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DRS RADIAN CTM 01646.1R0253/1R0254

I

COMMERCIAL TECHNICAL MANUAL

GENERATOR 840 KW MEP-PU-810A/BRadian Part Numbers: 1R0253-3/1R0254-3

OPERATION AND MAINTENANCE

CHAPTERS 1 THROUGH 22

2007 DRS RADIANALL RIGHTS RESERVED5845 RICHMOND HWY. SUITE 725 ALEXANDRIA, VIRGINIA 22303-1865

FEBRUARY 23, 2007 (REVISION 5) *

DISTRIBUTION STATEMENT: Approved for public release; distribution is unlimited. Questions pertaining to technicalcontent shall be referred to 542 SEVSG/GBZFM, Robins AFB, GA 31098. Other requests for this document shall bereferred to 542 MSUG/GBMUDE, Robins AFB, GA 31098.

*This manual supersedes USAF TO 35C2-3-518-1/ USA TM 9-6115-484-14, June 9, 2006, including all changes.

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II

RIGHTS IN DATA, EXPORT CONTROL, HANDLING AND DESTRUCTION

Operation and Maintenance Manual 01646.1R0253/1R0254

MODEL 1R0253, MEP-PU-810A, CLASS L CONNECTORS

NSN: 6115-01-486-4033

AND

MODEL 1R0254, MEP-PU-810B, CLASS L CONNECTORSNSN: 6115-01-486-4032

This Operation and Maintenance Manual has been prepared in accordance with

the requirements of Contract F08626-97-C-0236, Deployable Power Generationand Distribution System (DPGDS).

The following data rights are specified in accordance with Defense FederalAcquisition Regulation Supplement (DFARS), paragraph 227-7102. DRS Radiancopyrights this manual in accordance with DFARS paragraphs 227-7103, 7105,and 7106. Due to this copyright as well as the use of proprietary data andprocedures, DRS Radian proposes Government Purpose License Rights (GPLR)only.

WARNING--This document contains technical data whose export is restricted by

the Arms Export Control Act (Title 22, U.S.C., Sec 2751 et seq) or the ExportAdministration Act of 1979, as amended (Title 50, U.S.C., App. 2401 et seq).Violations of these export laws are subject to severe criminal penalties.

HANDLING AND DESTRUCTION NOTICEComply with distributionstatement and destroy by any method that will prevent disclosure of thecontents or reconstruction of the document.

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III

READ THIS SECTION, PRIOR TO PERFORMING ANY MAINTENANCE.

IMPORTANT SAFETY WARNINGS APPROPRIATE FOR ALL MAINTENANCEACTIVITIES.

THE EQUIPMENT COVERED IN THIS MANUAL MUST BE INSTALLED, OPERATED,AND MAINTAINED BY QUALIFIED PERSONS WHO ARE KNOWLEDGEABLE IN THEINSTALLATION, OPERATION, AND MAINTENANCE OF MEDIUM VOLTAGEELECTRICAL POWER GENERATION EQUIPMENT ALONG WITH ASSOCIATEDHAZARDS. A QUALIFIED PERSON IS ONE WHO IS TRAINED AND COMPETENT IN:

THE SKILLS AND TECHNIQUES NECESSARY TO DISTINGUISHENERGIZED PARTS FROM NON-ENERGIZED PARTS OF ELECTRICALEQUIPMENT.

THE SKILLS AND TECHNIQUES NECESSARY TO DETERMINE THEPROPER APPROACH DISTANCES CORRESPONDING TO THE VOLTAGESTO WHICH THE QUALIFIED PERSON WILL BE EXPOSED.

THE PROPER USE OF SPECIAL PRECAUTIONARY TECHNIQUES,

PERSONAL PROTECTIVE EQUIPMENT, INSULATING AND SHIELDINGMATERIALS, AND INSULATED TOOLS FOR WORKING ON OR NEARENERGIZED PARTS OF ELECTRICAL EQUIPMENT AND ROTATINGMACHINERY.

THE PROPER USE OF SPECIAL PRECAUTIONARY TECHNIQUES,PERSONAL PROTECTIVE EQUIPMENT, INSULATING AND SHIELDINGMATERIALS, AND INSULATED TOOLS FOR WORKING ON OR NEAREXPOSED HOT SURFACES OF ENGINE AND EXHAUST SYSTEMCOMPONENTS.

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.

WARNING

WARNING

WARNING

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IV

HEARING LOSS WILL OCCUR IF THIS WARNING IS NOT OBSERVED ANDENFORCED. NOISE LEVELS IN EXCESS OF 85 DB EXIST WITHIN AN 88-FOOTRADIUS OF AN OPERATING DPGDS. PERSONNEL MUST WEAR SINGLE HEARINGPROTECTION WITHIN 88 FEET OF AN OPERATING DPGDS.

HEARING LOSS WILL OCCUR IF THIS WARNING IS NOT OBSERVED ANDENFORCED. DURING MAINTENANCE ACTIVITIES WITH THE SIDEDOORS OPEN,NOISE LEVELS IN EXCESS OF 113 DB EXIST WITHIN A 12-FOOT RADIUS OF ANOPERATING DPGDS. PERSONNEL MUST WEAR DOUBLE HEARING PROTECTIONWITHIN 12 FEET OF AN OPERATING DPGDS. EXPOSURE MUST BE LIMITED TOUNDER 2.5 HOURS.

BATTERY ELECTROLYTE CONTAINS SULFURIC ACID, WHICH CAN CAUSESEVERE CHEMICAL BURNS. AVOID ALL CONTACT. SKIN AND EYE PROTECTIONIS REQUIRED. IN CASE OF CONTACT, IMMEDIATELY FLUSH WITH LARGEAMOUNTS OF CLEAN WATER AND OBTAIN MEDICAL AID.

WHEN DISCONNECTING BATTERY CABLES, ALWAYS DISCONNECT NEGATIVETERMINAL FIRST. WHEN RECONNECTING, CONNECT NEGATIVE TERMINALLAST. FAILURE TO COMPLY MAY CAUSE SPARKING AND CONSEQUENTBATTERY EXPLOSION.

HIGH VOLTAGE MAY CAUSE SEVERE INJURY OR DEATH UPON CONTACTDURING CHECKOUT OR MAINTENANCE OF THIS EQUIPMENT. USE CAUTIONAND AVOID CONTACT WITH ENERGIZED COMPONENTS. USE HOT STICK WHENLOAD CABLES ARE HANDLED.

WARNING

WARNING

WARNING

WARNING

WARNING

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VI

DO NOT COME IN CONTACT WITH LOAD TERMINAL DURING TEST. DEATH BYELECTROCUTION MAY RESULT.

FOLLOW MANUFACTURER'S TEST PROCEDURES INCLUDED WITH THE TESTEQUIPMENT.

ALWAYS CONSIDER AN ARRESTER TO BE ENERGIZED UNTIL THE LINE ANDGROUND LEADS HAVE BEEN DISCONNECTED FROM THE CIRCUIT. NEVERINSTALL A DAMAGED ARRESTER. A DAMAGED ARRESTER MAY MISSOPERATEVIOLENTLY, CAUSING SEVERE PERSONAL INJURY.

USE OF A LIFTING DEVICE IS RECOMMENDED FOR REMOVING THE STATIONPOWER TRANSFORMER. TRANSFORMER IS EXTREMELY HEAVY AND WEIGHSOVER 100 LBS.

PRIOR TO TROUBLESHOOTING THE POWER UNIT (PU), ENSURE THE TIE ANDFEEDER CABLES ARE ALL INSTALLED ON PARKING STANDS, TO PREVENT THEPOSSIBILITY OF UTILITY POWER BEING FED BACK INTO GENERATOR SET.ENSURE EQUIPMENT IS PROPERLY TAGGED AND NOT ENERGIZED. RESIDUALVOLTAGE IS PRESENT AT THE GENERATOR LEADS WITH THE REGULATORTURNED OFF, REACHING SEVERAL HUNDRED VOLTS ON THE GENERATOR SET.PROPER INSULATION AND ISOLATION OF METERING EQUIPMENT MUST BEOBSERVED WHEN TESTING GENERATOR. USE PROPER TEST EQUIPMENT TOCHECK FOR VOLTAGE BEFORE PROCEEDING. FAILURE TO COMPLY MAYRESULT IN DEATH BY ELECTROCUTION.

BEFORE WORKING ON THE BATTERY CHARGER, INSURE THAT AC POWER ISOFF AND DISCONNECTED. ALSO, DISCONNECT THE NEGATIVE BATTERY LEAD.

WARNING

WARNING

WARNING

WARNING

WARNING

WARNING

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ETHER IS HIGHLY FLAMMABLE AND TOXIC TO SKIN, EYES, AND RESPIRATORYTRACT. USE ONLY IN AN ADEQUATELY VENTILATED AREA. SKIN, EYE. ANDRESPIRATORY PROTECTION IS REQUIRED. FAILURE TO COMPLY MAY RESULTIN SERIOUS INJURY OR ILLNESS.

DIESEL FUEL IS FLAMMABLE AND MODERATELY TOXIC TO EYES, SKIN, ANDRESPIRATORY TRACT. SKIN AND EYE PROTECTION REQUIRED. AVOIDREPEATED OR PROLONGED CONTACT. USE IN WELL-VENTILATED AREA.FAILURE TO COMPLY MAY RESULT IN SERIOUS INJURY OR ILLNESS.

WHEN POWER GENERATION EQUIPMENT MUST BE IN OPERATION TO MAKETESTS AND/OR ADJUSTMENTS, HIGH VOLTAGE AND CURRENT ARE PRESENT.MAKE SURE THE TESTING EQUIPMENT IS DESIGNED FOR AND CORRECTLYOPERATED FOR THE HIGH VOLTAGE AND CURRENT TESTS. IMPROPER TESTEQUIPMENT MAY FAIL AND PRESENT A HIGH VOLTAGE SHOCK HAZARD TO ITSUSER.

ONLY ONE POWER UNIT (PU) MAY BE SELECTED TO ANY ONE UNIT SELECTORSWITCH (USS) POSITION DURING MULTIPLE (PU) OPERATIONS. OPERATINGWITH MORE THAN ONE UNIT AT THE SAME ADDRESS (A, B, C OR D) MAY CAUSEUNSAFE AND ERRATIC OPERATIONAL CONDITIONS.

EXPLOSION HAZARD WHEN IN HAZARDOUS LOCATIONS, DISCONNECTPOWER BEFORE REPLACING OR WIRING MODULES.

ALWAYS WEAR EYE PROTECTION WHEN YOU PERFORM ANY SERVICE WORKON A COOLING SYSTEM.

WARNING

WARNING

WARNING

WARNING

WARNING

WARNING

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RELEASE THE PRESSURE IN THE COOLING SYSTEM BEFORE PERFORMING ANYSERVICE WORK. IF THE PRESSURE IN THE COOLING SYSTEM IS NOTRELEASED OR THE TEMPERATURE OF THE SYSTEM IS NOT PERMITTED TOCOOL, STEAM OR HOT WATER MAY BE RELEASED WHEN YOU REMOVE THEFILLER CAP. THIS MAY CAUSE PERSONAL INJURY.

DO NOT ALLOW UNDILUTED CORROSION INHIBITORS OR DILUTED/UNDILUTEDRADIATOR CLEANERS TO COME IN CONTACT WITH THE SKIN OR EYES.

DO NOT USE CHROMATE CORROSION INHIBITORS IN A COOLING SYSTEM.

ALWAYS FOLLOW THE MANUFACTURERS INSTRUCTIONS WHEN HANDLINGCORROSION INHIBITORS, RADIATOR CLEANERS OR ANTIFREEZE. BEESPECIALLY SURE TO FOLLOW THE MANUFACTURERS RECOMMENDATIONSCONCERNING TOXICITY.

ETHYLENE GLYCOL MAY CATCH FIRE WHEN IT IS HOT OR EXPOSED TO ANOPEN FLAME. DO NOT WELD, CUT OR USE AN OPEN FLAME NEAR LEAKINGCOOLANT THAT CONTAINS ANTIFREEZE.

DO NOT USE ALCOHOL IN PLACE OF ANTIFREEZE. ALCOHOL HAS A LOWERBOILING TEMPERATURE AND FLASH POINT.

WARNING

WARNING

WARNING

WARNING

WARNING

WARNING

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X

HOT OIL AND HOT COMPONENTS CAN CAUSE PERSONAL INJURY. DO NOTALLOW HOT OIL OR HOT COMPONENTS TO CONTACT THE SKIN. DO NOT DRAINTHE OIL WHEN THE ENGINE IS COLD. AS THE OIL COOLS, SUSPENDED WASTEPARTICLES SETTLE ON THE BOTTOM OF THE OIL PAN. THE WASTE PARTICLESARE NOT REMOVED WHEN DRAINING COLD OIL. DRAIN THE CRANKCASE WITHTHE ENGINE STOPPED. DRAIN THE CRANKCASE WITH THE OIL WARM. THISDRAINING METHOD ALLOWS THE WASTE PARTICLES THAT ARE SUSPENDED INTHE OIL TO BE DRAINED PROPERLY.

DO NOT ALLOW GASKET MATERIAL TO FALL INSIDE ROCKER LEVER HOUSING.FAILURE TO COMPLY MAY RESULT IN DAMAGE TO ENGINE.

DO NOT RESET A FAULT BEFORE DETERMINING AND CORRECTING THE CAUSEOF THE FAULT. FAILURE TO CORRECT A FAULT BEFORE RESETTING CANRESULT IN DEATH, PERSONAL INJURY, OR EQUIPMENT DAMAGE.

HYDRAULIC FLUID IS HOT AND UNDER HIGH PRESSURE. DO NOT PLACE ANY

PART OF YOUR BODY OVER ANY LEAK. SEVERE INJURY CAN OCCUR IF THISHAPPENS.

THE HYDRAULIC PRESSURE HELD IN THE SYSTEM MAY CAUSE THE LEVER TOSNAP QUICKLY. KEEP HANDS AND FINGERS CLEAR, AS YOU RESET THEBREAKAWAY MECHANISM. WHEN TOWING, AVOID SHARP TURNS THAT CANCAUSE THE ACTUATOR TO BIND AGAINST THE TOW VEHICLE. THIS CANDAMAGE THE ACTUATOR AND TRAILER, CAUSING BRAKE FAILURE.

DO NOT MIX PETROLEUM BASED OIL WITH BRAKE FLUID. THIS WILL CAUSESEAL SWELLING AND NON-FUNCTIONING BRAKES.

WARNING

WARNING

WARNING

WARNING

WARNING

WARNING

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XI

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, ORGRINDING THE BRAKE LININGS. DO NOT USE COMPRESSED AIR OR DRYBRUSHING FOR CLEANING. DUST CAN BE REMOVED WITH A DAMP BRUSH.

SALTWATER, GRANULAR FERTILIZERS AND OTHER CORROSIVE MATERIALSARE DESTRUCTIVE TO METAL. TO PROLONG THE LIFE OF A BRAKING SYSTEMUSED UNDER CORROSIVE CONDITIONS, WE RECOMMEND THAT THEACTUATOR BE FLUSHED AFTER USE WITH A HIGH PRESSURE WATER HOSE.BE SURE TO RE-GREASE BEARINGS AND OIL ALL MOVING PARTS AFTER THEUNIT HAS DRIED. AT THE END OF THE SEASON, WHEN UNIT IS TO BE STORED,REMOVE THE BRAKE DRUMS AND CLEAN INSIDE THE BRAKES. PACK WHEELBEARINGS BEFORE DRUM IS INSTALLED. FAILURE TO PROPERLY ANDADEQUATELY GREASE AND MAINTAIN THE ACTUATOR COULD WEAKEN ITAND/OR CAUSE IT TO FAIL AND RESULT IN SERIOUS INJURY AND/ORPROPERTY DAMAGE.

PROPER MATCHING OF THE TIRE/WHEEL COMBINATION IS ESSENTIAL TOPROPER FUNCTION OF YOUR TRAILER RUNNING GEAR. SOME TIRES MAY CALLFOR A MAXIMUM INFLATION PRESSURE ABOVE THE RIM OR WHEEL CAPACITY.DO NOT EXCEED MAXIMUM INFLATION PRESSURES FOR RIMS OR WHEELS.CATASTROPHIC FAILURE MAY RESULT.

DO NOT GET GREASE OR OIL ON BRAKE LININGS. BRAKES WILL NOTFUNCTION PROPERLY.

WARNING

WARNING

WARNING

WARNING

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DO NOT MIX LITHIUM, CALCIUM, SODIUM OR BARIUM COMPLEX GREASES DUETO POSSIBLE COMPATIBILITY PROBLEMS. WHEN CHANGING FROM ONE TYPEOF GREASE TO ANOTHER, IT IS NECESSARY TO INSURE ALL THE OLD GREASEHAS BEEN REMOVED.

DO NOT DISASSEMBLE THE SPRING BRAKE. IT CONTAINS A COMPRESSEDSPRING THAT MAY CAUSE INJURY IF REMOVED. THE SPRING BRAKE MUST BECAGED BEFORE SERVICING AND SHOULD ONLY BE PERFORMED BY QUALIFIEDPERSONNEL.

FAILURE TO CORRECTLY LUBRICATE BEARINGS AND MAINTAIN PROPERLUBRICATION COULD CAUSE BEARING AND AXLE SPINDLE DAMAGE, WHICHCOULD RESULT IN THE WHEEL LOCKING UP OR COMING OFF DURING VEHICLEOPERATION.

DOUBLE HEARING PROTECTION IS MANDATORY WITHIN 50 FEET OF THISEQUIPMENT WHILE POWER UNITS ARE RUNNING.

CAUTION

SIGNIFICANT DIFFERENCES BETWEEN THE MEP-PU-810A AND MEP-PU-810BREQUIRE 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 THEMOTOR. OVERHEATING WILL DAMAGE THE MOTOR.

WARNING

WARNING

WARNING

WARNING

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CAUTION

TURBOCHARGER BEARING FAILURES CAN CAUSE LARGE QUANTITIES OF OILTO ENTER THE AIR INLET AND EXHAUST SYSTEMS AND AIR TO AIR AFTERCOOLER. LOSS OF ENGINE LUBRICANT CAN RESULT IN SERIOUS ENGINEDAMAGE. 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 OFTHE CARTRIDGE.

CAUTION

IF A TURBOCHARGER FAILURE OCCURS, REMOVE THE AIR TO AIR AFTERCOOLER CORE. FLUSH THE AIR TO AIR AFTER COOLER CORE INTERNALLYWITH A SAFE, BIODEGRADABLE AND LOCALLY APPROVED SOLVENT THAT ISSAFE FOR THE SURFACES TO BE CLEANED AND THAT REMOVES OIL ANDOTHER FORIEGN SUBSTANCES. SHAKE THE AFTER COOLER CORE ASSEMBLYIN ORDER TO REMOVE ANY TRAPPED DEBRIS. WASH THE AFTER COOLERCORE ASSEMBLY WITH HOT SOAPY WATER. THOROUGHLY RINSE THISASSEMBLY WITH CLEAN WATER, AND THEN BLOW DRY THE ASSEMBLY IN THEREVERSE DIRECTION OF NORMAL AIR FLOW. TO MAKE SURE THAT THEWHOLE SYSTEM IS CLEAN, CAREFULLY INSPECT THE SYSTEM.

CAUTION

BE EXTREMELY CAREFUL - WEIGHT HAZARD - THE TURBOCHARGER WEIGHS75 LBS.

CAUTION

WHEEL NUT OR BOLTS MUST BE APPLIED AND MAINTAINED AT THE PROPERTORQUE LEVELS TO PREVENT LOOSE WHEELS, BROKEN STUDS, ANDPOSSIBLE DANGEROUS SEPARATION OF WHEELS FROM YOUR AXLE.

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TABLE OF CONTENTS

CHAPTER TITLE PAGE

1 MEP-PU-810 A/B POWER UNIT INTRODUCTION 1-1

2 MEP-PU-810A/B POWER UNIT DESCRIPTION 2-1

3 DETAILED EQUIPMENT DESCRIPTION 3-1

4 RECEIPT AND MOVEMENT 4-1

5 OPERATING INSTRUCTIONS 5-1

6 SCHEDULED MAINTENANCE 6-1

7 UNSCHEDULED MAINTENANCE/TROUBLESHOOTING 7-1

8 HOUSING ASSEMBLY REPAIR 8-1

9 DIRECT CURRENT (DC) SYSTEM REPAIR 9-1

10 ALTERNATING CURRENT (AC) SYSTEM REPAIR 10-1

11 FUEL SYSTEM REPAIR 11-1

12 CONTROLS AND INSTRUMENTS REPAIR 12-1

13 COOLING SYSTEM REPAIR 13-1

14 LUBRICATION SYSTEM REPAIR 14-1

15 ENGINE ASSEMBLY REPAIR 15-1

16 AIR INTAKE AND EXHAUST SYSTEM REPAIR 16-1

17 OPERATOR'S REMOTE TERMINAL (ORT) REPAIR 17-1

18 RUNNING GEAR/TRAILER REPAIR 18-119 HYDRAULIC SYSTEM REPAIR 19-1

20 PU STORAGE PROCEDURES 20-1

21 ENGINE/ALTERNATOR REMOVAL AND INSTALLATION PROCEDURES 21-1

22 PDC REMOVAL AND INSTALLATION PROCEDURES 22-1
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TABLE OF ANNEXES

ANNEX TITLE PAGE

ANNEX A REFERENCES FOR PU MANUAL A-1

ANNEX B DPGDS GSC + PROGRAMMABLE SET POINTS B-1

ANNEX C ENGINE/GENERATOR ALARM AND SHUTDOWN POINTS C-1

ANNEX D BASLER OVERCURRENT RELAY SETPOINTS, ALARM AND SHUTDOWNPOINTS D-1

ANNEX E AUTOMATIC VOLTAGE REGULATOR (AVR) SETPOINTS E-1

ANNEX F 3456 EPG ADEM SETPOINTS F-1

ANNEX G CONSUMABLE OPERATING AND MAINTENANCE SUPPLIES G-1

ANNEX H SPECIAL TOOLS AND EQUIPMENT H-1

ANNEX I POWER UNIT LOGIC FLOWCHART I-1

ANNEX J FOLDOUTS J-1
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CHANGE RECORD

REVISION TITLE DATE

REVISION 0 ORIGINAL DOCUMENT 02/12/2003

REVISION 1 08/05/2003

CHANGE 1 09/16/2003

REVISION 2 02/02/2004

REVISION 3 11/01/2004

REVISION 3 INCLUDES OP SUP T.O. 35C2-3-518-C1 09/26/2005

REVISION 4 ENTIRE MANUAL 06/09/2006

REVISION 5 ENTIRE MANUAL 02/23/2007

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XVIII

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1-1

CHAPTER 1MEP-PU-810 A/B POWER UNIT INTRODUCTION

TABLE OF CONTENTS

SECTION TITLE PAGE

1.0 MEP-PU-810A / B POWER UNIT DESCRIPTION 31.1 SCOPE 31.2 REPORTING MANUAL/EQUIPMENT IMPROVEMENT

RECOMMENDATIONS (EIR) 31.3 ACRONYMS/ABBREVIATIONS 31.4 CONFIGURATION MANAGEMENT 91.5 HOW TO USE THIS MANUAL 9

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1-2

LIST OF TABLES

TABLE TITLE PAGE

TABLE 1.3-1 ACRONYMS/ABBREVIATIONS 4TABLE 1.5-1 MEP-PU-810A/B MANUAL TOPICS BY CHAPTER 10

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1-3

CHAPTER 1

INTRODUCTION

1.0 MEP-PU-810A / B POWER UNIT DESCRIPTION

1.1 SCOPE

This manual is a Commercial Technical Manual (CTM) for the operation and maintenance of the MEP-PU-810A/B Power Unit (PU) for the Deployable Power Generation and Distribution System (DPGDS).

The MEP-PU-810A/B is a wheel-mounted, diesel engine driven, prime power (Type II), utility (Class 2A),mode I unit that produces 840 kilowatts, 4160 volts line-to-line at 60 Hz and 700 kilowatts, 3800 voltsline-to-line at 50 Hz with an 0.8 power factor, lagging. The MEP-PU-810 is configured in two versions,the MEP-PU-810A, which is a towed trailer configuration that is capable of being air transported by a C-

130 aircraft, and the MEP-PU-810B, which is a 5th wheel configuration approved by the Department ofTransportation (DOT) for over the road use at 55 MPH. The MEP-PU-810B will need a Waiver becauseof the rear axle weight.

1.2 REPORTING MANUAL/EQUIPMENT IMPROVEMENT RECOMMENDATIONS (EIR)

If you find any mistakes in the manual, know a way to improve the procedures, or have suggestions thatwill improve the equipment, please let us know. Write a letter and mail it to Power Generation ProgramManager, Radian Inc., 5845 Richmond Highway, Alexandria, VA 22303.

1.3 ACRONYMS/ABBREVIATIONS

The following table is a list of acronyms of components, terms and organizations associated with theMEP-PU-810A/B:

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TABLE 1.3-1 ACRONYMS/ABBREVIATIONS

ACRONYMS/ABBREVIATION DESCRIPTION

ABC Auxiliary Battery Connector Plug

ABS Anti-lock Brake System

AC Alternating Current

AFJMAN Air Force Joint Manual

API American Petroleum Institute

ASTM American Society for Testing & Materials

ATAAC Air to Air After Cooler

ATB AC Transformer Box

AVR Automatic Voltage Regulator

AVRS Automatic Voltage Regulator Switch

AWG American Wire Gauge

BCS Breaker Control Switch

BCSF1 Breaker Control Switch, Feeder 1BCSF2 Breaker Control Switch, Feeder 2

BCSG1 Breaker Control Switch, Gen 1

BCSG2 Breaker Control Switch, Gen 2

BCST Breaker Control Switch, Tie

BSS Battle Short Switch

BSPB Buzzer Silence Pushbutton

BVFM Bus Voltage/Frequency Meter

C Degrees CentigradeCB Circuit Breaker

CBCP DC Control Power Circuit Breaker

CB1 Batter Charger, AC input Circuit Breaker

CB2 Batter Charger, DC output Circuit Breaker

CCM Customer Communication ModuleCM Centimeter

CT Current Transformer

dB Decibels

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TABLE 1.3-1 ACRONYMS/ABBREVIATIONS (CONTINUED)


DC Direct CurrentDCT Battery Bank DC Tie Switch

DEAC Diesel Engine Antifreeze Coolant

DIM Digital Input Module

DLRO Digital Low Resistance Ohmmeter

DOM Digital Output Module

DOT Department of Transportation

DPGDS Deployable Power Generation and Distribution System

DVR Digital Voltage Regulator

Ea Each

ECM Engine Control Module

ECS Engine Control Switch

ECU Electronic Control Unit

ELC Extended Life CoolantEMCP II+ Electronic Modular Control Panel II+ for EUI Engines

ESA Emergency Stop Actuator

ESPB Emergency Stop Push Button

ESG External Switch Gear

ET Caterpillar Electronic Technician

EUI Electronic Unit Injector

F Fuse

F Degrees Fahrenheit

FAR Frequency Adjust Rheostat

FFS Fuel Float Switch

FMVSS Federal Motor Vehicle Safety Standard

F1CL Feeder 1 Breaker Close Light (Red)

F2CL Feeder 2 Breaker Close Light (Red)F1OL Feeder 1 Breaker Open Light (Green)

F2OL Feeder Breaker Open Light (Green)

FO Fold Out

FPSS Fuel Pump Source Switch

FSPR Fuel Solenoid Permissive Relay

FSS Frequency Selector Switch

Ft-Lbs Foot Pounds

G Green Light

GAL Gallon

GCP Generator Control Panel

GFCI Ground Fault Circuit Interrupter

GDR1 Generator 1 Droop RelayGDR2 Generator 2 Droop Relay

GMS Generator Mode Switch

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LED Light Emitting DiodeLFTL Low Fuel Tank Level SwitchLFTLL Low Fuel Tank Level LightLSM Load Sharing ModuleL3 External Fuel Transfer Pump Solenoid ValveMCP Master Control Panel

Mg Milligrammm MillimeterMOV Metal Oxide VaristorMPH Miles per HourMPMG Multi-Purpose Lithium Complex Grease with MolybdenumMPU Magnetic Pick-Up

MSES Master Start Enable SwitchMs MillisecondNAC, CL Normal After Closed, Closed in Closed Position (BSS Switch)

NEC National Electric CodeNm Newton Meter

NFPA National Fire Protection Association

OCR Overcurrent Relay

OLG1/G2 G1/G2 Generator Overload Indicator Lights

OSHA Occupational Safety & Health Administration

ORT Operator Remote Terminal

PCM Protocol Communication Module

PDC Primary Distribution Center

Pf Power factor

PFFHWL Primary Fuel Filter High Water Level SwitchPFFHWLL Primary Fuel Filter High Water Level Light

PLC Programmable Logic Controller (see RTU)

PLS Panel Light Switch

PM Permanent Magnet

PMPE Permanent Magnet, Pilot Excited

PMCS Preventive Maintenance Checks and Services

PRL Phase Rotation Test Lights

PS Pinion Solenoid

PSC Primary Switching Center

PSI Pounds-force Per Square Inch

PSID Pounds-force Per Square Inch Differential

PT Potential Transformer

PU Power UnitP15 Power Converter

RCRA Recovery Conservation and Recovery Act

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RFA Rotating Field AssemblyRPM Revolutions per Minute

RTU Remote Terminal Unit

S1 External Fuel Transfer System Toggle Switch

S2 Fuel Pump Source Switch

S3 Minimum Fuel Level (Start Pump Switch)

S4 Maximum Fuel Level (Stop Pump Switch)

S5 High Fuel Tank Level Alarm (HFTL) Switch

S6 Low Fuel Tank Level Alarm (LFTL) Switch

SA1/2/3 Surge Arrestors

SAE Society of Automotive Engineers

SBL System in Battleshort Light

SBR System Bus Relay

SCA Supplemental Coolant AdditiveSC/25M Synchroscope / Synchcheck Relay

SIL Buzzer Silence Pushbutton

SMMS Start Motor Magnetic Switch

SMS System Mode Switch

SPMA Speed and Phase Matching Synchronizer

SPR Spare

SR Slave Relay

SSL System Status Light

SSS System Synchronizing Switch

SW Switch

T Trip Position (BCS Switch)

TBR Tie Bus Relay

TCL Tie Breaker Closed Light (Red)

TCLP Toxicity Characteristic Leaching Procedures

TM Technical Manual

TOL Tie Breaker Open Light (Green)

TTR Transformer Turns Ratio

USI Unit Selector Indicators

USS Unit Selector Switch

VAC Volts Alternating Current

VAR Voltage Adjust Rheostat

VCI Volatile Corrosion Inhibitors

VDC Volts Direct Current

XD Transducer

50L/60L 50Hz or 60Hz Mode Lights50/51G1 Generator 1 Overcurrent Relay

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1.4 CONFIGURATION MANAGEMENT

Radian Inc. provides configuration management for both the MEP-PU-810A/B and its technical

documentation. Accordingly, change pages and change record advisories regarding changes to theequipment and technical documentation will be developed and maintained. Serial number effectivity willbe stated for all changes and revisions.

1.4.1 WARRANTY TERMS AND CONDITIONS

The DPGDS Warranty remains in effect when maintenance is performed using approved parts inaccordance with DPGDS Technical Orders/Technical Manuals. Maintenance includes scheduledinspections/tests, preventive maintenance, and corrective maintenance. The MEP-PU-810A/B PowerUnit and its spares are covered by a Radian warranty. The warranty covers all defects in workmanshipand materials for a period of 30 months after Government acceptance. The warranty on replaced partsruns with the warranty of the end item. Refer to the equipment nameplate to find the acceptance monthand year for individual DPGDS equipment items. Refer to DPGDS System Manual, CTM01646.00015.001, Table 8.3.5-2 for DPGDS Warranty Claim procedures.

1.5 HOW TO USE THIS MANUAL

This manual has been written to support MEP-PU-810A/B operations and maintenance. THIS MANUALMUST BE READ THOROUGHLY BEFORE OPERATING OR MAINTAINING THE MEP-PU-810A/BPOWER UNIT. Table 1.5-1 provides a summary of the content of each Chapter.


50/51G2 Generator 2 Overcurrent Relay

50/51F1 Feeder 1 Overcurrent Relay

50/51F2 Feeder 2 Overcurrent Relay

50/51T Tie Overcurrent Relay

50N/51N Ground Fault Protection

50P Phase Short Circuit

51P Phase Time Overcurrent

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TABLE 1.5-1 MEP-PU-810A/B MANUAL TOPICS BY CHAPTER (CONTINUED)

CHAPTER TITLE SCOPE OF DISCUSSION

14 Lubrication System Repair Detailed repair procedures for the Lubrication System

15 Engine Assembly Repair Detailed repair procedures for the Engine/Alternator System

16Air Intake and ExhaustSystem Repair

Detailed repair procedures for the Air Intake and ExhaustSystem

17Operator's RemoteTerminal (ORT) Repair

Detailed repair procedures for the Operator's RemoteTerminal (ORT)

18Running Gear/TrailerRepair

Detailed repair procedures for the Running Gear/TrailerSystem

19 Hydraulic System Repair Detailed repair procedures for the Hydraulic System

20 PU Storage Procedures Detailed Storage Procedures

21Engine/Alternator Removaland Installation Procedures

Detailed procedures for the removal and replacement of theEngine/Generator

22PDC Removal andInstallation Procedures

Detailed procedures for the removal and replacement of thePrimary Distribution Center (PDC).

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THIS PAGE INTENTIONALLY LEFT BLANK

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CHAPTER 2MEP-PU-810 A/B POWER UNIT DESCRIPTION

TABLE OF CONTENTS

SECTION TITLE PAGE

2.1 GENERAL 4

2.2 DIFFERENCES BETWEEN VERSIONS 8

2.3 CHARACTERISTICS 9

2.4 ENVIRONMENTAL CAPABILITIES 10

2.5 SAFETY REQUIREMENTS 10

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LIST OF FIGURES

FIGURE TITLE PAGE

FIGURE 2.1-1 MEP-PU-810A REAR AND CURBSIDE VIEW 4

FIGURE 2.1-2 MEP-PU-810A FRONT AND STREETSIDE VIEW 5

FIGURE 2.1-3 MEP-PU-810A INTERIOR VIEW 5

FIGURE 2.1-4 MEP-PU-810B REAR AND CURBSIDE VIEW 6

FIGURE 2.1-5 MEP-PU-810B FRONT AND STREETSIDE VIEW 6

FIGURE 2.1-6 MEP-PU-810B INTERIOR VIEW 7

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LIST OF TABLES

TABLE TITLE PAGE

TABLE2.2-1 DIFFERENCESBETWEENVERSIONS 8

TABLE2.4-1 DPGDSENVIRONMENTALCAPABILITIES 10

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CHAPTER 2MEP-PU-810 A/B POWER UNIT DESCRIPTION

2.1 GENERAL

The MEP-PU-810 is a wheel-mounted, diesel engine driven, prime power (Type II), utility (Class 2A),

mode I unit that produces 840 kilowatts at 60 Hz and 700 kilowatts at 50 Hz with a 0.8 power factor,

lagging, and provides the following output voltages:

For 60 Hz operation: 2400/4160 volts, 3 phase, 3 wire, Wye connected generator

(2400 volts line-toneutral; 4160 volts Line-to-line.

For 50 Hz operation: 2200/3800 volts, 3 phase, 3 wire, Wye connected generator

(2200 volts line-to-neutral; 3800 volts line-to-line).

The MEP-PU-810 is configured in two versions, the MEP-PU-810A, which is a towed trailer configuration

that is capable of being air transported by a C-130 aircraft, and the MEP-PU-810B, which is a 5th wheel

configuration for over the road use at 55 MPH.

FIGURE 2.1-1 MEP-PU-810A REAR AND CURBSIDE VIEW

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FIGURE 2.1-4 MEP-PU-810B REAR AND CURBSIDE VIEW

FIGURE 2.1-5 MEP-PU-810B FRONT AND STREETSIDE VIEW

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FIGURE 2.1-6 MEP-PU-810B INTERIOR VIEW

The two engines are Caterpillar 3456 EPG Engines. They are Liquid-cooled, 6 cylinder, four-cycle, turbo-charged, and after-cooled and have a 15.8 Liter (964 cubic inch) displacement.

Both Generators are Caterpillar model SR4B. The generator is a brushless, rotating armature exciter,

single-bearing, air-cooled, open drip-proof unit. The generator is directly connected to the engine. Thegenerator is a permanent magnet pilot excited (PMPE) generator that receives power for the voltageregulator from the pilot exciter, rather than the main armature as in self-excited generators. The pilotexciter consists of permanent magnet (PM) rotor and PM armature (stator). The pilot exciter operatesindependently. The generator is Wye connected. For 60 Hz operation the output is 4160 volts line to line,2400 volts line to neutral, 3 phase, 4 wire, Wye connected generator. For 50 Hz operation the output is3800 volts, 3800 volts line to line, 2200 volts line to neutral, 3 phase, 4 wire, Wye connected generator.

The housing is a weather-tight enclosure that provides access for maintenance, overhaul, or replacementof major components. For proper airflow through the PU housing, all doors must be closed while the unitis running.

Lifting and Tie-downs - The van has standard ISO corner fittings on the top 4 corners for lifting by

a standard 20 foot ISO lifting frame using ISO Extenders, see Figure 2.1-1 and Figure 2.1-4. OneISO Extender is needed for each ISO Fitting on the PU. Although the van has ISO features it isNOT stackable. - The van has tie-down features rated to meet the system.

Engine Fluid Drains - Each PU is provided with a serviceable means of draining engine fluidssuch as oil, coolant and fuel through the bottom exterior of the van.

Fan Shroud - Each fan is provided with a metal shroud to protect personnel from accidentalcontact with the fan.

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Floor Vents - A section of the floor under the generators in the engine-generator compartment isventilated to allow air to be drawn through the compartment for ventilation air and enginecombustion air. A shield is provided below the floor vents to minimize debris such as rocks or dirt

from being thrown into the generator compartment during towing.

Grounding Lug Two Ground lugs are provided on the PU for connecting the external groundconnections. The ground lugs are a 4/0 split-bolt copper lug and are designed for repeated use.The ground lugs are located under the Local Control Panel (LCP). Refer to figures 5.1.3.1-1 and5.1.3.1-3 for the A and B models grounding lug locations.

2.2 DIFFERENCES BETWEEN VERSIONS

The "A" and "B" versions differ due to the two styles of trailers and associated hardware. See Table 2.2-1.

TABLE 2.2-1 DIFFERENCES BETWEEN VERSIONS

TRAILERTOWINGHITCH

The "A" version PU uses a trailer lunette with a 3 inch inside diameter. It hooks to thetow pintle of the towing vehicle. The "B" version PU uses a fifth wheel, which slides onand hooks to the fifth wheel plate of the towing vehicle.

RUNNINGBRAKES

The A version uses a surge brake system that is an integral part of the towing hitch.When braking, trailer inertia pushes a rod against the master cylinder and applies thetrailer brakes using a conventional hydraulic system. The B version uses a standardair DOT anti-lock brake system (ABS) for fifth wheel trailers. It includes a full functionservice and spring brake valve, ABS control module, service and supply hoses, gladhands, and a 2,800 cu. in. air tank.

BRAKES

The parking brake on the A version is a mechanical manual crank devise that clampsover the inside rear tires. The B version uses an air control spring brake system.When the trailer is being towed, powerful springs in the brake chamber are held back by

air pressure. When the parking brakes are applied or the PU is disconnected, airpressure is released from the chamber and the springs apply mechanical brakes toeach wheel hub.

VAN LIGHTS

The "B" version PU trailer has lights for clearance, reflectors, turn signals, and tail/stop-lights in accordance with Department Of Transportation (DOT) and Federal MotorVehicle Safety Standard (FMVSS), 121, 571.124 standards for commercial operations.For towing with a commercial truck, the commercial lights are powered by the vehicle12-volt electrical system and are provided with a 7-way intervehicular cable. Inaddition, a set of blackout lights including clearance, reflectors, turn signal, andtail/stop-lights powered by the vehicle 24-volt electrical system. A 12-way intervehicularcable is provided for towing with military vehicles. When in the blackout mode ofoperation, the commercial lights are non-operational

STEPSThe "B" version trailer is provided with a commercial ladder to allow access into the PUtrailer at any of the PU side doors. Ladder storage is above the PDC within the interiorPU when the ladder is not in use or during transportation of the PU.

TIRES The A version is provided with a LT235/85R16 with a load range of E.

TIRES The B version is provided with a 11R22.5 with a load range of G.

STORAGE The B version has a general cargo storage box 24IN. x 24IN. x 54IN.

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2.3 CHARACTERISTICS

a. Operating Temperature Range: -25 degF 125 deg

F.

b. Internal Day Tank: 120 Gallons

c. Cooling System Per Engine/Generator: 27 Gallons

d. Lubricating System Per Engine/Generator: 13 Gallons

e. Hydraulic System Per Engine/Generator: 21 Gallons

Tank: 18 Gallons

f. Dimensions:

(1) MEP-PU-810A:

Overall Length: 301 inches

Overall Width: 96 inches

Overall Height: 102 inches

Net Weight (Dry): 25,740 lbs

Front Axle Weight: 12,920 lbs

Rear Axle Weight: 12,820 lbs

Cubage Weight: 1706 cubic feet

(2) MEP-PU-810B:

Overall Length: 277 inches

Overall Width: 98 inches

Overall Height: 122 inches Net Weight (Dry) 29,100 lbs

Rear Axle Weight: 14,620 lbs

Landing Gear weight: 14,480 lbs

Fifth Wheel Weight: 7,840 lbs

Rear Axle Weight (with 5th

Wheel) 21,260 lbs

Cubage: 1917 cubic feet

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2.4 ENVIRONMENTAL CAPABILITIES

The MEP-PU-810 A/B meets the environmental requirements ofTable 2.4-1.

TABLE 2.4-1 DPGDS ENVIRONMENTAL CAPABILITIES

ALTITUDE

The PU operates and produces power at altitudes up to and including 10,000 feetabove sea level. The PU produces rated power at altitudes up to and including 4,000feet above sea level. At altitudes above 4,000 feet, the rated power may be de rated(if necessary) by a maximum of 3.5 percent per 1,000 feet above 4,000 feet up to themaximum service altitude of 10,000 feet above sea level.

TEMPERATUREThe PU operates in extreme climatic conditions: at full capability in the ambienttemperature range between 25 F and +125 F.

WINDThe PU withstands sustained winds of 80 mph sustained with gusts of 100 mphwithout damage and remains operational.

SALT SPRAY,OCEAN WINDS

The PU withstands the effects of salt spray caused by ocean winds with nodegradation of performance for the design service life.

HUMIDITYThe PU withstands the effects of all naturally occurring levels of humidity at thealtitude and temperature conditions with no degradation of performance for thedesign service life.

PRECIPITATIONThe PU withstands the effects of heavy rain, heavy snowfall, and dense fog with nodegradation of performance for the design service life.

ULTRAVIOLETRADIATION

The PU withstands the ultraviolet effects of sunshine with no degradation ofperformance for the units designed service life.

DUST & SANDThe PU starts and sustains operations in dust/sand particle concentrations up to1400 mg per cubic meter with particle sizes ranging from 74 micrometers to 1000micrometers in diameter.

AUDIONOISE/SOUND

With the engine compartment doors closed, audio noise sound pressure levelsemanating from the PU operating at any load from no load to and including rated loaddo not exceed 85 dBA at 7.0 meters.

2.5 SAFETY REQUIREMENTS

Compliance with appropriate military and industrial electric system safety standards to include NEC,OSHA, NFPA, TM 5-684, and AFJMAN 32-1082 has been established. The PU is safe to operate, store,and maintain and does not present hazards to support personnel as long as outlined procedures arefollowed.

MIL-STD-882C was used for system safety design guidance to ensure all tasks associated with thetransportation, installation, use, and reconstitution can be performed safely.

Hazardous components/parts exposed to personnel are electrically insulated or enclosed.

PU components are not exposed to open flames or hot surfaces that may be an ignition source forflammable or combustible materials, petroleum, oils, and lubricants. Camouflage and concealmentnetting can be used as long as they are lifted and supported from the mufflers a safe distance.

PU components are fire retardant or fire resistant. Materials used in the PU do not produce life-threatening levels of toxic fumes when burning or melting.

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CHAPTER 3

DETAILED EQUIPMENT DESCRIPTIONTABLE OF CONTENTS

SECTION TITLE PAGE

3.1 MEP-PU-810 POWER UNIT (PU) CONFIGURATION 143.2 PRIMARY DISTRIBUTION CENTER (PDC) 143.2.1 PDC DIMENSIONS, WEIGHT AND ELECTRICAL OUTPUT 143.2.2 RATINGS 153.2.3 PRIMARY DISTRIBUTION CENTER (PDC) EQUIPMENT 163.2.3.1 GENERATOR CONTROL PANEL (GCP) 173.2.3.1.1 OVERVIEW OF CONTROLS AND INDICATORS 173.2.3.1.2 DETAILED DISCUSSION OF CONTROLS AND INDICATORS 213.2.3.1.2.1 GSC+ GENERATOR SET CONTROL 213.2.3.1.2.1.1 FUNCTIONS 213.2.3.1.2.1.2 DISPLAYS 213.2.3.1.2.1.3 INDICATOR LIGHTS 233.2.3.1.2.2 GENERATOR BREAKER CONTROL SWITCH (BCSG1/G2) 243.2.3.1.2.4 GENERATOR OVER CURRENT RELAY (50/51G1/G2) 263.2.3.1.2.4.1 SETPOINTS 263.2.3.1.2.4.2 LOCKOUT FUNCTIONS 263.2.3.1.2.5 FEEDER OVER CURRENT RELAY (50/51F1/F2) 273.2.3.1.2.5.1 SETPOINTS 273.2.3.1.2.5.2 LOCKOUT FUNCTIONS 273.2.3.1.2.6 EMERGENCY STOP PUSH BUTTON (ESPB) 283.2.3.1.2.7 ENGINE CONTROL SWITCH (ECS) 293.2.3.1.2.8 PANEL LIGHT SWITCH (PLS) 303.2.3.1.2.9

FREQUENCY ADJUST RHEOSTAT (FAR) 30

3.2.3.1.2.10 VOLTAGE ADJUST RHEOSTAT (VAR) 303.2.3.1.2.11 CIRCUIT BREAKER CLOSED (RED) LED 303.2.3.1.2.12 CIRCUIT BREAKER OPEN (GREEN) LED 303.2.3.2 MASTER CONTROL PANEL (MCP) 313.2.3.2.1 OVERVIEW OF CONTROLS AND INDICATORS 313.2.3.2.2 DETAILED DISCUSSION OF CONTROLS AND INDICATORS 35

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3.2.3.2.2.1 SYNCHROSCOPE/SYNCHCHECK RELAY (SC/25M) 353.2.3.2.2.2 PHASE ROTATION TEST LIGHTS (PRL) 363.2.3.2.2.3

TIE OVERCURRENT RELAY (50/51T) 37

3.2.3.2.2.3.1 SETPOINTS 373.2.3.2.2.3.2 LOCKOUT FUNCTIONS 383.2.3.2.2.4 CIRCUIT BREAKER CLOSED (RED) LED (TCL) 383.2.3.2.2.5 CIRCUIT BREAKER OPEN (GREEN) LED (TOL) 383.2.3.2.2.6 BUS VOLTAGE/FREQUENCY METER (BVFM) 393.2.3.2.2.7 50/ 60 HERTZ INDICATOR LIGHTS (50L/60L) 403.2.3.2.2.8 DC CONTROL POWER CIRCUIT BREAKER (CBCP) 413.2.3.2.2.9 GENERATOR MODE SWITCH (GMS) 423.2.3.2.2.10 AUTOMATIC VOLTAGE REGULATOR SWITCH (AVRS) 433.2.3.2.2.11 TIE BREAKER CONTROL SWITCH (BCST) 443.2.3.2.2.12 MASTER START ENABLE SWITCH (MSES) 453.2.3.2.2.13 SYSTEM STATUS LIGHT (SSL) 463.2.3.2.2.14 BUZZER SILENCE PUSHBUTTON (BSPB) 473.2.3.2.2.15 BATTLE SHORT SWITCH (BSS) 483.2.3.2.2.16 SYSTEM SYNCHRONIZING SWITCH (SSS) 493.2.3.2.2.17 PANEL LIGHT SWITCH (PLS) 503.2.3.2.2.18 SYSTEM MODE SWITCH (SMS) 513.2.3.2.2.19 UNIT SELECTOR SWITCH (USS) 523.2.3.2.2.20 UNIT SELECTOR INDICATORS (USI) 533.2.3.2.2.21 FREQUENCY SELECTOR SWITCH (FSS) 543.2.3.2.2.22 ALARM/FAULT BUZZER 553.2.3.2.23 GENERATOR OVERLOAD INDICATORS (OLG1/G2) 573.2.3.3 CONTROL DEVICES 583.2.3.3.1 SPEED AND PHASE MATCHING AUTOMATIC (SPMA) 583.2.3.3.2 LOAD SHARE MODULE (LSM) 593.2.3.3.3 PROGRAMMABLE LOGIC CIRCUIT & INPUT/OUTPUT (RTU & I/O) 603.2.3.3.4 ETHERNET HUB 613.2.3.3.5 PROTOCOL COMMUNICATION MODULE (PCM) & CATERPILLAR

CUSTOMER COMMUNICATION MODULE (CCM) 623.2.3.3.6 POWER CONVERTER (P15) 633.2.3.3.7 TRANSDUCER 643.2.3.3.7.1 TRANSDUCER (XD) 64

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3.2.3.3.8 AUTOMATIC VOLTAGE REGULATOR (AVR) 653.2.3.3.9 AC TRANSFORMER BOX (ATB) 663.2.3.3.10

INSTRUMENT TRANSFORMERS 67

3.2.3.3.11 CIRCUIT BREAKERS GENERATOR, FEEDER AND TIE 693.3 POWER UNIT (PU) HOUSING 703.3.1 ACCESS DOORS AND ACCESS COVERS 703.3.2 PLENUM ASSEMBLY SCREENS 723.3.2.1 TOP PLENUM SCREENS 723.3.2.2 BOTTOM PLENUM SCREENS 733.3.3 PANELS 743.3.3.1 SIDE PANELS 743.3.3.2 TOP PANEL 753.3.4 BOTTOM PLATE ASSEMBLY 763.3.5 BATTERY BOX ASSEMBLY 773.3.6 FUEL TANK AND HYDRAULIC TANKS 783.3.7 MUFFLER ASSEMBLY 793.4 DIRECT CURRENT (DC) ELECTRICAL SYSTEM 803.4.1 BATTERY BANK 803.4.2 BATTERY CABLES 813.4.3 BATTERY CHARGER 823.4.4 DC TIE SWITCH 833.4.6 STARTER MOTOR 843.4.7 STARTER SOLENOID 843.4.8 FUEL TRANSFER PUMP 853.4.9 DC CONTROL POWER CIRCUIT BREAKER (CBCP) 863.4.10 DC PANEL LIGHT BULBS AND FAULT INDICATOR LIGHTS 873.4.11 BATTERY SLAVE RECEPTACLE 873.5 ALTERNATING CURRENT (AC) ELECTRICAL SYSTEM 883.5.1 STATION POWER TRANSFORMER 883.5.2 208/120VAC RECEPTACLES 893.5.3 WIRING HARNESSES 893.5.4 POWER PANEL BOARD 903.5.5 SR4B ALTERNATOR 913.5.7 MEDIUM VOLTAGE OUTPUT TERMINAL, TIE OUTPUT 923.5.8 MEDIUM VOLTAGE OUTPUT TERMINAL, FEEDER OUTPUT 92

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3.5.9 SURGE ARRESTORS (SA1, SA2 SA3) 933.5.10 SHORE POWER 943.5.11

CIRCUIT BREAKERS 95

3.6 FUEL SYSTEM 963.6.1 FUEL SYSTEM DESCRIPTION 963.6.2 FUEL SYSTEM COMPONENTS 983.6.2.1 EXTERNAL FUEL TRANSFER PUMP 993.6.2.1.1 EXTERNAL FUEL TRANSFER PUMP CONTROLS 1003.6.2.2 120 GALLON FUEL TANK 1013.6.2.3 FUEL INJECTION SYSTEM 1023.6.2.4 ELECTRONIC CONTROL MODULE (ECM) 1023.6.2.4.1 ELECTRONIC UNIT INJECTOR (EUI) 1033.6.2.5 PRIMARY FUEL FILTER 1043.6.2.6 SECONDARY FUEL FILTER 1063.6.2.7 FUEL PRIMER PUMP 1073.7 COOLING SYSTEM 1083.7.1 COOLING SYSTEM OPERATION 1083.7.2 COOLING SYSTEM COMPONENTS 1093.7.2.1 RADIATOR 1093.7.2.2 COOLANT TANKS 1113.7.2.3 COOLANT TEMPERATURE REGULATOR CIRCUIT 1123.7.2.4 COOLING SYSTEM AIR BLEED VALVE 1133.7.3 COOLANT CHARACTERISTICS 1143.7.4 COOLING FLUID SPECIFICATIONS 1143.7.4.1 WATER 1143.7.4.2 ADDITIVES 1153.7.4.3 ETHYLENE GLYCOL 1163.7.4.4 CATERPILLAR COOLANTS 1163.8 HYDRAULIC SYSTEM OPERATION 1183.9 LUBRICATION SYSTEM 1193.9.1 LUBRICATION SYSTEM OPERATION 1193.9.1.1 OIL FLOW THROUGH A WARM ENGINE 1193.9.1.2 OIL FLOW THROUGH A COLD ENGINE 1203.9.1.3 OIL FLOW THROUGH AN ENGINE BLOCK 1213.9.2 LUBRICATION SYSTEM COMPONENTS 122
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3.9.2.1 OIL PAN 1223.9.2.2 OIL PUMP 1233.9.2.3

OIL COOLER 124

3.9.2.4 OIL FILTER 1243.9.2.5 TURBOCHARGER OIL LINES 1253.9.2.6 OIL PASSAGES FOR THE CYLINDER HEAD AND BLOCK 1263.9.2.7 FUME DISPOSAL COLLECTOR 1273.9.3 LUBRICANT SPECIFICATIONS 1283.9.3.1 API AUTHORIZED OILS 1283.9.3.2 ENGINE OIL: CATERPILLAR DIESEL ENGINE OIL 1283.9.3.3 ENGINE OILS: COMMERCIAL OILS 1283.9.3.4 LUBRICANT VISCOSITY RECOMMENDATIONS 1303.10 ENGINE/ALTERNATOR SYSTEM 1313.10.1 CATERPILLAR 3456 EPG ENGINE 1313.10.2 STARTING THE ENGINE 1353.10.3 COLD MODE OPERATION 1353.10.4 MEP-PU-810 SPECIFIED PARAMETERS 1353.10.5 ALTERNATOR 1363.10.5.1 SR4B ALTERNATOR 1363.10.5.2 GENERATOR THEORY OF OPERATIONS 1363.10.5.3 PERMANENT MAGNET PILOT EXCITER (PMPE) 1373.10.5.4 GENERATOR COMPONENTS 1393.11 AIR INTAKE AND EXHAUST SYSTEM 1423.11.1 AIR INTAKE AND EXHAUST SYSTEM OPERATION 1423.11.1.1 COMBUSTION AIR FLOW 1423.11.1.2 EXHAUST GAS FLOW 1433.11.1.3 POWER UNIT INTERNAL COOLING AIR FLOW 1443.11.2 SYSTEM COMPONENTS 1453.11.2.1 AIR-TO-AIR AFTER COOLER (ATAAC) 1453.11.2.2 AIR FILTER 1463.11.2.3 TURBOCHARGER 1473.11.2.4 AIR INLET AND EXHAUST MANIFOLDS 1483.11.2.5 MUFFLER ASSEMBLY 1503.11.2.6 AIR FILTER HIGH DIFFERENTIAL PRESSURE ALARM (HAFDPA) 1513.12 OPERATOR'S REMOTE TERMINAL (ORT) 152
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3.12.1 ORT HARDWARE/SOFTWARE 1523.12.2 ORT SCREENS 1533.12.2.1

OVERVIEW SCREEN 153

3.12.2.2 INDIVIDUAL PU SCREENS 1533.12.3 POWER PLANT CONTROL AND MONITORING 1553.12.3.1 POWER PLANT CONTROL & MONITORING PROGRAM 1553.12.3.2 OVERVIEW POP-UP SCREEN 1563.12.3.3 PU CONTROL & MONITORING POP-UP SCREEN 1583.12.3.4 HARDWARE ALARM POP-UP SCREEN 1613.12.3.5 ALARM POP-UP SCREEN 1623.12.3.6 ALARM SUMMARY POP-UP SCREEN 1643.12.3.7 BASE-LOAD POP-UP SCREEN 1663.12.3.8 EQUIPMENT IDENTIFICATION POP-UP SCREEN 1683.12.3.9 LOW FUEL ELAPSED TIME POP-UP INDICATOR SCREEN 1703.12.3.10 EIGHT-HOUR ARCHIVE POP-UP SCREEN 1713.12.3.11 SHUTDOWN ARCHIVE POP-UP SCREEN 1723.12.3.12 DPGDS ONE-LINE POP-UP SCREEN 1733.12.3.13 PDC AND ORT LOAD LIMITING SOFTWARE 1743.12.3.13.1 PDC AND ORT LOAD LIMITING SOFTWARE DESCRIPTION 1743.12.3.13.2 POWER MONITOR 1743.12.3.13.3 60 HZ OPERATION 1743.12.3.13.4 50 HZ OPERATION 1753.12.3.13.5 WARNINGS 1753.12.3.13.6 BATTLE SHORT 1763.12.3.13.7 ORT OVERLOAD POP-UP SCREENS 1763.13 TRAILER RUNNING GEAR SYSTEMS 1803.13.1 TIRES 1803.13.1.1 MEP-PU-810A TIRES 1803.13.1.2 MEP-PU-810B TIRES 1803.13.2 WHEELS 1803.13.2.1 MEP-PU-810A WHEELS 1803.13.2.1.1 MEP-PU-810A WHEEL TORQUE REQUIREMENTS 1813.13.2.2.1 MEP-PU-810B WHEELS 1823.13.2.2.2 MEP-PU-810B WHEEL TORQUE REQUIREMENTS 1823.13.3 BRAKE SYSTEMS 183

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3.13.3.1 MEP-PU-810A BRAKE SYSTEM 1833.13.3.1.1 SURGE BRAKING SYSTEM 1833.13.3.1.2

BRAKE FLUID 184

3.13.3.1.3 HYDRAULIC BRAKE OPERATION 1853.13.3.1.4 HYDRAULIC BRAKE COMPONENTS 1863.13.3.1.5 SELF-ADJUSTING MECHANISM FOR HYDRAULIC BRAKES 1863.13.3.1.6 PARKING BRAKE 1863.13.3.2 MEP-PU-810B BRAKE SYSTEM 1873.13.3.2.1 AIR CHAMBERS 1873.13.3.2.2 SPRING BRAKES 1873.13.3.2.3 SLACK ADJUSTERS 1883.13.3.2.4 ANTI-LOCK BRAKE SYSTEM (ABS) 1883.13.3.2.5 HUB ODOMETER 1893.13.4 LIGHTING SYSTEMS 1903.13.4.1 MEP-PU-810A LIGHTING SYSTEM 1903.13.4.2 MEP-PU-810B LIGHTING SYSTEM 190
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LIST OF FIGURES

FIGURE TITLE PAGE

FIGURE 3.2.3-1 PDC LOCAL CONTROL PANEL (LCP) 16FIGURE 3.2.3.1-1 GENERATOR CONTROL PANEL (GCP) 17FIGURE 3.2.3.1.2.2-1 GENERATOR BREAKER CONTROL SWITCH (BCSG1) 24FIGURE 3.2.3.1.2.3-1 FEEDER BREAKER CONTROL SWITCH (BCSF1) 25FIGURE 3.2.3.1.2.4-1 GENERATOR OVER CURRENT RELAY (50/51G1) 26FIGURE 3.2.3.1.2.5-1 FEEDER OVER CURRENT RELAY (50/51F1) 27FIGURE 3.2.2.1.2.6-1 EMERGENCY STOP PUSHBUTTON (ESPB) 28FIGURE 3.2.3.1.2.7-1

ENGINE CONTROL SWITCH (ECS) 29

FIGURE 3.2.3.2.1-1 MASTER CONTROL PANEL (MCP) 31FIGURE 3.2.3.2.2.1-1 SYNCHRONIZING SCOPE METER (SC/25M) 35FIGURE 3.2.3.2.2.2-1 PHASE ROTATION LIGHTS (PRL) 36FIGURE 3.2.3.2.2.3-1 LOAD TIE OVERCURRENT RELAY (50/51T) 37FIGURE 3.2.3.2.2.6-1 BUS VOLTAGE/FREQUENCY METER (BVFM) 39FIGURE 3.2.3.2.2.7-1 SYSTEM FREQUENCY STATUS LIGHTS (SFSL) 40FIGURE 3.2.3.2.2.8-1 DC CONTROL POWER CIRCUIT BREAKER (CBCP) 41FIGURE 3.2.3.2.2.9-1 GENERATOR MODE SWITCH (GMS) 42FIGURE 3.2.3.2.2.10-1 AUTOMATIC VOLTAGE REGULATOR SWITCH (AVRS) 43FIGURE 3.2.3.2.2.11-1 TIE BREAKER CONTROL SWITCH (BCST) 44FIGURE 3.2.3.2.2.12-1 MASTER START ENABLE SWITCH (MSES) 45FIGURE 3.2.3.2.2.13-1 SYSTEM STATUS LIGHT (SSL) 46FIGURE 3.2.3.2.2.14-1 BUZZER SILENCE PUSHBUTTON (BSPB) 47FIGURE 3.2.3.2.2.15-1 BATTLESHORT SWITCH (BSS) 48FIGURE 3.2.3.2.2.16-1 SYSTEM SYNCHRONIZING SWITCH (SSS) 49FIGURE 3.2.3.2.2.17-1 PANEL LIGHT SWITCH (PLS) 50FIGURE 3.2.3.2.2.18-1 SYSTEM MODE SWITCH (SMS) 51FIGURE 3.2.3.2.2.19-1 UNIT SELECTOR SWITCH (USS) & UNIT SELECTOR

INDICATORS (USI) 52FIGURE 3.2.3.2.2.21-1 FREQUENCY SELECTOR SWITCH (FSS) 54FIGURE 3.2.3.2.2.22-1 ALARM/FAULT BUZZER 55FIGURE 3.2.3.2.23-1 GENERATOR OVERLOAD INDICATORS (OLG1/G2) 57FIGURE 3.2.3.3.1-1 SPEED AND PHASE MATCHING AUTOMATIC (SPMA) 58

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FIGURE 3.2.3.3.2-1 LOAD SHARE MODULE (LSM) 59FIGURE 3.2.3.3.3-1 PROGRAMMABLE LOGIC CIRCUIT & INPUT/OUTPUT (RTU & I/O) 60FIGURE 3.2.3.3.4-1

ETHERNET HUB 61

FIGURE 3.2.3.3.5-1 CUSTOMER COMMUNICATION MODULE (CCM) 62FIGURE 3.2.3.3.6-1 POWER CONVERTER (P15) 63FIGURE 3.2.3.3.7.1-1 TRANSDUCER (XD) 64FIGURE 3.2.3.3.8-1 AUTOMATIC VOLTAGE REGULATOR (AVR) 65FIGURE 3.2.3.3.9-1 AC TRANSFORMER BOX (ATB) 66FIGURE 3.2.3.3.10-1 POTENTIAL TRANSFORMERS 67FIGURE 3.2.3.3.10-2 CURRENT TRANSFORMER 68FIGURE 3.2.3.3.11-1 GENERATOR, FEEDER AND TIE CIRCUIT BREAKERS 69FIGURE 3.3.1-1 MEP-PU-810A/ B ACCESS DOORS AND COVERS 71FIGURE 3.3.2.1-1 MEP-PU-810A/B TOP PLENUM SCREENS 72FIGURE 3.3.2.2-1 BOTTOM PLENUM SCREENS 73FIGURE 3.3.3-1 SIDE PANEL 74FIGURE 3.3.3.2-1 TOP PANEL 75FIGURE 3.3.4-1 BOTTOM PLATE ASSEMBLY 76FIGURE 3.3.5-1 BATTERY BOX ASSEMBLY 77FIGURE 3.3.6-1 FUEL TANK AND HYDRAULIC RESERVOIRS 78FIGURE 3.3.7-1 MUFFLER ASSEMBLY 79FIGURE 3.4.1-1 POWER UNIT BATTERY ASSEMBLY 81FIGURE 3.4.3-1 BATTERY CHARGER 82FIGURE 3.4.4-1 DC TIE SWITCH 83FIGURE 3.4.6-1 STARTER MOTOR AND STARTER SOLENOID 84FIGURE 3.4.8-1 FUEL TRANSFER PUMP 85FIGURE 3.4.9-1 DC CONTROL POWER CIRCUIT BREAKER (CBCP) 86FIGURE 3.4.10-1 DC PANEL LIGHT BULBS AND FAULT INDICATOR LIGHTS 87FIGURE 3.5.1-1 STATION POWER TRANSFORMER 88FIGURE 3.5.2-1 208/120VAC EXTERIOR RECEPTACLES 89FIGURE 3.5.4-1 POWER PANEL BOARD 90FIGURE 3.5.5-1 SR4B ALTERNATOR 91FIGURE 3.5.7-1 MEDIUM VOLTAGE OUTPUT TERMINAL, TIE OUTPUT 92FIGURE 3.5.8-1 MEDIUM VOLTAGE FEEDER OUTPUT TERMINAL 92FIGURE 3.5.9-1 SURGE ARRESTORS (SA1, SA2 SA3) 93FIGURE 3.5.10-1 SHORE CONNECTION FOR BATTERY CHARGERS 94

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FIGURE 3.5.11-1 CIRCUIT BREAKERS 95FIGURE 3.6.2.1-1 EXTERNAL FUEL TRANSFER PUMP 99FIGURE 3.6.2.1.1-1

EXTERNAL FUEL PUMP CONTROL SWITCHES 100

FIGURE 3.6.2.2-1 120 GALLON FUEL TANK 101FIGURE 3.6.2.3-1 FUEL INJECTION MECHANISM 102FIGURE 3.6.2.4.1-1 ELECTRONIC UNIT INJECTOR (EUI) COMPONENTS 103FIGURE 3.6.2.5-1 PRIMARY FUEL FILTER 105FIGURE 3.6.2.5-2 PRIMARY FUEL FILTER DRAIN VALVE 105FIGURE 3.6.2.6-1 SECONDARY FUEL FILTER 106FIGURE 3.6.2.7-1 FUEL PRIMER PUMP 107FIGURE 3.7.1-1 COOLANT SYSTEM OPERATION 108FIGURE 3.7.2.1-1 DPGDS RADIATOR "A" FRAME HOUSING ASSEMBLY 109FIGURE 3.7.2.1-2 RADIATOR DRAIN 110FIGURE 3.7.2.1-3 RADIATOR HOSE DRAIN 110FIGURE 3.7.2.2-1 COOLANT TANK CUT-AWAY VIEW 111FIGURE 3.7.2.3-1 COOLANT TEMPERATURE REGULATOR CIRCUIT 112FIGURE 3.7.2.4-1 COOLING SYSTEM AIR BLEED VALVE 113FIGURE 3.8-1 HYDRAULIC SYSTEM OPERATION 118FIGURE 3.9.1.1-1 3456 EPG WARM ENGINE OIL FLOW 119FIGURE 3.9.1.2-1 3456 EPG COLD ENGINE OIL FLOW 120FIGURE 3.9.1.3-1 3456 EPG ENGINE OIL FLOW SCHEMATIC 121FIGURE 3.9.2.1-1 3456 EPG ENGINE OIL PAN CUTAWAY 123FIGURE 3.9.2.2-1 3456 EPG ENGINE OIL PUMP 123FIGURE 3.9.2.3-1 3456 EPG ENGINE OIL COOLER 124FIGURE 3.9.2.4-1 3456 EPG OIL FILTER 125FIGURE 3.9.2.5-1 3456 EPG TURBOCHARGER OIL LINES 125FIGURE 3.9.2.6-1 3456 EPG CYLINDER HEAD 126FIGURE 3.9.2.7-1 FUME DISPOSAL COLLECTOR 127FIGURE 3.10.1-1 CATERPILLAR 3456 EPG ENGINE, RIGHT SIDE VIEW 131FIGURE 3.10.1-2 CATERPILLAR 3456 EPG ENGINE, LEFT SIDE VIEW 132FIGURE 3.10.1-3 CATERPILLAR 3456 EPG ENGINE, TOP VIEW 133FIGURE 3.10.1-4 CATERPILLAR 3456 EPG ENGINE, REAR VIEW 133FIGURE 3.10.1-5 CATERPILLAR 3456 EPG ENGINE, FRONT VIEW 134FIGURE 3.10.5.1-1 DPGDS SR4B ALTERNATOR 136FIGURE 3.10.5.3-1 PMPE GENERATOR WIRING DIAGRAM 138
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FIGURE 3.10.5.4-1 RFA HEAT SINK 140FIGURE 3.10.5.4-2 SIX DIODE RECTIFIER BLOCK WITH VARISTOR CR7 140FIGURE 3.10.5.4-3

VARISTOR CR8 141

FIGURE 3.11.1.1-1 COMBUSTION AIR FLOW 142FIGURE 3.11.1.2-1 SYSTEM EXHAUST FLOW 143FIGURE 3.11.1.3-1 EXTERNAL AIR FLOW 144FIGURE 3.11.2.1-1 AIR-TO-AIR AFTER COOLER (ATAAC) 145FIGURE 3.11.2.2-1 AIR FILTER ASSEMBLY 146FIGURE 3.11.2.3-1 TURBOCHARGER 147FIGURE 3.11.2.4-1 AIR INLET MANIFOLD 148FIGURE 3.11.2.4-2 EXHAUST MANIFOLD 149FIGURE 3.11.2.5-1 MUFFLER ASSEMBLY 150FIGURE 3.11.2.6-1 AIR FILTER HIGH DIFFERENTIAL PRESSURE ALARM (HAFDPA) 151FIGURE 3.11.2.6-2 AIR FILTER DIFFERENTIAL GAUGE 151FIGURE 3.12-1 OPERATORS REMOTE TERMINAL 152FIGURE 3.12.2-1 OPERATORS REMOTE TERMINAL 153FIGURE 3.12.2.2-1 OPERATORS REMOTE TERMINAL 154FIGURE 3.12.3.2-1 OVERVIEW POP-UP SCREEN 157FIGURE 3.12.3.3-1 PU CONTROL & MONITORING POP-UP SCREEN 160FIGURE 3.12.3.4-1 CRITICAL ALARM POP-UP SCREEN 161FIGURE 3.12.3.5-1 ALARM POP-UP SCREEN 163FIGURE 3.12.3.6-1 ALARM SUMMARY POP-UP SCREEN 165FIGURE 3.12.3.7-1 BASE-LOAD POP-UP SCREEN 167FIGURE 3.12.3.8-1 EQUIPMENT IDENTIFICATION POP-UP SCREEN 169FIGURE 3.12.3.9-1 LOW FUEL ELAPSED TIME POP-UP INDICATOR SCREEN 170FIGURE 3.12.3.10-1 EIGHT HOUR ARCHIVE POP-UP SCREEN 171FIGURE 3.12.3.11-1 SHUTDOWN ARCHIVE POP-UP SCREEN 172FIGURE 3.12.3.12-1 DPGDS ONE-LINE 173FIGURE 3.12.3.13.5-1 PU GENERATOR OVERLOAD INDICATOR LIGHTS 175FIGURE 3.12.3.13.7-1 PLANT OVERLOAD OVERVIEW SCREEN 177FIGURE 3.12.3.13.7-2 PU CONTROL & MONITORING SCREEN 178FIGURE 3.12.3.13.7-3 ORT SERVICE PACK-3 SCREEN 179FIGURE 3.13.2.1.1-1 MEP-PU-810A TORQUE PATTERN 181FIGURE 3.13.2.2.2-1 MEP-PU-810B TORQUE PATTERN 182FIGURE 3.13.3.1-1 HYDRAULIC BRAKE ACTUATOR 183

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FIGURE 3.13.3.1-2 BREAK-AWAY LEVER AND CHAIN POSITIONS 184FIGURE 3.13.3.1.3-1 HYDRAULIC BRAKE FUNCTION DIAGRAM 185FIGURE 3.13.3.1.4-1

HYDRAULIC BRAKE COMPONENTS 186

FIGURE 3.13.3.2.1-1 S-CAM BRAKE ASSEMBLY 187FIGURE 3.13.3.2.2-1 BRAKE SYSTEM COMPONENTS 188FIGURE 3.13.3.2.4-1 ABS WIRING LAYOUT 189FIGURE 3.13.3.2.5-1 B MODEL HUB ODOMETER 189FIGURE 3.13.4.2-1 MEP-PU-810B LIGHTING 190
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LIST OF TABLES

TABLE TITLE PAGE

TABLE 3.2.1-1 PDC DIMENSIONS, WEIGHT AND ELECTRICAL OUTPUT 15TABLE 3.2.2-1 SINGLE GENERATOR OUTPUT 15TABLE 3.2.2-2 TWO GENERATOR OUTPUT 15TABLE 3.2.3.1.2.1.3-1 GSC+ SHUTDOWN INDICATOR LIGHTS 23TABLE 3.2.3.1.2.1.3-2 GSC+ WARNING INDICATOR LIGHTS 23TABLE 3.2.3.1.2.2-1 CIRCUIT BREAKER INDICATORS 24TABLE 3.2.3.1.2.3-1 CIRCUIT BREAKER INDICATORS 25TABLE 3.2.3.2.2.11-1

CIRCUIT BREAKER INDICATORS 44

TABLE 3.2.3.2.2.22-1 BUZZER ACTIVATION BY ALARM 56TABLE 3.2.3.2.2.22-2 BUZZER ACTIVATION BY FAULT 56TABLE 3.7.3-1 PROTECTION TEMPERATURES FOR ANTIFREEZE

CONCENTRATIONS 114TABLE 3.7.4.1-1 ACCEPTABLE CHARACTERISTICS OF WATER 115TABLE 3.7.4.4-1 COOLANT SERVICE LIFE 117TABLE 3.9.3.4-1 ENGINE OIL VISCOSITY 130TABLE 3.12.3.2-1 OVERVIEW POP-UP SCREEN ICONS 156TABLE 3.12.3.3-1 PU CONTROL & MONITORING POP-UP SCREEN ICONS 158TABLE 3.12.3.3-1 PU CONTROL & MONITORING POP-UP

SCREEN ICONS (CONTINUED) 159TABLE 3.12.3.5-1 ALARM POP-UP SCREEN ICONS 162TABLE 3.12.3.6-1 ALARM SUMMARY POP-UP SCREEN ICONS 164TABLE 3.12.3.7-1 BASE-LOAD POP-UP SCREEN ICONS 166TABLE 3.12.3.8-1 EQUIPMENT IDENTIFICATION POP-UP SCREEN ICONS 168
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CHAPTER 3

DETAILED EQUIPMENT DESCRIPTION3.1 MEP-PU-810 POWER UNIT (PU) CONFIGURATION

This Chapter describes the following major systems of the MEP-PU-810A/B Power Unit:

Primary Distribution Center (PDC), (Section 3.2)

Power Unit Housing, (Section 3.3)

Direct Current (DC) Electrical System, (Section 3.4)

Alternating Current (AC) Electrical System, (Section 3.5)

Fuel System, (Section 3.6)

Cooling System, (Section 3.7) Hydraulic System, (Section 3.8)

Lubrication System, (Section 3.9)

Engine/Alternator System, (Section 3.10)

Air Intake and Exhaust System, (Section 3.11)

Operators Remote Terminal (ORT), (Section 3.12)

Trailer Running Gear System, (Section 3.13)

3.2 PRIMARY DISTRIBUTION CENTER (PDC)

The PDC is an integral component of the Power Unit (PU) assembly. Two Feeder Outputs and one TieOutput are from the PDC. The output of the PDC is the same as the two Generators. The PDC contains

the following equipment:

Local Control Panel (LCP), which contains Generator Control Panels (GCP 1 and GCP 2)

Master Control Panel (MCP) (center panel on the Local Control Panel)

Internal power distribution bus and power distribution circuit breakers (Vacuum Contactors)

Potential transformers / current transformers required for providing low voltage sensinginformation for the PU control system

Controls for automated control and monitoring of the onboard generators

Distribution load-break connectors

Other connectors required so that allow multiple Power Units work together as a system

3.2.1 PDC DIMENSIONS, WEIGHT AND ELECTRICAL OUTPUT

Table 3.2.1-1 lists PDC dimensions, weights and electrical outputs for both 60 and 50 Hertz operations.
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TABLE 3.2.1-1 PDC DIMENSIONS, WEIGHT AND ELECTRICAL OUTPUT

PARAMETER VALUE

LENGTH 90 Inches

WIDTH 36.05 Inches

HEIGHT 60 Inches

WEIGHT 2,027 Pounds

SHIPPING VOLUME 110.6 Cubic Feet

HANDLINGFork Lift Not to Exceed (4,000 lbs), Due to the Size

of the Tine.

DISTRIBUTION OUTPUT4160 volts, 3 - phase, 60 hertz, 160 Amps

3800 volts, 3 phase, 50 hertz, 146 Amps

3.2.2 RATINGS

The PDC rating and Capacities are individually determined according to the operating frequency. ThePDC output is the same as the generator. Table 3.2.2-1 presents Power, Voltage and Amperage ratingsfor a single Generator Output. Table 3.2.2-2 presents Power, Voltage and Amperage ratings for a twoGenerator Output.

TABLE 3.2.2-1 SINGLE GENERATOR OUTPUT

FREQUENCYOUTPUT POWER

(KVA)OUTPUT POWER

(KW)OUTPUT

VOLTAGEAMPERAGE

60 Hz 525 KVA 420 KW 4160 VAC 80 amps

50 Hz 438 KVA 350 KW 3800 VAC 73 amps

TABLE 3.2.2-2 TWO GENERATOR OUTPUT

FREQUENCYOUTPUT POWER

(KVA)OUTPUT POWER

(KW)OUTPUT

VOLTAGEAMPERAGE

60 Hz 1050 KVA 840 KW 4160 VAC 160 amps

50 Hz 875 KVA 700 KW 3800 VAC 146 amps

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3.2.3 PRIMARY DISTRIBUTION CENTER (PDC) EQUIPMENT

The Local Control Panel Assembly, as illustrated in Figure 3.2.3-1, provides local control for the PowerUnit (PU). Located at the rear of the PU, the Local Control Panel (LCP) contains the Master Control

Panel (MCP), and the Generator Control Panel (GCP) for Generator 1 and Generator 2. All Automatic

and Manual operations are controlled from these panels.

The Local Control Panel (LCP) allows the operator the flexibility of controlling operations from the GCPs

including the ability to start, stop, add and remove load, parallel in and add or remove units from the bus,

as well as monitor all control functions. A capability for remote operations is provided through the

addition of a Operator Remote Terminal (ORT).

FIGURE 3.2.3-1 PDC LOCAL CONTROL PANEL (LCP)

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From the Generator Control Panel (GCP), the operator can manually start, stop, control, and operate theassociated generator and feeder breakers. Additionally the operator can observe engine and generator

parameters at the Generator Set Control GSC+ module. There are current protective relays installed inthe GCP for generator and feeder breaker protection. All controls and indicators described in this sectionrefer to the Generator 1 GCP and use the applicable component marking (A suffix) references. Thefollowing controls and indicators of the G1 GCP as illustrated in Figure 3.2.3.1-1 are:

a. System in Battleshort Mode Light(SBL)

This amber LED indicates that the PU is in Battleshort mode. This status is visible at both generatorcontrol panels, as it is common for both generators.

b. Primary Fuel Filter High Differential Alarm Light(HPFFDPL)

This amber LED indicates that the associated engine primary fuel filter has reached the highdifferential pressure setpoint and needs to be inspected and the filter replaced.

c. Secondary Fuel Filter High Differential Alarm Light(HSFFDPL)

This amber LED indicates that the associated engine secondary fuel filter has reached the highdifferential pressure setpoint and needs to be inspected and the filter replaced.

d. Primary Fuel Filter High Water Level Alarm Light(PFFHWLL)

This amber LED indicates that the associated engine fuel filter has reached the high level of wateraccumulated in the bowl setpoint and needs to be inspected and the bowl drained.

e. Oil Filter High Differential Alarm Light(HOFDPL)

This amber LED indicates that the associated engine oil filter has reached the high differentialpressure setpoint and needs to be inspected and the filter replaced.

f. Air Filter High Differential Alarm Light (HAFDPL)

This amber LED indicates that the associated engine air filter has reached the high differentialpressure setpoint and needs to be inspected and the filter replaced.

g. Fuel Tank High Level Alarm Light (HFTLL)

This amber LED indicates that the PU common fuel tank has a high fuel level. The fuel transfer pumpneeds to be checked to ensure that it is not running to prevent overflowing the tank.

h. Fuel Tank Low Level Alarm Light (LFTLL)

This amber LED indicates that the common fuel tank level is low. Verify the fuel transfer pump isrunning and make-up fuel is being transferred to the PU. Both generator sets can be operated at fullload in this condition for a maximum period of 10 minutes. The control system will automatically shutdown operating generator sets and prevent restarting until the fuel level reaches the minimumallowable level.

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i. Hydraulic Tank Low Level Shutdown Light (HTLLL)

This red LED indicates that the hydraulic fluid level is low. The affected engine will shutdownimmediately.

j. Generator Set Control (GSC +)

The GSC + provides control for the engine/generator and local monitoring for its associated generatorset. All metering parameters are available from the GSC +. The GSC + monitors and controls manyof the engine functions. Some of the more basic checks that the operator will be required to performon a routine operating basis have been provided for convenience.

k. Generator Breaker Control Switch (BCSG1/G2)

These switches have momentary positions and one maintained position. There is also a target toindicate the last mechanical operation performed by the switch. These switches are used for localgenerator breaker control, setting up the breaker for automatic operation, and disabling breakeroperation.

l. Feeder Breaker Control Switch (BCSF1/F2)

These switches have momentary positions and one maintained position. There is also a target toindicate the last mechanical operation performed by the switch. These switches are used for localfeeder breaker control, setting up the breakers for automatic operation, and disabling breakeroperation.

m. Generator Over Current Relay (50/51G1/G2)

There is a protective relay installed for each Generator Circuit Breaker (Gen 1 & Gen 2). Each

microprocessor-based relay provides Phase Time Overcurrent (51P), Phase Short Circuit (50P), andGround Fault Protection (50N, 51N). The relays are a draw-out design allowing easy replacement.Each relay has a LCD display and control keypad to allow the operator to program and monitorrequired parameters. The display, by default, scrolls through the phase currents, total current, andalarm log. The LCD display on each overcurrent relay provides a display of the current flow througheach phase of the associated breaker. This overcurrent relay monitors the common sensing return oftheir phase sensing current transformers. This provides each breaker with ground fault protection.

n. Feeder Over Current Relay (50/51F1/F2)

There is a protective relay installed for each Feeder Circuit Breaker (F1 & F2). Each microprocessor-based relay provides Phase Time Overcurrent (51P), Phase Short Circuit (50P), and Ground FaultProtection (50N, 51N). The relays are a draw-out design allowing easy replacement. Each relay has

a LCD display and control keypad to allow the operator to program and monitor required parameters.The display, by default, scrolls through the phase currents, total current, and alarm log. The LCDdisplay on each overcurrent relay provides a display of the current flow through each phase of theassociated breaker. This overcurrent relay monitors the common sensing return of their phasesensing current transformers. This provides each breaker with ground fault protection.

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o. Emergency Stop Push Button (ESPB)

This switch is the Emergency Stop Pushbutton. It shuts down the associated engine and preventsrestarting of the associated engine.

p. Engine Control Switch (ECS)

These rotary snap switches have four maintained positions. The switch may be rotated 360 in eitherdirection. The switch is used for local operation of the generator, setting up the generator for automaticoperation, and disabling generator operation.

q. Panel Light Switch (PLS)

This switch is used to turn on the panel lights on the panel, used for nighttime operations.

r. Frequency Adjust Rheostat (FAR)

This device is a 10-turn potentiometer that is used to adjust the frequency during initial set up.

s. Voltage Adjust Rheostat (VAR)

This device is a 5-turn potentiometer that is used to adjust the voltage during initial set up.

t. Circuit Breaker CLOSED (RED) LED:

Generator 1 (G1CL)

Generator 2 (G1CL)

Feeder 1 (F1CL)

Feeder 2 (F2CL)

This red LED indicates that its associated breaker is closed.

u. Circuit Breaker OPEN (GREEN) LED

Generator 1 (G1OL)

Generator 2 (G2OL)

Feeder 1 (F1OL)

Feeder 2 (F2OL)

This green LED indicates that its associated breaker is open.

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3.2.3.1.2 DETAILED DISCUSSION OF CONTROLS AND INDICATORS

3.2.3.1.2.1 GSC+ GENERATOR SET CONTROL

The GSC+ provides control for the engine/generator and local monitoring for its associated generator set.All metering parameters are available from the GSC+. The GSC+ monitors and controls many of theengine functions. Some of the more basic checks that the operator will be required to perform on aroutine operating basis have been provided for convenience.

The GSC+ is covered in detail in the Caterpillar service manual. For further operational instructions onusing the GSC+ see the Caterpillar (See RENR-1200 or later) manual (See Figure 3.2.3.1-1, Item 10).

3.2.3.1.2.1.1 FUNCTIONS

The GSC+ is designed to operate with a 24VDC battery system. The GSC+ monitors and controls manyof the generator set functions. The functions and features of the GSC+ are:

a. Provides generator AC output information including power metering.

b. Controls starting and stopping of the engine based on the input from the Engine Control Switch(ECS), and/or the internal Programmable Logic Computer (RTU).

c. Shows engine condition and generator output information on two displays. These displays alsoshow fault codes and GSC+ programming information.

d. Monitors the system for faults. If a fault occurs, the GSC+ performs a controlled fault shutdownor provides a fault alarm annunciation. The GSC+ uses indicators and displays to describe the

fault to the operator.

e. Contains programming features for the DPGDS system.

3.2.3.1.2.1.2 DISPLAYS

Upper Display:

The primary function of the upper display is to show AC voltage, current and frequency information of thegenerator output. There are several options available. These options can be viewed one at a time bypressing the AC meter key on the keypad:

Voltage (average), frequency, and current (total)

Voltage (line to line), frequency, or current on any phase

Current (line) for all three phases at once

Various fault codes for system faults. For detailed information on fault codes refer to theCaterpillar service manual.

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Lower Display:

The lower display shows values for power metering, engine parameters and the relay status. The leftside of the lower display functions as a generator set power meter. The following functions scrollautomatically:

Total real power (kW)

Total reactive power (kVAR)

Percent of rated power

Power factor

Total energy output (kVA)

Briefly pressing the Power Meter keypad will cause the display to start scrolling. Pressing a second timewill display the parameter continuously, indicated by the parameter label flashing.

The right side of the lower display shows the value of certain engine parameters. The parameters shownare:

System battery voltage (VDC)

Engine run time (Hours)

Engine speed (RPM)

Engine oil pressure (PSI)

Engine coolant temperature (F)

The value of each of these parameters is shown for two seconds and then the display scrolls to the nextparameter. A small pointer identifies the engine condition being displayed. When the Engine Meter keyis depressed, the information screen stops scrolling and continuously displays the selected parameter.

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3.2.3.1.2.2 GENERATOR BREAKER CONTROL SWITCH (BCSG1/G2)

Figure 3.2.3.1.2.2-1 illustrates the Generator Breaker Control Switch (BCSG1). This switch has twomomentary positions and one maintained position. There is also a target to indicate the last mechanicaloperation performed by the switch. This switch is used for local operation of the breaker, setting up thebreaker for automatic operation, and disabling the breakers operation.

FIGURE 3.2.3.1.2.2-1 GENERATOR BREAKER CONTROL SWITCH (BCSG1)

TRIP: Rotate handle counterclockwise 45 then release. This is a momentary position that trips theassociated breaker and reveals a green target. Once released, the handle returns to the center position.

CLOSE: Rotate the handle clockwise 45 then release. This is a momentary position that closes theassociated breaker and reveals a red target. Once released, the handle returns to the center position. Thered target must be visible for automatic operation.

PULL-TO-LOCK: Rotate handle counterclockwise 90 then pull out to lock in this position. This is themaintained position. The associated breaker trips, the green target appears, and the breaker cannot be re-closed until the handle is pushed back in.

TABLE 3.2.3.1.2.2-1 CIRCUIT BREAKER INDICATORS

BREAKER CLOSED LED (G1/G2CL)This red LED indicates that its associated breaker is closed.

BREAKER OPEN LED (G1/G2OL)This green LED indicates that its associated breaker isopen.

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3.2.3.1.2.3 FEEDER BREAKER CONTROL SWITCH (BCSF1/F2)

Figure 3.2.3.1.2.3-1 illustrates the Feeder Breaker Control Switch (BCSF1). This switch has two

momentary positions and one maintained position. There is also a target to indicate the last mechanicaloperation performed by the switch. This switch is used for local operation of the breaker, setting up thebreaker for automatic operation, and disabling the breakers operation.

FIGURE 3.2.3.1.2.3-1 FEEDER BREAKER CONTROL SWITCH (BCSF1)

TRIP: Rotate handle counterclockwise 45 then release. This is a momentary position that trips theassociat

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