TM_9-6115-751-10_(15kW).pdf

ARMY TM 9-6115-751-10

AIR FORCE TO 35C2-3-533-1

MARINE CORPS TM 11773A-OI

NAVY TM 7610-LL-L1A-0024

DISTRIBUTION STATEMENT A — Approved for public release; distribution is unlimited.

HEADQUARTERS, DEPARTMENTS OF THE ARMY,

AIR FORCE, NAVY, AND HEADQUARTERS,

US MARINE CORPS

1 FEBRUARY 2011

PCN 184 117730 00

TECHNICAL MANUAL

OPERATOR’S MANUAL

FOR

GENERATOR SET, SKID MOUNTED

15KW ADVANCED MEDIUM MOBILE POWER SOURCES

(AMMPS)

MEP-1050 50/60 Hz

(NSN: 6115-01-561-7634) (EIC: N/A)

MEP-1051 400 Hz

(NSN: 6115-01-561-7674) (EIC: N/A)

TM 9-6115-751-10

WARNING SUMMARY

FIRST AID

For First Aid information, refer to Field Manual (FM) 4-25.11.

5 SAFETY STEPS TO FOLLOW IF SOMEONE IS THE VICTIM OF ELECTRICAL SHOCK:

Do not try to pull or grab the individual.

If possible, turn off the electrical power.

If you cannot turn off the electrical power, pull, push, or lift the person to safety using a dry wooden pole, dry rope, or some other insulating material.

Send for help as soon as possible.

After the injured person is free of contact with the source of electrical shock, move the person a short distance away. Immediately start artificial respiration if necessary.

a

The Warning Summary summarizes critical safety and hazardous material warnings that must be understood and applied during operation and maintenance of the Advanced Medium Mobile Power Sources (AMMPS) generator sets.

These warnings are important.

Study and understand all warnings.

These warnings can save your life and the lives of personnel with whom you work.

Some general warnings found in the Warning Summary will not be repeated within the Technical Manual (TM).

Specific warnings will be listed above the task or paragraph to which they apply.

Operation and maintenance of the AMMPS generator set contains many possibilities for injury or death to personnel. Be sure to be familiar with general first aid procedures as references in FM 4-25.11, First Aid.

WARNING ICONS

The following icons are used in conjunction with warnings so that you do not miss important information. They are not meant to be a substitute for reading the warnings, but they give graphic descriptions of danger.

EAR PROTECTION — Headphones over ears shows that noise level will harm ears.

ELECTRICAL — Electrical wire to arm with electricity symbol running through human body shows that life-threatening shock hazard is present.

ELECTRICAL — Electrical wire to hand with electricity symbol running through hand shows that shock hazard is present.

FLYING PARTICLES — Objects striking person shows that the material presents a danger to life or health.

HEAVY OBJECT — Human figure stooping over heavy object shows physical injury potential from improper lifting technique.

HIGH PRESSURE — Human hand being penetrated by high pressure shows system pressures present a danger to life or limb.

HOT AREA — Hand over object radiating heat shows that part is hot and can burn.

b

MOVING PARTS — Human figure with an arm caught between the gears shows that the larger moving parts of the equipment present a danger to life or limb.

MOVING PARTS — Hand with fingers caught between gears shows that the smaller moving parts of the equipment present a danger to life or limb.

WARNING DESCRIPTIONS

WARNING

Electrical

High voltage is produced when generator set is in operation. Never attempt to start the generator set unless it is properly grounded. Do not ground yourself in standing water. Never attempt to connect or disconnect load cables while the generator set is running. Failure to comply may cause injury or death to personnel.

Ensure generator sets are shut down and output terminal board has no voltage prior to making any connections for operation or moving a generator set that has been operating. Operating generator sets always contain the risk of electrocution. Failure to comply may cause injury or death to personnel.

Ensure generator sets are shut down and output terminal board has no voltage prior to making any connections for parallel operation or moving a generator set that has been operating in parallel. Operating generator sets always contain the risk of electrocution. Failure to comply may cause injury or death to personnel.

Direct Current (DC) voltages are present at generator set electrical components even with generator set shut down. Avoid shorting any positive with ground/negative. Do not ground yourself in standing water. Failure to comply may cause injury or death to personnel and damage to equipment.

Generator set must be completely shut down prior to washing. Electrocution is possible. Failure to comply may cause injury or death to personnel.

Do not start generator set until all internal components are completely dry. Electrocution is possible. Failure to comply may cause injury or death to personnel.

North Atlantic Treaty Organization (NATO) slave receptacle is electrically live at all times and is not protected by a fuse. Disconnecting main DC circuit breaker does not ensure the circuit is dead. This circuit is only dead when the batteries are fully disconnected. Disconnect both batteries before performing maintenance on the slave receptacle. Failure to comply may cause injury or death to personnel.

c

Electrical — Continued.

Power is available to the Ground Fault Circuit Interrupter (GFCI) convenience receptacle only when the main contactor is closed. Avoid accidental contact. Electrocution is possible. Failure to comply may cause injury or death to personnel.

Ensure the frequency of any device powered by the GFCI convenience receptacle matches the frequency of the generator set. Failure to comply can cause serious injury or death to personnel.

High voltage is produced when this generator set is in operation. Do not contact output cables when operating this generator set. Failure to comply may cause injury or death to personnel.

High voltage is produced when generator set is in operation. Do not connect to a load that is not protected with appropriate safety devices. Do not connect from output terminal board to output terminal board unless directed by higher command. Never attempt to start the generator set unless it is properly grounded. Do not ground yourself in standing water. Never attempt to connect or disconnect load cables while the generator sets are running. Do not contact output cables when operating this generator set. Make sure that the connection between generator set and load is completely deenergized (safety device opens circuit) prior to disconnecting load cables or performing maintenance on the output terminal board. Failure to comply may cause injury or death to personnel.

High-voltage power is available when the main contactor is closed. Avoid accidental contact with live components. Ensure load cables are properly connected and the load cable door is shut before closing main contactor. Ensure that personnel working with/on loads connected to the generator set are aware that main contactor is about to be closed before closing main contactor.

Failure to comply may cause injury or death to personnel.

Shut down generator sets before performing inspection of load cables. Failure to comply may cause injury or death to personnel by electrocution.

Generator set operator is permitted to make connections to output terminal board only.

Connections to load distribution points or to equipment beyond the output terminal board shall only be made by properly trained and authorized personnel. Failure to comply may cause injury or death to personnel.

Do not remove the bonding jumper between GND and N unless the weapon system requires an underground system. Refer to applicable weapon system TM for specific guidance on power and connection requirements. Failure to comply may cause injury or death to personnel.

Ensure frequency of any device powered by the GFCI convenience receptacle matches the frequency of the generator set. Failure to comply can cause serious injury or death to personnel.

d

Heat

When operating, generator set engine has hot metal surfaces that will burn flesh on contact. Shut down generator set and allow engine to cool before checks, services, and maintenance. Wear gloves and additional protective clothing as required. Failure to comply may cause injury or death to personnel.

When operating, muffler has hot metal surfaces that will burn flesh on contact. Shut down generator set and allow muffler to cool before performing maintenance. Wear gloves and additional protective clothing as required. Failure to comply may cause injury or death to personnel.

Top and housing panels can get very hot. Allow panels to cool down before performing maintenance. Wear gloves and additional protective clothing as required. Failure to comply may cause injury or death to personnel.

Wear heat-resistant gloves and avoid contacting hot metal surfaces with hands and exposed skin after components have been heated. Wear additional protective clothing as required. Failure to comply may cause injury or death to personnel.

When operating, turbocharger has hot metal surfaces that will burn flesh on contact. Shut down generator set and allow heater to cool before performing maintenance. Wear gloves and additional protective clothing as required. Failure to comply may cause injury or death to personnel.

WARNING

Jewelry/Clothing

Metal jewelry can conduct electricity and become entangled in generator set components.

Remove all jewelry and do not wear loose clothing when working on equipment. Failure to comply may cause injury or death to personnel.

While inspecting the operation of the generator set, do not inadvertently reach into the generator set. Failure to comply can cause injury or death to personnel.

e

Lifting

Comply with all lifting requirements. Observe the decals on equipment and parts that identify the weight and determine if assistance is needed. Maximum lift is 37 lb (16.8 kg) for one person, 74 lb (33.6 kg) for two persons, and 101 lb (45.8 kg) for three persons. Failure to comply may cause

HAZARDOUS MATERIALS ICONS

BIOLOGICAL — Abstract symbol bug shows that material may contain bacteria or viruses that present a danger to life or health.

CHEMICAL — Drops of liquid on hand shows that material will cause burns or irritation to human skin or tissue.

CRYOGENIC — Hand in block of ice shows that material is extremely cold and can injure human skin or tissue.

EXPLOSION — Rapidly expanding symbol shows that material may explode if subjected to high temperature, source of ignition, or high pressure.

EYE PROTECTION — Person with goggles shows that material will injure the eyes.

FIRE — Flame shows that material may ignite and cause burns.

POISON — Skull and crossbones show that material is poisonous or is a danger to life.

RADIATION — Three circular wedges show that material emits radioactive energy and can injure human tissue.

f

VAPOR — Human figure in a cloud shows that material vapors present a danger to life or health.

HAZARDOUS MATERIALS WARNING DESCRIPTIONS

There is a potential risk that soldiers and other users may be exposed to chemical substances and diesel engine exhaust during the operation, maintenance, and repair of the AMMPS generator sets.

Potential sources of chemical substances include fuels, oils, lubricants, paints, cleaners/solvents, engine coolant fluids, cold start fluid, fire extinguishing agents, battery acid/chemicals, and miscellaneous chemicals used during the setup/operation/maintenance and sustainment throughout the life-cycle of the AMMPS generator sets.

This manual describes physical and chemical processes that may require the use of chemicals, solvents, paints, and/or other commercially available material. Users of the manual should obtain the Material Safety Data Sheets (MSDS) (Occupational Safety and Health Act (OSHA) Form 20 or equivalent) from the manufacturers or suppliers of materials to be used. Failure to comply with comply with all procedures, recommendations, warnings and cautions for safe use, handling, storage, and disposal of these materials may result in serious injury or death to personnel.

Batteries

Batteries give off combustible gas. Do not smoke or use open flame when performing maintenance. Failure to comply may cause injury or death to personnel and damage to equipment.

Battery acid can cause burns to skin and cause eye injury. Wear safety goggles and chemical gloves and avoid acid splash while working on the batteries. Failure to comply may cause injury or death to personnel.

Cold

In extremely cold weather, skin can stick to metal. Avoid contacting metal items with bare skin in extremely cold weather. Failure to comply may cause injury or death to personnel.

g

Exhaust

Hot exhaust gases can ignite combustible materials. Allow room for safe discharge of hot gases.

Failure to comply may cause injury or death to personnel.

Exhaust discharge contains deadly gases, including carbon monoxide. Exhaust gases are most dangerous in places with poor ventilation. Do not operate generator set in an enclosed area unless exhaust discharge is properly vented. Failure to comply may cause injury or death to personnel.

Exhaust gases are most dangerous in places with poor ventilation. The best defense against exhaust gas poisoning is very good ventilation. To protect yourself and others, always obey the following rules:

Do not run engine indoors unless you have very good ventilation.

Do not idle engine for a long time unless there is very good ventilation.

Be alert at all times. Check for smell of exhaust fumes.

Failure to comply may cause injury or death to personnel.

Exhaust gas poisoning causes dizziness, headache, loss of muscle control, sleepiness, coma, and death. If anyone shows signs of exhaust gas poisoning, get all personnel clear of AMMPS.

Make sure they have lots of fresh air. Keep them warm, calm, and inactive. Get medical help. If anyone stops breathing, give artificial respiration. Failure to comply may cause injury or death to personnel.

Eye

Flying debris or material may enter eyes or strike the face. Wear appropriate eye/face protection while performing maintenance tasks. Failure to comply may cause injury or death to personnel.

h

Fuel

Fuels used in the generator set are combustible. Do not smoke or use open fire when performing maintenance. Fire and possible explosion may result. Failure to comply may cause injury or death to personnel and damage to equipment.

Hot engine surfaces from engine and generator circuitry are possible sources of ignition. When refueling during unit operation with Diesel Fuel (DF)-1, DF-2, Jet Propulsion Fuel (JP) 5, or JP8, avoid fuel splash and fuel spill. Do not smoke or use open flame when performing refueling.

Remember Preventive Maintenance Checks and Services (PMCS) are still required. Flames and possible explosion may result. Failure to comply may cause injury or death to personnel.

Fuel is combustible and toxic to eyes, skin, and respiratory tract. Skin and eye protection are required when working in contact with fuel. Avoid repeated or prolonged contact. Provide adequate ventilation. Operators are to wash exposed skin and change soaked clothing promptly if exposed to fuel. Failure to comply may cause injury or death to personnel.

Fuels used in the generator set are combustible. Ensure fuel source grounding strap is connected to unit fuel fill grounding stud (fuel fill static ground). When filling the fuel tank, maintain metal-to-metal contact between filler nozzle and fuel tank opening to eliminate Electrostatic Discharge (ESD). Fire and possible explosion can result. Failure to comply may cause injury or death to personnel.

Do not operate generator set if any fuel leaks are present. Fuel is combustible. Always perform PMCS before operation. Failure to comply may cause injury or death to personnel.

High Temperature/Pressure

Hot coolant can burn. If the radiator cap is hot to the touch, it is too hot to open. Allow the coolant to cool before opening the radiator cap. Wear gloves, additional protective clothing, and goggles as required. Contact with high-pressure steam and/or liquids can cause burns and scalding.

Failure to comply may cause injury or death to personnel.

Cooling system operates at high temperature and pressure. Contact with high-pressure steam and/or liquids can cause burns and scalding. Shut down generator set and allow system to cool before performing checks, services, and maintenance. Wear gloves, additional protective clothing, and goggles as required. Contact with high-pressure steam and/or liquids can cause burns and scalding. Failure to comply may cause injury or death to personnel.

Engine coolant is toxic to eyes and poisonous if ingested. Eye protection is required when working with engine coolant. Avoid repeated or prolonged contact. Failure to comply may cause i

High Temperature/Pressure — Continued.

Cooling system operates at high temperature and pressure. Contact with high-pressure steam and/or liquids can cause burns and scalding. Do not open radiator cap unless coolant temperature is below 100°F (38°C). Failure to comply may cause injury or death to personnel.

Noise

Hearing protection requested during maintenance or repair with engine running. Failure to comply can cause hearing loss.

j

A/B blank USA

LIST OF EFFECTIVE PAGES/WORK PACKAGES

NOTE: Zero in the “Change No.” column indicates an original page or work package.

Date of issue for the original manual is:

Original 1 February 2011

TOTAL NUMBER OF PAGES FOR FRONT MATTER AND REAR MATTER IS 42 AND TOTAL

NUMBER OF WORK PACKAGES IS 21, CONSISTING OF THE FOLLOWING:

Page/WP No. Change No.

Front cover 0 Blank 0 Warning summary (8 pgs) 0 i – x 0 Chp 1 title page 0 Chp 1 index 0 WP 0001 (8 pgs) 0 WP 0002 (14 pgs) 0 WP 0003 (8 pgs) 0 Chp 2 title page 0 Chp 2 index 0 WP 0004 (24 pgs) 0 WP 0005 (54 pgs) 0 WP 0006 (20 pgs) 0 WP 0007 (8 pgs) 0 WP 0008 (4 pgs) 0 Chp 3 title page 0 Chp 3 index 0 WP 0009 (4 pgs) 0 WP 0010 (22 pgs) 0

Page/WP No. Change No.

WP 0011 (4 pgs) 0 Chp 4 title page 0 Chp 4 index 0 WP 0012 (4 pgs) 0 WP 0013 (24 pgs) 0 WP 0014 (4 pgs) 0 WP 0015 (10 pgs) 0 WP 0016 (6 pgs) 0 WP 0017 (6 pgs) 0 Chp 5 title page 0 Chp 5 index 0 WP 0018 (2 pgs) 0 WP 0019 (4 pgs) 0 WP 0020 (2 pgs) 0 WP 0021 (2 pgs) 0 Glossary-1 – Glossary-2 0

INDEX-1 – INDEX-4 0

Inside back cover 0 Back cover 0

ARMY TM 9-6115-751-10

AIR FORCE TO 35C2-3-533-1

MARINE CORPS TM 11773A-OI

NAVY TM 7610-LL-L1A-0024

DISTRIBUTION STATEMENT A –– Approved for public release; distribution is unlimited.

i

HEADQUARTERS,

DEPARTMENTS OF THE ARMY, AIR FORCE,

NAVY, AND HEADQUARTERS, US MARINE CORPS

WASHINGTON, D.C., 1 FEBRUARY 2011

TECHNICAL MANUAL

OPERATOR’S MANUAL

FOR

GENERATOR SET, SKID MOUNTED

15KW ADVANCED MEDIUM MOBILE POWER SOURCES (AMMPS)

MEP-1050 50/60 Hz

(NSN: 6115-01-561-7634) (EIC: N/A)

MEP-1051 400 Hz

(NSN: 6115-01-561-7674) (EIC: N/A)

REPORTING ERRORS AND RECOMMENDING IMPROVEMENTS

You can help improve this manual. If you find any mistakes or if you know of a way to improve the procedures, please let us know. Reports, as applicable by the requiring Service, should be submitted as follows:

(a) (A) Army — Mail your letter or DA Form 2028 (Recommended Changes to Publications and Blank Forms) located in the back of this manual, directly to: Commander, U.S. Army CECOM Life Cycle Management Command (LCMC) and Fort Monmouth, ATTN: AMSEL-LC-LEO-E-CM, Fort Monmouth, NJ 07703-5006. You may also send in your recommended changes via electronic mail or by fax. Our fax number is 732-532-1556, DSN 992-1556. Our e-mail address is MONM-AMSELLEOPUBSCHG@conus.army.mil. Our online web address for entering and submitting DA Form 2028s is http://edm.monmouth.army.mil/pubs/2028.html.

(b) (MC) Marine Corps — Submit notice of discrepancies or suggested changes on a NAVMC 10772.

The NAVMC may be submitted via the Internet using URL: http://192.156.19.109/ar/mcefs.nsf.

Once the form is completed click on file in the tool bar at top of screen, scroll to "Send" and select "Page by email", and enter SMB.LOG.Tech.Pubs.fct@usmc.mil, this will come in to the Pubs Sections mailbox. This method of submittal does not require a Common Access Card (CAC) to access the form. The https://pubs.ala.usmc.mil/front.htm URL will allow access to the Albany Publications web site where the form can be filled out and be submitted by electronic mail to mbmatcommarlogbases@logcom.usmc.mil. A paper copy NAVMC 10772 can be mailed in an envelope addressed to Commander, Marine Corps Systems Command (LOG/TP), 814 Radford Blvd, Suite 20343, Albany, GA 31704-0343. Problems or questions regarding the NAVMC 10772 program should be reported by calling DSN 567-7628, DSN 567-6439 or DSN 567-5017.

(c) (N) Navy — By letter directly to Commander, Space and Naval Warfare Systems Command, ATTN: SPAWAR 8122, Washington, DC 20363-5100.

(d) (F) Air Force — By Air Force AFTO Form 22 TM Change Recommendation and Reply in accordance with paragraph 6-5, Section VI, TO 00-5-1 directly to prime ALC/MST.

A reply will be furnished to you.

ii

TABLE OF CONTENTS

WP Sequence No.

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How To Use This Manual

Chapter 1 — General Information, Equipment Description, And Theory Of Operation

General Information................................................................................................................................ WP 0001 Scope......................................................................................................................................WP 0001-1 Table 1. Model Numbers and Equipment Names ..................................................................WP 0001-1 Figure 1. Skid-Mounted 15 kW AMMPS Generator Set .........................................................WP 0001-2 Maintenance Forms, Records, and Reports...........................................................................WP 0001-2 Reporting Equipment Improvement Recommendation (EIR).................................................WP 0001-2 Corrosion Prevention and Control (CPC) ...............................................................................WP 0001-2 Ozone-Depleting Substances (ODS)......................................................................................WP 0001-3 Destruction of Army Materiel to Prevent Enemy Use.............................................................WP 0001-3 Demolition of Marine Corps Materiel to Prevent Enemy Use.................................................WP 0001-3 Table 2. Demolition Priority Levels .........................................................................................WP 0001-4 Preparation for Storage or Shipment......................................................................................WP 0001-4 Warranty Information ..............................................................................................................WP 0001-4 List of Abbreviations/Acronyms ..............................................................................................WP 0001-4 Safety, Care, and, Handling ...................................................................................................WP 0001-8 Equipment Description And Data ........................................................................................................... WP 0002 Equipment Characteristics, Capabilities, and Features..........................................................WP 0002-1 Location and Description of Major Components ....................................................................WP 0002-1

Figure 1. AMMPS 15 kW Generator Set with Doors Closed..................................................WP 0002-1 Housing...................................................................................................................................WP 0002-1 Figure 2. Rear- and Right-Side View with Doors Open..........................................................WP 0002-2 Figure 3. Front- and Left-Side View with Door Open .............................................................WP 0002-3 Skid Assembly ........................................................................................................................WP 0002-4 Figure 4. Skid..........................................................................................................................WP 0002-4 Engine Assembly....................................................................................................................WP 0002-4 Figure 5. Engine Components — Left Side............................................................................WP 0002-5 Figure 6. Engine Components — Right Side .........................................................................WP 0002-6 Figure 7. Systems Components — Right Side.......................................................................WP 0002-7 Figure 8. Systems Components — Left Side .........................................................................WP 0002-8 Figure 9. 24-VDC Electrical and AC Generator — Left Side..................................................WP 0002-9 Figure 10. Output Box Components — Right Side...............................................................WP 0002-10 AC Generator........................................................................................................................WP 0002-11 Output Box Assembly ...........................................................................................................WP 0002-11 Differences Between Models................................................................................................WP 0002-11 Equipment Data ....................................................................................................................WP 0002-11 Table 1. Equipment Data......................................................................................................WP 0002-11 Theory Of Operation............................................................................................................................... WP 0003 Scope......................................................................................................................................WP 0003-1 Operation ................................................................................................................................WP 0003-1 DCS ........................................................................................................................................WP 0003-1 iii

WP Sequence No.

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Figure 1. AMMPS Control Overview ...................................................................................... WP 0003-2 Technical Principles of Operation...........................................................................................WP 0003-2 Figure 2. Engine Starting System........................................................................................... WP 0003-3 Figure 3. Fuel System ............................................................................................................ WP 0003-4 Figure 4. Engine Cooling System........................................................................................... WP 0003-5 Figure 5. Engine Lubrication System ..................................................................................... WP 0003-6 Figure 6. Air Intake and Exhaust System............................................................................... WP 0003-7 Figure 7. Output Supply System............................................................................................. WP 0003-8

Chapter 2 — Operator Instructions

Descriptions And Use Of Operator Controls And Indicators .................................................................. WP 0004 Introduction............................................................................................................................. WP 0004-1 DCS ........................................................................................................................................ WP 0004-1 Figure 1. Screen Navigation ................................................................................................... WP 0004-1 Table 1. Screen Navigation .................................................................................................... WP 0004-2 Figure 2. Generator Set DCS Control Panel .......................................................................... WP 0004-3 Table 2. Generator Set DCS Control Panel ........................................................................... WP 0004-3 Figure 3. DCS Control Panel .................................................................................................. WP 0004-4 Table 3. DCS Control Panel ................................................................................................... WP 0004-4 Figure 4. DEAD CRANK SWITCH ......................................................................................... WP 0004-5 Table 4. DEAD CRANK SWITCH........................................................................................... WP 0004-5 Figure 5. Engine Control Switch.............................................................................................WP 0004-6 Table 5. Engine Control Switch ..............................................................................................WP 0004-6 Figure 6. Main DC Circuit Breaker ......................................................................................... WP 0004-7 Table 6. Main DC Circuit Breaker........................................................................................... WP 0004-7 Figure 7. Voltage Selection Board.......................................................................................... WP 0004-8 Table 7. Voltage Selection Board........................................................................................... WP 0004-8 Figure 8. Main Display Screen (Showing 3-Phase Configuration) ......................................... WP 0004-9 Table 8. Main Display Screen................................................................................................. WP 0004-9 Figure 9. [Adjustments] Screen 1 — Select Parameter ....................................................... WP 0004-13 Table 9. [Adjustments] Screen 1 — Select Parameter......................................................... WP 0004-13 Figure 10. [Adjustments] Screen 1 — Adjust ....................................................................... WP 0004-14 Table 10. [Adjustments] Screen 1 — Adjust......................................................................... WP 0004-15 Figure 11. [Adjustments] Screen 2 — Select Parameter ..................................................... WP 0004-16 Table 11. [Adjustments] Screen 2 — Select Parameter....................................................... WP 0004-16 Figure 12. [Adjustments] Screen 2 — Adjust ....................................................................... WP 0004-17 Table 12. [Adjustments] Screen 2 — Adjust......................................................................... WP 0004-18 Figure 13. [Parallel Adj] Screen............................................................................................WP 0004-19 Table 13. [Parallel Adj] Screen.............................................................................................WP 0004-19 Figure 14. First [Maintenance] Screen ................................................................................. WP 0004-20 Table 14. First [Maintenance] Screen .................................................................................. WP 0004-20 Figure 15. [Maintenance Items] Screen ............................................................................... WP 0004-21 Table 15. [Maintenance Items] Screen.................................................................................WP 0004-21 Figure 16. [Maintenance Actions] Screen ............................................................................ WP 0004-22 Table 16. [Maintenance Actions] Screen.............................................................................. WP 0004-22 Figure 17. Generator Hour Meter ......................................................................................... WP 0004-23 Table 17. Generator Hour Meter .......................................................................................... WP 0004-23 Operation Under Usual Conditions......................................................................................................... WP 0005 Siting Requirements ............................................................................................................... WP 0005-2 Assembly and Preparation for Use......................................................................................... WP 0005-3 Screen Navigation .................................................................................................................. WP 0005-3 Figure 1. Screen Navigation ................................................................................................... WP 0005-3 iv

WP Sequence No.

Page No.

Installation of Ground Rod......................................................................................................WP 0005-4 Figure 2. Grounding Connections...........................................................................................WP 0005-4 Figure 3. Install Ground Rod with Slide Hammer ...................................................................WP 0005-6 Figure 4. Installing Ground Rods with Sledge Hammer .........................................................WP 0005-7 Removal of Ground Rod.........................................................................................................WP 0005-9 Installation of Auxiliary Fuel Lines ........................................................................................WP 0005-10 Figure 5. Auxiliary Fuel Supply Connections........................................................................WP 0005-10 Installation of Load Cables ...................................................................................................WP 0005-11 Figure 6. Installation of Load and Ground Cables................................................................WP 0005-11 Table 1. Load Terminal —Voltage Selection Board .............................................................WP 0005-12 Figure 7. Ground and Output Cable Attachment Detail .......................................................WP 0005-12 Initial Adjustments ................................................................................................................WP 0005-13 Figure 8. Configure Voltage Selection Board .......................................................................WP 0005-14 Operating Procedures ..........................................................................................................WP 0005-15 Starting Procedure................................................................................................................WP 0005-15 Figure 9. Main DC Circuit Breaker and DEAD CRANK SWITCH ........................................WP 0005-16 Figure 10. DCS Panel...........................................................................................................WP 0005-17 Figure 11. Main Screen Message 1......................................................................................WP 0005-18 Table 2. Delay to Crank Messages ......................................................................................WP 0005-19 Figure 12. Main Screen Message 2......................................................................................WP 0005-19 Figure 13. Operator Main Screen.........................................................................................WP 0005-20 Adjust Generator Set ............................................................................................................WP 0005-21 Figure 14. Main Screen Showing Adjustments — Location .................................................WP 0005-21 Figure 15. [Adjustments] Screen 1 — Select Option............................................................WP 0005-22 Figure 16. [Adjustments] Screen 1 — Set Configuration .....................................................WP 0005-23 Figure 17. [Adjustments] Screen 2 — Select Parameter .....................................................WP 0005-24 Figure 18. [Adjustments] Screen 2 — Set Configuration .....................................................WP 0005-25 Monitoring Generator Set Operational Status ......................................................................WP 0005-26 Figure 19. Main Control Screen Status Indicators 120/208 V 3 Phase................................WP 0005-26 Table 3. Screen Indicator Parameters..................................................................................WP 0005-26 Figure 20. Select Maintenance Screen ................................................................................WP 0005-28 Figure 21. First Maintenance Screen ...................................................................................WP 0005-29 Figure 22. Maintenance Item Display...................................................................................WP 0005-30 Figure 23. Next Items Display ..............................................................................................WP 0005-31 Operation with Remote Monitoring.......................................................................................WP 0005-31 Figure 24. Operator Display Panel — Remote Connection .................................................WP 0005-32 Figure 25. Remote PC — Connection..................................................................................WP 0005-33 Figure 26. Remote PC Display .............................................................................................WP 0005-34 Stopping Procedure..............................................................................................................WP 0005-36 Figure 27. Stopping Procedure.............................................................................................WP 0005-36 Decals and Instructions Plates .............................................................................................WP 0005-37 Figure 28. Decals and Instructions Plates, Right-Side — Model 1050/1051 .......................WP 0005-37 Table 4. Decals and Instructions Plates, Right-Side — Model 1050/1051 ..........................WP 0005-37 Figure 29. Decals and Instructions Plates, Rear — Model 1050/1051 ................................WP 0005-38 Table 5. Decals and Instructions Plates, Rear — Model 1050/1051....................................WP 0005-38 Figure 30. Decals and Instructions Plates, Top and Inside — Model 1050/1051 ................WP 0005-39 Table 6. Decals and Instructions Plates, Top and Inside — Model 1050/1051 ...................WP 0005-39 Figure 31. Decals and Instructions Plates, Front — Model 1050/1051................................WP 0005-40 Table 7. Decals and Instructions Plates, Front — Model 1050/1051...................................WP 0005-40 Figure 32. Decals and Instructions Plates, Left-Side — Model 1050/1051..........................WP 0005-41 Table 8. Decals and Instructions Plates, Left-Side — Model 1050/1051.............................WP 0005-41 Figure 33. Plate, Identification — Model 1050 .....................................................................WP 0005-42 Figure 34. Plate, Identification — Model 1051 .....................................................................WP 0005-42 v

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Figure 35. Name Plate, Identification — Model 1050........................................................... WP 0005-43 Figure 36. Name Plate, Identification — Model 1051........................................................... WP 0005-43 Figure 37. Label, Lifting and Tie Down — Model 1050/1051 ............................................... WP 0005-44 Figure 38. Plate, IUID Identification — Model 1050 ............................................................. WP 0005-44 Figure 39. Plate, IUID Identification — Model 1051 ............................................................. WP 0005-45 Figure 40. Plate, System Capacity — Model 1050/1051 ..................................................... WP 0005-45 Figure 41. Plate, Set Rating — Model 1050......................................................................... WP 0005-46 Figure 42. Plate, Set Rating — Model 1051......................................................................... WP 0005-46 Figure 43. Label, Fuel — Model 1050/1051 ......................................................................... WP 0005-47 Figure 44. Label, Convenience — Model 1050.................................................................... WP 0005-47 Figure 45. Label, Convenience — Model 1051.................................................................... WP 0005-47 Figure 46. Label, Fuel Diagram — Model 1050/1051 .......................................................... WP 0005-48 Figure 47. Label, Operating Instructions — Model 1050/1051............................................. WP 0005-49 Figure 48. Label, Dead Crank — Model 1050/1051............................................................. WP 0005-49 Figure 49. Label, Caution, Voltage Connection — Model 1050/1051.................................. WP 0005-50 Figure 50. Label, Grounding Stud — Model 1050/1051....................................................... WP 0005-50 Figure 51. Label, Diagram, Wiring — Model 1050/1051 ...................................................... WP 0005-51 Figure 52. Label, First Fuel Filter — Model 1050/1051........................................................ WP 0005-51 Figure 53. Label, Slave Receptacle — Model 1050/1051.................................................... WP 0005-52 Figure 54. Label, Schematic, Wiring — Model 1050/1051................................................... WP 0005-52 Figure 55. Label, Battery Connection — Model 1050/1051 ................................................. WP 0005-53 Preparation for Movement ....................................................................................................WP 0005-53 Parallel Operations ................................................................................................................................. WP 0006 Connecting Generator Sets Parallel Cables (Power Plant Configuration) ............................. WP 0006-2

Figure 1. Storage Box and Cable — Location........................................................................ WP 0006-3 Figure 2. DCS Panel — Parallel Setup .................................................................................. WP 0006-4

Parallel Operation with Switch Box (Two Like Sets) .............................................................. WP 0006-5 Figure 3. Switch Box Contactor Receptacle........................................................................... WP 0006-5 Figure 4. Main Display Screen — Parallel Mode....................................................................WP 0006-6 Parallel Operation Without Switch Box (Two Or More Like Sets) .......................................... WP 0006-8 Adjusting Parallel Operations ...............................................................................................WP 0006-11 Figure 5. Parallel Adjustment Screen, A .............................................................................. WP 0006-11 Figure 6. Parallel Adjustment Screen, B. ............................................................................. WP 0006-13

Figure 7. Parallel Adjustment Screen, C .............................................................................. WP 0006-15 Figure 8. Parallel Adjustment Screen, D .............................................................................. WP 0006-16 Figure 9. Parallel Adjustment Screen, E .............................................................................. WP 0006-17 Figure 10. Parallel Adjustment Screen, F............................................................................. WP 0006-18 Soft Removal From Parallel Operation With [Unload] Soft Key ........................................... WP 0006-19 Figure 11. Soft Unload Key ..................................................................................................WP 0006-19 Removal From Parallel Operation With UNIT PARALLEL Switch ....................................... WP 0006-20 Figure 12. DCS Panel, Remove From Parallel..................................................................... WP 0006-20 Operation Under Unusual Conditions..................................................................................................... WP 0007 Operation in Extreme Cold -25°F (-31°C)............................................................................... WP 0007-2 Operation in Extreme Heat Above 120°F (49°C) ................................................................... WP 0007-2 Operation in Dusty or Sandy Areas........................................................................................ WP 0007-2 Operation in Rainy or Humid Conditions ................................................................................WP 0007-3 Operation in Salt Water Areas................................................................................................ WP 0007-3 Operation in High Altitudes..................................................................................................... WP 0007-4 Operation Using BATTLESHORT Switch............................................................................... WP 0007-5 Figure 1. DCS Panel............................................................................................................... WP 0007-5 Operation While in Contaminated Areas ................................................................................ WP 0007-6 Use of the Ground Fault Circuit Interrupter (GFCI) Convenience Receptacle....................... WP 0007-7 Figure 2. GFCI Convenience Receptacle............................................................................... WP 0007-7 vi

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Emergency.............................................................................................................................................. WP 0008 NATO Slave Receptacle Start Operation ...............................................................................WP 0008-1 Figure 1. NATO Slave Receptacle .........................................................................................WP 0008-2 Emergency Stopping ..............................................................................................................WP 0008-3 Figure 2. DCS Panel...............................................................................................................WP 0008-3 Operation Using BATTLESHORT Switch...............................................................................WP 0008-4

Chapter 3 — Troubleshooting Procedures

Troubleshooting Index ............................................................................................................................ WP 0009 General Troubleshooting Information.....................................................................................WP 0009-1 Malfunction/Symptom Index ...................................................................................................WP 0009-1 Troubleshooting Procedures ................................................................................................................. WP 0010 Table 1. Voltage Parameters................................................................................................WP 0010-11 Table 2. Frequency Parameters ...........................................................................................WP 0010-12

DCS Fault And Warning Codes And Descriptions ................................................................................. WP 0011 DCS Fault And Warning Codes and Descriptions..................................................................WP 0011-1 Table 1. DCS Fault and Warning Codes and Descriptions ....................................................WP 0011-1

Chapter 4 —Maintenance Instructions

PMCS Introduction.................................................................................................................................. WP 0012 Introduction .............................................................................................................................WP 0012-1 General ...................................................................................................................................WP 0012-1 Explanation of the Columns Found in PMCS Table...............................................................WP 0012-1 Corrosion Prevention and Control (CPC) ...............................................................................WP 0012-1 Inspection ...............................................................................................................................WP 0012-2 Cleaning and Lubrication........................................................................................................WP 0012-3 Fluid Leakage .........................................................................................................................WP 0012-4

PMCS ................................................................................................................................................... WP 0013 Figure 1. Rear View................................................................................................................WP 0013-2 Figure 2. Right-Side View.......................................................................................................WP 0013-3 Figure 3. Front View ...............................................................................................................WP 0013-4 Figure 4. Left-Side View .........................