocharger does not spin freely or damaged.
PROBLEM 5: 2. Incorrect Engine Timing
ENGINE EXHAUST 3. Check for obstructions in the Air Plenum Assembly, refer to Section 16.3.2 for reference.
EXCESSIVELY BLACK. 3. Intake Air • Check Air Filter for obstructions, replace Air Filter as necessary, refer to Section 16.3.2
for reference.
4. Engine Overloading 4. Check for excessive engine overloading, correct as necessary.
1. Check Ether Injection System, refer to Section 11.3.4. If problem occurs after an ether start,
1. Ether Injection Assembly
check ether installation for defects resulting in applications of excessive ether to engine.
2. Check Cooling System for proper operation; refer to Section 13.4 for reference.
• Check coolant for low temperature.
2. Cooling System • Check for faulty (stuck open) thermostat.
PROBLEM 6: • Test engine coolant thermostats for proper operation. Refer to SENR1067-02, or later
version, SMCS CODE: 1355-081; 1355-081. Replace defective thermostats.
ENGINE EXHAUST 3. Check Turbocharger; refer to SENR1068-01 or later version, SMCS CODE: 1052-040.
WHITE OR BLUE. 3. Turbocharger • Replace if turbocharger does not spin freely or damaged.
• Check turbocharger seals for leakage..
4. Check for excessive oil consumption. If excessive oil consumption is noted, major rebuild
4. Lubrication System
may be necessary; refer to higher level maintenance.
5. Engine Timing
PROBLEM 7: 1. Check Engine Timing; refer to Section 15.4.8, Section 15.4.9, Section 15.4.10 and Section
1. Engine Timing
GENERATOR OUTPUT 2. Check the AVR for proper operations; refer to SENR5833-02 or later version, SMCS CODE:
2. Automatic Voltage Regulator (AVR)
4467 for reference.
FREQUENCY/VOLTAGE
CANNOT BE 3. Check the GSC+ for a shutdown fault, refer to RENR2227-02 or later version, for
3. Engine Fault
MAINTAINED. troubleshooting procedures.
PROBLEM 8: 1. Engine Performance

1. Perform all tests and inspections contained in Problems 4 through 7. Make appropriate
corrections.
LOW POWER OR LOSS 2. Check for high oil level; refer to Section 14.3.1 for reference.
OF POWER. • Drain excess oil.
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1. Check GSC Settings, refer to Annex B.

1. EMCP • GSC+ settings may be improperly set.
• Check and correct.
PROBLEM 9: • Prime Fuel System; refer to Section 11.3.5 for procedures.
ENGINE CANNOT • Check Fuel Quality (Have Fuel Sample Checked), refer to SENR1067-02 or later
REACH GOVERNED version, SMCS CODE: 1280-081 for procedures.
RPM. • Perform Fuel System Test and Adjusting; refer to SENR1067-02 or later version, SMCS
3. Engine Timing
4. Check Fuel Injector, refer to SENR1067-02 or later version, SMCS CODE: 1290-081 for
4. Fuel Injectors
procedures.
for reference.
2. Check Turbocharger; refer to Caterpillar Manual SENR1068-01 or later version, SMCS
CODE: 1052-040.
2. Turbocharger
• Replace if turbocharger does not spin freely or damaged.
• Check turbocharger seals.
PROBLEM 10: 3. Muffler 3. Check the Muffler, refer to Section 8.4.7.1 for reference.
EXCESSIVE FUEL • Check Fuel Level in Fuel Tank.
CONSUMPTION. • Prime Fuel System; refer to Section 11.3.5 for procedures.
5. Engine Timing
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1. Inspect Lubrication System for proper operation; refer to Section 14.3.2 for reference.
• Tighten all oil connections.
• Check for external oil leaks.
• Check grade of oil being used against weather conditions that unit is being operated in.
• Inspect for Excessive Oil Consumption; refer to RENRRENR1067-02 or later version,
PROBLEM 11: SMCS CODE: 1348-040 for reference.
2. Check Turbocharger; refer to Caterpillar Manual SENR1068-01 or later version, SMCS
CODE: 1052-040.
EXCESSIVE OIL • Replace if turbocharger does not spin freely or damaged.
CONSUMPTION.
2. Turbocharger • Check turbocharger seals.
• Check turbocharger crossover and exhaust casing for wetness. If wet, turbocharger is
defective.
• Replace defective turbocharger.
3. Check engine crankcase breathers for obstructions, refer to SEBU7163-01 or later version,
3. Engine Crankcase Breathers
SMCS CODE: 1317-070 for reference.
PROBLEM 12: • Tighten all oil connections.
CRANKCASE SLUDGE. 2. Lubrication System
• Check grade of oil being used against weather conditions that unit is being operated in.
• Check the oil filter to see if it is clogged.
• Change oil filters more often and observe for proper oil temperature.
• Check for faulty (stuck open) thermostat.
3. Coolant System
• Test engine coolant thermostats for proper operation. Refer to SENR1067-02, or later
version, SMCS CODE: 1355-081; 1355-081.
• Replace defective thermostats.
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• Check for faulty (stuck open) thermostat.
1. Coolant System • Check for proper coolant level and evidence of leaks.
• Test engine coolant thermostats for proper operation. Replace defective thermostats.
Refer to Caterpillar Manual SENR1067-02, Dated November 2001 or later, SMCS
CODE: 1355-081; 1355-081.
PROBLEM 13: • Prime Fuel System; refer to Section 11.3.5 for procedures.
OIL DILUTION • Check Fuel Quality (Have Fuel Sample Checked), refer to SENR1067-02 or later
(CRANKCASE). version, SMCS CODE: 1280-081 for procedures.
3. Lubrication System • Check grade of oil being used against weather conditions that unit is being operated in.
• Change oil filters more often and observe for proper oil temperature.
• Take oil sample from crankcase to see if there is evidence of coolant or fuel in the oil.
PROBLEM 14: • Check grade of oil being used against weather conditions that unit is being operated in.
LOW OIL PRESSURE. • Check oil level.
2. Engine Oil Pump 2. Check the Engine Oil Pump; refer to SENR1067-02 or later version, SMCS CODE:1304-040
3. Test Oil Pressure Sensor; refer to Caterpillar Manual RENR 2227-01 or later version, Section
3. Oil Pressure Sensor
P – 520.
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PROBLEM 15: • Check for faulty (stuck open) thermostat.
1. Thermostat • Check for proper coolant level and evidence of leaks.
COOLANT
version, SMCS CODE: 1355-081; 1355-081.
TEMPERATURE TOO
LOW. • Replace defective thermostats.
2. Refer to Section 12.4.1.1 and RENR 2227-01, Section P – 516 or later version and
2. Coolant Temperature Sensor Troubleshooting Procedures are found in RENR1067-01 or later version. Replace if
defective.
1. Cooling System Check (Overheating), refer to RENR1067-02 or later version, SMCS CODE:
PROBLEM 16: 1350-535 for reference.
1. Coolant System
• Check the Radiator Cooling fan to see if it functioning properly. Refer to Section 19.4.3
for reference.
COOLANT
2. Check the water pump to see if it functioning properly. Refer to RENR1067-02 or later
TEMPERATURE TOO 2. Water Pump
version, SMCS CODE: 1361-040; 1361-081 for reference.
HIGH. 3. Check crankcase oil level. Use proper grade for weather conditions. Refer to Annex G,
3. Oil Level and Grade
Consumable Operating and Maintenance Supplies.
1. Check crankcase oil level. Use proper grade for weather conditions. Refer to Annex G,
1. Oil Level and Grade
PROBLEM 17: Consumable Operating and Maintenance Supplies.
2. Inspect increased oil temperature. Refer to RENR1067-02 or later version, SMCS CODE:
2. Engine Oil
OIL TEMPERATURE 1348-040.
TOO HIGH.
3. Engine Load 3. Check KW load on the GSC. Make appropriate loading corrections.
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1. Ether 1. Check for possible improper use of starting aid.

2. Check Fuel Quality (Have Fuel Sample Checked), refer to SENR1067-02 or later version,
2. Fuel
SMCS CODE: 1280-081 for procedures.
PROBLEM 18: • Check for faulty (stuck open) thermostat.
3. Thermostat • Check for proper coolant level and evidence of leaks.
KNOCKS (COMBUSTION version, SMCS CODE: 1355-081; 1355-081.
NOISE). • Replace defective thermostats.
4. Engine Load 4. Check KW load on the GSC. Make appropriate corrections.
5. Engine Timing
6. Check grade of oil being used against weather conditions that unit is being operated in.
6. Engine Oil
Refer to Annex G.
1. Check for defective oil pressure sensor. Refer to RENR 2227-02 or later version, Section P –
PROBLEM 19: 520.
1. Oil Pressure Sensor
• Replace if defective.
EXCESSIVE OIL 2. Check grade of oil being used against weather conditions that unit is being operated in.
PRESSURE. 2. Engine Oil
Refer to Annex G.
1. External Fuel Transfer Pump Switch
1. Check that the External Fuel Transfer Pump Switch is in the G1 or G2 position.
PROBLEM 20: G1/G2
2. Battery Bank 2. Inspect the battery bank, refer to Section 9.4.1.1.
FUEL TRANSFER PUMP 3. Inspect the External Fuel Transfer Pump Assembly for proper operation. Refer to Section
3. External Fuel Transfer Pump.
11.4.2.1.
NOT WORKING.
4. Fuel Float Switch Assembly 4. Inspect the Fuel Float Switch Assembly. Refer to Section 11.4.5.1
PROBLEM 21: If engine does not start refer to RENR 2227-02 or later version, Section 3: Troubleshooting
All Without a Diagnostic Code; or Section 4: Troubleshooting With a Diagnostic Code. And refer to
RENR1200-01 or later version, SMCS CODE: 4490.
ALL ENGINE FAULTS
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3. Verify the A/B Control Cable is connected.
3. Control Cables
• Verify the ORT Cable is connected.
4. Control Switch Positions 4. Verify Switch Setup. Refer to Section 5.2.3.8.
5. Engine Faults 5. Clear all Active Engine Faults.
6. Advanced Troubleshooting Procedures: 6. Perform the following Steps:
• GSC+ • Place CBCP to the ON (Push-in) position.
• PCM • Place both ECS in AUTO
• Verify there are no GSC+ shutdowns active.
• CCM
• Place the SMS in AUTO position.
• ATB • Verify that the SSL two green lights are illuminated.
PROBLEM 22: • PT1 • Place running engine ECS to OFF/RESET.
• PT2 • Move the MSES to the ENABLE position (momentary)
• PT3 • Verify that associated ARR relay energizes. Indicator LED that is located on the relay
ENGINE WILL NOT
• CT1 module should illuminate. Refer to FO-22.
START IN AUTO • If the ARR relay does not energize, check for 24VDC between terminal “A1 and “A2” at
• CT2 the coil.
• CT3 • Check for continuity across the ARR contacts. Lack of continuity across the contacts
• CB2 indicates a failed relay module, replace the relay module. A verification check may be
• CB4 done by swapping the relay with one of the spare (SPR) modules.
• Check for 24VDC at the coil; if voltage is present continue to next step. If 24VDC is not
• ECS present; refer to Table 7.3.3-1, Problem 10 to troubleshoot RTU problems.
• ESPB • Check that the engine starts in MANUAL.
• ARR1 • If the engine starts in MANUAL check the wiring from the associated ARR contact to the
• SR GSC+ module.
• If engine does not start refer to RENR 2227-02 or later version, Section 3:
• SMMS
Troubleshooting without a Diagnostic Code; or Section 4: Troubleshooting With a
• FSPR Diagnostic Code. And refer to RENR1200-01 or later version, SMCS CODE: 4490.
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3. Control Cables
6. Advanced Troubleshooting Procedures: 6. Perform the following Steps:
• PCM • Place both ECS in AUTO
• Verify there are no GSC+ shutdowns active.
• CCM
• Place the SMS in AUTO position.
PROBLEM 23: • PT1 • Place running engine ECS to OFF/RESET.
ENGINE WILL NOT
module should illuminate. Refer to FO-22.
START IN MANUAL • CT1
• If the ARR relay does not energize, check for 24VDC between terminal “A1 and “A2” at
• CT2 the coil.
• Check for 24VDC at the coil; if voltage is present continue to next step. If 24VDC is not
• ECS present; refer to Table 7.3.3-1, Problem 10 to troubleshoot RTU problems.
• ARR1 • If the engine starts in MANUAL check the wiring from the associated ARR contact to the
• SR GSC+ module.
• SMMS Troubleshooting Without a Diagnostic Code; or Section 4: Troubleshooting With a
• FSPR Diagnostic Code. And refer to RENR1200-01 or later version, SMCS CODE: 4490.
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3. Control Cables

• Perform Fuel System Test and Adjusting; refer to SENR1067-02 or later version,
SMCS CODE: 1250-040 for procedures.
PROBLEM 24: 7. Advanced Troubleshooting Procedures: 7. Perform the following Steps:
ENGINE DOES NOT • PCM • Place both ECS in AUTO
STAY RUNNING ONCE • Verify there are no GSC+ shutdowns active.
• CCM
STARTED • Place the SMS in AUTO position.
• PT1 • Place running engine ECS to OFF/RESET.
• CT1 module should illuminate. Refer to FO-22.
• If the ARR relay does not energize, check for 24VDC between terminal “A1 and “A2” at
• CT2 the coil.
• Check for 24VDC at the coil; if voltage is present continue to next step. If 24VDC is
• ECS not present; refer to Table 7.3.3-1, Problem 10 to troubleshoot RTU problems.
• ARR1 • If the engine starts in MANUAL check the wiring from the associated ARR contact to
• SR the GSC+ module.
• SMMS
Troubleshooting Without a Diagnostic Code; or Section 4: Troubleshooting With a
• FSPR Diagnostic
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7.3.2 BASIC EMCP+ TROUBLESHOOTING PROCEDURES
Table 7.3.2-1 contains Basic EMCP+ Troubleshooting Procedures for locating and correcting operating troubles that may develop in the generator
set. Each malfunction, for either an individual component or entire system, is followed by a series of tests or inspections that will help determine
the probable cause and corrective actions to take.
The first task is to determine if the system or device is getting the proper inputs AC voltage, AC current, DC voltage and DC
current. Check for loose wires and blown fuses. By isolating the fault by eliminating obvious problems will make the technicians
job much easier.
TABLE 7.3.2-1 BASIC EMCP + TROUBLESHOOTING PROCEDURES

PROBLEM
3. Check for 24VDC on the GSC+ between Terminals “RM B+” and “RM28”, refer to FO-12A
EMCP+ NOT or 12B. If GSC still doesn’t function refer problem to Caterpillar.
FUNCTIONING 3. EMCP+ not functioning properly • Refer to 3456 DPGDS Generator Set Engine – Supplement, Dated November 1998.
PROPERLY • RENR1200-01 or later version.
• SEBU6918-02 or later version.
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7.3.3 BASIC GENERATOR OPERATIONS TROUBLESHOOTING PROCEDURES
Table 7.3.3-1 contains Basic Generator Operations Troubleshooting Procedures information for locating and correcting operating troubles that
may develop in the generator set. Each malfunction, for either an individual component or entire system, is followed by a series of tests or
inspections that will help determine the probable cause and corrective actions to take.
The first task is to determine if the system or device is getting the proper inputs AC voltage, AC current, DC voltage and DC current.
Check for loose wires and blown fuses. By isolating the fault by eliminating obvious problems will make the technicians job much
easier.
NOTE: This section of the troubleshooting procedures is needed for component isolation purposes. These procedures make it possible to
rapidly determine what component may be out of adjustment or defective.
NOTE: While troubleshooting within this section, keep in mind that you cannot check continuity across the HUB. You must check continuity
up to and then past the HUB.
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TABLE 7.3.3-1 BASIC GENERATOR OPERATIONS TROUBLESHOOTING PROCEDURES

COMPONENTS
MALFUNCTION SYMPTOM TEST PROCEDURES/ CORRECTIVE ACTION
AFFECTED
1. Place CBCP to the ON (Push-in) position.

3. Verify the ORT Cable is connected.
4. Verify that the load cables are connected properly to the load.
• Engine Not Sharing Load 5. Check that the Air Tubes rubber connectors have not become disconnected.
• Engine Will Not Operate In 6. Test the load-share wiring between both LSMs and external connectors:
Parallel • LSM • Place CBCP to the OFF (Pulled-out) position.
PROBLEM 1: • Undesirable Speed • PT4 • Disconnect LS-Net cable(s) from the PDC at 23PA & 23PB.
Decrease With Load • PT5 • Steps a, and b need to be performed with DC control power on.
Increase (a) Pull out on the blue test lever on relay 52CL3. This will manually operate the relay’s
• CT1
• Erratic Load Sharing contacts.
LOAD SHARING • CT2
Module Operation (b) Test the continuity from 23PA-C to 23PB-C and the continuity from 23PA-M to 23PB-
• CT3 M. This tests the load share signal lines through the PDC. Lack of continuity indicates
BETWEEN • Load Signal Voltage Low –
• GDR1 a bad 52CL3 relay or bad wiring.
LOAD GAIN Adjustment
GENERATORS • GDR2 • Pull out 52CL1-test lever and push in 52CL3-test lever.
Will Not Raise
• 52CL1 • Test the continuity from LSMA-10 to 23PA-M and from LSMA-11 to 23PA-C. This tests the
DURING PRIME • Load Signal Voltage High –
LOAD GAIN Adjustment • 52CL2 load share signal lines from generator A LSM to external connection 23PA. Lack of
POWER OPERATION • 52CL3 continuity indicates a bad 52CL1 relay or bad wiring.
Will Not Lower
• Engine Does Not Properly • BLR • Pull out 52CL2-test lever and push in 52CL1-test lever. Pull out 52CL3-test lever.
Share Load With Other • Test the continuity from LSMB-10 to 23PB-M and from LSMB-11 to 23PB-C. This tests the
Units load share signal lines from generator B LSM to external connection 23PB. Lack of
continuity indicates a bad 52CL2 relay or bad wiring.
• Push in all control relay test levers, which are pulled out.
• Refer toSENR6565-02 or later version. This manual combines two separate manuals.
Refer to RENR2471-01 or later version, SMCS CODE: 4490-035.
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TABLE 7.3.3-1 BASIC GENERATOR OPERATIONS TROUBLESHOOTING PROCEDURES (CONTINUED)

COMPONENTS
MALFUNCTION SYMPTOM TEST PROCEDURES
AFFECTED
1. Place CBCP to the ON (Push-in) position.

3. Verify the ORT Cable is connected.
4. Verify that the load cables are connected properly to the load.
5. Test the output of XD to be between 0-3VDC based on the ORT input of 0- 420KW:
(a) Connect an ORT to the PDC and start the PPCAMP software
NOTE: Ensure there is an "A" unit connected, or the ORT will not allow adjustment of the base load
level.
(b) Place ECS(s) in OFF/RESET

(c) Place GMS in UTILITY PARALLEL
• LSM
PROBLEM 2: (d). Place SMS in MANUAL
• PT4 (e) Disconnect the output of XD, terminal plug 8 & 9.
• PT5 (f) Toggle MSES.
• CT1 (g) Adjust the Baseload level and, using a Multimeter set on the VCD scale, measure the
LOAD SHARING VDC output of XD changing proportionally.
• Engine Does Not Carry • CT2 (h) If the signal is good then the Baseload control is functioning between the RTU and XD.
BETWEEN Set Baseload • CT3 Reconnect XD terminal plug.
GENERATORS • XD (i) If the XD is not functioning properly refer to Table 7.3.3-1.
DURING UTILITY • 52CL1 (j) Push-in all control relay test levers that are pulled out.
• 52CL2 (k) If proper voltage was detected at the LSM's refer to SENR6565-02 or later version SMCS
PARALLEL
CODE: 4490-035.
• BLR
6. Test the Paralleling Input of LSM to be between 0-3VDC:

(a) Check that the relay energized LED is lit on BLR. This indicates the PDC is in Baseload
Mode.
(b) Pull-out 52CL1(2)-test lever. This will manually operate the relay’s contacts.
(c) Check voltage at LSM terminals 10 & 11 matches the voltage out of XD.
(d) If the voltage was not present check the wiring between XD terminals 7 & 8 and LSM
terminals 10 & 11. See FO-21 for reference.
(e) Check the contact continuity of relays in the circuit. Replace any relay that is non-functional.
Relay BLR should be on, 52CL1(2) can be forced closed using the test lever.
(f) Push-in all control relays test levers that are pulled out.
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COMPONENTS
AFFECTED
1. Test the DC power to the Hub:

1. ‘B’, ‘C’, or ‘D’ Unit is not
(a) Place CBCP to the ON (Push-in) position.
responding to commands
(b) Visually observe that the power LEDs on the Hub and the RTU come on.
from ‘A’ unit.
(c) If the power LED does not energize on the Hub, check VDC power to the Hub at “PWR+ and
PWR –“, there should be 24VDC present.
2. Test the communications between an ORT and the RTU:

PROBLEM 3:
• RTU (a) Connect an ORT to the PDC.
(b) Start the ORT to the PPCAMP software.
• HUB
(c) Place SMS in MANUAL.
COMMUNICATIONS • PS5 (d) Toggle MSES.
BETWEEN PDC'S IS • IMA (e) Visually observe the Hub LED for port 2. This LED should be flashing. This indicates that
• IMB the ORT is communicating with the Hub.
NOT WORKING 2. ORT only recognizes unit (f) If the LED is not flashing check the RJ45 connections to make sure it is properly seated on
to which it is connected. both sides of the Ethernet connector.
(g) Check the connection to Hub port 2 is properly seated. Visually observe port 3 LED on the
Hub is flashing rapidly. Flashing indicates that the RTU is communicating with the Hub.
(h) Visually observe the LNK and ACT indicators on the RTU. Flashing LEDs indicate that the
RTU is communicating out its Ethernet port. If the LEDs are not flashing check the RJ45
connection to make sure it is properly seated on the RTU.
(i) Check the connection to Hub port 3 is properly seated.
(j) If the Ethernet LEDs on the RTU are flashing and no communications are visible through the
Hub, replace the Hub.
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COMPONENTS
AFFECTED
1. Generator will not auto-synchronize:

(b) Place affected generator ECS in AUTO.
(c) Verify there are no GSC+ shutdowns active.
(d) Place SMS in AUTO.
(e) Place functioning engine ECS to OFF/RESET.
(f) Toggle MSES and hold for 6 seconds. This allows the system to reset itself.
(g) Verify that associated ASR relay momentarily energizes. Indicator LED that is located on the
1. Generator does not auto relay module should illuminate momentarily.
synchronize to the bus. • SPMA (h) If the ASR relay does not energize, check for 24VDC at the coil terminals “A1 and A2”. Refer
(15/25) to FO-23.
• SC/25M (i) If there isn’t 24VDC at the coil, go to Table 7.3.3-1, Problem 10.
(j) Check for continuity across the ASR contacts. Lack of continuity across the contacts
• BVFM
indicates a failed relay module, replace the relay module. A verification check may be done
• PT6 swapping the relay with one of the spare (SPR) modules.
• PT7 (k) Check that the SYNC ENABLE LED on the SPMA is blinking. If the SPMA is enabled but the
PROBLEM 4: breaker will not close, go to Woodward Manual 82384R, Chapter 4, Calibration and Check
• PT8
procedure.
• SSS
GENERATOR WILL • SMS
• SBR1 2. Generator cannot be manually synchronized:
NOT SYNCHRONIZE
• SBR2
• SBR3 (a) Place CBCP to the ON (Push-in) position.
(b) Place affected engine ECS in STOP/COOLDOWN.
• ASR1
(c) Verify that there a HOT bus for these tests.
• ASR2 (d) Verify there are no GSC+ shutdowns active.
• 25M1 (e) Place affected engine ECS in MANUAL.
2. Generator cannot be • 25M2 (f) Select the associated generator on SSS.
manually synchronized (g) Check that the three LEDs on the Sync scope rotate clockwise around the meter. If the
to the bus. LEDs do not, replace the Syncscope meter. This is a diagnostic the meter goes through
upon energizing.
(h) Check operation of the Sync-check relay by confirming that the associated 25M relay
energizes when the Syncscope is at 12o’clock. The LED on the relay module will energize
when the sync-check contact closes.
(i) If the relay does not energize check the wiring from the Syncroscope relay contacts to the
25M relay.
(j) If the wiring is found to be good and the other generator can be manually synchronized
replace the affected 25M relay.
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COMPONENTS
AFFECTED
1. Generator breaker does not operate:
• 52G1 NOTE: Troubleshooting procedure written for generator #1; substitute 2 or B for troubleshooting
generator #2.
• 52G2
• 15/25A (a) Place CBCP to the ON (Push-in) position.
• 15/25B (b) Check the overcurrent relay for proper operation and active faults; clear any active faults.
Refer to Section 12.4.2.1.2.
• 50/51G1
(c) Place affected engine ECS in STOP/COOLDOWN.
• 50/512 (d) Verify there are no GSC+ shutdowns active.
• PT6 (e) Place affected engine ECS in MANUAL.
• BCSG1 (f) Select the associated generator on SSS.
PROBLEM 5: (g) Verify that relay G1BR has energized by inspecting its indicator.
• BCSG2 (h) If G1BR is not picked up, use a multimeter on the VAC scale, check for 120VAC at terminals
• SSS 300A & CP20A.
Generator breaker does not WARNING
GENERATOR • SBR2
close.
OUTPUT BREAKER • BRG1
• BRG2 EQUIPMENT.
WILL NOT OPERATE
• OCR1
• OCR2 (i) If 120VAC is not present at these terminals check transformer PT6 and its fuses.
(j) Check that 52T1 is not energized. If 52T1 is energized go to Table 7.3.3-1, Problem 10.
• 52T1
(k) Place CBCP to the OFF (Pull-out) position.
• 52T2 (l) Check continuity between terminal 300A and terminal 332 with BCSG1 in the CLOSE
• 52C1 position. This will indicate whether the door switches’ contacts are operating.
• 52C2 (m) Check continuity between terminals 332 and 334. This tests the manual sync and dead-bus
close circuit.
• 25M1 (n) Pull-out BRG1 test lever and test for continuity to 52G1 terminal 2. Continuity indicates the
• 25M2 circuit to the breaker close coil is good.
(o) Reset BRG1 test lever.
(p) Test 52G1 circuits on the breaker itself, including the fuse, bridge rectifier, and the coil itself.
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COMPONENTS
AFFECTED
WARNING

• 52F1
EQUIPMENT.
• 52F2
• 50/51F1 Generator breaker does not operate:
PROBLEM 6: • 50/51F2
NOTE: Procedure written for feeder #1. With power applied to the system bus, check that relay SBR
• PT6 is energized. Indicated by the indicator being lit.
• BCSF1
Feeder breaker does not (a) Place CBCP to the ON (Push-in) position.
FEEDER • BCSF2
close. (b) Check the overcurrent relay for proper operation and active faults; clear any active faults.
BREAKER WILL • OCR4
Refer to Section 12.4.2.1.2.
• OCR5 (c) If the relay is off, use a multimeter on the VAC scale and check for 120VAC between
NOT OPERATE
• 52T4 terminals SB31 and SBP20. If there is no voltage, check transformer PT7 and its fusing.
• 52T5 (d) Place CBCP to the OFF (Pull-out) position.
(e) Check continuity between terminal SB31 and terminal 324(328) with BCSF1 and BCSF2 in
• 52C4
the CLOSE position. This will indicate whether the door switch contacts are operating.
• 52C5 (f) Check continuity between terminals 324(328) and 52F1(52F2) terminal 2.
(g) Continuity indicates the circuit to the breaker close coil is good.
(h) Test 52F1 circuits on the breaker itself, including the fuse, bridge rectifier, and the coil itself.
1. Breaker does not close manually with System Bus energized:

• 52T
(b) Check the overcurrent relay for proper operation and active faults; clear any active faults.
• 50/51T Refer to Section 12.4.2.2.2.
PROBLEM 7: • PT7 (c) Check SBR relay is energized and TBR relay is de-energized.
• PT8 (d) Check for 120VAC at terminals SB31 and SBP20. If there is no voltage, check the medium
Breaker does not close voltage fuse on PT7, refer to FO-25, B-2.
• TBCS (e) Place SMS in MANUAL.
TIE BREAKER manually with System Bus
energized. • SMS (f) Hold BCST in the CLOSE position and check for 120VAC between terminals 313 and
WILL NOT • SBR2 SBP20, refer to FO-25, B-2.
• TBR (g) Place CBCP to the OFF (Pull-out) position.
OPERATE (h) De-energize AC power to PDC.
• 52T3 (i) Test wiring continuity between terminal SBP20 and 52T terminal “Neutral” refer to FO-25, B-
• 52C3 2.
(j) Pull-out SBR2 test lever. Test wiring continuity between terminal 313 and 52T terminal 2,
refer to FO-25, B-2.
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COMPONENTS
AFFECTED
2. Breaker does not close automatically with System Bus energized:
NOTE: The tie breaker will only automatically close if there is another MEP-PU-810 connected to the
LS-Net connector on the ‘B’ side of the PDC.

(b) Check SBR relay is energized and TBR relay is de-energized.
(c) Check for 120VAC at terminals SB31 and SBP20; refer to FO-25, B-2.
(d) Check for 120VAC at terminals SB31 and SBP20. If there is no voltage, check the medium
2. Breaker does not close voltage fuse on PT7, refer to FO-25, B-2.
automatically with System (e) Place SMS in AUTO.
Bus energized. (f) Toggle MSES.
(g) Check that 52C3 energizes and that 52T3 is not energized. If 52C3 LED is not visible
• 52T
check for 120VAC between terminal 313 and SBP20.
PROBLEM 7: • 50/51T (h) If there is no voltage at terminal 313, go to Table 7.3.3-1, Problem 10.
• PT7 (i) Place CBCP to the OFF (Pull-out) position.
• PT8 (j) De-energize AC power to PDC.
TIE BREAKER (k) Test wiring continuity between terminal SBP20 and 52T terminal “Neutral”, refer to FO-25,
• TBCS B-2.
WILL NOT • SMS (l) Pull-out SBR2 test lever. Test wiring continuity between terminal 313 and 52T terminal 2,
• SBR2 refer to FO-25, B-2.
OPERATE 3. Breaker does not close manually with Tie Bus energized:
• TBR
(CONTINUED) • 52T3
• 52C3 (b) Check TBR relay is energized and SBR relay is de-energized.
(c) Check for 120VAC at terminals B31 and BP20.
voltage fuse on PT8, refer to FO-25, B-2.
3. Breaker does not close (e) Place SMS in MANUAL.
manually with Tie Bus (f) Hold BCST in the CLOSE position and check for 120VAC between terminals 313 and BP20,
energized. refer to FO-25, B-2.
(g) Place CBCP to the OFF (Pull-out) position.
(h) De-energize AC power to PDC.
(i) Test wiring continuity between terminal BP20 and 52T terminal “Neutral”, refer to FO-25, B-
2.
(j) Pull-out TBR test lever. Test wiring continuity between terminal 313 and 52T terminal 2,
refer to FO-25, B-2.
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COMPONENTS
AFFECTED
4. Breaker does not close automatically with Tie Bus energized:
NOTE: The tie breaker will only automatically close if there is another MEP-PU-810 connected to the
LS-Net connector on the ‘A’ side of the PDC.

(b) Check TBR relay is energized and SBR relay is de-energized.
(c) Check for 120VAC at terminals B31 and BP20; refer to FO-25, B-2.
voltage fuse on PT8, refer to FO-25, B-2.
4. Breaker does not close (e) Place SMS in AUTO.
automatically with System (f) Toggle MSES.
Bus energized. (g) Check that 52C3 energizes and that 52T3 is not energized; refer to FO-25, B-2.
• 52T (h) If 52C3 LED is not visible check for 120VAC between terminal 313 and BP20, refer to FO-
PROBLEM 7: • 50/51T 25, B-2.
(i) If there is no voltage at terminal 313 go to Table 7.3.3-1, Problem 10.
• PT7 (j) Place CBCP to the OFF (Pull-out) position.
• PT8 (k) De-energize AC power to PDC.
TIE BREAKER • TBCS (l) Test wiring continuity between terminal BP20 and 52T terminal “Neutral”, refer to FO-25, B-
• SMS 2.
WILL NOT
• SBR2 (m) Pull-out TBR test lever. Test wiring continuity between terminal 313 and 52T terminal 2,
OPERATE refer to FO-25, B-2.
• TBR
(CONTINUED) • 52T3 5. Breaker does not open manually:
• 52C3
(b) Check SBR relay is energized.
(c) Check for 120VAC at terminals SB31 and SBP20. If there is no voltage transformer PT7 and
its fusing need checking.
5. Breaker does not open (d) Place SMS in MANUAL.
manually. (e) Hold BCST in the CLOSE position and check for 120VAC between terminals 320 and
SBP20.
(f) Place CBCP to the OFF (Pull-out) position.
(g) De-energize AC power to PDC.
(h) Pull-out SBR2 test lever. Test wiring continuity between terminal 320 and 52T terminal 6.
(i) Test wiring continuity between terminal SBP20 and 52T terminals 1 & 7.
(j) Test 52T circuits on the breaker itself, including the fuse, bridge rectifier, and the coil itself.
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COMPONENTS
AFFECTED
6. Breaker does not open automatically:

• 52T
PROBLEM 7: • 50/51T (a) Place CBCP to the ON (Push-in) position.
(b) Check SBR relay is energized.
• PT7
(c) Check for 120VAC at terminals SB31 and SBP20. If there is no voltage transformer PT7
• PT8 and its fusing need checking.
TIE BREAKER 6. Breaker does not open • TBCS (d) Check that 52T3 relay is energized.
automatically. • SMS (e) If 52T3 is not energized check, go to Table 7.3.3-1, Problem 10.
WILL NOT (f) Check for 120VAC between terminals 320 and SBP20.
• SBR2
OPERATE (g) Place CBCP to the OFF (Pull-out) position.
• TBR (h) De-energize AC power to PDC.
(CONTINUED)) • 52T3 (i) Pull-out SBR2 test lever. Test wiring continuity between terminal 320 and 52T terminal 6.
• 52C3 (j) Test wiring continuity between terminal SBP20 and 52T terminals 1 & 7.
(k) Test 52T circuits on the breaker itself, including the fuse, bridge rectifier, and the coil itself.
1. Generator reverse power shutdown:

1. Fault Code: 705 - Generator
• Follow troubleshooting procedures as described in Caterpillar’s Digital Voltage Regulator
reverse power shutdown.
Manual SENR5833-02 or later version, SMCS CODE: 4467.
2. Generator no voltage:
no voltage.
• AVRA Manual SENR5833-02 or later version, SMCS CODE: 4467.
3. Generator low voltage:
3. Fault Code: 701 - Generator • AVRB
PROBLEM 8: low voltage. • VAR Manual SENR5833-02 or later version, SMCS CODE: 4467.
• PT1 4. Generator high voltage:
• PT2 • Follow troubleshooting procedures as described in Caterpillar’s Digital Voltage Regulator
high voltage.
GENERATOR • PT3 Manual SENR5833-02 or later version, SMCS CODE: 4467.
5. Generator unstable voltage:
• CT4
VOLTAGE 5. Generator unstable voltage. • Follow troubleshooting procedures as described in Caterpillar’s Digital Voltage Regulator
• AVRSA
CONTROL Manual SENR5833-02 or later version, SMCS CODE: 4467.
• AVRSB
• PSR1 6. KVAR/PF control during Utility Parallel Operations:
• PSR2 • Check status LED of PSR. During parallel operations with the utility the relay should be on.
If the relay is off, go to Table 7.3.3-1, Problem 10.
6. KVAR/PF control during
• Test the energized relay, using a multimeter on the VDC scale, check voltage differential
Utility Parallel Ops.
between AVR terminals 41 & 50.
• No differential indicates that the voltage regulator is in KVAR/PF mode. Go to Caterpillar’s
Digital Voltage Regulator Manual SENR5833-02 or later version, SMCS CODE: 4467.
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COMPONENTS
AFFECTED
1. No DC control power: See NOTE 1
(a) Check Batteries. Refer to Section 9.4.1.1.

(b) Check D2A and D2B between terminals 1 & 2. A nominal voltage of 24VDC needs to be
present. Refer to FO-7, D-8, D-6 for reference. See NOTE 1.
(c) Check DC voltage D3 and D4 between terminals 1 & TBC 30. A nominal voltage of 24VDC
needs to be present. See NOTE 1 and Refer to FO-7 for reference.
(d) Check voltage between terminal 100 & 2AB. Refer to FO-7 for reference.
1. No DC control power. (e) If there is not 24VDC on terminal 100, check connection to CBCP. Refer to FO-7 for
reference.
PROBLEM 9: • D2A (f) Check the voltage at both terminals on CBCP. With the breaker closed 24VDC should be
• D2B present on terminal to ground. Refer to FO-7 for reference.
(g) Replace CB if not closing. If CB is tripping open, a ground in the DC circuit exists and must
• D3 be located.
DC CONTROL
• D4 (h) Place CBCP to the OFF (Pull-out) position.
POWER • CBCP (i) Check condition of the diodes D2A, D2B, D3, & D4. Replace any diode that has failed.
2. Operating generator shuts down when second unit on PU starts:
(a) Check the status of the Battery Tie Switch (located at front of PU). If closed, open the switch
to isolate engine battery circuits.
2. Operating generator shuts
(b) Check DC voltage between terminals 1A & 2AB. A nominal voltage of 24VDC needs to be
down when second unit on PU
present.
starts.
(c) Lack of DC voltage indicates Engine 1 batteries are not supplying 24VDC to the PDC.
(d) Check DC voltage between terminals 1A & 30AB. A nominal voltage of 24VDC needs to be
present.
(e) Lack of DC voltage indicates Engine 2 batteries are not supplying 24VDC to the PDC.
NOTE 1: Diode Test Procedure: The “Diode Check Function” on a Digital Multimeter should be used because the normal “Ohms Function” on a
digital multimeter does not produce enough voltage to properly test a diode.
1. Reverse Bias – Diode blocks – meter will read (Open Circuit).
2. Forward bias – Diode conducts – meter will read 0.05VDC – 0.8VDC.
3. Incorrect readings: If the diode reads 0 in both directions, it is shorted. If the diode reads (Open Circuit) in both directions.
Replace the defective diode.
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COMPONENTS
AFFECTED
1. No automatic engine start/stop: See FO-11 for reference.
(a) Check engine 1, check DOM1, Out-2 status LED.
(b) If the status LED is on, check for 24VDC at ARR1 terminal A1.
1. No automatic engine (c) If there is no voltage at ARR1-A1, check for 24VDC at DOM1-17.
start/stop. (d) If 24VDC is absent, check the wiring to the terminal.
• RTU
(e) If 24VDC is present, go to Sixnet, VersaTRAK Manual, Section 10 and Sixnet, SIXTRAK
• DIM1 manual, Section 9 for reference.
• DIM2 2. No automatic generator synchronizing: See FO-11 for reference.
• DIM3 (a) Check SPMA-A, check the DOM1 Out - 3 status LED.
(b) If the status LED is on, check for 24VDC at ASR1 terminal A1.
2. No automatic generator • DOM1
(c) If there is no voltage at ASR1-A1, check for 24VDC at DOM1 - 17.
synchronizing. • DOM2 (d) If 24VDC is absent, check the wiring to the terminal.
• PCM (e) If 24VDC is present, go to Sixnet, VersaTRAK Manual, Section 10 and Sixnet, SIXTRAK
• CCM manual, Section 9 for reference.
3. Breakers cannot be manually closed: See FO-23 for reference.
PROBLEM 10: • P15
(a) Check the “Uplink Port” LEDs on the RTU. Both should be flashing. This indicates the RTU
• SMS is communicating with the PCM.
• MSES (b) Check the display on the CCM for “E00” and for 3 small intermittently blinking LEDs. This
PROGRAMMABLE • BSS indicates that the PCM is communicating with the CCM and the CCM is communicating with
the GSC+ modules.
LOGIC CONTROL • GMS (c) Check SPR5 status LED and DOM1-16 LED is on. This indicates that power is being sent to
3. Breakers cannot be • FSS the PCM.
SYSTEM (RTU) manually closed. (d) Check for 24VDC at P15 “INPUT + - “ terminals and for 15VDC at “OUTPUT + - “ terminals.
• AVRS
This indicates that power is available for the PCM. See FO-22 for reference.
• USS
(e) Check status of 52T1. See FO-22 for reference.
(f) There will only be a light when synchronizing on to the bus. If the status LED is on, check
DOM1-6 status LED. See FO-22 for reference.
(g) If both above are on go to Sixnet, VersaTRAK Manual, Section 10 and Sixnet, SIXTRAK
manual, Section 9 for reference.
4. Generator operates in speed droop instead of isochronous:
(a) Check GDR1 status LED and DOM1-12 LED are off, this indicates that the control system is
not in speed droop. See FO-22 for reference.
4. Generator operates in
(b) If the status LED is on, check position of GMS not in UTILITY PARALLEL.
speed droop instead of
(c) With the generator breaker closed, check continuity between LSM terminals 13 & 14. An
isochronous.
open connection indicates that the generator is operating in speed droop.
(d) Check circuit wiring for improper connections.
(e) Check operation of relay 52CL1.
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7.3.4 TROUBLESHOOTING THE FUEL PRIMER PUMP
To troubleshoot the Fuel Primer Pump, perform the following:
a. Attempt to prime the fuel system according to Section 11.4.4.
b. If the procedure does not work, replace the Fuel Primer Pump.
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7.3.5 COOLING SYSTEM TROUBLE SHOOTING PROCEDURES
All Safety Warnings and Cautions in Section 7.1 apply to this table.
a. There are three basic problems typical of cooling systems:
• Overheating
• Loss of coolant
• Overcooling
b. A problem in the cooling system should first be diagnosed by visual inspection. If the problem cannot be diagnosed, tools must be used to
find the cause of the problem.

PROBLEM POSSIBLE CAUSES
• External leaks caused by loose connections, expansion tank cap or cooling system relief valve with defects.
PROBLEM 1: Internal leaks caused by cracked cylinder head, cracked cylinder block, loose cylinder heads, damaged radiator
LOW COOLANT LEVEL core, and damaged gaskets.
• See Note 1 and Note 2.
• Plugged radiator core.

• Damaged or bent radiator fins.
PROBLEM 2:
• Fan is damaged or installed backwards.
REDUCED AIR FLOW THROUGH
• Damaged fan shroud, wrong diameter fan or incorrect number of fan blades.
RADIATOR
• Incorrect fan blade position (Fan projection out of the shroud must be approximately 50%).
NOTE 1: Refer to Section 13.3.4 for additional information.

NOTE 2: Refer to SENR1067-02 or later version, SMCS CODE: 1350-040 for additional reference.
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TABLE 7.3.5-1 COOLANT SYSTEM TROUBLESHOOTING PROCEDURES (CONTINUED)

PROBLEM 3: • Defective expansion tank cap.

INSUFFICIENT COOLING SYSTEM • Detective radiator top tank neck or stud.
PRESSURE • See Note 1 and Note 2.
• Air in cooling system because of incorrect cooling system fill.

• Combustion gases in cooling system from loose cylinder head, cracked cylinder head, loose or defective pre-
PROBLEM 4: combustion chamber, defective cylinder head gasket, worn cylinder liner counter bore.
COOLANT OVERFLOW • Low coolant level.
• Steam in cooling system because of engine or low coolant level.
• Stuck water temperature regulator(s).

• Absence of water temperature regulator(s).
PROBLEM 5:
• Lose water pump impeller.
INSUFFICIENT COOLANT FLOW
• Internal radiator plugged.
• High ambient air temperature.
• Plugged openings in screens for engine compartment with a blower fan.
PROBLEM 6: • Disconnected inlet air pipe in engine room.
HIGH INLET AIR TEMPERATURE OR • Dirty after-cooler core.
RESTRICTION • Plugged air cleaner.
• Damaged or carbon packed turbocharger.
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TABLE 7.3.5-1 COOLANT SYSTEM TROUBLESHOOTING PROCEDURES (CONTINUED)

• Insufficient flow through coolant radiator.
PROBLEM 7:
• Scale on cylinder liners or cylinder head.
LOW HEAT TRANSFER
• Damaged turbocharger.
• Restriction in exhaust pipes.
PROBLEM 8:
• Water in muffler.
EXHAUST RESTRICTION
• Loose baffle in muffler.
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7.3.6 RUNNING GEAR/TRAILER TROUBLESHOOTING PROCEDURES
7.3.6.1 MEP-PU-810A RUNNING GEAR/TRAILER TROUBLESHOOTING PROCEDURES
TABLE 7.3.6.1-1 MEP-PU-810A RUNNING GEAR/TRAILER TROUBLESHOOTING PROCEDURES

SYMPTOM CAUSE REMEDIES
1. Broken or Kinked Brake Lines • Repair or Replace

PROBLEM 1:
2. Severe Under-adjustment • Adjust Brakes
NO BRAKES
3. Malfunctioning Actuation System • Troubleshoot System
1. Brake Adjustment Not Correct • Manual - Adjust Brakes; Automatic - Make Several Reverse Stops
2. Excessively Worn Brake Linings • Replace Shoe & Lining
3. Incorrect Lining • Install Correct Shoe & Lining
4. Grease or Fluid Soaked Lining • Repair Grease Seal or Wheel Cylinder. Install New Shoe and Lining
PROBLEM 2:
5. Frozen Master Cylinder or Wheel Cylinder Pistons • Recondition or Replace All Cylinders, Brake Fluid
WEAK BRAKES
6. Glazed Lining • Refurbish or Replace
7. Excessive Drum Wear • Replace
8. Trapped Air in Lines • Bleed System
9. Malfunctioning Actuating System • Troubleshoot System
PROBLEM 3: 1. Brake Adjustment Not Correct • Manual - Adjust Brakes; Automatic - Make Several Reverse Stops
HARSH BRAKES 2. Grease or Fluid on Linings • Replace Shoe & Lining
NOTE: Refer to Section 18.3.1 for reference.
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TABLE 7.3.6.1-1 MEP-PU-810A RUNNING GEAR/TRAILER TROUBLESHOOTING PROCEDURES (CONTINUED)

PROBLEM 4: 1. Grease or Oil on Linings • Clean or Replace

SURGING BRAKES 2. Out of Round Drums or Cracked Drums • Machine or Replace
1. Under-adjustment • Adjust
PROBLEM 5: 2. Lack of Lubrication • Lubricate
NOISY BRAKES 3. Broken Brake Components • Replace Components
4. Incorrect Brake Components • Correct
1. Loose, Bent or Broken Brake Components • Replace Components

PROBLEM 6:
LOCKING BRAKES
3. Out of Round Drums • Machine or Replace
1. Incorrect Tire Pressure • Inflate Evenly on Both Sides to Req. Pressures

2. Unmatched Tires on Same Axle • Match Tires on Axles
PROBLEM 7: 3. Restricted Brake Lines or Hoses • Repair or Replace
PULLS TO ONE SIDE 4. Malfunctioning Cylinder Assembly • Check for Stuck or Sluggish Pistons
5. Defective or Damaged Shoe and Lining • Install New Shoe and Lining-Complete Axle
6. One Side Out-of-Adjustment • Adjust
1. Improper Fluid • Replace Rubber Parts, Fill with DOT4 Fluid

PROBLEM 8: 2. Blocked Master Cylinder • Open with Compressed Air or Replace Cylinder
DRAGGING 3. Parking Brake Set or Frozen • Free Brake and Lubricate
4. Improper Lining Thickness or Location • Install New Shoes and Linings
NOTE: Refer to Section 18.3.1 for reference.
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7.3.6.2 MEP-PU-810B RUNNING GEAR/TRAILER TROUBLESHOOTING PROCEDURES
7.3.6.2.1 TROUBLESHOOTING THE ABS SYSTEM
In-Service ABS Dynamic Check: (DO NOT use a battery charger)
To check the operation of the entire ABS system, hook a tractor to the trailer and charge the trailers air tank. Ensure that the petcock is closed
(Figure 18.3.2.2-1). Turn on the ignition key and ensure that the warning light (Figure 18.2.1.2.5-3) comes on briefly, and then goes out. Pull the
trailer at a speed above 6 mph and make a brake application until the tractor-trailer has come to a complete stop. Verify that the ABS light has
remained OFF. If the light remains OFF, the system is functioning properly. If the ABS system detected an error during the stop, the warning
light will be ON. If the light never comes on, then refer to the Troubleshooting Information – “No ABS Warning Light illumination”. If the light
stays ON with the ignition key ON, refer to the Troubleshooting Information – “ABS light stays ON when there is Power to the ABS System”.
NOTE 1: Disconnect power from the ABS system before testing continuity for opens or shorts, or making any repairs.
NOTE 2: Most ABS problems are related to:

• Cut, corroded, or abraded wires.
• Corroded connectors and terminals,
• Connector terminals not latched or seated correctly to mating assemblies.
• Excessive sensor air gap, sensor clip retention, or bearing endplay.
NOTE 3: Refer to Foldout FO-55 and FO-56 for a complete wiring diagram of the ABS system
Before Getting Started:
This guide lists the most typical problems only. Consult Radian Inc for anything not addressed here.
• Power is required at Stop light circuit, pin 4, and air is needed to both the supply and service glad hands.
• Do NOT use a battery charger- to power the ABS.
• A Volt/Ohm Meter is needed for some of the troubleshooting procedures.
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• Before disconnecting anything, remove electrical power and air pressure from the system.
• The numbers in parentheses ( ) refer to the callouts in the wiring layout shown in Figure 18.2.1.2.5-1.
Start Here:
Don't overlook the obvious. Check to make sure that you have power and that everything is connected properly.
TABLE 7.3.6.2.1-1 TROUBLESHOOTING THE ABS SYSTEM

SYMPTOM REMEDY
a. Check the bulb to verify that it is functional. If not functional, replace it.
b. Verify that there is power to the ECU. Disconnect the main wire harness 19 pin connector and check for B+ (positive power) at
either pin #3 or pin #1. The voltage drop between the SAE. J560-7 way and the ECU should not exceed 2 volts. If no power exists
at either pin, then check continuity between these pins and the SAE J560-7 way connector red and blue circuits. Make necessary
PROBLEM 1: repairs and retest.
c. If the problem is still present, remove the main wire harness 19 pin connector at the ECU and verify continuity between pin #10 and
NO ABS WARNING LIGHT the light. The remaining light wire must be grounded to the trailer chassis or connected to the SAE J560-7 way connector ground
ILLUMINATION wire.
d. Check for continuity between the light wire and ground.
e. Repair as necessary and retest.
f. Listen for 2 clicks when reconnecting the main wire harness to the ECU and secure the connection with the attached metal latch.
g. ABS brakes only work when connected to a 12VDC system.
NOTE: Refer to Section 18.2.1.2.5 and 18.3.2 for additional information.
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TABLE 7.3.6.2.1-1 TROUBLESHOOTING THE ABS SYSTEM (CONTINUED)

SYMPTOM REMEDY
a. While the trailer is sitting still only, there is also a valve blow down (air exhausts from ABS relay valve).
PROBLEM 2: b. This is normal and indicates that the ABS system is Ok.
c. The ABS light will come on and go off.
ABS LIGHT COMES ON AND GOES OFF d. The valve blow down is an audio check of the solenoids (located on the top of the ABS relay valve).
e. If the ABS is powered up when traveling above 6 mph, the ABS light will stay off unless there is a fault.
a. This troubleshooting procedure requires that electrical power be connected, Refer to FO-51, for the following steps:
• Older tractors power ABS through the stop light circuit and the ABS light will come on when the brakes are applied. Verity that
there is adequate power at the trailer 7-way, pin 4 (1).
• There should be 12-14VDC for test purposes.
• If there is no power then the tractor wiring or coiled power cable needs repaired.
• If there is power at the 7-way, check for 10-14VDC at the power cord connector (2).
• If no power exists, then the trailer ABS power cord needs repair.
PROBLEM 3: • Most trailers have Integral ABS power in the main trailer wiring.
• Check the bulb to verity that it is functional. If not functional, replace it.
ABS LIGHT NEVER COMES ON OR IS
• Disconnect the ABS wire harness at the power Cord (2). Check for continuity through the light wiring (3). The resistance
VERY DIM
should be 3-6 Ohms. If this is not the case, then the light wiring needs to be repaired.
• Check connections for excessive pin spread and/or corrosion.
b. If the problem remains, disconnect the ABS ECU connector (4).
• Check for bent pins, repair and test.
• Test for continuity between pins in the valve connector and ABS ECU connector a multimeter.
• See FO-51 for pin assignments.
• Replace harness if bad, and ECU if problem continues to exist (5).
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SYMPTOM REMEDY
a. This troubleshooting procedure requires that power be applied to the trailer for 30 seconds/off to verity. The ABS is powered through
the auxiliary circuit whenever the key is in the “on" position and the stop light circuit with the brakes applied.
NOTE: For some sensor faults the trailer must be driven above 6 mph for the light to go off.
b. Verify the voltage at the 7-way (pin #4) is 12-14 volts and that a valve blow down occurs when powering the ABS. If there is no
blow down, then verify that air pressure was applied to the service brakes.
c. If there is air pressure to the service bakes, then disconnect the solenoid connector (6) and check the resistance at the solenoid
pins:
• Readings across the two bottom pins should be 7-9 Ohms.
• Readings between either the bottom pin and the top pin should be 3.5-4.5 Ohms.
PROBLEM 4: • If resistance is okay, then check the female pins in the connector for excessive pin spread and/or corrosion.
• Repair and test.
ABS LIGHT STAYS ON WHEN THERE IS d. If there is a valve blow down, then a sensor is the most likely issue. The sensor gap could be too large. Try pushing the sensors
POWER TO THE ABS SYSTEM in until they touch the exciter (7).
e. If the problem remains, disconnect the sensor connectors from the sensors and measure the resistance between the two pins in
the sensor connector housing (8). The reading for each sensor should be between 980 and 2350 Ohms. Check for pin spread
and/or corrosion also. The sensor should be replaced, if an issue is found.
f. Measure the AC voltage at each sensor while rotating the wheel at a rate of 1 revolution every two seconds. The reading should
average greater than .200 Volts. If this is not the case, replace the sensor.
g. If the problem persists, disconnect the ECU connector (4).
• Check for bent pins.
• Repair and retest.
• Test for continuity between pins in the valve connector and ABS ECU connector a multimeter.
• See FO-51 for pin assignments.
• Replace harness if bad, and ECU if problem continues to exist (5).
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SYMPTOM REMEDY
a. Intermittent problems are the most difficult to diagnose.
b. The best place to start is at the speed sensors:
• Sensor gap could be too large.
• Try pushing in the sensors until they touch the exciter.
c. Next, check for loose sensor and excess wheel endplay:
• The sensor should fit tight in its mounting.
• If the sensor feels loose, replace the sensor clip.
• If wheel-bearing endplay is excessive, or if the wheel bearing is worn, the sensor can produce an intermittent signal and cause
PROBLEM 5: a fault.
ABS WARNING LIGHT ONLY COMES • Repair as needed and retest.
d. Another possible cause is a damaged exciter ring.
ON SOMETIMES • Inspect the exciter ring teeth closely.
• If any damage is found, replace the exciter.
e. If no problem is found, then the rest of the electrical system needs to be inspected.
• The most common cause of ABS faults involves wires and connectors.
• This can include connectors not latched properly, bad splices, abrasions, spread or bent pins, pin corrosion, and wire strand
breaks.
• Check for these conditions at each connection.
• Inspect all splices for tightness and damage.
• Repair or replace as required.
a. A dragging service or parking break, a pinched or kinked delivery hose can all cause wheel lock. A perfectly functioning ABS
system may not be able to overcome these problems.
PROBLEM 6: • Examine hoses and breaks for these conditions.
ABS WARNING LIGHT COMES ON • Replace, repair, or adjust any defective hardware and retest.
b. If both sensors have excessive gap or if both exciters are missing, the ABS system will always assume that the vehicle is sitting still.
WHEN POWERED UP, GOES OFF There will be no indication of a fault. In this case, the ABS system cannot respond to a locked wheel condition.
ABOVE 6 MPH, BUT WHEELS LOCK UP • Reseat the sensors until they touch the exciter.
• Inspect for missing exciters.
c. If the problem still exists, contact Radian Inc.
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7.3.6.2.2 MEP-PU-810A RUNNING GEAR/TRAILER TROUBLESHOOTING PROCEDURES
TABLE 7.3.6.2.2-1 MEP-PU-810B RUNNING GEAR/TRAILER TROUBLESHOOTING PROCEDURES

PROBLEM 1: 1. Broken or Kinked Brake Lines • Repair or Replace

2. Severe Under-adjustment • Adjust Brakes
NO BRAKES 3. Malfunctioning Actuation System • Troubleshoot System
1. Brake Adjustment Not Correct • Manually - Adjust Brakes; Automatic - Make Several Reverse Stops
2. Excessively Worn Brake Linings • Replace Shoe & Lining
3. Incorrect Lining • Install Correct Shoe & Lining
PROBLEM 2: 4. Grease or Fluid Soaked Lining • Repair Grease Seal or Wheel Cylinder. Install New Shoe and Lining
5. Frozen Master Cylinder or Wheel Cylinder Pistons • Recondition or Replace All Cylinders, Brake Fluid
WEAK BRAKES 6. Glazed Lining • Refurbish or Replace
7. Excessive Drum Wear • Replace
8. Trapped Air in Lines • Bleed System
9. Malfunctioning Actuating System • Troubleshoot System
PROBLEM 3:
1. Brake Adjustment Not Correct • Manually - Adjust Brakes; Automatic - Make Several Reverse Stops
HARSH BRAKES 2. Grease or Fluid on Linings • Replace Shoe & Lining
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TABLE 7.3.6.2.2-1 MEP-PU-810B RUNNING GEAR/TRAILER TROUBLESHOOTING PROCEDURES (CONTINUED)

PROBLEM 4: 1. Grease or Oil on Linings • Clean or Replace

SURGING BRAKES 2. Out of Round Drums or Cracked Drums • Machine or Replace
PROBLEM 5: 2. Lack of Lubrication • Lubricate
NOISY BRAKES 3. Broken Brake Components • Replace Components
4. Incorrect Brake Components • Correct
• Replace Components
1. Loose, Bent or Broken Brake Components
• Adjust
PROBLEM 6: 2. Under-adjustment
• Machine or replace
LOCKING BRAKES 3. Out of Round Drums
4. Insufficient Air Pressure to release brakes • Check air lines for leaks
• Check towing vehicle for proper air pressure
1. Incorrect Tire Pressure • Inflate tires to proper pressure

2. Unmatched Tires on Same Axle • Match tires on axles
PROBLEM 7: 3. Restricted Brake Lines or Air Hoses • Repair or replace
PULLS TO ONE SIDE 4. Malfunctioning Cylinder Assembly • Check for stuck or sluggish pistons
5. Defective or Damaged Shoe and Lining • Install new shoes and linings for the axle
6. One Side Out-of-Adjustment • Adjust
1. Improper Fluid • Replace rubber parts, fill with DOT4 Fluid

PROBLEM 8: 2. Blocked Master Cylinder • Open with compressed air or replace cylinder
DRAGGING 3. Parking Brake Set or Frozen • Free brake and lubricate
4. Improper Lining Thickness or Location • Install new shoes and linings
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7.3.7 HYDRAULIC SYSTEM TROUBLESHOOTING PROCEDURES
TABLE 7.3.7-1 HYDRAULIC SYSTEM TROUBLESHOOTING PROCEDURES

SYMPTOM REMEDY
a. Ensure hydraulic fluid level is correct and that the pump is not cavitating. Refer to Section 19.3 for additional information.
b. If all fan motors are turning slowly, you should ensure that the engine is turning at the correct RPM. The pumps and motors are all
the same displacement, therefore, motor speed is directly proportional the engine speed:
• At 60 Hz, the fan RPM should be 1750 RPM or greater.
• At 50 Hz, the fan RPM should be 1650 RPM or greater.
c. Next, check the Pressure Relief Valves. They are preset at the factory and cannot be changed. Refer to Section 19.4.1 for
reference.
SLOW FAN SPEED
d. If the problem still persists, then the pump should be tested for volumetric efficiency and repaired or replaced as necessary. Refer
to Section 19.4.2.1 for additional information.
e. If problem still persists, then the motor or motor(s) should be repaired or replaced. Refer to Section 19.4.2.1 for additional
information.
f. Check hydraulic fluid temperature, ensure the hydraulic fluid being used is within the proper temperature range for the location.
NOTE: If fans do not spin at all, then the suction line shutoff valves may be closed or oil level may be too low.
NOTE: Refer to Section 19.2 and 18.3.2 for additional information.
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CHAPTER 8
HOUSING ASSEMBLY REPAIR
TABLE OF CONTENTS
SECTION TITLE PAGE

8.0 REPAIR OF HOUSING ASSEMBLY 5
8.2 BRIEF DESCRIPTION 7
8.3 SERVICE REQUIREMENTS 7
8.3.1 INSPECT POWER UNIT HOUSING 7
8.3.2 CLEAN POWER UNIT HOUSING 8
8.4 COMPONENT REPAIR PROCEDURES 8
8.4.1 ACCESS DOORS AND FRONT SIDE PANELS 8
8.4.1.1 INSPECT THE ACCESS DOORS AND FRONT SIDE PANELS 10
8.4.1.2 REMOVE THE ACCESS DOORS AND FRONT SIDE PANELS 10
8.4.1.3 INSTALL THE ACCESS DOORS AND FRONT SIDE PANELS 11
8.4.1.4 SERVICE THE ACCESS DOORS AND FRONT SIDE PANELS 11
8.4.1.5 REPAIR THE ACCESS DOORS AND FRONT SIDE PANELS 11
8.4.2 PLENUM ASSEMBLY SCREENS 12
8.4.2.1 INSPECT THE PLENUM ASSEMBLY SCREENS 13
8.4.2.2 REMOVE THE PLENUM ASSEMBLY SCREENS 14
8.4.2.3 INSTALL THE PLENUM ASSEMBLY SCREENS 14
8.4.2.4 SERVICE THE PLENUM ASSEMBLY SCREENS 15
8.4.2.5 REPAIR THE PLENUM ASSEMBLY SCREENS 15
8.4.3 SIDE PANELS 16
8.4.3.1 INSPECT THE SIDE PANELS 17
8.4.3.2 REMOVE THE SIDE PANELS 17
8.4.3.3 INSTALL THE SIDE PANELS 17
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8.4.3.4 SERVICE THE SIDE PANELS 18
8.4.3.5 REPAIR THE SIDE PANELS 18
8.4.4 “A” AND “B” MODEL TOP PANEL ASSEMBLY 19
8.4.4.1 INSPECT THE “A” AND “B” MODEL TOP PANEL ASSEMBLY 20
8.4.4.2 REMOVE THE “A” AND “B” MODEL TOP PANEL ASSEMBLY 20
8.4.4.2.1 REMOVE THE REAR ROOF PANEL SECTION 20
8.4.4.2.2 REMOVE THE FRONT ROOF PANEL SECTION 21
8.4.4.3 INSTALL THE “A” AND “B” MODEL TOP PANEL ASSEMBLY 21
8.4.4.3.1 INSTALL THE REAR ROOF PANEL SECTION 21
8.4.4.3.2 INSTALL THE FRONT ROOF PANEL SECTION 22
8.4.4.4 SERVICE THE TOP PANEL ASSEMBLY 23
8.4.4.5 REPAIR THE TOP PANEL ASSEMBLY 23
8.4.5 BATTERY BOX ASSEMBLY 24
8.4.5.1 INSPECT THE BATTERY BOX ASSEMBLY 26
8.4.5.2 REMOVE THE BATTERY BOX ASSEMBLY 26
8.4.5.3 INSTALL THE BATTERY BOX ASSEMBLY 27
8.4.5.4 SERVICE THE BATTERY BOX ASSEMBLY 28
8.4.5.5 REPAIR THE BATTERY BOX ASSEMBLY 28
8.4.6 FUEL TANK AND HYDRAULIC RESERVOIR ASSEMBLIES 29
8.4.6.1 INSPECT THE FUEL TANK AND HYDRAULIC RESERVOIR ASSEMBLIES 29
8.4.6.2 REMOVE THE FUEL TANK AND HYDRAULIC RESERVOIR ASSEMBLIES 30
8.4.6.2.1 REMOVE THE FUEL TANK 32
8.4.6.2.2 REMOVE THE HYDRAULIC RESERVOIR 34
8.4.6.3 INSTALL THE FUEL TANK AND HYDRAULIC RESERVOIR ASSEMBLIES 36
8.4.6.3.1 INSTALL THE FUEL TANK 36
8.4.6.3.2 INSTALL THE HYDRAULIC RESERVOIR 37
8.4.6.3 SERVICE THE FUEL TANK AND HYDRAULIC RESERVOIR ASSEMBLIES 39
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8.4.6.4 REPAIR THE FUEL TANK AND HYDRAULIC RESERVOIR ASSEMBLIES 39
8.4.7 MUFFLER ASSEMBLY 40
8.4.7.1 INSPECT THE MUFFLER ASSEMBLY 40
8.4.7.2 REMOVE THE MUFFLER ASSEMBLY 41
8.4.7.3 INSTALL THE MUFFLER ASSEMBLY 41
8.4.7.4 SERVICE THE MUFFLER ASSEMBLY 42
8.4.7.5 REPAIR THE MUFFLER ASSEMBLY 42
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LIST OF FIGURES
FIGURE TITLE PAGE

FIGURE 8.4.1-1 MEP-PU-810, ACCESS DOORS AND FRONT SIDE PANELS 9
FIGURE 8.4.2-1 MEP-PU-810 A & B, TOP PLENUM SCREENS 12
FIGURE 8.4.2.1-1 MEP-PU-810 A & B, BOTTOM PLENUM SCREENS 13
FIGURE 8.4.3-1 MEP-PU-810 SIDE PANELS 16
FIGURE 8.4.4-1 “A” MODEL TOP PANEL ASSEMBLY 19
FIGURE 8.4.5-1 BATTERY BOX ASSEMBLY 24
FIGURE 8.4.5-2 BATTERY BOX ASSEMBLY (SIDE VIEW) 25
FIGURE 8.4.5-3 BATTERY BOX ASSEMBLY (TOP VIEW) 25
FIGURE 8.4.6-1 REMOVABLE TANK ASSEMBLIES 29
FIGURE 8.4.6.2-1 EXTERNAL FUEL DISTRIBUTION MANIFOLD, SHUTOFF VALVE 30
FIGURE 8.4.6.2-2 FUEL TANK SUPPLY, SHUTOFF VALVE 30
FIGURE 8.4.6.2-3 EXTERIOR FUEL PUMP ASSEMBLY (NEW AND OLD) 31
FIGURE 8.4.6.2.2-1 HYDRAULIC RESERVOIR SUPPLY, SHUTOFF VALVE 34
FIGURE 8.4.7-1 MUFFLER ASSEMBLY 40
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8.0 REPAIR OF HOUSING ASSEMBLY
The following areas are covered in this Chapter:
• Safety
• Brief Description
• Service Requirements
• Component Repair Procedures
following:

• Rotating Parts


due maintenance.
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function. Place the Fuel Pump Source Switch (FPSS) into the (G1 or G2 position). Place the
FPSS in the (G1 or G2) position, for the generator set not receiving maintenance.

5.9.6.15, Unit Isolation Procedure with PSC. (Note 1 and 2.)
NOTE 2: A Qualified Electrician needs to ensure load cables are not energized by opening the
circuit breaker of the Primary Switching Center (PSC), then disconnect Load Cables (Using
the proper safety gear) on the PU and place them on the Parking Stands.
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8.2 BRIEF DESCRIPTION
The Power Unit Housing is a weather tight enclosure that provides easily removable access panels,
doors, and screens for major maintenance, overhaul, and replacement of all major mechanical and
electrical components. This includes easy access and removal of the Primary Distribution Center (PDC)
and both engine/generator sets. The housing provides ISO container features. Air intake and exhaust
openings allow operation with all doors closed. A three-step ladder is provided to assist personnel
access to the interior of the MEP-PU 810B model.
8.3 SERVICE REQUIREMENTS
8.3.1 INSPECT POWER UNIT HOUSING
WARNING

WARNING
ACCESS DOORS AND PANELS ARE HEAVY. USE EXTREME CAUTION WHEN
UNBOLTING AND REMOVING. THIS TASK IS A TWO PERSON LIFT.
WARNING

Inspect the interior and exterior of the Power Unit Housing for the following:
unable to start. See procedures in paragraph 8.1.d.
b. Inspect the interior and exterior of the Power Unit Housing for weather-stripping for cracks,
deterioration and signs of water leaks.
c. Inspect the interior and exterior of the Power Unit Housing for housing frame for cracks, dents,
corrosion, rust, and deterioration.
d. Inspect the interior and exterior of the Power Unit Housing for hardware for damage, missing
components, corrosion and broken locking mechanisms.
e. Inspect the Power Unit Housing air cleaner plenum assembly screens and upper and lower
plenum screens for debris, mounting and missing hardware.
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f. Inspect the interior and exterior of the Power Unit Housing mounting hardware for corrosion and
missing components.
8.3.2 CLEAN POWER UNIT HOUSING
WARNING

WARNING
WARNING

Clean the interior and exterior of the Power Unit Housing as follows:
b. Clean the interior and exterior of the Power Unit Housing using stiff brushes, clean cloths, and
cleaning detergent.
c. Repaint as necessary.
8.4 COMPONENT REPAIR PROCEDURES
• Access Doors and Front Side Panels

• Plenum Assembly Screens
• Side Panels
• “A” and “B” Model Top Panels Assembly
• Battery Box Assembly
• Fuel Tank and Hydraulic Reservoir Assemblies
• Muffler Assembly
8.4.1 ACCESS DOORS AND FRONT SIDE PANELS
The following maintenance procedures are provided for the access doors and front side panels.
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Inspect
Remove
Install
Service
Repair
FIGURE 8.4.1-1 MEP-PU-810, ACCESS DOORS AND FRONT SIDE PANELS
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8.4.1.1 INSPECT THE ACCESS DOORS AND FRONT SIDE PANELS
Inspect the Access Doors and Front Side Panels for the following:
a. Inspect the Access Doors and Front Side Panels hinges for rust, bends, and ease of operation.
b. Inspect the Access Doors and Front Side Panels frames for corrosion, rust, dents, and binding.
c. Inspect the Access Doors and Front Side Panels latches for condition and proper operation.
d. Inspect the Access Doors and Front Side Panels interior door panels for mounting, sharp edges
and missing components.
e. Inspect the Access Doors and Front Side Panels mounting hardware for missing or damaged
components.
8.4.1.2 REMOVE THE ACCESS DOORS AND FRONT SIDE PANELS
WARNING

WARNING
WARNING

To remove the Access Doors and Front Side Panels, proceed as follows:
b. Remove and retain the mounting hardware that secures the Access Doors and Front Side
Panels to the Power Unit. Open the door latch use Figure 8.4.1-1 as reference.
c. Carefully remove the Access Doors and Front Side Panels. Use two people for removal of the
Access Doors and Front Side Panels.
d. Store removed items in an area where they will not be damaged.
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8.4.1.3 INSTALL THE ACCESS DOORS AND FRONT SIDE PANELS
WARNING

WARNING
WARNING

To install the Access Doors and Front Side Panels, proceed as follows:
b. Carefully place door or front side panel in place. Use two people for installation of the Access
Doors and Front Side Panels.
c. Reinstall retained mounting hardware.
8.4.1.4 SERVICE THE ACCESS DOORS AND FRONT SIDE PANELS
Service the removed Access Doors and Front Side Panels by cleaning using stiff brushes, clean cloths,
and cleaning detergent.
8.4.1.5 REPAIR THE ACCESS DOORS AND FRONT SIDE PANELS
To repair the removed the Access Doors and Front Side Panels, proceed as follows:
a. Straighten bent doors and frames.
b. Repaint as required in accordance with MIL-T-7O4.
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c. If locking door latch is damaged, remove latch by removing mounting hardware that secures the
latch to the access door. Replace the latch.
d. If sharp areas or burrs are found, use a file to smooth the area and repaint the area.
8.4.2 PLENUM ASSEMBLY SCREENS
The following maintenance procedures are provided for the plenum assembly screens.
Inspect
Remove
Install
Service
Repair
FIGURE 8.4.2-1 MEP-PU-810 A & B, TOP PLENUM SCREENS
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8.4.2.1 INSPECT THE PLENUM ASSEMBLY SCREENS
Inspect the Plenum Assembly Screens for the following:
a. Inspect the Plenum Assembly Screens for rust.
b. Inspect the Plenum Assembly Screens for bends or distortion.
c. Inspect the Plenum Assembly Screens for missing mounting hardware.
FIGURE 8.4.2.1-1 MEP-PU-810 A & B, BOTTOM PLENUM SCREENS
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8.4.2.2 REMOVE THE PLENUM ASSEMBLY SCREENS
WARNING

WARNING

To remove the Plenum Assembly Screens, proceed as follows:
b. Remove and retain the mounting hardware that secures the Plenum Assembly Screens to the
Power Unit use Figure 8.4.2-1 and Figure 8.4.2.1-1 as reference.
c. Carefully lift screens (From on top of Power Unit) or drop plenum screens (From beneath the
Power Unit). This task requires two people to lift the Plenum Assembly Screens.
8.4.2.3 INSTALL THE PLENUM ASSEMBLY SCREENS
WARNING

WARNING

To install the Plenum Assembly Screens, proceed as follows:
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b. Carefully place the Plenum Assembly Screens back into position. Use two people for
installation of the Plenum Assembly Screens; use Figure 8.4.2-1 and Figure 8.4.2.1-1, as
references.
c. Replace the retained mounting hardware that secures the Plenum Assembly Screens to the PU.
8.4.2.4 SERVICE THE PLENUM ASSEMBLY SCREENS
Service the removed Plenum Assembly Screens by cleaning using stiff brushes, clean cloths, and
cleaning detergent.
8.4.2.5 REPAIR THE PLENUM ASSEMBLY SCREENS
To repair the removed Plenum Assembly Screens, proceed as follows:
a. Straighten bent or distorted plenum screens.
b. Repaint as required .
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8.4.3 SIDE PANELS
The following maintenance procedures are provided for the side panels.
Inspect
Remove
Install
Service
Repair
FIGURE 8.4.3-1 MEP-PU-810 SIDE PANELS
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8.4.3.1 INSPECT THE SIDE PANELS
Inspect the Side Panels for the following:
a. Inspect the Side Panels for bent or distorted side panels, and ease of fit.
b. Inspect the Side Panels for corrosion, rust, dents, and binding.
8.4.3.2 REMOVE THE SIDE PANELS
WARNING

WARNING
REMOVING.
WARNING

To remove the side panels, proceed as follows:
b. Remove and retain the mounting hardware that secures the Side Panels to the MEP-PU-810 use
Figure 8.4.3-1 for reference.
c. Carefully remove the Side Panel. Use two people for removing the Side Panels.
d. Check gaskets for cracks and deterioration and replace, if necessary, before re-installing the
Side Panels.
8.4.3.3 INSTALL THE SIDE PANELS
WARNING

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WARNING
REMOVING.
WARNING

To install the Side Panels, proceed as follows:
b. Check gaskets for cracks and deterioration and replace, if necessary, before re-installing the
Side Panels use Figure 8.4.3-1 for reference.
c. Carefully place the Side Panels back into position. Use two people for installation of the Side
Panels.
d. Install the retained mounting hardware that secures the Side Panels to the MEP-PU-810.
8.4.3.4 SERVICE THE SIDE PANELS
Service the Side Panels by cleaning using stiff brushes, clean cloths, and cleaning detergent.
8.4.3.5 REPAIR THE SIDE PANELS
To repair the Side Panels, proceed as follows:
a. Straighten bent or distorted Side Panels.
b. Repaint as required .
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8.4.4 “A” AND “B” MODEL TOP PANEL ASSEMBLY
NOTE: The rear roof section on the “B” model is permanent and cannot be removed.
The following maintenance procedures are provided for the top panel assembly.
Inspect
Repair
Install
Service
Repair
FIGURE 8.4.4-1 “A” MODEL TOP PANEL ASSEMBLY
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8.4.4.1 INSPECT THE “A” AND “B” MODEL TOP PANEL ASSEMBLY
Inspect the Top Panel Assembly for the following:
a. Inspect the Top Panel Assembly for bent or damaged top panels, and leakage.
b. Inspect the Top Panel Assembly for corrosion, rust, and tightness of mounting hardware.
8.4.4.2 REMOVE THE “A” AND “B” MODEL TOP PANEL ASSEMBLY
8.4.4.2.1 REMOVE THE REAR ROOF PANEL SECTION
NOTE: The Rear Roof Panel Section on the “B” model is permanently mounted and cannot be
removed.
WARNING

WARNING
TOP PANELS ARE HEAVY. USE EXTREME CAUTION WHEN HANDLING.
WARNING

To remove the Rear Roof Panel Section, proceed as follows:
b. Remove and retain the mounting hardware securing the Muffler to the Rear Roof Panel Section
use Figure 8.4.4-1 for reference.
c. Remove and retain the mounting hardware securing the Rear Roof Panel Section to the Power
Unit frame from inside the unit.
d. Remove the Muffler Assembly use Section 8.4.7, Muffler Assembly for reference.
e. Using a forklift or crane, carefully lift and remove the Rear Roof Panel Section.
f. Clean off sealing compound from Rear Roof Panel Section and Muffler.
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8.4.4.2.2 REMOVE THE FRONT ROOF PANEL SECTION
WARNING

WARNING
WARNING

To remove the Front Roof Panel Section, proceed as follows:
b. Remove and retain the mounting hardware securing the Muffler and the Front Roof Panel
Section.
c. Remove and retain the mounting hardware securing the Front Top Panel Section to the Power
Unit frame from inside the unit.
d. Remove the Muffler Assembly use Section 8.4.7, Muffler Assembly for reference.
e. Using a forklift or crane, carefully lift and remove the Front Top Panel Section.
f. Clean off sealing compound from the Front Top Panel Section and Muffler.
8.4.4.3 INSTALL THE “A” AND “B” MODEL TOP PANEL ASSEMBLY
8.4.4.3.1 INSTALL THE REAR ROOF PANEL SECTION
WARNING

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WARNING
WARNING

To install the Rear Roof Panel Section, proceed as follows:
unable to start. See procedures in paragraph 8.1.d..
b. Using a forklift or crane, carefully lift and place the top rear panel on the unit.
c. Install the mounting hardware securing the Rear Roof Panel Section to the frame.
d. Install the Muffler Assembly use Section 8.4.7, Muffler Assembly for reference.
8.4.4.3.2 INSTALL THE FRONT ROOF PANEL SECTION
WARNING

WARNING
WARNING

To install the Front Roof Panel Section, proceed as follows:
b. Using a forklift or crane, carefully lift and place the top front panel on the unit.
c. Install retained the mounting hardware securing the Front Roof Panel Section to the frame.
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d. Install the Muffler Assembly use Section 8.4.7, Muffler Assembly for reference.
8.4.4.4 SERVICE THE TOP PANEL ASSEMBLY
Service the removed Front Roof Panel Section by cleaning using stiff brushes, clean cloths, and cleaning
detergent.
8.4.4.5 REPAIR THE TOP PANEL ASSEMBLY
To repair the removed Front Roof Panel Section, proceed as follows:
a. Straighten top panels.
b. Repaint as required.
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8.4.5 BATTERY BOX ASSEMBLY
The following maintenance procedures are provided for the battery box assembly:
Inspect
Remove
Install
Service
Repair
FIGURE 8.4.5-1 BATTERY BOX ASSEMBLY
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FIGURE 8.4.5-2 BATTERY BOX ASSEMBLY (SIDE VIEW)
FIGURE 8.4.5-3 BATTERY BOX ASSEMBLY (TOP VIEW)
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8.4.5.1 INSPECT THE BATTERY BOX ASSEMBLY
Inspect the Battery Box Assembly for the following:
a. Inspect the Battery Box Assembly for corrosion or damage.
b. Inspect the Battery Box Assembly for security of attachment.
c. Inspect the Battery Box Assembly for missing components or hardware.
8.4.5.2 REMOVE THE BATTERY BOX ASSEMBLY
WARNING

WARNING

TERMINAL FIRST. WHEN RECONNECTING. CONNECT POSITIVE TERMINAL
FIRST. FAILURE TO COMPLY MAY CAUSE SPARKING AND CONSEQUENT
BATTERY EXPLOSION.
WARNING

WARNING

WARNING

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To remove the Battery Box Assembly, proceed as follows:
b. Remove Items 3, 4, 5, and 6, use Figure 8.4.5-1, Figure 8.4.5-2 and Figure 8.4.5-3 for reference.
c. Remove the batteries use Chapter 9.4.1.3. for removal procedures.
d. Remove Items 1, 2, and 7.
8.4.5.3 INSTALL THE BATTERY BOX ASSEMBLY
WARNING

WARNING

TERMINAL FIRST. WHEN RECONNECTING. CONNECT POSITIVE TERMINAL
FIRST. FAILURE TO COMPLY MAY CAUSE SPARKING AND CONSEQUENT
BATTERY EXPLOSION.
WARNING

WARNING

WARNING

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To install the Battery Box Assembly, proceed as follows:
b. Clean mounting points, repainting as necessary, prior to assembly.
c. Reinstall Items 1, 2, and 7, use Figure 8.4.5-1, Figure 8.4.5-2 and Figure 8.4.5-3 for reference.
d. Reinstall the batteries. Use Section 9.4.1.4, for install procedures.
e. Reinstall Items 3, 4, 5, and 6.
8.4.5.4 SERVICE THE BATTERY BOX ASSEMBLY
Service the Battery Box Assembly by cleaning using stiff brushes, clean cloths, and cleaning detergent.
8.4.5.5 REPAIR THE BATTERY BOX ASSEMBLY
To repair the Battery Box Assembly, proceed as follows:
a. Repair or replace damaged or missing components and hardware.
b. Repaint as required.
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8.4.6 FUEL TANK AND HYDRAULIC RESERVOIR ASSEMBLIES
The following maintenance procedures are provided for the Fuel Tank and Hydraulic Reservoir
Assemblies:
Inspect
Remove
Install
Service
Repair
FIGURE 8.4.6-1 REMOVABLE TANK ASSEMBLIES
8.4.6.1 INSPECT THE FUEL TANK AND HYDRAULIC RESERVOIR ASSEMBLIES
Inspect the Fuel Tank and Hydraulic Reservoir Assemblies for the following:
a. Inspect the Fuel Tank and Hydraulic Reservoir Assemblies for damage and leaks.
b. Inspect the Fuel Tank and Hydraulic Reservoir Assemblies for security of attachment.
c. Inspect the Fuel Tank and Hydraulic Reservoir Assemblies for damaged, loose or missing
hardware.
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8.4.6.2 REMOVE THE FUEL TANK AND HYDRAULIC RESERVOIR ASSEMBLIES
FUEL SHUTOFF VALVE
FIGURE 8.4.6.2-1 EXTERNAL FUEL DISTRIBUTION MANIFOLD, SHUTOFF VALVE
FIGURE 8.4.6.2-2 FUEL TANK SUPPLY, SHUTOFF VALVE
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FIGURE 8.4.6.2-3 EXTERIOR FUEL PUMP ASSEMBLY (NEW AND OLD)
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8.4.6.2.1 REMOVE THE FUEL TANK
WARNING

WARNING

TERMINAL FIRST. WHEN RECONNECTING, CONNECT NEGATIVE TERMINAL
LAST. FAILURE TO COMPLY MAY CAUSE SPARKING AND CONSEQUENT
BATTERY EXPLOSION.
WARNING

WARNING

WARNING

CAUTION

To remove the Fuel Tank, proceed as follows:
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b. Shut off respective Fuel Shutoff Valve on External Fuel Distribution Manifold use Figure 8.4.6.2-1
for reference.
c. Shut off the Fuel Tank Supply Shutoff Valve use Figure 8.4.6.2-2 for reference.
d. Drain the Fuel Tank into an approved container with a capacity of at least 120 gallons. Loosen
and Remove the plug on either side of the bottom of the fuel tank to drain fuel.
e. Place drain pan under the External Fuel Manifold Hose connection at the Power Unit.
f. Disconnect the External Fuel Manifold Supply Hose at the Fuel Solenoid Valve Strainer fitting
and cap hose, use Figure 8.4.6.2-3 for reference.
g. Place a Cap fitting on Fuel Solenoid Valve Strainer fitting, to prevent contamination.
h. Remove the Batteries, use Chapter 9.4.1.3. for removal procedures.
i. Remove the Battery Box Assembly use, Section 8.4.5.2 for reference.
j. Tag and disconnect the Fuel Transfer Pump wires inside Float Control Box Assembly. Use FO-
43A, FO-43B, FO-44A, FO-44B and FO-43C for reference.
k. Tag and disconnect fuel solenoid valve wires inside Float Control Box Assembly.
l. Tag and disconnect the 6 Deutsch connectors for Fuel Control Box Wiring.
m. Remove and retain conduit nuts and remove conduit fittings from Float Control Box assembly.
n Remove and retain bolts securing Fuel Pump Bracket Assembly to the Fuel Tank and remove
the assembly.
o. Remove and retain both Top Plenum Screens per Section 8.4.2.
p. Protect and cover both radiator cores to prevent damage.
q. Remove and retain bolts, washers and nuts securing both Front Center Covers.
r. Disconnect two Fuel Supply hoses from rear of the fuel tank.
s. Disconnect two fuel return hoses from rear of the fuel tank.
t. Support the fuel tank with forklift or crane.
u. Remove and retain the bolts and washers securing the Fuel Tank and remove the Fuel Tank.
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8.4.6.2.2 REMOVE THE HYDRAULIC RESERVOIR
FIGURE 8.4.6.2.2-1 HYDRAULIC RESERVOIR SUPPLY, SHUTOFF VALVE
WARNING

WARNING

BATTERY EXPLOSION.
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WARNING

WARNING

WARNING

CAUTION

To remove the Hydraulic Fluid Reservoir, proceed as follows:
NOTE: The following procedures are for either hydraulic reservoir. Repeat steps for second reservoir
if second reservoir removal is required.
b. Remove and retain Top Plenum Screens per Section 8.4.2.
c. Cut the Tie Strap on the Hydraulic Reservoir Supply Shutoff Valve. Rotate the handle 90
degrees to close the valve. Use Figure 8.4.6.2.2-1 for reference.
d. Drain the Hydraulic Fluid Reservoir into approved container(s). Replace plug using thread-
sealing compound. Dispose of fluid per local facility procedures. Use Figure 8.4.6-1 as a
reference.
e. Remove and retain the hose clamp securing the Return Hose to access cover.
f. Disconnect the Return Hose at “T” fitting. Cap/plug both ends to prevent dirt from entering.
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g. Disconnect the float level wire harness from the rear of tank.
h. Disconnect supply hose. Cap/plug both ends to prevent dirt from entering.
i. Disconnect Case Return Hose. Cap/plug both ends to prevent dirt from entering.
j. Support tank with forklift or crane.
k. Remove and retain mounting bolts, nuts and washers and remove hydraulic reservoir.
8.4.6.3 INSTALL THE FUEL TANK AND HYDRAULIC RESERVOIR ASSEMBLIES
8.4.6.3.1 INSTALL THE FUEL TANK
WARNING

WARNING

BATTERY EXPLOSION.
WARNING

WARNING

WARNING

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To install the fuel tank, proceed as follows: (Use Figure 8.4.6-1 as a reference)
b. Using a forklift or crane, carefully raise the fuel tank into place. Use Figure 8.4.6-1 as a
reference.
c. Reinstall with retained bolts, washers, and nuts securing fuel tank.
d. Reinstall two fuel supply hoses from rear of the fuel tank using thread-sealing compound.
e. Reinstall two fuel return hoses from rear of the fuel tank using thread-sealing compound.
f. Reinstall Front Center Covers with retained bolts, washers and nuts.
g. Reinstall both Top Plenum Assembly Screens per Section 8.4.2.
h. Reinstall Fuel Pump Bracket Assembly to the Fuel Tank with retained bolts and washers.
i. Reinstall the Fuel Transfer Pump and Solenoid Valve conduit and attach to the Float Control
Box assembly with conduit nuts. Use FO-43A, FO-43B, FO-44A, FO-44B and FO-43C for
reference.
j. Reinstall Fuel Transfer Pump wires inside the Float Control Box Assembly box and remove tags.
k. Reinstall the Solenoid Valve wires inside the Float Control Box Assembly box and remove tags.
l. Reinstall the batteries and Battery Box Assembly per 8.4.5.
m. Remove cap covering the fitting on Fuel Solenoid Valve Strainer fitting.
n. Reinstall Fuel Manifold Hose to the Fuel Solenoid Valve Strainer fitting.
o. Open respective hand valve on Fuel Distribution Manifold.
8.4.6.3.2 INSTALL THE HYDRAULIC RESERVOIR
WARNING

WARNING

BATTERY EXPLOSION.
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WARNING

WARNING

WARNING

To install the Hydraulic Fluid Reservoir, proceed as follow:
b. Using a forklift or crane, lift hydraulic reservoir into place. Use Figure 8.4.6-1 as a reference.
c. Reinstall the Hydraulic Fluid Reservoir to the Power Unit using retained bolts, nuts and washers.
d. Remove cap/plug and Reinstall Return Hose at “T” fitting.
e. Remove cap/plug and Reinstall Case Return Hose.
f. Remove cap/plug and Reinstall Supply Hose.
g. Open hand valve 90 degrees and tie strap open.
h. Reinstall the fluid level switch harness.
i. Reinstall the hose at access cover plate.
j. Refill reservoir with applicable hydraulic fluid.
k. Reinstall the Top Plenum Assembly Screens per Section 8.4.2.
l. Operate unit and check for leaks.
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8.4.6.3 SERVICE THE FUEL TANK AND HYDRAULIC RESERVOIR ASSEMBLIES
Service the exterior of the Removable Tank Assemblies by cleaning using stiff brushes, clean cloths, and
cleaning detergent.
8.4.6.4 REPAIR THE FUEL TANK AND HYDRAULIC RESERVOIR ASSEMBLIES
To repair the Removable Tank Assemblies, proceed as follows:
a. Remove large dents as necessary.
b. Holes or cracks must be welded and pressure tested.
NOTE: Welding must be done by a certified welder, applying all safety requirements necessary for
fuel tank welding.
NOTE: The interior of the hydraulic reservoir must be maintained in an absolutely clean condition or
professionally cleaned to be absolutely clean of contamination.
c. Repaint the exterior surfaces as required.
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8.4.7 MUFFLER ASSEMBLY
The following maintenance procedures are provided for the muffler assembly:
Inspect
Remove
Install
Service
Repair
FIGURE 8.4.7-1 MUFFLER ASSEMBLY
8.4.7.1 INSPECT THE MUFFLER ASSEMBLY
Inspect the Muffler Assembly for the following conditions:
a. Inspect the Muffler Assembly, Rain-caps to ensure they open and close freely.
b. Inspect the Muffler Assembly to ensure the Exhaust Wrap is secure and not damaged.
c. Inspect the Muffler Assembly for Exhaust leaks.
d. Inspect the Muffler Assembly for loose and missing hardware.
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8.4.7.2 REMOVE THE MUFFLER ASSEMBLY
WARNING

WARNING

WARNING

To remove the Muffler Assembly, proceed as follows:
b. Remove and retain the mounting hardware between the Flex Connector and Muffler. Use
Figure 8.4.7-1 as a reference.
c. Remove the Muffler mounting hardware.
d. Clean all mating surfaces.
e. Connect lifting straps to the Muffler and lift the muffler from the PU with a minimum of 1 ton
capacity lifting device.
f. Remove all old or excess caulk and mastic from the PU.
8.4.7.3 INSTALL THE MUFFLER ASSEMBLY
WARNING

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WARNING

WARNING

To install the Muffler Assembly, proceed as follows:
b. Connect lifting straps to the Muffler and lift the Muffler with a minimum of 1-ton capacity lifting
device and place the Muffler into position on the Power Unit (Use Figure 8.4.7-1 as a reference).
c. Reinstall the Muffler using Mastic Sealant (CMCO Part# 633270).
d. Reinstall the Muffler mounting hardware.
e. Reinstall the gasket and retained mounting hardware between flex connector and muffler.
8.4.7.4 SERVICE THE MUFFLER ASSEMBLY
To service the Muffler Assembly, proceed as follows:
Service the exterior of the Muffler Assembly by cleaning using stiff brushes, clean cloths, and detergent.
8.4.7.5 REPAIR THE MUFFLER ASSEMBLY
To repair the Muffler Assembly, proceed as follows:
a. Replace missing or damaged hardware.
b. Replace missing or damaged rain caps.
c. Holes or cracks must be welded and pressure tested.
d. Repaint muffler exterior as required.
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CHAPTER 9
DIRECT CURRENT (DC) SYSTEM REPAIR
TABLE OF CONTENTS
SECTION TITLE PAGE

9.0 DIRECT CURRENT (DC) SYSTEM REPAIR 6
9.2 DIRECT CURRENT (DC) SYSTEM DESCRIPTION 8
9.4.1 BATTERIES 9
9.4.1.1 INSPECT BATTERIES 9
9.4.1.2 TEST BATTERIES 10
9.4.1.3 REMOVE BATTERIES 10
9.4.1.4 INSTALL BATTERIES 11
9.4.1.5 SERVICE BATTERIES 12
9.4.2 BATTERY CABLES 12
9.4.2.1 INSPECT BATTERY CABLES 12
9.4.2.2 TEST BATTERY CABLES 12
9.4.2.3 REMOVE BATTERY CABLES 13
9.4.2.4 INSTALL BATTERY CABLES 13
9.4.2.5 SERVICE BATTERY CABLES 13
9.4.3 BATTERY CHARGER 14
9.4.3.1 INSPECT BATTERY CHARGER 15
9.4.3.2 TEST BATTERY CHARGER 15
9.4.3.3 REMOVE BATTERY CHARGER 16
9.4.3.4 INSTALL BATTERY CHARGER 17
9.4.3.5 SERVICE BATTERY CHARGER 18
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TABLE OF CONTENTS
SECTION TITLE PAGE

9.4.4 WIRING HARNESS 18
9.4.4.1 INSPECT WIRING HARNESS 18
9.4.4.2 TEST WIRING HARNESS 19
9.4.4.3 REMOVE WIRING HARNESSES 20
9.4.4.4 INSTALL WIRING HARNESS 20
9.4.4.5 WIRING HARNESSES REPAIR 20
9.4.5 BATTERY BANK DC TIE SWITCH 21
9.4.5.1 INSPECT BATTERY BANK DC TIE SWITCH 22
9.4.5.2 TEST BATTERY BANK DC TIE SWITCH 22
9.4.5.3 REMOVE BATTERY BANK DC TIE SWITCH 24
9.4.5.4 INSTALL BATTERY BANK DC TIE SWITCH 24
9.4.6 STARTER MOTOR AND STARTER SOLENOID 25
9.4.6.1 INSPECT STARTER MOTOR AND STARTER SOLENOID 25
9.4.6.2 TEST STARTER MOTOR AND STARTER SOLENOID 27
9.4.6.3 REMOVE STARTER MOTOR AND STARTER SOLENOID 29
9.4.6.4 INSTALL STARTER MOTOR AND STARTER SOLENOID 31
9.4.6.5 ADJUST STARTER PINION CLEARANCE 34
9.4.7 DC CONTROL POWER CIRCUIT BREAKER (CBCP) 36
9.4.7.1 INSPECT DC CONTROL POWER CIRCUIT BREAKER (CBCP) 36
9.4.7.2 TEST DC CONTROL POWER CIRCUIT BREAKER (CBCP) 37
9.4.7.3 REMOVE DC CONTROL POWER CIRCUIT BREAKER (CBCP) 38
9.4.7.4 INSTALL DC CONTROL POWER CIRCUIT BREAKER (CBCP) 38
9.4.8 DC PANEL LIGHTS AND FAULT INDICATOR LIGHTS 39
9.4.8.1 INSPECT DC PANEL LIGHTS AND FAULT INDICATOR LIGHTS 39
9.4.8.2 TEST DC PANEL LIGHTS AND FAULT INDICATOR LIGHTS 40
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TABLE OF CONTENTS
SECTION TITLE PAGE

9.4.8.3 REMOVE DC PANEL LIGHT BULBS AND FAULT INDICATOR LIGHTS 40
9.4.8.4 INSTALL DC PANEL LIGHT BULBS AND FAULT INDICATOR LIGHTS 40
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LIST OF FIGURES
FIGURE TITLE PAGE

FIGURE 9.2-1 BATTERY INTERCONNECT DIAGRAM 8
FIGURE 9.4.1-1 BATTERY BOX ASSEMBLY 9
FIGURE 9.4.3-1 BATTERY CHARGER 14
FIGURE 9.4.5-1 SCHEMATIC OF BATTERY BANK DC TIE SWITCH 21
FIGURE 9.4.5-2 BATTERY BANK DC TIE SWITCH 21
FIGURE 9.4.6-1 STARTER MOTOR 25
FIGURE 9.4.6.2-1 STARTER MOTOR 28
FIGURE 9.4.6.4-1 STARTER MOTOR SIDE VIEW 31
FIGURE 9.4.6.4-2 STARTER MOTOR FRONT VIEW 32
FIGURE 9.4.6.4-3 STARTER MOTOR FRONT VIEW 32
FIGURE 9.4.6.5-1 PINION CLEARANCE 34
FIGURE 9.4.6.5-2 PINION ADJUSTMENT 34
FIGURE 9.4.7-1 DC CONTROL POWER CIRCUIT BREAKER (CBCP) 36
FIGURE 9.4.8-1 DC PANEL LIGHTS AND FAULT INDICATOR LIGHTS 39
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LIST OF TABLES
TABLE TITLE PAGE

TABLE 9.4.6.4-1 STARTER TORQUE SPECIFICATIONS 33
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9.0 DIRECT CURRENT (DC) SYSTEM REPAIR
The DC electrical system consists of relays, solenoids, motors, indicators and other components that
combine to start, stop control, and monitor the MEP-PU-810. This section contains maintenance
procedures for the DC electrical system. Test, adjust, replace and repair components of the DC system
in accordance with the following procedures.
Maintenance procedures are provided for the following Direct Current (DC) System Components:
• Batteries
• Battery Cables
• Battery Charger
• Wiring Harnesses
• Battery Bank DC Tie Switch
• Starter Motor and Starter Solenoid
• Fuel Transfer Pump
• DC Control Breaker
• DC Panel Light Bulbs and Fault Indicator Lights
following:

• Rotating Parts

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due maintenance.

5.9.6.15, Unit Isolation Procedure with PSC. Note 1 and 2.
(5) Push to OPEN both Emergency Stop Switches.
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9.2 DIRECT CURRENT (DC) SYSTEM DESCRIPTION
CHASSIS
GROUND
INTERCONNECT
SWITCH G1A+ 20A BATTERY
20A BATTERY G2A+ CHARGER
CHARGER
DC OUTPUT
DC OUTPUT
G1B+
NATO
CHASSIS PLUG
GROUND
G2B+
G2- FUEL
TRANSFER*
G1- CONTROL
G2- G1-
+ - + -
BATTERIES BATTERIES
(2) 8D (2) 8D
- + - +
* WHEN MAINTENANCE WILL BE PERFORMED ON GEN-SET REQUIRING BATTERIES TO BE

DISCONNECTED, PLACE BATTERY SOURCE SWITCH ON FUEL TRANSFER CONTROL BOX TO
POSITION OF OPERATIONAL GEN-SET (G1 OR G2)
EACH BATTERY IS 12 VOLT MAINTENANCE FREE 1260 CRANKING AMPS @ 32°F
FIGURE 9.2-1 BATTERY INTERCONNECT DIAGRAM
The DC system has two functions, Starting and Control. Foldouts FO - 7 to FO – 12B are the DC
Electrical Schematics for Primary Distribution Center (PDC) control and Engine control systems.
Service requirements for the DC system:
There are no general DC System service requirements. However, each component that requires specific
services is listed in the Component Repair Procedures, Section 9.4.
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9.4.1 BATTERIES
The following maintenance procedures are provided for the batteries:
Inspect
Test
Remove
Install
Service
FIGURE 9.4.1-1 BATTERY BOX ASSEMBLY
9.4.1.1 INSPECT BATTERIES
Inspect the Batteries for the following:
a. Inspect the Batteries for cracks, leaks, or damaged cover.
b. Inspect the Batteries to ensure they are Maintenance Free Batteries.
c. Inspect the Battery Cables for corrosion, cracks, or breaks.
d. Inspect the Battery Terminals for corrosion and proper connection of cables.
e. Inspect the Battery Box hardware for damage, corrosion, and loose or missing components.
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9.4.1.2 TEST BATTERIES
To test the Batteries, proceed as follows:
a. The batteries supplied with the PU are maintenance free. Water or electrolyte is not added to the
batteries.
b. Use the Caterpillar Battery Load Tester, 4C-4911, or equivalent, to test the battery condition.
Use the test equipment manufacturers instructions for testing batteries. Refer to Caterpillar
manual SEHS9249 for operation of the Caterpillar Operation Manual for the 4C-4911, Battery
Load Tester.
9.4.1.3 REMOVE BATTERIES
WARNING

WARNING

AMOUNTS OF CLEAN WATER. OBTAIN MEDICAL AID WHEN EYES ARE
AFFECTED.
WARNING

BATTERY EXPLOSION.
WARNING

WARNING

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To remove the Batteries, proceed as follows using Figure 9.2-1 as a reference:
rerouted to the next PU. This is accomplished by performing the following:

(10)Place a DO NOT OPERATE tag on both Battery Banks.
(11)Place all Circuit Breakers in the LOCK OUT position.
(12)Disconnect both 7P1 and 7P2 Connectors located on the inside panel of the PDC.
(13)Close and Lock both generator set control panels.
function. Place the Fuel Pump Source Switch (S2) into the (G1 or G2 position). Place the S2 in
the (G1 or G2) position, for the generator set not receiving maintenance.
b. Ensure the Battery Bank DC Tie Switch is in the “OFF” position.
c. Disconnect both negative battery cables from the batteries.
d. Remove the jumper cables from both sets of batteries.
e. Disconnect both positive battery cables from the batteries.
f. Remove both battery hold down brackets and bolts.
g. Remove batteries carefully using proper lifting technique and/or appropriate material handling
equipment.
9.4.1.4 INSTALL BATTERIES
To install Batteries, proceed as follows using FO-37, as a reference:
rerouted to the next PU. See procedures and warnings in paragraph 9.4.1.3.
c. Reinstall battery on battery tray carefully using proper lifting technique and/or appropriate
material handling equipment.
d. Reinstall battery hold down brackets and bolts.
e. Connect both positive battery cables to the batteries.
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f. Reinstall the jumper cables onto both sets of batteries.
g. Connect both negative battery cables to the batteries.
9.4.1.5 SERVICE BATTERIES
Service the Batteries as follows:
a. Replace damaged clamps, nuts, lock washers, and hold-down channels.
b. If battery terminal corrosion is present, disconnect both negative battery cables, disconnect the
cable from corroded terminal, clean terminal with a solution of baking soda and water; then flush
with clean water, reconnect to cleaned terminal, reconnect both battery cables.
c. Repaint areas where required.
9.4.2 BATTERY CABLES
The following maintenance procedures are provided for the battery cables:
Inspect
Test
Remove
Install
Service
9.4.2.1 INSPECT BATTERY CABLES
Inspect the Battery Cables as follows (Using FO – 37A and FO – 37B as a reference):
b. Check the cables for corrosion, insulation breaks, deterioration, or other damage.
c. Check the cable connectors for corrosion and security of attachment.
9.4.2.2 TEST BATTERY CABLES
To test the Battery Cables, proceed as follows:
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f. Using a multimeter, set to OHMS (Ω) Rx1 scale, test continuity of each cable.
g. Replace the cable if the reading is above zero ohms.
9.4.2.3 REMOVE BATTERY CABLES
To remove the Battery Cables, proceed as follows:
f. Remove damaged battery cable.
9.4.2.4 INSTALL BATTERY CABLES
To install the Battery Cables, proceed as follows:
c. Connect both positive battery cables to the batteries.
d. Reinstall the jumper cables onto both sets of batteries.
e. Connect both negative battery cables to the batteries.
9.4.2.5 SERVICE BATTERY CABLES
To service the Battery Cables, proceed as follows:
b. If battery cable terminal corrosion is present, disconnect both negative battery cables;
disconnect corroded battery cable terminal, clean battery cable terminal with a solution of
baking soda and water; flush with clean water.
c. Using a stiff bristle brush, clean battery cable connector.
d. Reconnect cleaned terminal, reconnect negative battery cables.
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9.4.3 BATTERY CHARGER
The following maintenance procedures are provided for the Battery Charger:
Inspect
Test
Remove
Install
Service
DC CIRCUIT BREAKER (CB2)

AC CIRCUIT BREAKER (CB1)
FIGURE 9.4.3-1 BATTERY CHARGER
The MBC6 Battery Charger will switch modes (float or equalize) depending on the state of charge in the
battery and upon external loads. The mode switching decision is based on the charger output current at
the “+”’ and “-“ terminals. When the battery and/or other loads require much over 50% of rated current,
the charger switches to equalize mode and remains there until the battery is charged (and/or loads are
reduced) and the output current drops below 50% of rated current. At that point the charger will switch to
the float mode, with a corresponding reduction in output current, and remain in ‘float’ until the next
demand occurs.
For complete charger details, refer to the Master Control System Battery Charger Instruction Manual,
MBC6X-24V-20A-LA.
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9.4.3.1 INSPECT BATTERY CHARGER
Inspect the Battery Charger as follows, using Figure 9.4.3-1 as a reference.
a. Inspect input and output cables for deterioration or physical damage.
b. Inspect charger mounting for security of attachment.
c. Inspect gauges for deterioration or physical damage.
d. Inspect input AC Power Circuit Breaker (CB1) for proper mechanical function.
e. Inspect output DC Power Circuit Breaker (CB2) for proper mechanical function.
9.4.3.2 TEST BATTERY CHARGER
To test the Battery Charger, proceed as follows using Figure 9.4.3-1 as a reference:
a. Ensure that the Battery Charger input power cable is connected to an active source of 120VAC
electrical power.
b. Ensure that the battery bank is properly connected and the Battery Charger is properly
connected to the battery bank.
c. Push CB1 to close the AC input power circuit breaker.
d. Push CB2 to close the DC output circuit breaker.
e. Observe that the DC Ammeter indicates a low rate of charging current flow.
f. Observe that the DC Voltmeter indicates 26 VDC, + 3 volts.
g. Recheck AC supply and/or DC output if there is no DC output.
h. Replace the Battery Charger if it does not function properly.
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9.4.3.3 REMOVE BATTERY CHARGER
WARNING

WARNING

WARNING

To remove the Battery Charger, proceed as follows:
unable to start. This is accomplished by performing the following:

5.9.6.15, Unit Isolation Procedure with PSC.
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b. Disconnect the 120 VAC battery charger power plug from the receptacle underneath the panel
board box.
c. Place a tag on the battery charger power plug noting that the battery charger has been removed.
d. Open the front cover to gain access to the inside of the charger.
e Tag and disconnect the Neutral, Hot and Ground wires at the AC terminal board and tape leads
to prevent shorting should the power plug get reconnected accidentally.
f. Unscrew conduit clamp nut holding AC wires to the charger and pull wire harness out of charger.
g. Tag and disconnect the + and – wires at DC terminal board and tape leads to prevent shorting
should the batteries get reconnected accidentally.
h. Unscrew conduit clamp nut holding DC wires to charger and pull wire harness out of charger.
i. Remove the 4 nuts securing the battery charger to station transformer. The charger is now free
to be lifted off the vibration mounts.
j. Reinstall the securing hardware and vibration mounts to prevent loss. Inspect hardware and
vibration mounts for damage, Replace if necessary.
9.4.3.4 INSTALL BATTERY CHARGER
To install the Battery Charger, proceed as follows:
unable to start. See procedures and warnings in paragraph 9.4.3.3.
b. Install and Secure the Battery Charger on the 4 vibration mounts using existing hardware.
c. Open the front-cover to obtain access to the AC and DC terminals.
d. Insert the DC power harness into the Battery Charger and secure with conduit clamp nut.
e. Remove tape and attach the wires to the DC terminal board. Remove tag.
f. Install the AC power harness into the charger and secure with conduit clamp nut.
g. Remove the marking tape and attach the wires to the AC terminal board.
h. Close the Battery Charger cover and reinstall the mounting screws.
i. Reconnect the positive and then the negative battery cables to the batteries. Remove marking
tag.
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l. Plug in the 120VAC plug. Remove marking tag.
m. Check operation as described in 9.4.3.2 above.
9.4.3.5 SERVICE BATTERY CHARGER
To service the battery charger, proceed as follows:
b. Clean the exterior by wiping the surface with a rag and with water based degreaser.
c. Open the front cover by loosening the securing hardware.
d. Clean the interior of dust with low pressure compressed air or vacuum cleaner.
e. Close the front cover and replace the securing hardware.
9.4.4 WIRING HARNESS
The following maintenance procedures are provided for the Wiring Harnesses:
Inspect
Test
Remove
Install
Repair
9.4.4.1 INSPECT WIRING HARNESS
WARNING

WARNING

WARNING

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To inspect the Wiring Harness, proceed as follows:

5.9.6.15, Unit Isolation Procedure with PSC. See Notes 1 and 2.
b. Check Wiring Harness for cracking insulation or frayed areas.
c. Check that all terminal lugs are securely attached to wire ends.
d. Ensure that the Wiring Harness are bundled and tied together securely.
e. Check security of all hangers, clamps, and hardware that secure the Wiring Harness to the
generator set or other support.
f. Check that no wire is in contact with any sharp edge or any heat producing surface of the engine
or exhaust system or other support.
9.4.4.2 TEST WIRING HARNESS
To test the Wiring Harness, proceed as follows:
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b. Test the suspect wiring harness wires for continuity and internal shorts using a multimeter set to
check OHMS (Ω) Rx1 scale. Use FO-1 to FO-44C for reference.
9.4.4.3 REMOVE WIRING HARNESSES
To remove the Wiring Harness, proceed as follows:
b. Tag both ends of all wires to be removed.
c. Disconnect all wire harness wire terminations.
b. Unfasten all wire harness attachments.
e. Remove wire harness from PU.
9.4.4.4 INSTALL WIRING HARNESS
To install the Wiring Harness, proceed as follows:
b. Install the wire harness into the PU in the same physical place that the old harness was
removed.
c. Fasten all wire harness attachments to the harness.
d. Reconnect all wire harness connections.
e. Secure loose or excess wire with wire ties.
f. Remove all tags.
9.4.4.5 WIRING HARNESSES REPAIR
To repair the Wiring Harness, proceed as follows:
b Repair wiring harnesses by splicing, and replacing damaged terminal lugs and connections, and
soldering damaged components.
c. Repair wiring harnesses in accordance with AFTO 1-1A-14.
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9.4.5 BATTERY BANK DC TIE SWITCH
The following maintenance procedures are provided for the Battery Bank DC Tie Switch:
Inspect
Test
Remove
Install
FIGURE 9.4.5-1 SCHEMATIC OF BATTERY BANK DC TIE SWITCH
FIGURE 9.4.5-2 BATTERY BANK DC TIE SWITCH
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a. The Battery Bank DC Tie Switch is located at the front of the PU, above and centered between
the two hydraulic tanks, next to the NATO slave receptacle. Use Figure 9.4.5-1 for reference.
b. It is a two-position switch that is normally open. The operator can close the switch, which then
parallels the two battery banks together when additional cranking power is needed for starting
either generator set.
c. When the NATO slave receptacle is used for starting or charging, the Battery Bank DC Tie Switch
must be closed to start the roadside generator or charge its batteries.
9.4.5.1 INSPECT BATTERY BANK DC TIE SWITCH
WARNING

To inspect the Battery Bank DC Tie Switch, proceed as follows:
a. Check the Battery Bank DC Tie Switch for physical damage, deterioration, or missing parts.
b. Check the wires for cracking insulation or frayed areas.
c. Check that all terminal lugs are securely attached to terminals and to wire ends.
d. Check security of all hangers, clamps, and mounting hardware.
e. Check that no wire is in contact with any sharp surface.
9.4.5.2 TEST BATTERY BANK DC TIE SWITCH
WARNING

WARNING

BATTERY EXPLOSION.
WARNING

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WARNING

To test the Battery Bank DC Tie Switch, proceed as follows:

b. Tag and disconnect cables from the Battery Bank DC Tie Switch.
c. Using a multimeter set on OHMS (Ω) Rx1 scale:
(1) Place the Battery Bank DC Tie Switch in the “ON” position, the meter should read 1
OHM or less.
(2) Place the Battery Bank DC Tie Switch in the “OFF” position, the meter should read
infinite Ohms.
d. Replace the Battery Bank DC Tie Switch if it fails any of the above tests.
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9.4.5.3 REMOVE BATTERY BANK DC TIE SWITCH
To remove the Battery Bank DC Tie Switch, proceed as follows:
b. Tag and disconnect cables from the Battery Bank DC Tie Switch.
c. Remove the handle set screw and remove handle. See Figure 9.4.5-2.
d. Remove the Battery Bank DC Tie Switch mounting nut and washer. See Figure 9.4.5-2.
e. Remove the Battery Bank DC Tie Switch.
9.4.5.4 INSTALL BATTERY BANK DC TIE SWITCH
To install the Battery Bank DC Tie Switch, proceed as follows:
b. Place the Battery Bank DC Tie Switch into position. See Figure 9.4.5-1.
c. Reinstall the Battery Bank DC Tie Switch mounting nut and washer. See Figure 9.4.5-2
d. Reinstall the handle and Reinstall handle set screw. See Figure 9.4.5-2.
e. Remove tags and connect the Battery Cables to the Battery Bank DC Tie Switch.
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9.4.6 STARTER MOTOR AND STARTER SOLENOID
The following maintenance procedures are provided for the Starter Motor and Starter Solenoid:
Inspect
Test
Remove
Install
Adjust
STARTER MOUNTING BOLT
FIGURE 9.4.6-1 STARTER MOTOR
9.4.6.1 INSPECT STARTER MOTOR AND STARTER SOLENOID
To inspect the Starter Motor and Starter Solenoid, proceed as follows:
WARNING

WARNING

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WARNING


b. Corrosion on solenoid terminals. Disconnect battery cable and clean terminals as required.
c. Damage and security of mounting.
d. Discoloration and other signs of overheating.
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9.4.6.2 TEST STARTER MOTOR AND STARTER SOLENOID
WARNING

WARNING

WARNING

CAUTION

ALLOW IT TO COOL AT LEAST 2 MINUTES BEFORE RE-ENERGIZING THE MOTOR.
OVERHEATING WILL DAMAGE THE MOTOR.
CAUTION
TWO PEOPLE ARE REQUIRED TO PERFORM THIS TASK THE STARTER WEIGHS 70 LBS.
To test the Starter Motor and Starter Solenoid, proceed as follows:
a. This maintenance requires that the PU MUST be shutdown, and cool enough for the test to be
performed, and Communication Cable (A) and (B) rerouted to the next PU. This is
accomplished by performing the following:

NOTE 1: When the DC Control Breaker is in the (OFF) position (Pulled – Out), all control power is
turned off to the PU. This will cause the HUB to stop functioning. This causes the network to
not see the equipment shutdown and all PU’s after it. When pulling major maintenance the
(A) (B) Communication Cable must be routed to the next PU in order to reestablish the
communication network.
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FIGURE 9.4.6.2-1 STARTER MOTOR
b. Test of the starter motor and electrical solenoid assembly consists of a test of the complete unit
followed by a pinion clearance check and adjustment. Refer to Figure 9.4.6.2-1 for the following
steps:
c. Use a multimeter in the DC voltage range to find starting system components that do not function.
d. Move the Engine Control Switch (ECS) to the Manual Start position in order to activate the
starting solenoid. The starting solenoid’s operation can he heard as the pinion of the starting
motor is engaged with the ring gear on the engine flywheel.
e. If a solenoid for a starting motor will not operate, it is possible that the current from the battery did
not reach the solenoid. Fasten one lead of the multimeter to the connection (1) for the battery
cable on the solenoid. Put the other lead to a good ground. A zero reading indicates that there is
a broken circuit from the battery. More testing is necessary when there is a voltage reading on
the multimeter. Turn ECS to “OFF/RESET”.
f. The solenoid operation also closes the electric circuit to the motor. Connect one lead of the
multimeter to the solenoid connection (2) that is fastened to the motor. Put the other lead to a
good ground. Move the Engine Control Switch (ECS) to the Manual Start position to activate the
starting solenoid and look at the multimeter. A reading of 24VDC shows that the problem is in the
motor. The motor must be removed for further testing. A reading of 0VDC, on the multimeter
shows that the solenoid contacts do not close. This is an indication of the need for repair to the
solenoid or an adjustment to be made to the starting motor pinion clearance. Turn ECS to
“OFF/RESET”.
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g. To test, fasten one multimeter lead to the connection (3) for the small wire at the solenoid and
fasten the other lead to the ground. Move the Engine Control Switch (ECS) to the Manual Start
position to activate the starting solenoid and look at the multimeter. A voltage reading shows that
the problem is in the solenoid. A 0VDC reading indicates that the problem is in the ECS or the
wires to the ECS. Turn ECS to “OFF/RESET”.
h. Refer to FO-15, D6, for this task. Fasten one multimeter lead to the ECS at the terminal ECSA
(1) for the wire from the battery. Fasten the other lead to a good ground. A 0VDC reading
indicates a broken circuit from the battery. Make a check of the circuit breaker and associated
wiring. If there is a voltage reading, the problem is in the ECS or in the wires for the ECS.
i. Starting motors that operate too slowly can have an overload because of too much friction in the
engine that is being started. Slow operation of the starting motors can also be caused by a short
circuit, loose connections and/or dirt in the motor.
9.4.6.3 REMOVE STARTER MOTOR AND STARTER SOLENOID
WARNING

WARNING

WARNING

CAUTION
To remove the Starter Motor and Starter Solenoid, proceed as follows:

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b. Remove the PU side panel see Section 8.4.1 for reference.
c. Remove the Fumes Disposal Collector mounting bolts and set Fumes Disposal Collector aside.
d. Tag and disconnect wiring from the Starter Motor and Starter Solenoid.
e Using Figure 9.4.6-1 as a reference, fasten a hoist to the starting motor. Remove the three
Starter mounting bolts that hold the starting motor to flywheel housing.
f. Remove Starter Motor and Starter Solenoid from the flywheel housing. The weight of the Starter
Motor and Starter Solenoid is 32 kg (70 lb).
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9.4.6.4 INSTALL STARTER MOTOR AND STARTER SOLENOID
CAUTION
To install the Starter Motor and Starter Solenoid, proceed as follows:
b. Using a hoist, position the Starter Motor and Starter Solenoid into the flywheel housing. The
weight of the Starter Motor and Starter Solenoid is 32 kg (70 lb).
c. Reinstall the mounting bolts, washers, and lock washers. Torque all mounting bolts and
electrical connections according to Table 9.4.6.4-1 using Figure 9.4.6.4-1, Figure 9.4.6.4-2 and
Figure 9.4.6.4-3.
d. Remove Tags and connect wiring.
e. Reinstall the Fumes Disposal Collector.
f. Reinstall the PU Side Panel see Section 8.4.1 for reference.
FIGURE 9.4.6.4-1 STARTER MOTOR SIDE VIEW
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FIGURE 9.4.6.4-2 STARTER MOTOR FRONT VIEW
FIGURE 9.4.6.4-3 STARTER MOTOR FRONT VIEW
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TABLE 9.4.6.4-1 STARTER TORQUE SPECIFICATIONS
STARTER TORQUE SPECIFICATIONS
ITEM TORQUE REFERENCE

ACTION REQUIRED
NUMBER REQUIREMENTS FIGURE
Tighten the nut on the battery terminal 22 ± 3 Ft-Lbs

1 9.4.6.4-1
to the following torque (30.5 ± 3.5 Nm)
Tighten the nut to the following 22 ± 3 Ft-Lbs
2 9.4.6.4-1 & 9.4.6.4-2
torque. (30.5 ± 3.5 Nm)
Tighten the nut on the ground 22 ± 3 Ft-Lbs
3 9.4.6.4-2
terminal to the following torque. (30.5 ± 3.5 Nm)
Tighten the nut on the switch terminal 20 ± 2 In-Lbs
4 9.4.6.4-2 & 9.4.6.4-3
to the following torque. (2.25 ± 0.25 Nm)
Tighten the nut on the motor terminal 22 ± 3 Ft-Lbs
5 9.4.6.4-2 & 9.4.6.4-3
to the following torque. (30.5 ± 3.5 Nm)
Tighten the nut on the motor frame 13 ± 2 Ft-Lbs
6 9.4.6.4-2 & 9.4.6.4-3
terminal to the following torque. (17.5 ± 2.5 Nm)
Tighten the Starter Mounting Bolts to 160 + 30 Ft-Lbs
7 9.4.6.4-3
the following torque. (215 + 40 Nm)
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9.4.6.5 ADJUST STARTER PINION CLEARANCE
FIGURE 9.4.6.5-1 PINION CLEARANCE
FIGURE 9.4.6.5-2 PINION ADJUSTMENT
To adjust the Starter Pinion Clearance, proceed as follows:
a. This procedure is conducted with the starter motor removed from the PU.
b. Use a screwdriver to turn the pinion on the exposed drive assembly in the drive housing. Tight
bearings, bent armature shaft, or a loose pole shoe screw will cause armature binding. If
armature does not turn freely, replace the starter. If armature rotates freely, conduct the testing
as follows:
• Reinstall the solenoid without connector (1) from the MOTOR connections (terminal) on the
solenoid to the motor. Use Figure 9.4.6.5-1 for reference.
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• Connect a 24VDC Power Source, to the solenoid, to the "SW” terminal (2). Use Figure
9.4.6.5-1 for reference.
• Connect the other side of the 24VDC Power Source to connector (3). Use Figure 9.4.6.5-1
for reference.
• For a moment, connect a wire from the solenoid connection (terminal), which is marked
“MOTOR”, to the ground connection (terminal). The pinion will shift to the crank position and
the pinion will stay there until the battery is disconnected.
• Push the pinion toward the end with the commutator in order to remove free movement.
• Pinion clearance (6) must be 9.1 mm (0.358 inch). Use Figure 9.4.6.5-2 for reference.
• In order to adjust the pinion clearance, remove the plug and turn the shaft nut (4). Use
Figure 9.4.6.5-2 for reference.
• After the adjustment is completed, reinstall the plug over the nut (4) and reinstall the
connector (1) between the MOTOR terminal on the solenoid and the starter motor.
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9.4.7 DC CONTROL POWER CIRCUIT BREAKER (CBCP)
The following maintenance procedures are provided for the DC Control Power Circuit Breaker (CBCP):
Inspect
Test
Remove
Install
RETAINING NUT
FIGURE 9.4.7-1 DC CONTROL POWER CIRCUIT BREAKER (CBCP)
See Figure 9.4.7-1 for reference. The DC Control Power Circuit Breaker (CBCP) provides G1 and G2 an
automatic safety disconnect of battery power from its circuits in case of short circuit or circuit overload.
9.4.7.1 INSPECT DC CONTROL POWER CIRCUIT BREAKER (CBCP)
To inspect the DC Control Power Circuit Breaker (CBCP), proceed as follows:
a. Check for discoloration and signs of overheating.
b. Check for cracks, breaks, evidence of damage, and corrosion.
c. Check for freedom of movement.
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9.4.7.2 TEST DC CONTROL POWER CIRCUIT BREAKER (CBCP)
WARNING

WARNING

WARNING

To test the DC Control Power Circuit Breaker (CBCP), proceed as follows:

b. Tag and disconnect wires from the DC Control Breaker.
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c. Test the DC Control Breaker using a Multi-Amp MS-2 Circuit Breaker Tester or equivalent
according to the test equipment and breaker manufacturer instructions.
d. Ensure that the Circuit Breaker will continuously carry rated current. Must trip at 135% rated
current within one hour.
e. Replace the DC Control Breaker if it fails testing.
9.4.7.3 REMOVE DC CONTROL POWER CIRCUIT BREAKER (CBCP)
To remove the DC Control Power Circuit Breaker (CBCP), proceed as follows:
b. Open the Master Control Panel (MCP) door.
c. Tag and disconnect the wiring to DC Control Breaker.
d. Remove retaining nut and remove the DC Control Breaker.
9.4.7.4 INSTALL DC CONTROL POWER CIRCUIT BREAKER (CBCP)
To install the DC Control Power Circuit Breaker (CBCP), proceed as follows:
b. Position the DC Control Power Circuit Breaker into the MCP and secure it with its retaining nut.
c. Connect the wiring as tagged and discard tags.
d. Close the MCP door and tighten captive screws.
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9.4.8 DC PANEL LIGHTS AND FAULT INDICATOR LIGHTS
The following maintenance procedures are provided for the DC Panel Lights and Fault Indicator Lights:
Inspect
Test
Remove
Install
PANEL LIGHTS
PANEL LIGHTS
FAULT INDICATOR LIGHTS
CONTACTOR
INDICATOR LIGHTS
CONTACTOR
INDICATOR LIGHTS
FIGURE 9.4.8-1 DC PANEL LIGHTS AND FAULT INDICATOR LIGHTS
9.4.8.1 INSPECT DC PANEL LIGHTS AND FAULT INDICATOR LIGHTS
Inspect the DC Panel Lights and Fault Indicator Lights every 250 hours for the following conditions:
a. Check for loose wires and terminal screws.
b. Check for burnt out bulbs or indicator lamps.
c. Check for loose Mounting hardware.
d. Check for security of attachment and signs of overheating.
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9.4.8.2 TEST DC PANEL LIGHTS AND FAULT INDICATOR LIGHTS
To test the DC Panel Lights and Fault Indicator Lights, proceed as follows:
a. Close the DC Control Power Circuit Breaker (Push-in). Push the “Press to Test” ring on each of
the fault indicator lamps that have that feature. The light should illuminate. If the light does not
illuminate or on lights that do-not have the press to test feature, remove the bulb and test it. Use
an ohmmeter to check continuity.
b. Test DC Panel Lights by placing the PANEL LIGHTS toggle switch to the ON position. The DC
Panel Lights should illuminate. If not, remove the bulb and test it using an ohmmeter to check
continuity.
c. Replace bulbs that fail test.
9.4.8.3 REMOVE DC PANEL LIGHT BULBS AND FAULT INDICATOR LIGHTS
To remove the DC light bulbs and indicators, proceed as follows:
a. Pull-out the DC Control Circuit Breaker.
b. Remove defective light bulb.
9.4.8.4 INSTALL DC PANEL LIGHT BULBS AND FAULT INDICATOR LIGHTS
To install the DC light bulbs and indicators, proceed as follows:
a. Install new serviceable light bulb.
b. Push-in the DC Control Circuit Breaker.
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CHAPTER 10
ALTERNATING CURRENT (AC) SYSTEM REPAIR
TABLE OF CONTENTS
SECTION TITLE PAGE

10.0 ALTERNATING CURRENT (AC) SYSTEM REPAIR 7
10.1 SAFETY INSTRUCTIONS 7
10.2 BRIEF SYSTEM DESCRIPTION 9
10.4.1 STATION POWER TRANSFORMER 12
10.4.1.1 INSPECT STATION POWER TRANSFORMER 13
10.4.1.2 TEST STATION POWER TRANSFORMER 14
10.4.1.2.1 INSULATION RESISTANCE TEST 15
10.4.1.2.2 TURNS RATIO TEST 16
10.4.1.3 REMOVE STATION POWER TRANSFORMER 17
10.4.1.4 INSTALL STATION POWER TRANSFORMER 18
10.4.2 208/120VAC RECEPTACLES 19
10.4.2.1 INSPECT 208/120VAC RECEPTACLES 20
10.4.2.2 TEST 208/120VAC RECEPTACLES 21
10.4.2.2.1 TEST 208/120VAC RECEPTACLES (INTERNAL AND EXTERNAL) 21
10.4.2.2.2 TEST 120-VAC (GFCI) DUPLEX RECEPTACLES 21
10.4.2.2.3 REMOVE 120/208 VAC RECEPTACLES (EXTERNAL) 21
10.4.2.2.4 INSTALLL 120/208 VAC RECEPTACLES (EXTERNAL) 21
10.4.3 WIRING HARNESSES 24
10.4.3.1 INSPECT WIRING HARNESS 24
10.4.3.2 TEST WIRING HARNESS 25
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TABLE OF CONTENTS
SECTION TITLE PAGE

10.4.3.3 REMOVE WIRING HARNESS 26
10.4.3.4 INSTALL WIRING HARNESS 26
10.4.3.5 REPAIR WIRING HARNESS 26
10.4.4 POWER PANEL BOARD 27
10.4.4.1 INSPECT PANEL BOARD 27
10.4.4.2 TEST PANEL BOARD AND BREAKERS 28
10.4.4.3 REMOVE PANEL BOARD 29
10.4.4.4 INSTALL PANEL BOARD 30
10.4.5 ALTERNATOR 31
10.4.5.1 INSPECT ALTERNATOR 31
10.4.5.2 TEST ALTERNATOR 32
10.4.5.2.1 RECOMMENDED PERIODIC INSULATION CHECKS 33
10.4.5.2.2.1 TEST PROCEDURES 34
10.4.5.2.2.1.1 MAIN ARMATURE (STATOR-L4) TEST 35
10.4.5.2.2.1.2 EXCITER FIELD (STATOR-L1) TEST 36
10.4.5.2.2.1.3 EXCITER ARMATURE (ROTOR-L2) TEST 37
10.4.5.2.2.1.4 PILOT EXCITER ARMATURE (L5) TEST 38
10.4.5.2.2.1.5 MAIN ROTOR (L3) TEST 36
10.4.5.3 REMOVE ALTERNATOR 41
10.4.5.4 INSTALL ALTERNATOR 41
10.4.5.5 GENERATOR STARTUP CHECKLIST 42
10.4.6 VARISTOR AND RECTIFIER BLOCK ASSEMBLY 44
10.4.6.1 INSPECT VARISTOR AND RECTIFIER BLOCK ASSEMBLY 46
10.4.6.2 TEST RECTIFER BLOCK AND VARISTOR (CR7) ASSEMBLY 46
10.4.6.3 TEST RECTIFER BLOCK ASSEMBLY 49
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TABLE OF CONTENTS
SECTION TITLE PAGE

10.4.6.4 REMOVE VARISTOR AND RECTIFIER BLOCK ASSEMBLY 49
10.4.6.5 INSTALL RECTIFIER BLOCK ASSEMBLY 50
10.4.7 MEDIUM VOLTAGE OUTPUT TERMINALS 51
10.4.7.1 INSPECT MEDIUM VOLTAGE OUTPUT TERMINAL 52
10.4.7.2 TEST MEDIUM VOLTAGE OUTPUT TERMINAL 54
10.4.7.3 REMOVE MEDIUM VOLTAGE OUTPUT TERMINAL 56
10.4.7.4 INSTALL MEDIUM VOLTAGE OUTPUT TERMINAL 58
10.4.8 SURGE ARRESTERS (SA1, SA2, SA3) 59
10.4.8.1 INSPECT SURGE ARRESTER (SA1, SA2, SA3) 60
10.4.8.2 TEST SURGE ARRESTER (SA1, SA2, SA3) 61
10.4.8.3 REMOVE SURGE ARRESTER (SA1, SA2, SA3) 62
10.4.8.4 INSTALL SURGE ARRESTER (SA1, SA2, SA3) 63
10.4.9 INSTRUMENT POTENTIAL TRANSFORMERS (PT) 64
10.4.9.1 INSPECT INSTRUMENT POTENTIAL TRANSFORMERS (PT) 65
10.4.9.2 TEST INSTRUMENT POTENTIAL TRANSFORMERS (PT) 65
10.4.9.2.2 TURN RATIO TEST 68
10.4.9.3 REMOVAL INSTRUMENT POTENTIAL TRANSFORMERS (PT) 68
10.4.9.4 INSTALL INSTRUMENT POTENTIAL TRANSFORMERS (PT) 69
10.4.10 INSTRUMENT CURRENT TRANSFORMER (CT) 70
10.4.10.1 INSPECT INSTRUMENT CURRENT TRANSFORMER (CT) 71
10.4.10.2 TEST INSTRUMENT CURRENT TRANSFORMER (CT) 72
10.4.10.3 REMOVAL INSTRUMENT CURRENT TRANSFORMER (CT) 72
10.4.10.4 INSTALL INSTRUMENT CURRENT TRANSFORMER (CT) 72
10.4.11 GENERATOR, FEEDER AND TIE BREAKERS 73
10.4.11.1 INSPECT GENERATOR, FEEDER AND TIE BREAKERS 74
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TABLE OF CONTENTS
SECTION TITLE PAGE

10.4.11.2 TEST GENERATOR, FEEDER AND TIE BREAKERS 75
10.4.11.3 REMOVE GENERATOR, FEEDER AND TIE BREAKERS 76
10.4.11.4 INSTALL GENERATOR, FEEDER AND TIE BREAKERS 77
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LIST OF FIGURES
FIGURE TITLE PAGE

FIGURE 10.4.1-1 STATION POWER TRANSFORMER 12
FIGURE 10.4.2-1 208VAC AND 120VAC EXTERNAL RECEPTACLES 19
FIGURE 10.4.2-2 120VAC INTERNAL RECEPTACLES 20
FIGURE 10.4.4-1 POWER PANEL BOARD 27
FIGURE 10.4.5-1 ALTERNATOR 31
FIGURE 10.4.5-2 TEMPERATURE CORRECTION CHART 40
FIGURE 10.4.6-1 ROTATING FIELD ASSEMBLY 44
FIGURE 10.4.6-2 RECTIFIER BLOCK ASSEMBLY LABELED 45
FIGURE 10.4.6-3 DIODE RECTIFIER BLOCK 45
FIGURE 10.4.6-4 VARISTOR CR8 46
FIGURE 10.4.7-1 TIE OUTPUT TERMINALS 51
FIGURE 10.4.7-2 FEEDER OUTPUT TERMINALS 52
FIGURE 10.4.7.3-1 TYPICAL LOAD TERMINAL BREAKOUT 56
FIGURE 10.4.7.3-2 LOWER FRONT COVER 57
FIGURE 10.4.8-1 SURGE ARRESTERS (SA1, SA2, SA3) 59
FIGURE 10.4.8-2 LEFT REAR OF PDC 62
FIGURE 10.4.9-1 POTENTIAL TRANSFORMERS LEFT OR RIGHT SECTION 64
FIGURE 10.4.9-2 POTENTIAL TRANSFORMERS CENTER SECTION 65
FIGURE 10.4.10-1 INSTRUMENT CURRENT TRANSFORMERS 70
FIGURE 10.4.11-1 GENERATOR, FEEDER & TIE BREAKER 73
FIGURE 10.4.11.3-1 TIE BREAKER MECHANICAL LATCH STIFFNER PLATE 77
FIGURE 10.4.11.4-1 CONTACTOR CONTROL BOARD 78
FIGURE 10.4.11.4-2 CONTROL BOARD DIPSWITCH 79
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LIST OF TABLES
TABLE TITLE PAGE

TABLE 10.2-1 FOLDOUT DESCRIPTIONS 10
TABLE 10.4.5-1 GENERATOR INSULATION RESISTANCE TEST MAINTENANCE RECORD

(EXAMPLE FORM) 40
TABLE 10.4.5.5-1 GENERATOR START-UP CHECKLIST (1 OF 2) (EXAMPLE FORM) 42
TABLE 10.4.5.5-1 GENERATOR START-UP CHECKLIST (2 OF 2) (EXAMPLE FORM) 43
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10.0 ALTERNATING CURRENT (AC) SYSTEM REPAIR
Maintenance procedures are provided for the following AC System Components:
• Station Power Transformer

• 208/120VAC Receptacles
• Wiring Harnesses
• Power Panel Board
• Alternator
• Varistor and Rectifier Block Assembly
• Medium Voltage Output Terminals
• Surge Arrestors
• Instrument Potential Transformer (PT)
• Instrument Current Transformer (CT)
• Generator, Feeder, and Tie Breakers
10.1 SAFETY INSTRUCTIONS
following:

• Rotating Parts

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due maintenance.

(2) Isolate the PU from any power plant or utility connection in accordance with Section 5.9.6.15,
Unit Isolation Procedure with PSC. See Note 1 and 2.
(5) Push to OPEN both Emergency Stop Switches.
(10)Disconnect the negative and positive cables from both Battery Banks.
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WARNING

10.2 BRIEF SYSTEM DESCRIPTION
• Alternator
• Distribution System
• AC Prints
a. The SR4B is a three phase, alternating current and brushless type generator. It is a four pole
design. The stationary main armature bolts to the engine flywheel housing. A flexible plate type
coupling connects the rotor shaft to the engine flywheel. The rotating main field is keyed directly
to the rotor shaft. The generator is self-ventilated with air entry through screened openings at the
rear of the generator and air discharge through screened openings at the drive-coupling end. The
fan attaches to rotor shaft. A bearing supports the exciter end of the rotor shaft.
b. The PU is configured for 840Kw at 60Hz at a .8 power factor, 4160/2400 VAC at 1800 rpm.
c. The PU is configured for 700Kw at 50Hz at a .8 power factor, 3800/2200 VAC at 1500 rpm.
d. Internally connected in a “Y” configuration.
e. Voltage is regulated by the Caterpillar Automatic Voltage Regulator (AVR).
f. Parking Stands are supplied for Medium Voltage Cables when disconnected from the PU.
g. Each Feeder Breaker is set to operate with a 100-amp load.
h. The Tie Breaker is designed to operate at 200 amps.

• Contactors use 120VAC as control voltage for opening and closing.
• All contactors require a constant 120VAC signal to stay closed except for the Tie Breaker,
which has a mechanical interlock to keep it closed.
i. The AC & DC prints called Foldouts are structured as follows:
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TABLE 10.2-1 FOLDOUT DESCRIPTIONS

POWER UNIT LIST OF FOLDOUTS
FOLDOUT
DESCRIPTION
NUMBER
DPGDS ABBREVIATIONS FOLDOUT 1
DPGDS ABBREVIATIONS, DEVICES AND NOTES FOLDOUT 2
PU - ONE-LINE ELECTRICAL DIAGRAM, (WITH PROTECTIVE DEVICES) FOLDOUT 3
DPGDS AC SCHEMATIC, SHEET 1 OF 4 FOLDOUT 4A
DPGDS AC SCHEMATIC, SHEET 2 OF 4 FOLDOUT 4B
DPGDS AC SCHEMATIC, SHEET 3 OF 4 FOLDOUT 5
DPGDS AC SCHEMATIC, SHEET 4 OF 4 FOLDOUT 6
DPGDS DC SCHEMATIC, PDC DC CONTROL SCHEMATIC, SHEET 1 OF 7 FOLDOUT 7
DPGDS DC SCHEMATIC, PDC DC RTU AND I/O SCHEMATIC, SHEET 2 OF 7 FOLDOUT 8
DPGDS DC SCHEMATIC, PDC DC DISCRETE INPUT SCHEMATIC, SHEET 3 OF 7 FOLDOUT 9
DPGDS DC SCHEMATIC, PDC DC DISCRETE INPUT SCHEMATIC, SHEET 4 OF 7 FOLDOUT 10
DPGDS DC SCHEMATIC, PDC DC DISCRETE OUTPUT SCHEMATIC, SHEET 5
FOLDOUT 11
OF 7
DPGDS DC SCHEMATIC, PDC DC PANEL SCHEMATIC, SHEET 6 OF 7 FOLDOUT 12A
DPGDS DC SCHEMATIC, PDC DC PANEL SCHEMATIC, SHEET 7 OF 7 FOLDOUT 12B
WIRING DIAGRAMS POWER SUPPLIES FOR PCM AND HUB, SHEET 1 OF 30 FOLDOUT 13
WIRING DIAGRAMS GENERATOR 1/FEEDER 1 DOOR SUBPAN, SHEET 2 OF 30 FOLDOUT 14
WIRING DIAGRAMS GENERATOR 1/FEEDER 1 DOOR, SHEET 3 OF 30 FOLDOUT 15
WIRING DIAGRAMS GENERATOR 1/FEEDER 1 DOOR, SHEET 4 OF 30 FOLDOUT 16
WIRING DIAGRAMS GENERATOR 1/CONTACTOR & POTENTIAL
FOLDOUT 17
TRANSFORMER, SHEET 5 OF 30
WIRING DIAGRAMS GENERATOR 1 TERMINAL BOARD, SHEET 6 OF 30 FOLDOUT 18
WIRING DIAGRAMS LOAD TIE DOOR, SHEET 7 OF 30 FOLDOUT 19
WIRING DIAGRAM MASTER CONTROL PANEL DOOR CONTACTOR AND
FOLDOUT 20
POTENTIAL TRANSFORMER, SHEET 8 OF 30
WIRING DIAGRAM MASTER CONTROL PANEL “SWING DOOR”, SHEET 9 OF 30 FOLDOUT 21
WIRING DIAGRAM MASTER CONTROL PANEL TERMINAL BOARD, SHEET 12 OF
FOLDOUT 24
30
WIRING DIAGRAM MASTER CONTROL PANEL TERMINAL BOARD, SHEET 13 OF
FOLDOUT 25
30
WIRING DIAGRAM GENERATOR 2/FEEDER 2 DOOR, SHEET 14 OF 30 FOLDOUT 26
WIRING DIAGRAM GENERATOR 2/FEEDER 2 CONTACTOR – POTENTIAL
FOLDOUT 29
TRANSFORMERS, SHEET 17 OF 30
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TABLE 10.2-1 FOLDOUT DESCRIPTIONS (CONTINUED)

POWER UNIT LIST OF FOLDOUTS
FOLDOUT
DESCRIPTION
NUMBER
WIRING DIAGRAM GENERATOR 2 TERMINAL BOARD, SHEET 18 OF 30 FOLDOUT 30
WIRING DIAGRAM PDC ENGINE/GENERATOR CONTROL PLUGS, SHEET 19 OF
FOLDOUT 31
30
WIRING DIAGRAM A-B COMMUNICATION CABLE, SHEET 20 OF 30 FOLDOUT 32
WIRING DIAGRAM ENGINE FLUID LEVEL SWITCHES, SHEET 21 OF 30 FOLDOUT 33
WIRING DIAGRAM POWER UNIT HARNESS, SHEET 22 OF 30 FOLDOUT 34
WIRING DIAGRAM POWER UNIT HARNESS - GENERATOR TO BUS, SHEET 23
FOLDOUT 35A
OF 30
WIRING DIAGRAM POWER UNIT HARNESS - GENERATOR TO BUS, SHEET 24
FOLDOUT 35B
OF 30
WIRING DIAGRAM SYSTEM POWER DISTRIBUTION TO LOAD BREAK ELBOWS,
FOLDOUT 35 C
SHEET 25 OF 30
WIRING DIAGRAM POWER DISTRIBUTION 4160/2400 VAC 3 TO 208/120 VAC 3
FOLDOUT 36A
PHASE, SHEET 26 OF 30
FOLDOUT 36B
FOLDOUT 36C
WIRING DIAGRAM, POWER DISTRIBUTION DEVICES, SHEET 29 OF 30 FOLDOUT 36D
WIRING DIAGRAM BATTERY LEAD INSTALLATION AND INTERCONNECT,
FOLDOUT 37
SHEET 30 OF 30
ENGINE WIRING DIAGRAM, SHEET 1 OF 5 FOLDOUT 38
SCHEMATIC, FUEL TRANSFER CONTROL BOX ASSEMBLY, SHEET 1 OF 5 FOLDOUT 43A
WIRING DIAGRAM, FUEL TRANSFER CONTROL BOX ASSEMBLY, SHEET 2 OF 5 FOLDOUT 43B
WIRING DIAGRAM, FUEL TRANSFER CONTROL BOX ASSEMBLY, SHEET 3 OF 5 FOLDOUT 44A
WIRING DIAGRAM, FUEL TRANSFER CONTROL BOX ASSEMBLY, SHEET 4 OF 5 FOLDOUT 44B
WIRING DIAGRAM, FUEL TRANSFER CONTROL BOX ASSEMBLY, SHEET 5 OF 5 FOLDOUT 44C
SCHEMATIC DIAGRAM INTERNAL FUEL SYSTEM, SHEET 1 OF 2 FOLDOUT 48
SCHEMATIC DIAGRAM EXTERNAL FUEL SYSTEM, SHEET 2 OF 2 FOLDOUT 49
SCHEMATIC DIAGRAM, B MODEL, 7-PIN CONNECTOR, SHEET 1 OF 4 FOLDOUT 50
SCHEMATIC DIAGRAM, B MODEL, 7-PIN CONNECTOR, SHEET 3 OF 4 FOLDOUT 52A
SCHEMATIC DIAGRAM, B MODEL, 7-PIN CONNECTOR, SHEET 4 OF 4 FOLDOUT 52B
SCHEMATIC DIAGRAM, B MODEL, ABS BRAKE SYSTEM, SHEET 1 OF1 FOLDOUT 55
NOTE: The MEP-PU-810A and MEP-PU-810B use medium voltage vacuum breakers for the
distribution.
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The AC “System” does require service. Each subcomponent that requires a service will be addressed in
that section.
10.4.1 STATION POWER TRANSFORMER
The following maintenance procedures are provided for the Station Power Transformer:
Inspect
Test:
• Test Fuses
• Insulation Resistance Test
• Turns Ratio Test
Remove
Install
STATION POWER TRANSFORMER
FIGURE 10.4.1-1 STATION POWER TRANSFORMER
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10.4.1.1 INSPECT STATION POWER TRANSFORMER
WARNING
REMOVE ALL RINGS, NECKLACES, JEWELERY AND LOOSE CLOTHING. FAILURE TO

DO SO COULD CAUSE SEVERE INJURY OR DEATH.
WARNING
WARNING
Inspect the station power transformer for the following conditions:

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b. Remove the four screws from the Tie Panel and swing it outward exposing the transformer fuse
block and Tie Breaker.
c. Discharge capacitive charge from exposed conductors.
d. Visually inspect Fuse 12, Fuse 13 and Fuse 14 and fuse block for looseness, burning, corrosion,
and physical damage. Ensure fuses are properly rated (5A-4800 VAC).
e. Remove both Battery Chargers. See Section 9.4.3.3 for reference.
f. Remove transformer access panels.
g. Discharge capacitive charge from all exposed conductors.
h. Visually inspect the transformer for the following:
• Corrosion
• Physical damage
• Loose connections
• Shorted, frayed, or broken wires
• Loose mountings
• Damage and signs of overheating
i. Install all access panels and secure with mounting hardware.
j. Install both Battery Chargers.
10.4.1.2 TEST STATION POWER TRANSFORMER
To test the Station Power Transformer, proceed as follows:
block and load Tie Breaker.
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Test Fuses:
d. Visually inspect Fuse 12, Fuse 13 and Fuse 14 and fuse block for looseness, burning, corrosion,
and physical damage. Ensure fuses are properly rated (5A-4800 VAC).
e. Remove fuses from the fuse block using the proper fuse puller and high voltage gloves.
f. Test fuses for continuity. Replace if defective.
g. Perform appropriate tests if neccessary. (See Section 10.4.1.2.1 and/or Section 10.4.1.2.2)
h. Reinstall fuses using the proper fuse puller and high voltage gloves.
i. Reinstall all access panels and secure with mounting hardware.
10.4.1.2.1 INSULATION RESISTANCE TEST
To test the transformer proceed as follows:
block and Tie Breaker.
d. Remove fuses prior to this test.
g. Disconnect high voltage and low voltage leads from the transformer.
h. Using a multimeter set to OHMS (Ω) Rx1 scale, perform individual continuity checks on
transformer primary and secondary windings.
i. Connect a 500V Megger to either primary lead and to ground. Short the secondary terminals to
ground before connecting the Megger leads to primary terminals. Operate the Megger for 60
seconds and observe resistance. Reading on each transformer should be not less than 20
megohm. Short the primary lead to ground before disconnecting.
j. Short high voltage terminals to ground before connecting the Megger. Connect the Megger to
either secondary lead and to ground. Operate the Megger for 60 seconds and observe
resistance. Reading should be not less than 1 megohm. Short the secondary lead to ground
before disconnecting.
k. Connect Megger leads between primary and secondary windings. Operate the Megger for 60
seconds and observe resistance. Reading should not be less than 20 megohm. Short both
windings to ground before disconnecting.
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10.4.1.2.2 TURNS RATIO TEST
Turns ratio testing of transformers provides a direct means to detect loose or open connections, shorted
or open turns in the transformer windings, incorrect polarity connections, and to verify precisely the no-
load voltage ratio of the transformer, at all tap positions. The turns ratio of a transformer is defined as the
number of turns in one winding in relation to the number of turns in the other winding of the same phase,
which is also equal to the no-load voltage ratio.
To test the transformer proceed as follows:
b. Remove the four screws from the Load Tie Panel and swing it outward exposing the transformer
fuse block and Tie Breaker.
d. Remove fuses prior to this test.
g. Tag and disconnect wiring leads from the transformer to include the panel board wiring.
h. Perform a TTR test using the test equipment’s manufactures procedures. The turns ratio is
required to be within ±1/2 percent or (.005), of the indicated nameplate voltage ratio.
• If the transformer fails any of the above requirements, remove and forward to next higher
level of maintenance.
• If the transformers meet above requirements, connect wiring leads and discard tags.
i. Reinstall access panel and both Battery Chargers with securing hardware.
a. Using a multimeter set to OHMS (Ω) Rx1 scale, perform individual continuity checks on
b. Connect a 500V Megger to either primary lead and to ground. Short the secondary terminals to
ground before connecting Megger leads to primary terminals. Operate Megger for 60 seconds
and observe resistance. Reading on each transformer should be not less than 20 meg-ohms.
Short the primary lead to ground before disconnecting.
c. Short the high voltage terminals to ground before connecting Megger. Connect Megger to either
secondary lead and to ground. Operate the Megger for 60 seconds and observe resistance.
Reading should be not less than 1 meg-ohm. Short the secondary lead to ground before
disconnecting.
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d. Connect Megger between primary and secondary windings. Operate the Megger for 60 seconds
and observe resistance. Reading should not be less than 20 meg-ohms. Short both windings to
ground before disconnecting.
10.4.1.3 REMOVE STATION POWER TRANSFORMER
WARNING

WARNING
WARNING
WARNING

To remove the station power transformer, proceed as follows:
unable to start. See procedures in paragraph 10.4.1.1.
b. Remove the four screws from the Load Tie Panel and swing it outward exposing the transformer
fuse block and Tie Breaker.
d. Remove the three transformer fuses.
g. Tag and disconnect wiring leads from the transformer.
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h. Remove conduit and wires from the PDC and panel board.
i. Place a strap around the transformer and connect it to a lift. Remove mounting hardware and
carefully, remove the transformer from the PU. Extra care must be taken due to the
transformer’s weight and size of work area.
10.4.1.4 INSTALL STATION POWER TRANSFORMER
WARNING

WARNING
WARNING
WARNING

To install the Station Power Transformer, proceed as follows:
unable to start. See procedures in paragraph 10.4.1.1.
b. Reinstall the transformer from either side of the PU, and secure with the mounting hardware.
c. Reinstall the conduit from the PDC and Panel Board.
d. Connect wiring to the transformer and discard tags.
e. Reinstall and secure access cover panels with mounting hardware.
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f. Reinstall both Battery Chargers. See Section 9.4.3.4 for reference.
f. Reinstall the transformer fuses. Close the Tie Panel by swinging it inward and secure the door
with the four (4) mounting screws.
10.4.2 208/120VAC RECEPTACLES
The following maintenance procedures are provided for the 208/120VAC Receptacles:
Inspect
Test
Remove
Install
FIGURE 10.4.2-1 208VAC AND 120VAC EXTERNAL RECEPTACLES
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FIGURE 10.4.2-2 120VAC INTERNAL RECEPTACLES
There are two 120 VAC, 20-amp, single-phase, GFCI duplex receptacles and one 208 VAC, three-phase,
60 amp receptacle located under the trailer housing on the roadside of the unit. (See Figure 10.4.2-1).
There are also two 120VAC internal receptacles, located under the panel board, near the rear of the
alternator (See Figure 10.4.2-2).
10.4.2.1 INSPECT 208/120VAC RECEPTACLES
Inspect the 208/120VAC receptacles for the following conditions:
a. Loose connections and shorted, frayed, or broken wires.
b. Security of attachment.
c. Signs of burning or overheating.
d. Cover for proper operation.
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10.4.2.2 TEST 208/120VAC RECEPTACLES
10.4.2.2.1 TEST 208/120VAC RECEPTACLES (INTERNAL AND EXTERNAL)
To test the 208/120VAC receptacle, proceed as follows:
WARNING

a. Ensure receptacles are free of foreign matter.
b. Using a multimeter set to AC scale,
• Check presence of 120VAC in receptacles phase to neutral.

• Check 208VAC, phase to phase, and 120VAC phase to neutral in the three phase
receptacle.
• Using a phase rotation meter, Check for proper phase rotation (A, B, C) at the 208 VAC
receptacle
10.4.2.2.2 TEST 120-VAC (GFCI) DUPLEX RECEPTACLES
To test the GFCI Receptacles, proceed as follows:
a. With the system energized, press the (TEST) button on the receptacle.
b. Press the (RESET) button. The receptacle should reset.
c. Test receptacle with multimeter in “AC” mode. Ensure the receptacle is energized with the
RESET in and de-energized with the reset out (TRIPPED).
10.4.2.2.3 REMOVE 120/208 VAC RECEPTACLES AND (EXTERNAL)
WARNING
REMOVE ALL RINGS, NECKLACES, JEWELERY AND LOOSE CLOTHING. FAILURE TO

DO SO COULD CAUSE SEVERE INJURY OR DEATH.
WARNING
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To Remove the 120/208 VAC Receptacles (External):

b. Place the correct circuit brekaer located in PU Distribution Center to the OFF position.
CB2 is the 120/208 VAC 3-phase 60 amp receptacle.
CB3 is the 120 VAC GFI receptacles
c. Ensure power is removed from the receptacles by checking for AC voltage with a multimeter.
d. Remove screws from receptacle cover plate.
e. Remove screw from receptacle and remove.
f. Tag and Disconnect wires from receptacle.
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10.4.2.2.4 INSTALL 120/208 VAC RECEPTACLES AND (EXTERNAL)
To Install the 120/208 VAC Receptacles (External)
unable to start. See procedures and warnings in paragraph 10.4.2.2.3.
b. Reconnect the wires to the receptacles.
c. Attach receptacle to the box.
d. Replace gasket and cover plate and secure with screws.
e. Turn Circuit Breaker ON.
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10.4.3 WIRING HARNESSES
The following maintenance procedures are provided for the Wiring Harnesses:
Inspect
Test
Remove
Install
Repair
Harnesses interconnect elements of the AC electrical power generation and control system. Refer to the
drawing Fold-outs (FO) FO - 1 and FO – 44C to provide representations of components and circuit
interconnection within the generator set. For the following tasks, isolate the PU from the high voltage
source.
10.4.3.1 INSPECT WIRING HARNESS
WARNING

WARNING
WARNING
To inspect the wiring harnesses, proceed as follows:

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b. Check wires for cracking insulation or frayed areas.
c. Check that all terminal lugs and screws are securely attached to wire ends.
d. Ensure that wires are tied together as tightly as possible to avoid rubbing.
e. Check security of all hangers, clamps, and hardware that secure wiring harnesses to generator
set.
10.4.3.2 TEST WIRING HARNESS
To test the wiring and harnesses using the following steps:
b. Check all suspect wires for continuity to ground. Refer to applicable wiring diagram FO - 1
through FO – 44C.
c. Test wires relating to malfunctioning circuit for continuity and internal shorts, where there is an
indication that a given harness is causing a malfunction.
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10.4.3.3 REMOVE WIRING HARNESS
To remove the wiring and harnesses, proceed as follows:
b. Remove all hangers, clamps, and ties attaching harness being removed from generator set.
c. Tag and disconnect all wires terminating in lugs from their mountings by removing nuts and
washers attached to their lugs.
d. Where wires are soldered to a connector, the connector is considered part of the harness and is
reinstalled with the harness. Remove screws, nuts, and washers, as necessary, to remove
multiple connectors.
e. Remove harness from generator set by withdrawing wires past any obstruction until wires are
free of generator set.
10.4.3.4 INSTALL WIRING HARNESS
To install wiring and harnesses, proceed as follows:
b. Refer to the appropriate wiring diagram FO - 1 through FO – 44C for the routing of harness being
reinstalled.
c. Carefully feed replacement wires in the harness past any obstruction into position as follows:
• Ensure there is no strain on any wire when it is in place and its connectors and mounting
lugs are attached to the generator set.
• Ensure no wire is bent over any sharp surface that might wear through wire insulation in
normal service.
• Ensure no wire is in contact with any heat producing part of the engine or exhaust system.
d. Attach multiple connectors using screws, nuts, and washers removed previously.
e. Attach all wires terminating in lugs to the correct stud or terminal by replacing mounting hardware
removed in the prior section.
10.4.3.5 REPAIR WIRING HARNESS
To repair the wiring and harnesses, proceed as follows:
b. Repair wiring and harnesses in accordance with Technical Order TO 1-1A-14.
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10.4.4 POWER PANEL BOARD
The following maintenance procedures are provided for the Power Panel Board:
Inspect
Test
Remove
Install
FIGURE 10.4.4-1 POWER PANEL BOARD
10.4.4.1 INSPECT PANEL BOARD
To inspect the panel board, proceed as follows:
a. Inspect the Panel Board for damage.
b. Inspect for looseness of hardware.
c. Inspect for missing hardware.
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10.4.4.2 TEST PANEL BOARD AND BREAKERS
WARNING

WARNING

THE TEST LEADS.
WARNING

EQUIPMENT
WARNING
To test the power panel board, proceed as follows:

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b. The MS-2 Circuit Breaker Tester or equivalent is required to test the circuit breakers.
c. Connect the test cables according to the test equipment manufactures recommendations.
d. Test each breaker according to the test equipment manufactures recommendations.
e. No testing for the panel enclosure is required.
10.4.4.3 REMOVE PANEL BOARD
To remove the power panel board, proceed as follows:
b. Remove the 6 front cover-mounting screws and remove the front cover.
c. Remove the 5 interior cover-mounting screws and remove the interior cover.
d. Tag and disconnect the wiring from each circuit breaker and remove all conduit mounting
hardware and remove all conduit from the panel.
e. Disconnect wires, conduit hardware and box for switch, for interior lighting.
f. Remove the power distribution panel mounting bolts and remove the panel.
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10.4.4.4 INSTALL PANEL BOARD
To install the panel board, proceed as follows:
b. Reinstall the power distribution panel and secure with mounting hardware.
c. Reinstall all conduits with mounting hardware. Reconnect all wiring and remove wire tags.
d. Reinstall wires, conduit hardware and box for switch, for interior lighting.
e. Reinstall the interior cover with the 5 mounting screws.
f. Reinstall the front cover with the 6 mounting screws.
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10.4.5 ALTERNATOR
The following maintenance procedures are provided for the Alternator:
Inspect
Test
Remove
Install
Generator Startup Checklist
FIGURE 10.4.5-1 ALTERNATOR
10.4.5.1 INSPECT ALTERNATOR
To inspect generator assembly, proceed as follows:
a. Check that no wire is in contact with any sharp surface or any heat producing surface of the
engine or exhaust system.
b. Check for obstructions to air intakes and air outlets.
c. Check for signs of burning or overheating.
d. Before initial start-up or after storage of a generator, use a Megger to check insulation resistance
for moisture and/or foreign material. See Section 10.4.5.2 for the procedure. A resistance
reading of one megohm or less is an indication that the winding has absorbed too much moisture.
Refer to SENR5359-01 or later version, SMCS CODE 4450 for additional reference.
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NOTE: If an oven is used for drying, use a forced air rather than a radiant oven because radiant
ovens can cause localized overheating. If there is a possibility that insulation resistance has
lowered to a dangerous level, contact your local Caterpillar Dealer.
e. The Strip Heater is not connected for DPGDS, there are no thermostats installed. The strip
heater heats the windings to remove moisture and should be connected at all times in high
humidity conditions. Use the strip heater only when the unit is not operating. To power the space
heaters, connect an outside 115-volt or 220-volt cable to the space heater terminal block, located
on top of the alternator housing. Stop the drying procedure every hour and check the insulation
resistance. Remember, the only way to turn off the strip heaters is to unplug it from the power
source. Continue the drying process until the insulation resistance is acceptable.
f. Alternative drying methods are explained in the Caterpillar manual SENR5359-01 or SEHS9124-
01 or later versions.
10.4.5.2 TEST ALTERNATOR
WARNING
REMOVE ALL RINGS, NECKLACES, JEWELERY AND LOOSE HANGING

CLOTHING. FAILURE TO DO SO COULD CAUSE SEVERE BURNS, LOSS OF LIMB
AND OR DEATH.
WARNING
WARNING
WARNING

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WARNING

THE TEST LEADS.
10.4.5.2.1 RECOMMENDED PERIODIC INSULATION CHECKS
a. Periodically use a Megger to check generator main stator winding insulation resistance. The
frequency of the insulation resistance test is determined by the generator’s environment and by
previous Megger test indicators.
b. Test the main stator windings with a Megger in the following situations:
(1) Before initial startup of generator set.
(2) After generator storage.
(3) Every three months if generator is operating in a humid environment or is not protected
from the elements by an enclosed area.
(4) Every six months if the generator is installed in an enclosed area with relatively low
humidity and minimal temperature variations.
(5) If generator has not been run under load for three months or more.
(6) Test every week and use space heaters if the generator is exposed to a seawater
environment or if the surrounding conditions are very humid (relative humidity above
75%) or if a recent test reading was less than three megohm. In applications where salt
and high humidity are present, space heaters must be operated whenever the generator
is not operating under load. This is the only way to maintain Megger test readings above
one megohm.
c. The insulation resistance check is described in Caterpillar Special Instruction Manual SEHS
9124-01. A reading of one megohm or less indicates that the winding has absorbed too much
moisture.
NOTE: This is a guideline only. It may be necessary to Megger more frequently if the environment is
extremely humid, salty or if the last Megger test was close to one megohm.
a. The presence of moisture, dust, grease and other foreign matter within the generator, causes the
insulation on the coils of wire (windings) to deteriorate. This deterioration reduces the resistance
of the insulation.
b. The insulation resistance (Megger) test measures the resistance of the insulation on the
windings. The insulation tester (Megger) produces a high potential voltage between the test
leads. During the test, a small current flows which the tester converts to a resistance reading.
This test is performed as part of periodic maintenance to detect the deterioration of the winding
insulation. A rapid decrease of insulation resistance over a short period of time indicates the
need for generator cleanup.
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c. The Megger test should also be performed to detect the presence of moisture on any generators
that have not been used for a period of time. If moisture is present, the windings must be dried
prior to testing. If the measured insulation resistance is less than specified and the clean up or
drying procedure does not correct the discrepancy, the winding needs to be reconditioned or
replaced.
d. The specified insulation resistance is an approximate value. It is possible to operate the generator
with less than the specified value. However, a generator with low winding insulation resistance is
far more likely to have a failure than a generator with acceptable insulation resistance. The test
gives accurate results only when the generator windings are dry and at room temperature.
e. The minimum recommended insulation resistance of each winding must be one meg-ohm
(1,000,000 ohms) or greater.
10.4.5.2.2.1 TEST PROCEDURES
Refer to SENR5359-01 or later version, SMCS CODE 4450 for test procedures. The following
test procedures are to be used as a guide only.
WARNING

AND OR DEATH.
WARNING
WARNING
WARNING

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WARNING

THE TEST LEADS.
WARNING

EQUIPMENT
10.4.5.2.2.1.1 MAIN ARMATURE (STATOR-L4) TEST
To test the Main Armature (Stator L4), proceed as follows:

b. Remove the upper most access panel from the PDC (generator side).
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c. Discharge capacitive charges (with grounding stick) from all bus work and conductors.
d. Disconnect load cables T1, T2, T3, and T0 from PDC bus work.
e. Isolate Isolate the main armature (L4) from the voltage regulator by disconnecting J11 and
generator lead (T0) from the enclosure ground. Connector J11 is the deutsch connector on top of
the alternator housing.
f. Remove the protective shroud from the rear of the generator.
g. Inspect all wiring, cables, and connectors for moisture, dirt and grime, etc. If moisture is present,
DO NOT TEST. Dry unit first in accordance with Special Instructions SEHS 9124-01, Cleaning
and Drying of Electrical Set Generators.
h. Connect one test lead of the insulation tester (Megger) to the generator enclosure (ground).
i. Connect the other test lead of the Megger to generator lead T1.
j. Apply 1,000 volts DC.
k. The insulation resistance must be one megohm or greater.
l. Repeat steps h – k for generator leads T2, T3, and T0.
m. Reconnect load cables T1, T2, T3, and T0 to the PDC bus work.
n. Reconnect J11 connector and generator lead (T0) to the enclosure ground.
o. Record the results on Table 10.4.5-1, using Figure 10.4.5-2 for temperature correction.
p. Reinstall the PDC access panel
q. Reinstall the generator protective shroud.
10.4.5.2.2.1.2 EXCITER FIELD (STATOR-L1) TEST
To test the Exciter Field (Stator L1), proceed as follows:
unable to start. See procedures and warnings in paragraph 10.4.5.2.2.1.
c. Discharge capacitive charges (with grounding stick) from all bus work and conductors.
d. Disconnect load cables T1, T2, T3, and T0 from bus work.
e. Isolate the exciter field (L1) from the voltage regulator by disconnecting J11 connector.
g. Connect one test lead of the Megger to the generator enclosure (ground).
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h. Connect the other test lead of the Megger to generator exciter field lead F1 or F2 (pin 6 or 7 of
J11 connector).
i. Apply 1,000 volts DC.
j. Measure the resistance of the exciter field winding insulation to ground. The resistance must be
0.25 megohm (250,000 ohms) or greater.
k. Reconnect the J11 connector.
l. Reconnect the load cables T1, T2, T3 and T0 to the PDC bus work.
m. Reinstall the PDC access panel.
n. Reinstall the generator protective shroud.
10.4.5.2.2.1.3 EXCITER ARMATURE (ROTOR-L2) TEST
To test the Exciter Armature (Rotor L2), proceed as follows:
c. Discharge capacitive charges (with a grounding stick) from all bus work and conductors.
d. Disconnect load cables T1, T2, T3, and T0 from the PDC bus work.
e. Remove the protective shroud from the rear of the generator.
f. Isolate the exciter armature (L2) from the rectifier circuit. Disconnect AC1, AC2, and AC3 from
the rectifier block. Refer to figure 10.4.6-2, pg. 10-58. Prevent these wires from touching one
another or contacting ground.
g. Connect one Megger test lead to the rotor shaft.
h. Connect the other test lead of the Megger to one of the exciter leads.
j. Repeat steps g, h, and i for the remaining two leads.
k. The insulation resistance must be 0.25 megohm (250,000 ohms) or greater.
l. Reconnect the exciter armature (L2) AC1, AC2 and AC3 to the rectifier block. Torque screws to
20 – 25 in-lbs.
m. Reconnect the load cables T1, T2, T3 and T0 to the PDC bus work.
n. Reinstall the PDC access panel.
o. Reinstall the generator protective shroud.
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10.4.5.2.2.1.4 PILOT EXCITER ARMATURE (L5) TEST
To test the Pilot Exciter Armature (L5), proceed as follows:
d. Disconnect load cables T1, T2, T3, and T0 from the PDC bus work.
e. Remove the protective shroud from the rear of the generator.
f. Isolate the pilot exciter armature (L5) from the PDC AVR (Voltage Regulator) by disconnecting
PMG 11, 12, and 13 from termination points J11-1, J11-2, and J11-3 (Refer to FO 35A).
g. Connect one test lead of the Megger to the generator enclosure (ground).
h. Connect the other lead of the Megger to one lead of the pilot exciter armature (J11-1, 2 or 3).
j. Repeat steps g, h and i for the other two leads.
l. Record the results on Table 10.4.5-1, using Figure 10.4.5-2 for temperature correction.
m. Reinstall the shroud.
n. Reconnect J11 connector.
o. Reconnect load cables T1, T2, T3, and T0 to bus work.
p. Reinstall PDC access panel.
10.4.5.2.2.1.5 MAIN ROTOR (L3) TEST
To test the Main Rotor (L3), proceed as follows:
d. Disconnect load cables T1, T2, T3, and T0 from bus work.
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e. Isolate the PDC AVR (Voltage Regulator) by disconnecting the J11 connector.
g. Isolate the main rotor field (L3) from the rectifier circuit (diode block containing CR1 – CR6, Fig
10.4.6-2) by Disconnecting the positive and negative output wire from the diode block.
h. Connect one test lead of the Megger to one of the main field wires (either positive or negative).
i. Connect the other lead of the Megger to any part of the main rotor shaft. The bolts which hold the
rectifier block assembly onto the end of the main rotor is acceptable.
j. Apply 1,000 volts DC.
l. Record the results on Table 10.4.5-1, using Figure 10.4.5-2 for temperature correction.
m. Reinstall the positive and negative leads to the rectifer block. Torque to 20 to 25 in-lbs.
n. Reinstall the shroud.
o. Reconnect load cables T1, T2, T3, and T0 to bus work.
p. Reinstall the J11 connector.
q. Reinstall PDC access panel.
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TABLE 10.4.5-1 GENERATOR INSULATION RESISTANCE TEST MAINTENANCE RECORD

(EXAMPLE FORM)
Engine S/N ________________________________________________________________________
Generator S/N ______________________________________________________________________
30 Sec Ambient Correction 30 Sec. 60 Sec.

Date 60 Sec Read
Read Temperature factor Corrected Corrected
T1-GND
T2-GND
T3-GND
T0-GND
T1-T2
T2-T3
T1-T3
Comments:
_____________________________________________________________________________________
_____________________________________________________________________________________
_____________________________________________________________________________________
_________________________________________________________________________________
FIGURE 10.4.5-2 TEMPERATURE CORRECTION CHART
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10.4.5.3 REMOVE ALTERNATOR
Refer to Caterpillar SR4B Service Manual SENR5359-01, dated September 1999, or later.
Separating the generator from the engine and reattaching it are normally dealer level task. If this must be
done in the field, follow the instructions in the Caterpillar manual SENR 5359-01.
10.4.5.4 INSTALL ALTERNATOR
Refer to Caterpillar SR4B Service Manual SENR5359-01, dated September 1999, or later.
Separating the generator from the engine and reattaching it are normally dealer level task. If this must be
done in the field, follow the instructions in the Caterpillar manual SENR 5359-01.
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10.4.5.5 GENERATOR STARTUP CHECKLIST
TABLE 10.4.5.5-1 GENERATOR START-UP CHECKLIST (1 OF 2) (EXAMPLE FORM)

GENERATOR START-UP CHECKLIST
RATING INFORMATION
Engine Serial Number______________________ Arrangement Number______________________
Generator Serial Number___________________ Arrangement Number______________________
GENERATOR NAME PLATE INFORMATION
Voltage__________________________________ Package______________ PRIME_____________
Amperage________________________________
Storage Location__________________________________________________________
Main stator Megger reading: Before Storage__________________ After Storage________________
Generator dried 24 hours prior to startup? (Y/N)______ Drying Method________________________
30 Sec 60 Sec
Megger Test 30 Sec 60 Sec Ambient
Reading Reading Comments
(SEHS 9124) Reading Reading Temperature
Corrected Corrected
Main
Stator
Main
Rotor
Beginning Exciter
of storage Stator
Exciter
Rotor
PMG
Stator
Main
Stator
Main
Rotor
Exciter
Start-up
Stator
Exciter
Rotor
PMG
Stator
REGULATOR Voltage Amps Comments
F1 to F2 DC
20 to 22 AC
20 to 24 AC
No Load 22 to 24 AC
26 to 28 AC
26 to 30 AC
28 to 30 AC
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TABLE 10.4.5.5-1 GENERATOR START-UP CHECKLIST (2 OF 2) (EXAMPLE FORM)

Generator Start-up Checklist (Continued)
Generator Excitation name plate
DC Compare to F1 to F2
information
F1 to F2 AC
20 to 22 AC
Full Load 20 to 24 AC
22 to 24 AC
26 to 28 AC
26 to 30 AC
28 to 30 AC
ELECTRICAL Yes No Comments
Unit properly grounded:
Check diodes
Over current protection
Over voltage protection
Check for loose wiring
Adjust voltage
Adjust frequency
MECHANICAL Data Comments
Bearing temperature Front Rear
Stator temperature A∅ B∅ C∅
Air gap on main stator Top Bottom
Air gap on exciter stator Top Bottom
Air gap of PMG Top Bottom
Ambient air generator at Full Load Supply Temperature
air opening to generator Size of Opening
(See Table 10.4.5.5-1) This form is optional and may be used at your organization. The form is used to
create baseline information. It should be used whenever major maintenance is accomplished, such as an
overhaul or alternator replacement. The form should be kept on file and referred to during the life of the
equipment.
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10.4.6 VARISTOR AND RECTIFIER BLOCK ASSEMBLY
The following maintenance procedures are provided for the Varistor (CR8) and Rectifier Block Assembly
Inspect
Test
Remove
Install
RECTIFIER
BLOCK CR8
W/VARISTOR VARISTOR
CR7
FIGURE 10.4.6-1 ROTATING FIELD ASSEMBLY
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FIGURE 10.4.6-2 RECTIFIER BLOCK ASSEMBLY LABELED
FIGURE 10.4.6-3 DIODE RECTIFIER BLOCK
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FIGURE 10.4.6-4 VARISTOR CR8
10.4.6.1 INSPECT VARISTOR AND RECTIFIER BLOCK ASSEMBLY
To inspect the Rectifier Block assembly, perform the following:
a. Check for signs of burning or overheating.
b. Check for loose or missing hardware.
10.4.6.2 TEST RECTIFER BLOCK AND VARISTOR (CR7) ASSEMBLY
Refer to Caterpillar Manual SENR5359-01 or later for reference. The following test procedures
are to be used as a guide only.
WARNING

AND OR DEATH.
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WARNING
WARNING
WARNING

WARNING

THE TEST LEADS.
WARNING

EQUIPMENT
To test the Rectifier Block and varistor (CR7) assembly, perform the following:

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b. The following procedure tests all six diodes within the block. Replace the rectifier block if any
meter reading differs from the one given. Refer to Figure 10.4.6-3 for referance.
c. Remove grounds from the alternator.
d. Remove the protective shroud from the rear of the generator.
e. Set the digital multimeter on the diode range.
f. Tag all leads then remove all leads from the rectifier block.
g. Place the black lead on the positive (+) rectifier terminal. Place the red test lead on the following
rectifier terminals: AC1, then AC2, and then AC3. All readings on the meter should be between
0.4 and 1.0. Refer to Figure 10.4.6-3 for referance.
h. Place the red lead on the negative (-) rectifier terminal. Place the black test lead on the following
rectifier terminals: AC1, then AC2, and then AC3. All readings on the meter should be between
0.4 and 1.0.
i. Place the red test lead on the positive (+) rectifier terminal. Place the black test lead on rectifier
terminals: AC1, then AC2, and then AC3. In all cases, the meter should be OL (overload).
j. Place the black test lead on the negative (-) rectifier terminal. Place the red test lead on rectifier
terminals: AC1, then AC2, and then AC3. In all cases, the meter should be OL (overload).
NOTE: A shorted diode can cause damage to the exciter rotor. If a diode is shorted, check the
exciter rotor. Refer to the Caterpillar manual SENR5359-01, Testing and Adjusting Section,
"Winding-Test".
NOTE: This rectifier block also contains Varistor "CR7". "CR7" can be checked by measuring the
resistance between the positive (+) rectifier terminal and the negative (-) rectifier terminal.
The resistance should be a minimum of 15,000 ohms.
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10.4.6.3 TEST RECTIFER BLOCK ASSEMBLY
To test the varistor assembly (CR8), perform the following:
b. To check the varistor (CR8), first disconnect the two leads from the (+) and (-) terminals of the
varistor, then measure the resistance between the positive (+) rectifier terminal and the negative
(-) rectifier terminal. The resistance reading should be 15,000 ohms or greater. Refer to Figure
10.4.6-4.
10.4.6.4 REMOVE VARISTOR AND RECTIFIER BLOCK ASSEMBLY
To remove the varistor and rectifier block assembly, perform the following:
unable to start. See procedures and warnings in paragraph 10.4.6.2
b. Remove the alternator protective cover.
c. Tag and Remove all wires on the rectifier block and varistor.
NOTE: The wires are not marked at the factory. The wires must be marked prior to removal.
d. Loosen the four bolts and Remove entire Heat Sink Assembly with rectifier block and varistor still
attached.
e. Remove as required the rectifier or varistor.
f. Clean the heat sink assembly of old thermal compound.

NOTE: A thermal heat sink compound must be used between the rectifier components and the heat
sink.
g. Place Thermal Compound (CAT part number 5P-8937) on new rectifier block as required
following manufacturer’s instructions.
NOTE: Thermal Compound not required on Varistor.
h. Replace rectifier block or varistor on heat sink assembly using existing hardware.
i. Paint Stripe the nut and threads of the rectifier block or varistor mounting hardware to prevent
from loosening.
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10.4.6.5 INSTALL VARISTOR AND RECTIFIER BLOCK ASSEMBLY
To install the varistor and rectifier block assembly, perform the following:
b. Place Thread Lock Compound on Heat Sink bolt threads following the manufacturer’s
instructions.
c. Remount the entire heat sink assembly with rectifier block and varistor attached using the four
mounting bolts. Torque to 26 lbs/ft ± 3. Use Figure 10.4.6-1 and Figure 10.4.6-2 for reference.
d. Reconnect all wires to the rectifier block or varistor as required using new hardware provided and
Remove tags. Torque nuts and screws as follows:
Rectifier Block (22 lb/in ± 2)

Varistor (18 lb/in ± 2)
e. Secure wires with wire ties as needed.
f. Reinstall the alternator protective cover.
g. Prepare the unit for operation.
h. Start the PU according to the Operation Section Chapter 5. Ensure that voltage is being
produced on all three phases. Shut down unit.
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10.4.7 MEDIUM VOLTAGE OUTPUT TERMINALS
The following maintenance procedures are provided for the Medium Voltage Output Terminals:
Inspect
Test
Remove
Install
The Feeder Output Terminals (F1 and F2) are located on the lower street-side of the PDC. The Tie
Output Terminals are located on the lower curb-side of the PDC. The Feeder Output Terminals are used
to connect the PU to Secondary Distribution Center (SDC). In addition, the Tie Output Terminals are
used connect the PU to another PU, PSC or utility. See Figure 10.4.7-1 and Figure 10.4.7-2 for
reference.
FIGURE 10.4.7-1 TIE OUTPUT TERMINALS
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FIGURE 10.4.7-2 FEEDER OUTPUT TERMINALS
10.4.7.1 INSPECT MEDIUM VOLTAGE OUTPUT TERMINAL
WARNING

AND OR DEATH.
WARNING
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WARNING
To inspect Medium Voltage Output Terminals, proceed as follows:

b. Remove access panels. Refer to Figure 10.4.7-1 and 10.4.7-2.
c. Visually inspect all load terminal bushings for cracks, signs of overheating, and other damage.
d. Check terminal lug connections for secure mounting. Check wiring for signs of insulation
e. Inspect all cable terminal bushings for cleanliness, cracks, signs of overheating, and secure
mounting. Check that the conductor terminal inside each bushing is clean and free from any
obstruction.
f. Apply a light coat of silicon lubricant to the exterior of the bushing well.
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10.4.7.2 TEST MEDIUM VOLTAGE OUTPUT TERMINAL
WARNING

AND OR DEATH.
WARNING
WARNING
WARNING

THE TEST LEADS.
WARNING

WARNING

EQUIPMENT
To test Medium Voltage Output Terminals, proceed as follows:
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b. Isolate the bushing by disconnecting the load cable from the rear of the bushing.
c. Turn off test equipment before connecting a 30 kV DC hi-pot tester to the load terminal.
d. Connect the positive lead of the 30 kV DC hi-pot tester to the center conductor of the load
terminal.
e. Connect negative lead of tester to outer shield of parallel or feeder cable terminal.
f. Set all controls on tester to zero and turn tester on.
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g. Slowly increase output voltage of tester to 5 kV and maintain for 1 minute. Record current meter
reading.
h. Slowly increase tester output to 10 kV for one minute and record current meter reading.
i. Slowly increase tester output to 15 kV and maintain for 15 minutes. Record readings at one
minute intervals.
j. After 15 minutes, slowly decrease tester output to zero volts and turn tester off.
k. Use ground discharging stick to discharge any residual voltage.
l. Ensure tester is turned off.
NOTE: Leakage current is dependent on insulation condition as well as atmospheric conditions

(humidity). Leakage current normally should not exceed 50 microamperes.
m. Disconnect leads from load terminal. Compare all meter readings taken during test. Any sharp
increase in readings during waiting periods indicates insulation breakdown of load terminal and
terminal should be replaced.
10.4.7.3 REMOVE MEDIUM VOLTAGE OUTPUT TERMINAL
1 2
3
4
6
5
(1) Load Terminal Insert (2) Load Terminal Bushing (3) Mounting Plate
(4) Protective Cover (5) Securing Cable (6) Load Terminal
(7) Load Terminal Mounting Bolt
FIGURE 10.4.7.3-1 TYPICAL LOAD TERMINAL BREAKOUT
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To remove the Medium Voltage Output Terminals, proceed as follows:
FIGURE 10.4.7.3-2 LOWER FRONT COVER
b. Remove lower front cover of the PDC. Refer to Figure 10.4.7.3-2.
c. Remove protective cover (4), and load terminal insert (1), of the output terminal you wish to
remove.
d. Remove the mounting plate (3)and securing cable (5) mounting hardware for the entire bank of
output terminals.
e Remove the (3M) Heat Shrink Tubing from the terminal connection.
f. Remove the Load terminal mounting bolt (7) and load terminal (6).
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10.4.7.4 INSTALL MEDIUM VOLTAGE OUTPUT TERMINAL
To install the Medium Voltage Output Terminals, proceed as follows:
b. Reinstall the Load Terminal bushing (2). Reinstall load terminal mounting bolt (7), load terminal
(6) and (3M, BBI-3A Heat Shrinkable Tubing) or equivalant. (For torque requirements
manufactures reinstallation literature). Refer to Figure 10.4.7.3-1.
c. Reinstall the mounting plate (3)and securing cable (5) mounting hardware for the entire bank of
output terminals.
d. Reinstall the load terminal insert (1) and torque to manufactures specifications. (Special tool may
be required).
e. Reinstall the load output terminal protective covers (4).
f. Reinstall lower front cover of the PDC.
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10.4.8 SURGE ARRESTERS (SA1, SA2, SA3)
The following maintenance procedures are provided for the Surge Arresters:
Inspect
Test
Remove
Install
FIGURE 10.4.8-1 SURGE ARRESTERS (SA1, SA2, SA3)
Surge Arresters are connected to the system bus bars, internal to the PDC. They are UltraSil heavy-duty
type UHS (MOV) Metal Oxide Varistors, rated at 3 kV, and 2.55 kV Maximum Continuous Overvoltage
(MCOV). The MOVs are contained in a silicone rubber housing. There is one arrester for each phase of
the bus, for a total of three.
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10.4.8.1 INSPECT SURGE ARRESTER (SA1, SA2, SA3)
WARNING

AND OR DEATH.
WARNING
WARNING
WARNING

MISSOPERATE VIOLENTLY, CAUSING SEVERE PERSONAL INJURY.
CAUTION
ALWAYS HANDLE SURGE ARRESTERS PACKED OR UNPACKED-VERY

To inspect the Surge Arrestor, proceed as follows:

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b. Remove left rear access panels.
c. Visually inspect Surge Arrestors for cracks, signs of overheating, and other damage.
d. Check Surge Arrestor electrical connections for tightness. Check wiring for signs of insulation
10.4.8.2 TEST SURGE ARRESTER (SA1, SA2, SA3)
All UltraSil arresters have passed a complete series of production tests prior to shipment; therefore, no
field-testing is required.
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10.4.8.3 REMOVE SURGE ARRESTER (SA1, SA2, SA3)
To remove the surge arrester, perform the following:
FIGURE 10.4.8-2 LEFT REAR OF PDC
b. Remove the lower left rear PDC panel. Refer to Figure 10.4.8-2 for reference.
c. Discharge the arrester by shorting the line terminal temporarily to ground.
d. Remove the line and ground leads from the arrester.
e. Remove the hex nut, lock washer, and flat washer from the mounting bracket.
f. Remove the arrester.
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10.4.8.4 INSTALL SURGE ARRESTER (SA1, SA2, SA3)
To install the surge arrestor, proceed as follows:
b. Install the arrester on the hanger bracket with the bolt washer and nut. Refer to Figure 10.4.8-2
for reference.
c. Torque the arrester hanger bracket nut between 20 and 25 ft-lbs.
d. Reinstall the line and ground wires to each arrester.
e. Torque the nuts on the line and ground wires to 20 ft-lbs.
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10.4.9 INSTRUMENT POTENTIAL TRANSFORMERS (PT)
The following maintenance procedures are provided for the Instrument Potential Transformers (PT)
Inspect
Test
Remove
Install
PT 6A
PT 1A
PT 2A
PT 3A
FIGURE 10.4.9-1 POTENTIAL TRANSFORMERS LEFT OR RIGHT SECTION
See Figures 10.4.9-1 and 10.4.9-2 for reference. These transformers are used to step the
3800/4160VAC down to 110/120VAC for use by control system. The transformers are located behind the
cover plates on the PDC. Potential Transformers PT1, PT2 PT3, PT4 and PT5 are 5 Volt Amps (VA),
50/60 Hertz (HZ), with a 34.56:1 Ratio. PT6, PT7 and PT8 are dual primary fuse, 50 HZ with a 35:1 ratio.
The Potential Transformers are step-down transformers, which furnish voltage input for the various
generator control, metering, and fault protection circuits.
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PT 7 PT 8
FIGURE 10.4.9-2 POTENTIAL TRANSFORMERS CENTER SECTION
10.4.9.1 INSPECT INSTRUMENT POTENTIAL TRANSFORMERS (PT)
To inspect the Instrument Potential Transformer, proceed as follows:
a. Inspect for proper mounting.
b. Check for loose connections, physical damage and heat damage.
c. Check wiring for signs of insulation breakdown such as cracked sleeves and burned insulation.
10.4.9.2 TEST INSTRUMENT POTENTIAL TRANSFORMERS (PT)
WARNING

AND OR DEATH.
WARNING
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WARNING
DISCHARGE CAPACITIVE CHARGE FROM ALL EXPOSED CONDUCTORS TO PT
WARNING

THE TEST LEADS.
WARNING

EQUIPMENT
To test an Instrument Potential Transformer, proceed as follows:
There are two recommended tests for the station transformer. They are the Insulation Resistance Test
and the Turns Ratio Test. Both tests are to be performed during maintenance. To test the transformer
perform the following:

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b. Remove retaining screws and take off access panel.
c. Test fuses first. If fuses are good or bad, continue the test procedure.
d. Tag and disconnect wiring leads from the suspect transformer.
e. Perform the following tests:
a. Using a multimeter set to OHMS (Ω) Rx1 scale, perform individual continuity checks on
b. Connect a 500V Megger to either primary lead and to ground. Short the secondary terminals to
ground before connecting Megger leads to primary terminals. Operate Megger for 60 seconds
and observe resistance. Reading on each transformer should be not less than 20 meg-ohms.
Short the primary lead to ground before disconnecting.
c. Short the high voltage terminals to ground before connecting Megger. Connect Megger to either
secondary lead and to ground. Operate the Megger for 60 seconds and observe resistance.
Reading should be not less than 1 meg-ohm. Short the secondary lead to ground before
disconnecting.
d. Connect Megger between primary and secondary windings. Operate the Megger for 60 seconds
and observe resistance. Reading should not be less than 20 meg-ohms. Short both windings to
ground before disconnecting.
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10.4.9.2.2 TURN RATIO TEST
a. Tag and disconnect wiring leads from the suspect transformer.
b. Turns ratio testing of transformers provides a direct means to detect loose or open connections,
shorted or open turns in the transformer windings, incorrect polarity connections and to verify
precisely the no-load voltage ratio of the transformer at all tap positions.
c. Perform a TTR test using the test equipments manufactures procedures. The turns ratio is
required to be within ±1/2 percent or (.005), of the indicated nameplate voltage ratio.
Ep Np
= = TR
Es Ns
Ep =voltage primary
Es =voltage secondary
Np =number of turns primary
Ns =number of turns secondary
TR =turns ratio (primary to secondary
d. If the transformer fails any of the above requirements, remove and forward to next higher level of
maintenance.
e. If the transformers meet above requirements, connect wiring leads and discard tags.
10.4.9.3 REMOVE INSTRUMENT POTENTIAL TRANSFORMERS (PT)
To remove an Instrument Potential Transformer, proceed as follows:
b. Open Generator and Tie Breaker Control panel doors.
c. Remove access covers retaining screws and set access covers aside.
WARNING
DISCHARGE CAPACITIVE CHARGE FROM ALL EXPOSED CONDUCTORS TO PT
d. Tag and disconnect all wires leading to and from the transformer.
e. Remove mounting hardware for fuses if necessary and hardware from PT and remove PT from
the switchgear panel in the PDC.
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10.4.9.4 INSTALL INSTRUMENT POTENTIAL TRANSFORMERS (PT)
To install an Instrument Potential Transformer, proceed as follows
b. Reinstall the transformer from front of the switchgear panels, and secure with the mounting
hardware.
c. Reinstall fuses and hardware as necessary.
d. Connect wiring to the transformer and discard tags.
e. Reinstall and secure access cover panels with mounting hardware.
f. Close Generator and Tie Breaker Control panel doors.
g. Ensure no equipment is energized prior to reconnecting cables.
h. Reconnect Parallel and Load cables to load terminals.
i. Place the CBCP to ON.
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10.4.10 INSTRUMENT CURRENT TRANSFORMER (CT)
The following maintenance procedures are provided for the Instrument Current Transformers (CT):
Inspect
Test
Remove
Install
GENERATOR
BREAKER CT
GENERATOR
BREAKER CT
LOAD TIE CT
FEEDER CT
FEEDER CT
FIGURE 10.4.10-1 INSTRUMENT CURRENT TRANSFORMERS
See Figure 10.4.10-1 for reference. These transformers are used to step the various current level
primaries down to a 5-amp secondary for use by control system. The transformers are located between
the rear of the circuit breakers and the rear wall of the PDC. Some of the Generator CTs are partially
accessible through a bolted on panel on the rear wall of the PDC.
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10.4.10.1 INSPECT INSTRUMENT CURRENT TRANSFORMER (CT)
WARNING

AND OR DEATH.
WARNING
WARNING
DISCHARGE CAPACITIVE CHARGE FROM ALL EXPOSED CONDUCTORS TO CT
Inspect the Instrument Current Transformers, for the following:

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b. Remove the PDC from the PU. See Chapter 22 for reference.
c. Inspect for proper mounting.
d. Check for loose connections, physical damage and heat damage.
e. Check wiring for signs of insulation breakdown such as cracked sleeves and burned insulation.
10.4.10.2 TEST INSTRUMENT CURRENT TRANSFORMER (CT)
This Task is above this Echelon of Maintenance. (The PDC must be removed from the PU to perform this
task).
10.4.10.3 REMOVAL INSTRUMENT CURRENT TRANSFORMER (CT)
This Task is above this Echelon of Maintenance. (The PDC must be removed from the PU to perform
this task).
10.4.10.4 INSTALL INSTRUMENT CURRENT TRANSFORMER (CT)
This Task is above this Echelon of Maintenance. The (The PDC must be removed from the PU to
perform this task).
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10.4.11 GENERATOR, FEEDER AND TIE BREAKERS
The following maintenance procedures are provided for the Generator, Feeder and Tie Breakers:
Inspect
Test
Remove
Install
Generator
Breaker
Feeder Breaker
Tie Breaker
FIGURE 10.4.11-1 GENERATOR, FEEDER & TIE BREAKER
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See Figure 10.4.11-1 for reference. The breakers installed within the PDC are actually vacuum
contactors; however, for consistency through the manual they are referred to as breakers. These
components use 120VAC as control voltage for opening and closing. All breakers require a constant
120VAC signal to stay closed except for the Tie Breaker. The Tie Breaker has a mechanical latch to
keep it closed even when the PU is off. This circuit also requires a 120VAC to open the breaker, which is
available from either side of the Tie Breaker. The breakers are located behind the cover plates on the
PDC.
10.4.11.1 INSPECT GENERATOR, FEEDER AND TIE BREAKERS
WARNING

AND OR DEATH.
WARNING
WARNING
DISCHARGE CAPACITIVE CHARGE FROM ALL EXPOSED CONDUCTORS TO

BREAKERS
Inspect the Generator, Feeder and Tie Breakers, for the following:

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b. Inspect for proper mounting.
c. Check for loose connections, physical damage and heat damage.
d. Check for proper operation
e. Check for missing damaged or missing hardware.
10.4.11.2 TEST GENERATOR, FEEDER AND TIE BREAKERS
WARNING

This Task is above this Echelon of Maintenance.
For additional reference see Cutler-Hammer Manual I.B. 48018N
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10.4.11.3 REMOVE GENERATOR, FEEDER AND TIE BREAKERS
WARNING

AND OR DEATH.
WARNING
WARNING
DISCHARGE CAPACITIVE CHARGE FROM ALL EXPOSED CONDUCTORS TO

BREAKERS
To remove the Generator, Feeder and Tie Breakers, proceed as follows:

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b. Remove the PDC from the PU.
c. Open Generator and Tie Breaker Control panel doors.
d. Remove the retaining screws to the access covers to the breaker needing to be removed. If
necessary remove the front, rear and adjacent panels to allow access to the breaker mounting
retaining screws and set access covers aside.
e. Remove the heat-shrink protection from the cables to the breaker.
f. Tag and remove the wiring harness and power cables.
j. Remove the four breaker mounting bolts and remove the breaker from the front of the PDC.
NOTE: The Tie Breaker has a plate installed on the front visible portion of the mechanical
latch. Ensure the Breaker is tripped open before attempting removal of the plate. This plate
must be removed by loosening of the two bolts attaching it and saved for use on the new Tie
Breaker Mechanical Latch Assembly.
FIGURE 10.4.11.3-1 TIE BREAKER MECHANICAL LATCH STIFFNER PLATE
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10.4.11.4 INSTALL GENERATOR, FEEDER AND TIE BREAKERS
To install the Generator, Feeder and Tie Breakers, proceed as follows:
b. Reinstall the breaker and the four breaker mounting bolts. Torque to 27 Ft-Lbs.
c. Reinstall the wiring harness and power cables. Ensure that the insulating material is reinstalled
on the power cables. Torque all power distribution bus bolts to 20 Ft-Lbs. Torque the power
cable to breaker connection to 20 Ft-Lbs.
d. Reinstall the Bakelite mounting bolts from the rear of the breaker section divider, torque to 20 in.
lbs.
e. Reinstall rear panels of the PDC and reinstall the retaining screws.
NOTE: The Contactor Dip Switch Settings must be verified prior to operation.
Generator and Feeder Contactors Dip Switch Settings

Set the contactor for 120VAC, 60Hz, 130ms by setting dipswitches 2,3, and 7 in “ON” position. This
setting is applicable to both generator and feeder contactors. This setting has been determined to
function best in the DPGDS application, regardless of bus voltage or frequency. See figure 10.4.11.4-2.
Tie Contactor Dip Switch Settings

Set the contactor for 110 VAC, 50Hz, 130ms by setting dipswitches 1,2, and 7 in “ON” position. This
setting has been determined to function best in the DPGDS application, regardless of bus voltage or
frequency. See figure 10.4.11.4-2.
CONTROL
BOARD
FIGURE 10.4.11.4-1 CONTACTOR CONTROL BOARD
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FIGURE 10.4.11.4-2 CONTROL BOARD DIPSWITCH
f. To verify/change Dipswitch settings the Control Board must be removed.
- Tag and Disconnect wires on the Control Board. See Figure 10.4.11.4-1.
- Tag and Disconnect wires for auxiliary switch.
- Remove Control Board mounting screws and pull Control Board out.
- Verify/Change Dip Switch settings. See Figure 10.4.11.4-2.
- Reinstall Control Board, secure with screws and attach wires to Control Board and Auxiliary
Switch.
g. Reinstall all of the front access covers removed with the retaining screws.
h. Close Generator and Tie Breaker Control panel doors.
i. Reinstall the PDC.
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USAF TO 35C2-3-518-1

5.5.3.3 DISTRIBUTION AND CONTROL CABLING

DO NOT PERFORM THE FOLLOWING TASK WHEN THE GENERATOR SET IS

HIGH VOLTAGE MAY CAUSE SEVERE INJURY OR DEATH UPON CONTACT

VERIFY THAT CONNECTION POINTS ARE DE-ENERGIZED BEFORE MAKING ANY

c. Connect each load cables drain wire to the grounding grid.

f. Close and lock the Tie Output connector covers.

g. Repeat steps ‘a’ through ‘f’ on each remaining PU.

i. Route the first (A) (B) communication cable to second PU.

l. Route the second (A) (B) communication cable to second PU.

o. Route the third (A) (B) communication cable to fourth PU.

5.5.3.4 SETPOINT VERIFICATION

a. Turn on PU DC control power by pushing in on the DC Control Power breaker.

b. On each of the five overcurrent relays, verify the settings:

(2) Press the [►] key 5 times to display “6 GENERAL SETTINGS”.

(3) Press the [▼] key to display “6.1 COM SETTINGS”.

(5) Press the [▼] key to display “6.3.1 CT RATIO”.

(7) Press the [▲] key 2 times to display “6 GENERAL SETTINGS”.

(9) Press the [▼] key 3 times to display “5.1.1.1 50TP”.

(12) Verify the “50TN” settings.

(13) Press the [►] key to display “5.1.1.3”.

(14) Verify the “50TQ” settings.

(15) Press the [▲] key to display “5.1.1 50T SETTINGS”.

(17) Press the [▼] key to display “5.1.2.1 51P”.

19) Press the [►] key to display “5.1.2.2 51N”.

(20) Verify the 51N settings.

(1) Place ECS in the COOLDOWN/STOP position.

(3) Press SCROLL UP key until “OP3” is showing.

(10) Press ENTER key. “PE PASS” is showing.

(11) Press EXIT key. “OP4” is showing.

(15) Press EXIT key. “OP5-0” is showing on the lower display.

(16) Press SCROLL UP key until “OP5-1” is showing.

(17) Press SELECT key.

(19) Press EXIT key. “OP5-1” is showing.

(20) Press SCROLL UP key. “OP6” is showing.

(21) Press SELECT key.

(23) Press EXIT key twice. The display returns to normal.

(d)Press SCROLL UP or SCROLL DOWN key to continue to verify the remaining

NOTE: Use up or down keys to change values.

(1) Open the GCPG1 cabinet door.

(2) Press the [▼] key to display parameter “90”.

(3) Press the [◄►] key to display the current value.

(7) Press the [◄►] key to display the current value.

(8) Press the [▲] or [▼] key to change the value.

(11) When complete, press the [▼] to display parameter “01”.

(12) When complete, press the [▼] to display parameter “90”.

(13) Press the [◄►] key to display the current value.

(16) Press the [▲] key to change to display parameter “01”.

(17) Close the GCPG1 cabinet door.

(18) Repeat steps ‘1 ‘through ‘16’ for Generator 2.

5.5.3.5 PRE-OPERATION CHECKS

5.5.3.6 PRE-OPERATION RUN

HEARING LOSS WILL OCCUR IF THIS WARNING IS NOT OBSERVED AND

HEARING LOSS WILL OCCUR IF THIS WARNING IS NOT OBSERVED AND

BY CLOSING THE FEEDER OR TIE BREAKER, HIGH VOLTAGE WILL BE PRESENT

TABLE 5.5.3.6-1 PRE-OPERATION RUN INSTRUCTION SEQUENCE

1 Verify System Mode Switch (SMS) is in MANUAL

2 Verify DC Control Power is on

3 Verify Emergency Stop is pulled out