TM 9-6115-484-14 Mep-Pu-810a/b Part 4

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DRS RADIAN CTM 01646.1R0253/1R0254
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CHAPTER 11
FUEL SYSTEM REPAIR
TABLE OF CONTENTS
SECTION TITLE PAGE

11.0 REPAIR OF FUEL SYSTEM 5
11.1 SAFETY INSTRUCTIONS 5
11.2 FUEL SYSTEM DESCRIPTION 7
11.2.1 FUEL INJECTION 8
11.2.2 THE UNIT INJECTOR MECHANISM 10
11.2.3 SYSTEM MAINTENANCE 11
11.3 SERVICE REQUIREMENTS OF THE FUEL SYSTEM 12
11.3.1 PRIMARY FUEL FILTER 12
11.3.1.1 INSPECT THE PRIMARY FUEL FILTER 12
11.3.1.2 SERVICE THE PRIMARY FUEL FILTER 13
11.3.2 SECONDARY FUEL FILTER 16
11.3.2.1 INSPECT THE SECONDARY FUEL FILTER 16
11.3.2.2 SERVICE THE SECONDARY FUEL FILTER 17
11.3.3 FUEL STRAINER 18
11.3.3.1 INSPECT THE FUEL STRAINER 18
11.3.3.2 SERVICE THE FUEL STRAINER 19
11.3.4 ETHER INJECTION 21
11.3.4.1 INSPECT THE ETHER INJECTION ASSEMBLY 21
11.3.4.2 SERVICE THE ETHER INJECTION ASSEMBLY 21
11.3.5 FUEL SYSTEM PRIMING PROCEDURE 23
11.4 COMPONENT REPAIR PROCEDURES 26
11.4.1 FUEL SOLENOID VALVE (L3) 26
11.4.1.1 INSPECT THE FUEL SOLENOID VALVE (L3) 27
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TABLE OF CONTENTS
SECTION TITLE PAGE

11.4.1.2 REMOVE THE FUEL SOLENOID VALVE (L3) 27
11.4.1.3 INSTALL THE FUEL SOLENOID VALVE (L3) 28
11.4.2 EXTERNAL FUEL TRANSFER PUMP ASSEMBLY 30
11.4.2.1 INSPECT THE EXTERNAL FUEL TRANSFER PUMP ASSEMBLY 31
11.4.2.2 TEST THE EXTERNAL FUEL TRANSFER PUMP ASSEMBLY 31
11.4.2.3 REMOVE THE EXTERNAL FUEL TRANSFER PUMP ASSEMBLY 31
11.4.2.4 INSTALL THE EXTERNAL FUEL TRANSFER PUMP ASSEMBLY 33
11.4.3 FUEL PRIMER PUMP 34
11.4.3.1 INSPECT THE FUEL PRIMER PUMP 34
11.4.3.2 REMOVE THE FUEL PRIMER PUMP 35
11.4.3.3 INSTALL THE FUEL PRIMER PUMP 36
11.4.4 ENGINE MOUNTED FUEL PUMP 37
11.4.4.1 INSPECT THE ENGINE MOUNTED FUEL PUMP 37
11.4.4.2 REMOVE THE ENGINE MOUNTED FUEL PUMP 38
11.4.4.3 INSTALL THE ENGINE MOUNTED FUEL PUMP 39
11.4.5 FUEL FLOAT SWITCH ASSEMBLY 40
11.4.5.1 INSPECT THE FUEL FLOAT SWITCH ASSEMBLY 41
11.4.5.2 TEST THE FUEL FLOAT SWITCH ASSEMBLY 41
11.4.5.3 REMOVE THE FUEL FLOAT SWITCH ASSEMBLY 42
11.4.5.4 INSTALL THE FUEL FLOAT SWITCH ASSEMBLY 43
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LIST OF FIGURES
FIGURE TITLE PAGE

FIGURE 11.2-1 FUEL SYSTEM COMPONENTS 7
FIGURE 11.2.1-1 UNIT INJECTOR MECHANISM 9
FIGURE 11.2.2-1 UNIT INJECTOR COMPONENTS 10
FIGURE 11.3.1-1 PRIMARY FUEL FILTER 12
FIGURE 11.3.1.2-1 PRIMARY FUEL FILTER DRAIN VALVE 15
FIGURE 11.3.2-1 SECONDARY FUEL FILTER 16
FIGURE 11.3.3-1 FUEL STRAINER ASSEMBLY 18
FIGURE 11.3.4-1 ETHER INJECTION ASSEMBLY 21
FIGURE 11.3.5-1 CYLINDER HEAD AIR BLEED CAP 24
FIGURE 11.3.5-2 FUEL PRIMING PUMP 24
FIGURE 11.3.5-3 FUEL SYSTEM AIR BLEED PLUG 25
FIGURE 11.4.1-1 FUEL SOLENOID VALVE (L3) 26
FIGURE 11.4.2-1 FUEL TRANSFER PUMP 30
FIGURE 11.4.3-1 FUEL PRIMER PUMP 34
FIGURE 11.4.4-1 ENGINE MOUNTED FUEL PUMP 37
FIGURE 11.4.5-1 FUEL FLOAT SWITCHES 40
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LIST OF TABLES
TABLE TITLE PAGE

TABLE 11.4.5-1 FFS CONTACT POSITION 42
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11.0 REPAIR OF FUEL SYSTEM
Maintenance procedures are provided for the following Fuel System Components:
• Primary Fuel Filter

• Secondary Fuel Filter
• Fuel Strainer
• Ether Injection
• Fuel System Priming Procedures
• Filter Monitoring Panel
• Fuel Solenoid Valve (L3)
• External Fuel Transfer Pump Assembly
• Fuel Primer Pump
• Engine Mounted Fuel Transfer Pump
11.1 SAFETY INSTRUCTIONS
a. Safety precautions must be observed while any maintenance is being performed. Safety
precautions must be observed to ensure that the operator/technician cannot have contact with the
following:
• Hot engine parts

• Hot engine fluids
• Medium Voltage AC electricity
• Low Voltage AC electricity
• Low Voltage DC electricity
• Rotating Parts
• High noise levels
b. Minor troubleshooting can be performed while both engines are running as long as safety
precautions are taken.
c. Minor maintenance can be performed while one generator set is running and the other
generator set has been shutdown. Some examples of this maintenance are:
• Lubrication System – Oil and Filter Change.

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

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

(2) Isolate the PU from any power plant or utility connection in accordance with Section
5.9.6.15, Unit Isolation Procedure with PSC. See Note 1 and 2.
(3) Isolate the PU from any power plant control system in accordance with Note 3.
(4) Pull to open the PU DC Power Control Breaker.
(5) Push to OPEN both Emergency Stop Switches.
(6) Place both Engine Control Switches (ECS) in the OFF position.
(7) Place a DO NOT OPERATE tag on both generator control panels.
(8) Turn the Battery Bank Parallel Switch to the OFF position.
(9) De-energize both Battery Chargers.
(10) Disconnect the negative and positive cables from both Battery Banks.
(11) Place a DO NOT OPERATE tag on both Battery Banks.
(12) Place all Circuit Breakers in the LOCK OUT position.
(13) Disconnect both 7P1 and 7P2 Connectors located on the inside panel of the PDC.
(14) Close and Lock both generator set control panels.
NOTE 1: Also the PU must be completely electrically isolated from the power distribution bus and
any other electrical source that can back feed into the PU. All medium voltage cables need to
be placed on the standoff insulators by use of hot sticks and other safety gear.
NOTE 2: Ensure cables are not energized by opening the circuit breaker of the Primary Switching
Center (PSC), then disconnect Load Cables (Using the proper safety gear) on the PU and
place them on the Parking Stands.
NOTE 3: When the DC Control Power Circuit Breaker is in the (OFF) position (Pulled – Out), all control
power is turned off to the PU. This will cause the HUB to stop functioning. This causes the
network to not see the equipment shutdown and all PU’s after it. When pulling major
maintenance the (A) (B) Communication Cable must be routed to the next PU in order to
reestablish the communication network.
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11.2 FUEL SYSTEM DESCRIPTION
FIGURE 11.2-1 FUEL SYSTEM COMPONENTS
a. The fuel supply circuit is a conventional design for unit-injected engines. Refer to Figure 11.2-1
for reference. The External Fuel Transfer Pump, of the circuit is a 24VDC, gear type pump
with fixed clearance. The Engine Fuel Transfer Pump pulls fuel from the PU 120 Gallon Fuel
Tank, and delivers it to the EUI Fuel Injectors. The Engine Fuel Transfer Pump pulls fuel from
the fuel tank. The Engine Fuel Transfer Pump incorporates a check valve in order to permit a
fuel flow around the gears for hand priming. The Engine Fuel Transfer Pump also incorporates
a Relief Valve in order to protect the system from extreme pressure. The excess fuel flow that is
provided by the fuel transfer pump cools the fuel from the unit injectors. The excess fuel flow
purges the air from the unit injectors.
NOTE: The inlet fuel temperature to the fuel transfer pump must not exceed 175°F (79°C) when the
engine has reached normal operating temperature. Fuel temperatures above 175°F (79°C)
will reduce the life of the electronics in the ECM and the fuel transfer pump check valves. The
fuel efficiency and the engine power output are reduced when the fuel temperature increases
from 86°F (30°C) to 158° (70°C) F. The GSC+ will give an AL4 Alarm after 30 seconds.
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b. The fuel in the fuel transfer pump flows through the cored passages in the Fuel Block and
through a 2-micron fuel filter. The Fuel Priming Pump is positioned on the fuel filter base in order
to fill the system after the fuel supply and the return manifolds are drained. The fuel supply and
the return passages in the cylinder head are drained in order to reinstall the unit injectors. The
filtered fuel enters the housing for the Electronic Control Module (ECM). This fuel cools the
module as the fuel passes through the ECM. The fuel enters the fuel manifold at the rear of the
cylinder head. The fuel flows continuously from the fuel supply through the Cylinder Head Fuel
Gallery through the EUI Fuel Injectors. This fuel then returns to the fuel tank through the Fuel
Cooler by the return line on the fuel manifold.
c. Fuel is displaced by the EUI Fuel Injector Plunger when the fuel is not being injected into the
cylinder. A Fuel Pressure Regulator is located in the Fuel Block. The Fuel Pressure
Regulator maintains a sufficient amount of backpressure in the system in order to fill the EUI
Fuel Injectors. The Engine Fuel Transfer Pump is located in the front of the engine at the
lower left corner. The Engine Fuel Transfer Pump is mounted to either the front timing gear
cover or a plate. The Engine Fuel Transfer Pump is driven by the gear train.
d. The injection pump, the fuel lines, and the nozzles that are used in the traditional Caterpillar
diesel engines have been replaced with an electronically controlled, mechanically actuated EUI
Fuel Injectors in each cylinder. A solenoid on each injector controls the amount of fuel that is
delivered by the injector and Electronic Control Module (ECM), sends a signal to each injector
solenoid in order to provide complete control of the engine.
11.2.1 FUEL INJECTION
a. The Electronic Control Module (ECM) controls the amount of fuel that is injected by varying the
signals to the injectors. The injectors will inject fuel only if the injector solenoid is energized. The
Electronic Control Module (ECM) sends a 90-volt signal to the solenoid in order to energize the
solenoid. By controlling the timing and the duration of the 90-volt signal, the Electronic Control
Module (ECM) can control injection timing and the amount of fuel that is injected.
b. The Electronic Control Module (ECM) sets certain limits on the amount of fuel that can be
injected “FRC Fuel Pos” is a limit which controls the amount of air and of fuel for the purpose of
emission control. This limit is based on the boost pressure When the Electronic Control
Module (ECM) senses a higher boost pressure, the Electronic Control Module (ECM)
increases the ‘FRC Fuel Pos” limit “Rated Fuel Pos” is a limit that is based on the horsepower
rating of the engine. This is similar to the rack stops and to the torque spring on a mechanically
governed engine “Rated Fuel Pos” provides horsepower and torque curves for a specific engine
family and for a specific engine rating. All of these limits are programmed into the personality
module by the factory. These limits are not programmable in the field.
c. Injection timing depends on three factors:
(1) The Engine rpm

(2) The Engine Load
(3) Other operational conditions including:
• Fuel Temperature
• Ambient Temperature
• Altitude
• Boost Pressure (Turbocharger)
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d. The Electronic Control Module (ECM) can determine the top center position of cylinder number
1 from the signal that is provided by the engine speed-timing sensor. The Electronic Control
Module (ECM) decides when the injection should occur relative to the top center position. The
Electronic Control Module (ECM) then provides the signal to the injector at the desired time.
(1) Unit Injector, (2) Adjusting Nut, (3) Rocker Arm Assembly, (4) Camshaft
FIGURE 11.2.1-1 UNIT INJECTOR MECHANISM
The rocker arm lobe provides the downward force that is required to pressurize the fuel in the unit injector
pump. The unit injector (1) allows fuel to be injected into the combustion chamber at the precise time.
The camshaft gear is driven by two idler gears and a cluster gear that is driven off the crankshaft gear.
The timing marks on the crankshaft gear, on the cluster gear, and on the housing of the timing cover are
aligned in order to provide the correct relationship between the piston and the valve movement. The
camshaft has three lobes for each cylinder. Two lobes operate the inlet valves and the exhaust valves,
and one lobe operates the unit injector mechanism (See Figure 11.2.1-1 Unit Injector Mechanism). Force
is transmitted from the unit injector lobe on the camshaft (4) to the top of the unit injector (1) through the
rocker arm assembly (3). The adjusting nut (2) allows the injector lash to be set.
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11.2.2 THE UNIT INJECTOR MECHANISM
(1) Spring, (2) Solenoid Connection to ECM, (3) Solenoid Valve Assembly, (4) Plunger, (5) Barrel, (6)
Seal, (7) Seal, (8) Spring, (9) Spacer, (10) Body, (11) Check Valve, (12) Seal
FIGURE 11.2.2-1 UNIT INJECTOR COMPONENTS
a. The fuel exits the fuel supply manifold. The fuel flows through the drilled passages in the cylinder
head. This fuel enters the unit injector at the fill port. Refer to Figure 11.2.2-1 for reference: As
the unit injector mechanism produces force to the top of the unit injector, spring (1) and plunger
(4) is moved downward this causes fuel to be displaced through the valve in the solenoid valve
assembly (3), and into the return manifold to the tank. The fuel passage into barrel (5) is closed
by the outside diameter of the plunger (4). The passages to the injector tip within the body (10)
and along the check valve (11) are filled with fuel as the plunger moves down. After the fuel
passage in the plunger barrel is closed, fuel can be injected at any time. These requirements are
programmed into the electronic control module.
b. When the solenoid valve assembly (3) is energized from a signal across the solenoid connection
(2), the solenoid valve closes and the pressure in the injector tip is increased. Injection starts at
5000 ± 275 PSI (34474 ± 1896 kPa) as the force of spring (8) is overcome. This causes the
check valve to rise from the seat. The pressure continues to increase as the plunger cycles
through the full stroke. After the correct amount of fuel has been discharged into the cylinder, the
electronic control module signals across the solenoid connection. This signal indicates that the
solenoid valve assembly is de-energized and that the solenoid valve is opened. The high-
pressure fuel is dumped through the spill port, to the fuel return manifold and then to the tank.
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c. The length of time for the injection will meter the fuel that is consumed during the fuel injection
into the cylinder. Injection length is controlled by the governor logic that is programmed into the
electronic control module of the fuel system electronic control circuit.
d. After the maximum lift point is achieved, the force to the top of the unit injector is removed as
spring (1) expands. The plunger returns to the original position. This uncovers the fuel supply
passage to the plunger barrel in order to refill the injector pump body. The low-pressure fuel
circulates through the injector body. The fuel then exits through the spill port. This occurs until
solenoid valve assembly (3) is again energized.
11.2.3 SYSTEM MAINTENANCE
a. Fuel System Inspection:
(1) Check the fuel level in the fuel tank.
(2) Check the vent in the cap for the fuel tank for dirt.
(3) Check the fuel lines for fuel leakage.
(4) Check the fuel lines for a defective bend or a restriction.
(5) Check that the fuel return line has not collapsed within the sections that are exposed to
heat.
(6) Remove any air that may be in the fuel system. Refer to Section 11.3.5 “Fuel System
Priming Procedure”.
b. Fuel System Pressure
(1) The typical fuel pressure of the engine at operating temperature can vary. At low idle,
the fuel pressure can be 45 PSI (310 kPa). At high rpm, the fuel pressure can be 65 PSI
(448 kPa). The check valve is designed to open between 60 PSI (413 kPa) and 65 PSI
(448 kPa). This will control the fuel system pressure. The fuel transfer pump contains
an internal relief valve that is designed to open around 90 PSI (620 kPa). This valve will
not open during normal operation.
(2) The performance of the unit injector deteriorates when the fuel pressure drops below 35
PSI (241 kPa). Low power complaints and erratic operation can occur in this situation.
Check for a plugged fuel filter or air in the fuel lines as possible causes for these
problems before replacing fuel system components.
c. Fuel Pressure
(1) To check the engine mounted fuel transfer pump pressure, remove the plug from the fuel
filter base. Install a pressure gauge, and start the engine.
• Tools Needed: The 1U-5470 Engine Pressure Group can be used to check the fuel
pressure of the engine. The engine pressure group includes Special Instruction,
SEHS89O7. This instruction provides information about the usage of the group and
installation of the group to the engine.
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11.3 SERVICE REQUIREMENTS OF THE FUEL SYSTEM
11.3.1 PRIMARY FUEL FILTER
FUEL SHUTOFF VALVE

(SHOWN IN CLOSED POSITION)
PRIMARY FUEL FILTER
FUEL/WATER
SEPARATOR BOWL
FIGURE 11.3.1-1 PRIMARY FUEL FILTER
11.3.1.1 INSPECT THE PRIMARY FUEL FILTER
Inspect the primary fuel assembly for the following conditions using Figure 11.3.1-1 as a reference:
a. Check for fuel leakage.
b. Check for security of attachment.
c. Empty sediment trap daily. See Figure 11.3.1.2-1 for reference.
d. Inspect connecting hoses and fittings for damage and tightness.
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11.3.1.2 SERVICE THE PRIMARY FUEL FILTER
WARNING
REMOVE ALL RINGS, NECKLACES, JEWELERY AND LOOSE CLOTHING.

FAILURE TO DO SO COULD CAUSE SEVERE INJURY OR DEATH.
WARNING
DO NOT PERFORM THE FOLLOWING TASK WHEN THE GENERATOR SET IS

OPERATING. DO NOT TOUCH EXPOSED ELECTRICAL CONNECTION WHEN A
SOURCE OF POWER SUCH AS UTILITY POWER OR ANOTHER GENERATOR SET
IS CONNECTED TO THE LOAD TERMINALS. DEATH OR INJURY MAY RESULT
FROM FAILURE TO OBSERVE THIS WARNING.
WARNING
DIESEL FUEL IS FLAMMABLE (WHEN ATOMIZED) AND MODERATELY TOXIC TO

EYES, SKIN, AND RESPIRATORY TRACT. SKIN AND EYE PROTECTION REQUIRED.
AVOID REPEATED OR PROLONGED CONTACT. USE IN WELL-VENTILATED AREA.
FAILURE TO COMPLY MAY RESULT IN SERIOUS INJURY OR ILLNESS.
WARNING
TURN MAIN FUEL VALVE INTO THE OFF POSITION. IT IS LOCATED IN THE
FRONT ENGINE COMPARTMENT UNDER THE ENGINE MONITORING GAUGES.
CAUTION
CARE MUST BE TAKEN TO ENSURE THAT FLUIDS ARE CONTAINED DURING

PERFORMANCE OF INSPECTION, MAINTENANCE, TESTING, ADJUSTING AND
REPAIR OF THE PU. BE PREPARED TO COLLECT THE FLUID WITH SUITABLE
CONTAINERS BEFORE OPENING ANY COMPARTMENT OR DISASSEMBLY ANY
COMPONENT CONTAINING FLUIDS. DISPOSE OF FLUIDS ACCORDING TO
LOCAL REGULATIONS AND MANDATES.
To service the Primary Fuel Filter, proceed as follows:
a. This maintenance can be performed while the generator set not requiring maintenance is
running and the generator set requiring maintenance has been shutdown.
b. The generator set that requires the maintenance (G1 or G2) has been shut down, and must be
rendered unable to start, and be cool enough for the maintenance to be performed.
Procedures to render a generator set unable to start are:
(1) Shutdown the generator set (G1 or G2) in accordance with Section 5.1.6.1 Shutdown
Generators.
(2) Push to OPEN the Emergency Stop Switch.
(3) Place the Engine Control Switch (ECS) in the OFF position.
(4) Place a DO NOT OPERATE tag on the generator control panel.
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(6) De-energize the Battery Charger.
(7) Disconnect the negative and positive cables from the Battery Bank for the engine due
maintenance.
(8) Place a DO NOT OPERATE tag on the Battery Bank.
(9) Place the generator Circuit Breaker in the LOCK OUT position.
(10) Disconnect the 7P1 and 7P2 Connectors located on the inside panel of the PDC.
(11) Close and Lock the generator set control panel.
function. Place the Fuel Pump Source Switch (S2) into the (G1 or G2 position), for the
generator set not receiving maintenance.
c. Turn-Off the fuel supply to the engine by placing the Fuel Shut-Off Valve to the closed position.
d. The 3456 EPG Engine is equipped with a Primary Fuel Filter and a Bowl. Use Figure 11.3.1-1
and Figure 11.3.1.2-1 for reference. Primary Fuel Filter consists of an Element. The Element
includes the larger upper beveled seal and the smaller lower seal. The Bowl includes the smaller
lower seal.
e. Loosen the Primary Fuel Filter Drain Valve and empty the fuel from the filter into a suitable
container; dispose of the fuel properly. Close the Primary Fuel Filter Drain Valve.
f. Disconnect the Fuel Water Separator Sensor
g. Unscrew the Fuel Filter Bowl and wash the Primary Fuel Filter Bowl with clean diesel fuel. Use
Figure 11.3.1-1 for reference.
h. Unscrew the Primary Fuel Filter Element from the Filter Head Assembly.
i. Clean the gasket-sealing surface of all the old gasket material.
j. Apply clean diesel fuel to the new Primary Fuel Filter Gasket.
NOTE: Do not fill the fuel filters with fuel before installing them. The fuel would not be filtered and
could be contaminated. Contaminated fuel will cause accelerated wear to fuel systems parts.
k. Install the new Primary Fuel Filter. Spin the Primary Fuel Filter onto the Fuel Filter Base. Use
the Rotation Index marks on the filter as a guide for proper tightening. Tighten the filter for an
additional ¾ turn by hand. Do not over tighten the filter.
NOTE: The water separator is under suction during normal engine operation. Ensure that the drain
plug is tightened securely to prevent air from entering the fuel system.
l. Install the clean Fuel Filter Bowl on the Primary Fuel Filter.
m. Install the clean Fuel Water Separator Sensor.
n. Open the fuel tank supply valve.
NOTE: Leaks are difficult to detect while the engine is running. The Primary Fuel Filter/Water
Separator Bowl is under suction. A leak will allow air to enter the fuel. The air in the fuel can
cause low power due to aeration of the fuel. If air enters the fuel, check the components for
over tightening or under tightening.
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o. Start the Engine and check for leaks. Run the engine for one minute. Stop the engine and
check the engine for leaks again.
p. The water the Primary Fuel Filter/Water Separator Bowl removes from the fuel accumulates in the
Water Separator Bowl. A drain valve is part of the bowl. The drain valve allows any water that
accumulates in the bowl to be drained. If the water is not drained when the bowl becomes full, an
increased resistance to fuel flow will result.
PRIMARY FUEL FILTER DRAIN VALVE
FIGURE 11.3.1.2-1 PRIMARY FUEL FILTER DRAIN VALVE
NOTE: 90 inch pounds of torque is required to tighten the bowl to the bottom of the fuel filter
q. Maintenance Schedule for the Primary Fuel Filter is as follows:
• Every 10 hours of operation or daily, drain the water separator bowl as needed.
• Change the Primary Fuel Filter every 250 hours of operation or annually.
• Check Filter Monitoring Panel gauge range. The Primary Fuel Filter must be replaced if 5
PSID is reached.
• Annually, drain sediment from the Fuel Tank.
NOTE: Fuel quality is very important. The fuel supply should be maintained properly and kept free of
contamination by water and sediment. Water contamination of the fuel can be minimized by
obtaining fuel from reliable sources and by draining the fuel tank regularly.
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11.3.2 SECONDARY FUEL FILTER
SECONDARY FUEL FILTER
FIGURE 11.3.2-1 SECONDARY FUEL FILTER
11.3.2.1 INSPECT THE SECONDARY FUEL FILTER
Inspect the Secondary Fuel Filter for the following conditions using Figure 11.3.2-1 as a reference:
a. Check the Filter Head Assembly for leakage.
b. Check hoses connection for leakage and security of attachment.
c. Check the Secondary Fuel Filter Differential Gauge mounted on the Filter Monitoring Panel
Gauge for proper operation and setting. The setpoint for the Secondary Fuel Differential Gauge
is 30 PSID.
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11.3.2.2 SERVICE THE SECONDARY FUEL FILTER
To service the Secondary Fuel Filter, proceed as follows:
Procedures to render a generator set unable to start are: See procedures and warnings in
paragraph 11.3.1.2.
c. Turn-Off the fuel supply by placing the Fuel Shut-Off Valve to the closed position.
d. Unscrew the Secondary Fuel Filter from the Filter Head Assembly and discard properly.
e. Lightly coat the new Secondary Fuel Filter Gasket with clean fuel.
f. Do not pre-fill the Secondary Fuel Filter before installation. Unfiltered fuel will cause damage to
the fuel system.
g. Tighten the new Secondary Fuel Filter until the gasket makes contact with the base; use the
index marks on the filter as a guide, continue to tighten for ¾ of a turn.
h. Fill the Secondary Fuel Filter by priming the fuel system. See Section 11.3.5 for reference.
i. Maintenance Schedule for the Secondary Fuel Filter Element is as follows:
• Change the Secondary Fuel Filter every 250 hours of operation or annually.
• Check the Secondary Fuel Filter Differential Gauge mounted on the Filter Monitoring Panel
Gauge for proper operation and setting. The setpoint for the Secondary Fuel Differential
Gauge is 30 PSID.
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11.3.3 FUEL STRAINER
FUEL STRAINER
FIGURE 11.3.3-1 FUEL STRAINER ASSEMBLY
11.3.3.1 INSPECT THE FUEL STRAINER
Inspect the External Fuel Transfer Pump Assembly for the following conditions using Figure 11.3.3-1 as
a reference:
a. Check the Fuel Lines and Fittings for cracks, leaks, and security of attachment.
b. Check for dirt, dust, oil, or other foreign matter.
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11.3.3.2 SERVICE THE FUEL STRAINER
WARNING
REMOVE ALL RINGS, NECKLACES, JEWELERY AND LOOSE HANGING

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

WARNING

CAUTION

To service the Fuel Strainer, proceed as follows:
a. This maintenance can be performed while the generator set is running.
NOTE: The fuel storage tank on the PU contains enough fuel to operate both engines for
approximately 2 hours. If service requires longer than this time you will receive a low fuel
level alarm and the operator will have to take steps to prevent shutdown.
b. Turn fuel transfer pump off by setting the pump control switch to the center postion
(OFF).
c. Close the Fuel Shut-Off Valve on the External Fuel Manifold before continuing. Failure
to comply may result in serious injury and fuel spill.
d. Unscrew the Cap for the Fuel Strainer. See Figure 11.3.3-1 for reference.
e. Pullout the Fuel Strainer and clean the Fuel Strainer and Cap with clean diesel fuel.
f. Reinstall the Fuel Strainer and Cap.
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g. Open the Fuel Shut-Off Valve on the External Fuel Manifold.
h. Turn the Fuel Transfer Pump on by setting the pump control switch to “A” (Automatic).
i. Maintenance Schedule for the Fuel Strainer Element is as follows:
• Clean the strainer every 250 hours of operation or annually.
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11.3.4 ETHER INJECTION
MOUNTING STRAP
ETHER BOTTLE
PROTECTIVE CAP
FIGURE 11.3.4-1 ETHER INJECTION ASSEMBLY
11.3.4.1 INSPECT THE ETHER INJECTION ASSEMBLY
Inspect the ether injection assembly for the following conditions using Figure 11.3.4-1 as a reference:
a. Check the Ether tank for amount of ether left in the cylinder.
b. Check the Ether tank for security of attachment.
c. Check the Ether lines for damage, kinks, ruptures, or breaks.
d. Check for missing or damaged clamps and brackets and hardware.
11.3.4.2 SERVICE THE ETHER INJECTION ASSEMBLY
WARNING

AND OR DEATH.
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WARNING

WARNING
ETHER IS HIGHLY FLAMMABLE AND TOXIC TO SKIN, EYES, AND RESPIRATORY

TRACT. USE ONLY IN AN ADEQUATELY VENTILATED AREA. SKIN, EYE. AND
RESPIRATORY PROTECTION IS REQUIRED. FAILURE TO COMPLY MAY RESULT
IN SERIOUS INJURY OR ILLNESS.
To Service the Ether Injection Assembly, proceed as follows:
NOTE: When ether injection assembly is not required, remove ether start tank and store in a safe
designated area. The Protective Cap must be installed on the Solenoid Valve when the
Ether Bottle has been removed to prevent contamination and damage to the valve.
a. Remove Ether Bottle from Solenoid Valve and Bottle Clamp. Install the Protective Cap if a new
Bottle is not being installed.
b. Determine the amount of Ether left in the bottle by shaking the bottle back and forth. If there is
fluid in it you will feel it move. If you don’t feel fluid moving back and forth while shaking the
bottle, replace the Ether Bottle with a new one.
c. If required, install new Ether Bottle on the Solenoid Valve Assembly. Tighten the bottle Clamp
wing nut.
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11.3.5 FUEL SYSTEM PRIMING PROCEDURE
WARNING

AND OR DEATH.
WARNING

WARNING

EYES, SKIN, AND RESPIRATORY TRACT. SKIN AND EYE PROTECTION
REQUIRED. AVOID REPEATED OR PROLONGED CONTACT. USE IN WELL-
VENTILATED AREA. FAILURE TO COMPLY MAY RESULT IN SERIOUS INJURY OR
ILLNESS.
CAUTION

Fuel Priming Procedure
Fuel leaked or spilled onto hot surfaces or electrical components can cause
a fire. To help prevent possible injury, turn the start switch off when
changing fuel filters or water separator elements. Clean up fuel spills
immediately.
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NOTICE
Use a suitable container to catch any fuel that might spill. Clean up any spilled
fuel immediately.
NOTICE
Do not allow dirt to enter the fuel system. Thoroughly clean the
area around a fuel system component that will be disconnected.
Fit a suitable cover over disconnected fuel system component.
NOTE: Each time the fuel system is run out of fuel or air is introduced into the system the following
procedure must be followed. Use steps a to c if a filter has been changed for
maintenance. (System is otherwise operable)
a. Turn the Fuel Supply Valve to the on position.
b. Loosen the Air Bleed Cap at rear of Cylinder Head use Figure 11.3.5-1 for reference.
FIGURE 11.3.5-1 CYLINDER HEAD AIR BLEED CAP
c. Unlock and operate the Fuel-Priming Pump until fuel appears at the Air Bleed Cap. Tighten the
Air Bleed Cap. Use Figure 11.3.5-2 for reference.
FIGURE 11.3.5-2 FUEL PRIMING PUMP
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d. Loosen the fuel system Air Bleed Plug two full turns. Continue operating the Fuel Priming Pump
until fuel appears at Air Bleed Plug. Tighten the Air Bleed Plug. Use Figure 11.3.5-3 for
reference.
FIGURE 11.3.5-3 FUEL SYSTEM AIR BLEED PLUG
e. Continue operating the Fuel Priming Pump until a resistance is felt. Push in and re-lock the
Fuel Priming Pump.
f. Start the engine as soon as you can after pressurizing the system. It should start within 15
seconds. If not started after 30 seconds, stop and wait two minutes for the Engine Starter to
cool.
g. Repeat the entire procedure if needed to start the engine.
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11.4 COMPONENT REPAIR PROCEDURES
11.4.1 FUEL SOLENOID VALVE (L3)
The following maintenance procedures are provided for the Fuel Solenoid Valve (L3):
Inspect
Remove
Install
FUEL SOLENOID VALVE

NEW STYLE
FUEL SOLENOID VALVE

OLD STYLE
FIGURE 11.4.1-1 FUEL SOLENOID VALVE (L3) (NEW AND OLD STYLE )
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11.4.1.1 INSPECT THE FUEL SOLENOID VALVE (L3)
Note: There are two versions of the fuel transfer pump assembly, both are interchangeable.
Inspect the Fuel Solenoid Valve for the following conditions using Figure 11.4.1-1 for a reference:
a. Check for Excessive noise or sluggish operation and security of attachment.
b. Check the Fuel Lines and Fittings for cracks, leaks, and security of attachment.
c. Check the Fuel Solenoid Valve for broken or frayed wires and evidence of overheating.
d. Check for dirt, dust, oil, or other foreign matter.
11.4.1.2 REMOVE THE FUEL SOLENOID VALVE (L3)
WARNING

AND OR DEATH.
WARNING

WARNING

CAUTION

To remove the Fuel Solenoid Valve (L3), proceed as follows:
a. This maintenance requires that the PU MUST be shutdown, rendered unable to start, cool
enough for the maintenance to be performed, and Communication Cable (A) and (B)
rerouted to the next PU. This is accomplished by performing the following:
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(4) Push to open both Emergency Stop Switches.
b. Shut off respective hand valve on External Fuel Transfer Distribution Manifold.
c. Place a drain pan under the External Fuel Transfer Hose connection point at the PU.
d. Disconnect the supply fuel hose, then plug the hose to prevent contamination of the fuel system.
e. Place a cap fitting on the Fuel Strainer to protect against contamination.
f. Tag and disconnect the Solenoid Valve wires from inside the External Fuel Transfer Pump
Controls. Use FO – 43A through FO – 44C for reference.
g. Remove the 4 bolts securing the External Fuel Transfer Pump Assembly to fuel tank.
h. Slide the External Fuel Transfer Pump Assembly forward several inches.
i. Place a drain pan under the Solenoid Valve.
j. Disconnect the fuel lines on either side of the Solenoid Valve and drain the fuel.
k. Remove the mounting hardware securing the Solenoid Valve to the bracket.
l. Remove the Solenoid Valve.
m. Remove electrical connection conduit and elbow.
11.4.1.3 INSTALL THE FUEL SOLENOID VALVE (L3)
To install the Fuel Solenoid Valve (L3), proceed as follows:
rerouted to the next PU. See procedures and warnings in paragraph 11.3.4.2.
b. Attach the conduit elbow to the Solenoid Valve.
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c. Attach the longer leads to the Solenoid Coil.
d. Slip the Flex Conduit over the wires and secure at the elbow.
e. Position the Solenoid Valve on the bracket and secure with the previously removed mounting
hardware.
f. Attach the External Fuel Transfer Pump Assembly to the fuel tank with the previously removed 4
bolts and washers.
g. Using Teflon tape or sealing compound, connect the hose from the fuel pump to the solenoid
valve. Connect the remaining fuel hose to the Solenoid Valve at the flare joint.
h. Un-cap the External Fuel Manifold Hose and Fuel Strainer and connect the External Fuel
Manifold Hose to the PU.
i. Connect the Solenoid Valve wires inside the External Fuel Transfer Pump Controls. Use FO –
43A through FO – 44C for reference. Remove the wire tags.
j. Open the External Fuel Distribution Manifold valve.
k. After installing the Fuel Solenoid Valve, prepare the PU for operation and inspect the Fuel
Solenoid Valve according to Section 11.4.1.1.
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11.4.2 EXTERNAL FUEL TRANSFER PUMP ASSEMBLY
The following maintenance procedures are provided for the External Fuel Transfer Pump Assembly:
Inspect
Test
Remove
Install
POSITIVE DISPLACEMENT PUMP
24VDC FUEL TRANSFER PUMP MOTOR
POSITIVE DISPLACEMENT PUMP
24VDC FUEL TRANSFER PUMP MOTOR
FIGURE 11.4.2-1 FUEL TRANSFER PUMP ASSEMBLY (NEW AND OLD STYLE)
The Fuel Transfer Pump is 24VDC, 1/3 hp and 2.25 GPM. The Fuel Transfer Pump works in conjunction
with the Fuel Level Float Switches and Fuel Transfer Solenoid Valve. Use Figure 11.4.2-1 for reference.
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11.4.2.1 INSPECT THE EXTERNAL FUEL TRANSFER PUMP ASSEMBLY
Inspect the External Fuel Transfer Pump Assembly for the following conditions using Figure 11.4.2-1 for
reference:
a. Check for Excessive noise or sluggish operation and security of attachment.
b. Check the Fuel Lines and Fittings for cracks, leaks, and security of attachment.
c. Check the External Fuel Transfer Pump Motor for broken or frayed wires and evidence of
overheating.
d. Check for dirt, dust, oil, or other foreign matter.
11.4.2.2 TEST THE EXTERNAL FUEL TRANSFER PUMP ASSEMBLY
To test the External Fuel Transfer Pump Assembly, proceed as follows:
a. Place the fuel transfer pump control switch to the TEST position. Observe the fuel transfer
pump operating. Release the toggle switch. If the pump does not operate proceed with the next
step.
b. With a multimeter on the VDC Scale, check for voltage at the motor terminals. If there is voltage
between 18 to 24 volts and the motor is not operating, this indicates a defective motor, replace
the motor.
11.4.2.3 REMOVE THE EXTERNAL FUEL TRANSFER PUMP ASSEMBLY
WARNING

AND OR DEATH.
WARNING

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WARNING

ILLNESS.
CAUTION

To remove the External Fuel Transfer Pump Assembly, proceed as follows:

b. Tag and disconnect the wiring from the External Fuel Transfer Pump Assembly.
c. Remove the fuel lines.
d. Remove External Fuel Transfer Pump Assembly by removing machine bolts, washers, and lock
washers.
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11.4.2.4 INSTALL THE EXTERNAL FUEL TRANSFER PUMP ASSEMBLY
To install the External Fuel Transfer Pump Assembly, proceed as follows:
b.. Place the Fuel Transfer Pump in mounted position then, reinstall the mounting hardware.
c. Reconnect the fuel lines.
d. Remove tags and connect wiring to the External Fuel Transfer Pump Assembly.
d. Reconnect the batteries.
e. Test the Fuel Transfer Pump for operation.
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11.4.3 FUEL PRIMER PUMP
The following maintenance procedures are provided for the Fuel Primer Pump:
Inspect
Remove
Install
MOUNTING BOLTS
FUEL PRIMER PUMP
MOUNTING BOLTS
FIGURE 11.4.3-1 FUEL PRIMER PUMP
11.4.3.1 INSPECT THE FUEL PRIMER PUMP
Inspect the Fuel Primer Pump for the following conditions using Figure 11.4.3-1 for a reference:
b. Check for dirt, dust, oil, or other foreign matter that could damage the pump.
c. Check for damage, and loose connections.
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11.4.3.2 REMOVE THE FUEL PRIMER PUMP
WARNING

AND OR DEATH.
WARNING

WARNING

CAUTION

To remove the Fuel Primer Pump, perform the following:
Generators.
maintenance.
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function. Place the Fuel Pump Source Switch (FPSS) into the (G1 or G2 position), for the
generator set not receiving maintenance.
c. Remove the two mounting bolts.
d. Separate the Fuel Primer Pump from the Fuel Primer Pump Base.
e. Clean gasket material from mating surfaces.
11.4.3.3 INSTALL THE FUEL PRIMER PUMP
To install the Fuel Primer Pump, perform the following:
rendered unable to start, and be cool enough for the maintenance to be performed. See
Procedures and warnings in paragraph 11.4.3.2
c. Install a new gasket on the Fuel Primer Pump Base.
d. Place the Fuel Primer Pump in position on the Fuel Primer Pump Base. Make sure the gasket is
in the proper position then reinstall and tighten the mounting bolts. Torque to 21 + 5 Ft-Lbs (28
+ 7 Nm).
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11.4.4 ENGINE MOUNTED FUEL PUMP
The following maintenance procedures are provided for the Engine Mounted Fuel Pump:
Inspect
Remove
Install
2
4
FIGURE 11.4.4-1 ENGINE MOUNTED FUEL PUMP
11.4.4.1 INSPECT THE ENGINE MOUNTED FUEL PUMP
Inspect the Engine Mounted Fuel Pump for the following:
c. Check for damage, and loose connections.
NOTE: This procedure is covered in the Caterpillar Manual SENR1068-01, or later version
SMCS CODE 1256-010.
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11.4.4.2 REMOVE THE ENGINE MOUNTED FUEL PUMP
WARNING

AND OR DEATH.
WARNING

WARNING

CAUTION

To remove the Engine Mounted Fuel Pump, proceed as follows:
Generators.
maintenance.
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c. Remove the fuel lines (1) and (2). Refer to Figure 11.4.4-1 for reference.
d. Plug and cap all openings to prevent fuel system contamination.
e. Remove the mounting bolts (3) and the Engine Mounted Fuel Pump (4).
f. Check condition of the O-ring seal on the Engine Mounted Fuel Pump. If the O-ring seal is worn
or damaged, replace with a new seal.
11.4.4.3 INSTALL THE ENGINE MOUNTED FUEL PUMP
To install the Engine Mounted Fuel Pump, proceed as follows:
rendered unable to start, and be cool enough for the maintenance to be performed. See
procedures and warnings in paragraph 11.4.4.2.
c. Place the O-ring seal on the Engine Mounted Fuel Pump. If the O-ring seal is worn or damaged,
replace with a new seal. Put clean engine oil on the O-ring seal. Refer to Figure 11.4.4-1 for
reference.
d. Put the Engine Mounted Fuel Pump (4) into position, and Reinstall the mounting bolts (3) that
hold the Engine Mounted Fuel Transfer Pump into place.
e. Remove the protective caps from the Engine Mounted Fuel Pump openings. Reinstall the fuel
lines (1) and (2).
NOTE: Refer to Caterpillar Manual SENR3130-06 or later version for torque specifications.
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11.4.5 FUEL FLOAT SWITCH ASSEMBLY
FIGURE 11.4.5-1 FUEL FLOAT SWITCHES
The fuel tank float switch assembly is located in the top of the fuel tank. The switches are used to turn the
fuel transfer pump on and off and give a warning indication if fuel is low or high, and unit timed shutdown
before the PU runs out of fuel. The External Fuel Transfer Pump is turned off if fuel level is too high. Use
Figure 11.4.5-1 for reference.
There are four Fuel Float Switches mounted inside of the 120-gallon fuel tank. The Fuel Float Switches
are mounted in the fuel tank at the end of tubes whose lengths are determined by specific fuel level.
A. Low Fuel Level Alarm Switch/Timed shutdown: Functions at 20% Fuel.
B. Fuel Transfer Pump Start Switch: Functions at 40% Fuel.
C. Fuel Transfer Pump Stop Switch: Functions at 90% Fuel.
D. High Fuel Level Alarm Switch: Functions at 95% Fuel.
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11.4.5.1 INSPECT THE FUEL FLOAT SWITCH ASSEMBLY
Inspect the Fuel Float Switch Assembly for the following:
c. Check for damage, and loose electrical and mechanical connections.
11.4.5.2 TEST THE FUEL FLOAT SWITCH ASSEMBLY
WARNING

AND OR DEATH.
WARNING

WARNING

ILLNESS.
CAUTION

To test the Fuel Float Switch Assembly, proceed as follows:

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b. Leave the switches mounted to the Inspection Plate for testing.
c. Disconnect the two switch wires for each switch. Refer to FO-43A, FO-43B, FO-44A, FO-44B
and FO44C for reference.
d. Using a multimeter set to OHMS (Ω) Rx1 scale, test switch’s wires for contact continuity in the
switch positions specified. Multimeter should indicate zero ohms at points marked in chart as
shown in Table 11.4.5-1.
e. Multimeter should indicate infinite ohms at all open contacts in chart as shown in Table 11.4.5-1.
f. Replace any Fuel Float Switch if it fails any of the above requirements.
TABLE 11.4.5-1 FFS CONTACT POSITION

S3 S4 S5 S6
FLOAT (START) (STOP) (HFTL) (LFTL)
POSITION MINIMUM FUEL MAXIMUM FUEL HIGH FUEL TANK LOW FUEL TANK
LEVEL SWITCH LEVEL SWITCH LEVEL SWITCH LEVEL SWITCH
NORMALLY
X
OPEN
NORMALLY
X X X
CLOSED
11.4.5.3 REMOVE THE FUEL FLOAT SWITCH ASSEMBLY
To remove the Fuel Float Switch Assembly, proceed as follows:
b. Remove the 2 retaining screws from the cover of the Fuel Float Assembly and remove cover.
c. Remove the 8 mounting bolts from the inspection cover.
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d. Tag and disconnect the Fuel Float Switch (FFS). Refer to FO-43A, FO-43B, FO-44A, FO-44B
and FO44C for reference.
e. Remove the Inspection Cover from the fuel tank.
f. Remove the Fuel Float Switch Assembly.
g. Remove the Fuel Float Switch by unscrewing them from their mounting tubes, and then pulling
the wiring out of the mounting tubes.
11.4.5.4 INSTALL THE FUEL FLOAT SWITCH ASSEMBLY
To install the Fuel Float Switch Assembly, proceed as follows:
b. If any of the Fuel Float Switches were replaced, start by reinstalling the Fuel Float Switch (FFS)
by pushing the Fuel Float Switch wiring into the mounting tubes then by screwing them to the
mounting tubes.
c. Reinstall the Fuel Float Switch Assembly.
d. Reinstall the inspection cover and Reinstall the 8 mounting bolts.
e. Connect and remove the tags of the Fuel Float Switch (FFS). Refer to FO-43A, FO-43B, FO-
44A, FO-44B and FO44C for reference.
f. Reinstall the 2 retaining screws from the electrical inspection plate mounted on the fuel tank
inspection cover.
g. Test Fuel Float Switch Assembly for operation.
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CHAPTER 12
CONTROLS AND INSTRUMENTS REPAIR
TABLE OF CONTENTS
SECTION TITLE PAGE

12.0 CONTROLS AND INSTRUMENTS REPAIR 13
12.1 SAFETY INSTRUCTIONS 13
12.2 BRIEF DESCRIPTION 14
12.3 SERVICE REQUIREMENTS 14
12.4 COMPONENT REPAIR PROCEDURES 15
12.4.1 ENGINE CONTROL DEVICES 15
12.4.1.1 COOLANT TEMPERATURE SENSOR 16
12.4.1.1.1 INSPECT COOLANT TEMPERATURE SENSOR 16
12.4.1.1.2 TEST COOLANT TEMPERATURE SENSOR 16
12.4.1.1.3 REMOVE COOLANT TEMPERATURE SENSOR 17
12.4.1.1.4 INSTALL COOLANT TEMPERATURE SENSOR 18
12.4.1.2 COOLANT LEVEL SENSOR 20
12.4.1.2.1 INSPECT COOLANT LEVEL SENSOR 20
12.4.1.2.2 TEST COOLANT LEVEL SENSOR 21
12.4.1.2.3 REMOVE COOLANT LEVEL SENSOR 21
12.4.1.2.4 INSTALL COOLANT LEVEL SENSOR 22
12.4.1.3 FILTERED ENGINE OIL PRESSURE SENSOR 24
12.4.1.3.1 INSPECT FILTERED ENGINE OIL PRESSURE SENSOR 24
12.4.1.3.2 TEST FILTERED ENGINE OIL PRESSURE SENSOR 25
12.4.1.3.3 REMOVE FILTERED ENGINE OIL PRESSURE SENSOR 25
12.4.1.4 FLYWHEEL MOUNTED ENGINE SPEED SENSOR 27
12.4.1.4.1 INSPECT FLYWHEEL MOUNTED ENGINE SPEED SENSOR 27
12.4.1.4.2 REMOVE FLYWHEEL MOUNTED ENGINE SPEED SENSOR 28
12.4.1.4.3 INSTALL FLYWHEEL MOUNTED ENGINE SPEED SENSOR 30
12.4.1.5 COLD START STRATEGY 31
12.4.1.6 ENGINE SPEED GOVERNING 31
12.4.1.7 PASSIVE SPEED/TIMING SENSORS 32
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12.4.1.7.1 INSPECT PASSIVE SPEED/TIMING SENSORS 32

12.4.1.7.2 TEST PASSIVE SPEED/TIMING SENSORS 33
12.4.1.7.3 REMOVE PASSIVE SPEED/TIMING SENSORS 33
12.4.1.7.4 INSTALL PASSIVE SPEED/TIMING SENSORS 35
12.4.1.8 INLET MANIFOLD AIR TEMPERATURE SENSOR 36
12.4.1.8.1 INSPECT INLET MANIFOLD AIR TEMPERATURE SENSOR 36
12.4.1.8.2 TEST INLET MANIFOLD AIR TEMPERATURE SENSOR 37
12.4.1.8.3 REMOVE INLET MANIFOLD AIR TEMPERATURE SENSOR 37
12.4.1.8.4 INSTALL INLET MANIFOLD AIR TEMPERATURE SENSOR 38
12.4.1.9 TURBOCHARGER COMPRESSOR OUTLET PRESSURE SENSOR 39
12.4.1.9.1 INSPECT TURBOCHARGER COMPRESSOR OUTLET PRESSURE SENSOR 39
12.4.1.9.2 TEST TURBOCHARGER COMPRESSOR OUTLET PRESSURE SENSOR 40
12.4.1.9.3 REMOVE TURBOCHARGER COMPRESSOR OUTLET PRESSURE SENSOR 40
12.4.1.9.4 INSTALL TURBOCHARGER COMPRESSOR OUTLET PRESSURE SENSOR 42
12.4.1.10 ATMOSPHERIC PRESSURE SENSOR 43
12.4.1.10.1 INSPECT ATMOSPHERIC PRESSURE SENSOR 43
12.4.1.10.2 TEST ATMOSPHERIC PRESSURE SENSOR 44
12.4.1.10.3 REMOVE ATMOSPHERIC PRESSURE SENSOR 44
12.4.1.10.4 INSTALL ATMOSPHERIC PRESSURE SENSOR 45
12.4.1.11 FUEL TEMPERATURE SENSOR 46
12.4.1.11.1 INSPECT FUEL TEMPERATURE SENSOR 46
12.4.1.11.2 TEST FUEL TEMPERATURE SENSOR 47
12.4.1.11.3 REMOVE FUEL TEMPERATURE SENSOR 47
12.4.1.11.4 INSTALL FUEL TEMPERATURE SENSOR 48
12.4.1.12 ENGINE DIAGNOSTICS 49
12.4.1.12.1 SELF-DIAGNOSTICS 49
12.4.1.12.2 PERMANENT FAULT LOGGING 49
12.4.1.12.3 ENGINE OPERATION WITH ACTIVE DIAGNOSTIC CODES 49
12.4.1.13 FILTER MONITORING PANEL 51
12.4.1.13.1 INSPECT FILTER MONITORING PANEL 52
12.4.1.13.2 REMOVE FILTER MONITORING PANEL 52
12.4.1.13.3 INSTALL FILTER MONITORING PANEL 53
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12.4.1.13.4 SERVICE FILTER MONITORING PANEL 54

12.4.2 PDC CONTROLS AND INSTRUMENTS 55
12.4.2.1 GENERATOR CONTROL PANEL CONTROLS AND INSTRUMENTS 56
12.4.2.1.1 GENERATOR SET CONTROLLER (GSC+) 57
12.4.2.1.1.1 INSPECT GENERATOR SET CONTROLLER (GSC+) 58
12.4.2.1.1.2 TEST GENERATOR SET CONTROLLER (GSC+) 58
12.4.2.1.1.3 REMOVE GENERATOR SET CONTROLLER (GSC+) 58
12.4.2.1.1.4 INSTALL GENERATOR SET CONTROLLER (GSC+) 59
12.4.2.1.1.5 GSC+ SET POINTS 59
12.4.2.1.2 GENERATOR / FEEDER OVERCURRENT RELAY 60
12.4.2.1.2.1 INSPECT GENERATOR / FEEDER OVERCURRENT RELAY 62
12.4.2.1.2.2 TEST GENERATOR / FEEDER OVERCURRENT RELAY 62
12.4.2.1.2.3 REMOVE GENERATOR / FEEDER OVERCURRENT RELAY 62
12.4.2.1.2.4 INSTALL GENERATOR / FEEDER OVERCURRENT RELAY 63
12.4.2.1.2.5 SERVICE GENERATOR / FEEDER OVERCURRENT RELAY 63
12.4.2.1.2.6 OVERCURRENT RELAY SET POINTS 64
12.4.2.1.3 GENERATOR AND FEEDER BREAKER CONTROL SWITCHES (BCS) 65
12.4.2.1.3.1 INSPECT GENERATOR AND FEEDER BREAKER CONTROL SWITCHES 66
12.4.2.1.3.2 TEST GENERATOR AND FEEDER BREAKER CONTROL SWITCHES 66
12.4.2.1.3.3 REMOVE GENERATOR AND FEEDER BREAKER CONTROL SWITCHES 68
12.4.2.1.3.4 INSTALL GENERATOR AND FEEDER BREAKER CONTROL SWITCHES 68
12.4.2.1.4 ENGINE CONTROL SWITCH (ECS) 69
12.4.2.1.4.1 INSPECT ENGINE CONTROL SWITCH (ECS) 70
12.4.2.1.4.2 TEST ENGINE CONTROL SWITCH (ECS) 70
12.4.2.1.4.3 REMOVE ENGINE CONTROL SWITCH (ECS) 71
12.4.2.1.4.4 INSTALL ENGINE CONTROL SWITCH (ECS) 72
12.4.2.1.5 EMERGENCY STOP PUSHBUTTON (ESPB) 73
12.4.2.1.5.1 INSPECT EMERGENCY STOP PUSHBUTTON (ESPB) 73
12.4.2.1.5.2 TEST EMERGENCY STOP PUSHBUTTON (ESPB) 74
12.4.2.1.5.3 REMOVE EMERGENCY STOP PUSHBUTTON (ESPB) 75
12.4.2.1.5.4 INSTALL EMERGENCY STOP PUSHBUTTON (ESPB) 75
12.4.2.1.6 EMERGENCY STOP ACTUATOR (ESA) 76
12-3
USAF TO 35C2-3-518-1
USA TM 9-6115-484-14
12.4.2.1.6.1 INSPECT EMERGENCY STOP ACTUATOR (ESA) 76

12.4.2.1.6.2 TEST EMERGENCY STOP ACTUATOR (ESA) 77
12.4.2.1.6.3 REMOVE EMERGENCY STOP ACTUATOR (ESA) 78
12.4.2.1.6.4 INSTALL EMERGENCY STOP ACTUATOR (ESA) 78
12.4.2.1.7 AUTOMATIC VOLTAGE REGULATOR (AVR) 79
12.4.2.1.7.1 INSPECT AUTOMATIC VOLTAGE REGULATOR (AVR) 83
12.4.2.1.7.2 TEST AUTOMATIC VOLTAGE REGULATOR (AVR) 83
12.4.2.1.7.3 REMOVE AUTOMATIC VOLTAGE REGULATOR (AVR) 83
12.4.2.1.7.4 INSTALL AUTOMATIC VOLTAGE REGULATOR (AVR) 84
12.4.2.1.7.5 SERVICE AUTOMATIC VOLTAGE REGULATOR (AVR) 85
12.4.2.2 MASTER CONTROL PANEL 86
12.4.2.2.1 SYNCHROSCOPE / SYNCH-CHECK RELAY (SC/25M) 87
12.4.2.2.1.1 INSPECT SYNCHROSCOPE / SYNCH-CHECK RELAY (SC/25M) 88
12.4.2.2.1.2 TEST SYNCHROSCOPE / SYNCH-CHECK RELAY (SC/25M) 88
12.4.2.2.1.3 REMOVE SYNCHROSCOPE / SYNCH-CHECK RELAY (SC/25M) 88
12.4.2.2.1.4 INSTALL SYNCHROSCOPE / SYNCH-CHECK RELAY (SC/25M) 89
12.4.2.2.2 TIE OVERCURRENT RELAY 90
12.4.2.2.2.1 INSPECT TIE OVERCURRENT RELAY 92
12.4.2.2.2.2 TEST TIE OVERCURRENT RELAY 92
12.4.2.2.2.3 REMOVE TIE OVERCURRENT RELAY 92
12.4.2.2.2.4 INSTALL TIE OVERCURRENT RELAY 93
12.4.2.2.2.5 SERVICE TIE OVERCURRENT RELAY 93
12.4.2.2.2.6 OVERCURRENT RELAY SET POINTS 94
12.4.2.2.3 BUS VOLT / FREQUENCY METER 95
12.4.2.2.3.1 INSPECT BUS VOLT / FREQUENCY METER 95
12.4.2.2.3.2 TEST BUS VOLT / FREQUENCY METER 96
12.4.2.2.3.3 REMOVE BUS VOLT/FREQUENCY METER 96
12.4.2.2.3.4 INSTALL BUS VOLT / FREQUENCY METER 97
12.4.2.2.3.5 SERVICE BUS VOLT/FREQUENCY METER 98
12.4.2.2.4 TIE BREAKER CONTROL SWITCH (BCST) 100
12.4.2.2.4.1 INSPECT TIE BREAKER CONTROL SWITCH (BCST) 101
12.4.2.2.4.2 TEST TIE BREAKER CONTROL SWITCH (BCST) 101
12-4
USAF TO 35C2-3-518-1
USA TM 9-6115-484-14
12.4.2.2.4.3 REMOVE TIE BREAKER CONTROL SWITCH (BCST) 103

12.4.2.2.4.4 INSTALL TIE BREAKER CONTROL SWITCH (BCST) 103
12.4.2.2.5 SYSTEM MODE SWITCH (SMS) 104
12.4.2.2.5.1 INSPECT SYSTEM MODE SWITCH (SMS) 105
12.4.2.2.5.2 TEST SYSTEM MODE SWITCH (SMS) 105
12.4.2.2.5.3 REMOVE SYSTEM MODE SWITCH (SMS) 106
12.4.2.2.5.4 INSTALL SYSTEM MODE SWITCH (SMS) 107
12.4.2.2.6 SYSTEM SYNCHRONIZING SWITCH (SSS) 108
12.4.2.2.6.1 INSPECT SYSTEM SYNCHRONIZING SWITCH (SSS) 108
12.4.2.2.6.2 TEST SYSTEM SYNCHRONIZING SWITCH (SSS) 109
12.4.2.2.6.3 REMOVE SYSTEM SYNCHRONIZING SWITCH (SSS) 111
12.4.2.2.6.4 INSTALL SYSTEM SYNCHRONIZING SWITCH (SSS) 111
12.4.2.2.7 GENERATOR MODE SWITCH (GMS) 112
12.4.2.2.7.1 INSPECT GENERATOR MODE SWITCH (GMS) 112
12.4.2.2.7.2 TEST GENERATOR MODE SWITCH (GMS) 113
12.4.2.2.7.3 REMOVE GENERATOR MODE SWITCH (GMS) 114
12.4.2.2.7.4 INSTALL GENERATOR MODE SWITCH (GMS) 114
12.4.2.2.8 MASTER SYSTEM ENABLE SWITCH (MSES) 115
12.4.2.2.8.1 INSPECT MASTER SYSTEM ENABLE SWITCH (MSES) 116
12.4.2.2.8.2 TEST MASTER SYSTEM ENABLE SWITCH (MSES) 116
12.4.2.2.8.3 REMOVE MASTER SYSTEM ENABLE SWITCH (MSES) 117
12.4.2.2.8.4 INSTALL MASTER SYSTEM ENABLE SWITCH (MSES) 117
12.4.2.2.9 BATTLESHORT SWITCH (BSS) 118
12.4.2.2.9.1 INSPECT BATTLESHORT SWITCH (BSS) 118
12.4.2.2.9.2 TEST BATTLESHORT SWITCH (BSS) 119
12.4.2.2.9.3 REMOVE BATTLESHORT SWITCH (BSS) 120
12.4.2.2.9.4 INSTALL BATTLESHORT SWITCH (BSS) 120
12.4.2.2.10 AUTOMATIC VOLTAGE REGULATOR SWITCH (AVRS) 121
12.4.2.2.10.1 INSPECT AUTOMATIC VOLTAGE REGULATOR SWITCH (AVRS) 121
12.4.2.2.10.2 TEST AUTOMATIC VOLTAGE REGULATOR SWITCH (AVRS) 122
12.4.2.2.10.3 REMOVE AUTOMATIC VOLTAGE REGULATOR SWITCH (AVRS) 123
12.4.2.2.10.4 INSTALL AUTOMATIC VOLTAGE REGULATOR SWITCH (AVRS) 123
12-5
USAF TO 35C2-3-518-1
USA TM 9-6115-484-14
12.4.2.2.11 UNIT SELECTOR SWITCH (USS) 124

12.4.2.2.11.1 INSPECT UNIT SELECTOR SWITCH (USS) 125
12.4.2.2.11.2 TEST UNIT SELECTOR SWITCH (USS) 125
12.4.2.2.11.3 REMOVE UNIT SELECTOR SWITCH (USS) 127
12.4.2.2.11.4 INSTALL UNIT SELECTOR SWITCH (USS) 127
12.4.2.2.12 UNIT SELECTOR INDICATORS (USI) 128
12.4.2.2.12.1 INSPECT UNIT SELECTOR INDICATORS (USI) 128
12.4.2.2.12.2 TEST UNIT SELECTOR INDICATORS (USI) 128
12.4.2.2.12.3 REMOVE UNIT SELECTOR INDICATORS (USI) 129
12.4.2.2.12.4 INSTALL UNIT SELECTOR INDICATORS (USI) 130
12.4.2.2.13 BUZZER SILENCE PUSHBUTTON (SIL) 131
12.4.2.2.13.1 INSPECT BUZZER SILENCE PUSHBUTTON (SIL) 132
12.4.2.2.13.2 TEST BUZZER SILENCE PUSHBUTTON (SIL) 132
12.4.2.2.13.3 REMOVE BUZZER SILENCE PUSHBUTTON (SIL) 133
12.4.2.2.13.4 INSTALL BUZZER SILENCE PUSHBUTTON (SIL) 134
12.4.2.2.14 SYSTEM STATUS LIGHT (SSL) 135
12.4.2.2.14.1 INSPECT SYSTEM STATUS LIGHT (SSL) 136
12.4.2.2.14.2 TEST SYSTEM STATUS LIGHT (SSL) 136
12.4.2.2.14.3 REMOVE SYSTEM STATUS LIGHT (SSL) 137
12.4.2.2.14.4 INSTALL SYSTEM STATUS LIGHT (SSL) 138
12.4.2.2.15 50/60 HERTZ INDICATOR LIGHTS 139
12.4.2.2.15.1 INSPECT 50/60 HERTZ INDICATOR LIGHTS 139
12.4.2.2.15.2 TEST 50/60 HERTZ INDICATOR LIGHTS 140
12.4.2.2.15.3 REMOVE 50/60 HERTZ INDICATOR LIGHTS 140
12.4.2.2.15.4 INSTALL 50/60 HERTZ INDICATOR LIGHTS 141
12.4.2.2.16 PHASE ROTATION TEST LIGHTS (PRL) 142
12.4.2.2.16.1 INSPECT PHASE ROTATION TEST LIGHTS (PRL) 143
12.4.2.2.16.2 TEST PHASE ROTATION TEST LIGHTS (PRL) 143
12.4.2.2.16.3 REMOVE PHASE ROTATION TEST LIGHTS (PRL) 144
12.4.2.2.16.4 INSTALL PHASE ROTATION TEST LIGHTS (PRL) 146
12.4.2.2.17 ALARM / FAULT BUZZER 147
12.4.2.2.17.1 INSPECT ALARM/FAULT BUZZER 149
12-6
USAF TO 35C2-3-518-1
USA TM 9-6115-484-14
12.4.2.2.17.2 TEST ALARM/FAULT BUZZER 149

12.4.2.2.17.3 REMOVE ALARM/FAULT BUZZER 150
12.4.2.2.17.4 INSTALL ALARM/FAULT BUZZER 152
12.4.3 CONTROLS AND INSTRUMENTS WITHIN CABINET A, B, AND C 153
12.4.3.1 FREQUENCY SELECTOR SWITCH (FSS) 153
12.4.3.1.1 INSPECT FREQUENCY SELECTOR SWITCH (FSS) 154
12.4.3.1.2 TEST FREQUENCY SELECTOR SWITCH (FSS) 154
12.4.3.1.3 REMOVE FREQUENCY SELECTOR SWITCH (FSS) 155
12.4.3.1.4 INSTALL FREQUENCY SELECTOR SWITCH (FSS) 155
12.4.3.2 AUTOMATIC SYNCHRONIZER (SPMA) 156
12.4.3.2.1 INSPECT AUTOMATIC SYNCHRONIZER (SPMA) 157
12.4.3.2.2 TEST AUTOMATIC SYNCHRONIZER (SPMA) 157
12.4.3.2.3 REMOVE AUTOMATIC SYNCHRONIZER (SPMA) 157
12.4.3.2.4 INSTALL AUTOMATIC SYNCHRONIZER (SPMA) 158
12.4.3.3 LOAD SHARING MODULE (LSM) 159
12.4.3.3.1 INSPECT LOAD SHARING MODULE (LSM) 160
12.4.3.3.2 TEST LOAD SHARING MODULE (LSM) 160
12.4.3.3.3 REMOVE LOAD SHARING MODULE (LSM) 160
12.4.3.3.4 INSTALL LOAD SHARING MODULE (LSM) 161
12.4.3.4 REMOTE TERMINAL UNIT (RTU) 162
12.4.3.4.1 INSPECT REMOTE TERMINAL UNIT (RTU) 163
12.4.3.4.2 TEST REMOTE TERMINAL UNIT (RTU) 164
12.4.3.4.3 REMOVE REMOTE TERMINAL UNIT (RTU) 165
12.4.3.4.4 INSTALL REMOTE TERMINAL UNIT (RTU) 166
12.4.3.4.4.1 INSTALL RTU SOFTWARE (NEW INSTALL) 167
12.4.3.5 MODULAR DIN RAIL (I/O) 193
12.4.3.5.1 INSPECT MODULAR DIN RAIL (I/O) 194
12.4.3.5.2 TEST MODULAR DIN RAIL (I/O) 194
12.4.3.5.3 REMOVE MODULAR DIN RAIL (I/O) 195
12.4.3.5.4 INSTALL MODULAR DIN RAIL (I/O) 196
12.4.3.6 HUB 197
12.4.3.6.1 INSPECT HUB 197
12-7
USAF TO 35C2-3-518-1
USA TM 9-6115-484-14
12.4.3.6.2 TEST HUB 198

12.4.3.6.3 REMOVE HUB 198
12.4.3.6.4 INSTALL HUB 199
12.4.3.7 PROTOCOL COMMUNICATION MODULE (PCM) 200
12.4.3.7.1 INSPECT PROTOCOL COMMUNICATION MODULE (PCM) 200
12.4.3.7.2 TEST PROTOCOL COMMUNICATION MODULE (PCM) 201
12.4.3.7.3 REMOVE PROTOCOL COMMUNICATION MODULE (PCM) 201
12.4.3.7.4 INSTALL PROTOCOL COMMUNICATION MODULE (PCM) 202
12.4.3.8 CUSTOMER COMMUNICATION MODULE (CCM) 203
12.4.3.8.1 INSPECT CUSTOMER COMMUNICATION MODULE (CCM) 203
12.4.3.8.2 TEST CUSTOMER COMMUNICATION MODULE (CCM) 204
12.4.3.8.3 REMOVE CUSTOMER COMMUNICATION MODULE (CCM) 204
12.4.3.8.4 INSTALL CUSTOMER COMMUNICATION MODULE (CCM) 205
12.4.3.8.5 SERVICE CUSTOMER COMMUNICATION MODULE (CCM) 205
12.4.3.9 POWER CONVERTER 206
12.4.3.9.1 POWER CONVERTER (P15) 206
12.4.3.9.1.1 INSPECT POWER CONVERTER (P15) 207
12.4.3.9.1.2 TEST POWER CONVERTER P15 207
12.4.3.9.1.3 REMOVE POWER CONVERTER (P15) 207
12.4.3.9.1.4 INSTALL POWER CONVERTER P15 209
12.4.3.10 TRANSDUCER (XD) 210
12.4.3.10.1 INSPECT TRANSDUCER (XD) 210
12.4.3.10.2 TEST TRANSDUCER (XD) 211
12.4.3.10.3 REMOVE TRANSDUCER (XD) 211
12.4.3.10.4 INSTALL TRANSDUCER (XD) 212
12.4.3.10.5 SERVICE TRANSDUCER (XD) 213
12.4.3.11 AC TRANSFORMER BOX (ATB) 214
12.4.3.11.1 INSPECT AC TRANSFORMER BOX (ATB) 215
12.4.3.11.2 TEST AC TRANSFORMER BOX (ATB) 215
12.4.3.11.3 REMOVE AC TRANSFORMER BOX (ATB) 215
12.4.3.11.4 INSTALL AC TRANSFORMER BOX (ATB) 216
12-8
USAF TO 35C2-3-518-1
USA TM 9-6115-484-14
LIST OF FIGURES
FIGURE TITLE PAGE

FIGURE 12.4.1.1-1 COOLANT TEMPERATURE SENSOR 16
FIGURE 12.4.1.2-1 COOLANT LEVEL SENSORS 20
FIGURE 12.4.1.2.4-1 COOLANT SYSTEM AIR BLEED VALVE 23
FIGURE 12.4.1.3-1 FILTERED ENGINE OIL PRESSURE SENSOR 24
FIGURE 12.4.1.4-1 FLYWHEEL MOUNTED ENGINE SPEED SENSOR 27
FIGURE 12.4.1.4.4-1 FLYWHEEL MOUNTED ENGINE SPEED SENSOR DIAGRAM 30
FIGURE 12.4.1.7-1 ELECTRONIC TIMING SENSOR 32
FIGURE 12.4.1.8-1 AIR INLET TEMPERATURE SENSOR 36
FIGURE 12.4.1.9-1 TURBOCHARGER COMMPRESSOR OUTLET
PRESSURE SENSOR 39
FIGURE 12.4.1.10-1 ATMOSPHERIC PRESSURE SENSOR CONNECTOR 43
FIGURE 12.4.1.11-1 FUEL TEMPERATURE SENSOR 46
FIGURE 12.4.1.13-1 FILTER MONITORING PANEL 51
FIGURE 12.4.2-1 PDC LOCAL CONTROL PANEL (LCP) 55
FIGURE 12.4.2.1-1 GENERATOR CONTROL PANEL CONTROLS / INSTRUMENTS 56
FIGURE 12.4.2.1.1-1 GENERATOR SET CONTROLLER (GSC+) 57
FIGURE 12.4.2.1.2-1 GENERATOR AND FEEDER OVERCURRENT RELAY 60
FIGURE 12.4.2.1.3-1 BREAKER CONTROL SWITCHES 65
FIGURE 12.4.2.1.4-1 ENGINE CONTROL SWITCH (ECS) 69
FIGURE 12.4.2.1.5-1 EMERGENCY STOP PUSHBUTTON (ESPB) 73
FIGURE 12.4.2.1.6-1 EMERGENCY STOP ACTUATOR (ESA) 76
FIGURE 12.4.2.1.7-1 AUTOMATIC VOLTAGE REGULATOR (AVR) 79
FIGURE 12.4.2.1.7-2 AUTOMATIC VOLTAGE REGULATOR (AVR) 81
FIGURE 12.4.2.1.7-3 AUTOMATIC VOLTAGE REGULATOR KEY PAD 82
FIGURE 12.4.2.1.7-4 AUTOMATIC VOLTAGE REGULATOR KEY PAD 85
FIGURE 12.4.2.2-1 MASTER CONTROL PANEL (MCP) 86
FIGURE 12.4.2.2.1-1 SYNCHROSCOPE / SYNCH-CHECK RELAY (SC/25M) 87
FIGURE 12.4.2.2.2-1 TIE OVERCURRENT RELAY 90
FIGURE 12.4.2.2.3-1 BUS VOLT / FREQUENCY METER 95
FIGURE 12.4.2.2.3.5-1 BUS VOLT/FREQUENCY METER
(WITH FRONT COVER REMOVED) 98
FIGURE 12.4.2.2.4-1 TIE BREAKER CONTROL SWITCH (BCST) 100
FIGURE 12.4.2.2.5-1 SYSTEM MODE SWITCH (SMS) 104
FIGURE 12.4.2.2.6-1 SYSTEM SYNCHRONIZING SWITCH (SSS) 108
12-9
USAF TO 35C2-3-518-1
USA TM 9-6115-484-14
FIGURE 12.4.2.2.7-1 GENERATOR MODE SWITCH (GMS) 112

FIGURE 12.4.2.2.8-1 MASTER SYSTEM ENABLE SWITCH (MSES) 115
FIGURE 12.4.2.2.9-1 BATTLESHORT SWITCH (BSS) 118
FIGURE 12.4.2.2.10-1 AUTOMATIC VOLTAGE REGULATOR SWITCH (AVRS) 121
FIGURE 12.4.2.2.11-1 UNIT SELECTOR SWITCH (USS),
UNIT SELECTOR INDICATORS (USI) 124
FIGURE 12.4.2.2.13-1 BUZZER SILENCE PUSHBUTTON (SIL) 131
FIGURE 12.4.2.2.14-1 SYSTEM STATUS LIGHT (SSL) 135
FIGURE 12.4.2.2.15-1 50/60 HERTZ INDICATOR LIGHTS 139
FIGURE 12.4.2.2.16-1 PHASE ROTATION TEST LIGHTS (PRL) 142
FIGURE 12.4.2.2.17-1 ALARM / FAULT BUZZER 147
FIGURE 12.4.3.1-1 FREQUENCY SELECTOR SWITCH (FSS) 153
FIGURE 12.4.3.2-1 AUTOMATIC SYNCHRONIZER (SPMA) 156
FIGURE 12.4.3.3-1 LOAD SHARING MODULE 159
FIGURE 12.4.3.4-1 REMOTE TERMINAL UNIT (RTU) 162
FIGURE 12.4.3.4.4.1-1 IO TOOLKIT ICON 167
FIGURE 12.4.3.4.4.1-2 DEVICE SCREEN 168
FIGURE 12.4.3.4.4.1-3 USE COMM PORT SCREEN 168
FIGURE 12.4.3.4.4.1-4 PDC 1 SCREEN 169
FIGURE 12.4.3.4.4.1-5 NULL MODEM/GENDER CHANGER 169
FIGURE 12.4.3.4.4.1-6 FILE OPERATIONS SCREEN 170
FIGURE 12.4.3.4.4.1-7 RTU CONTENTS SCREEN 170
FIGURE 12.4.3.4.4.1-8 ISA11.X6M SCREEN 171
FIGURE 12.4.3.4.4.1-9 DELETE FILE SCREEN 171
FIGURE 12.4.3.4.4.1-10 FILE DELETED SCREEN 172
FIGURE 12.4.3.4.4.1-11 ACTION. 6TL SCREEN 172
FIGURE 12.4.3.4.4.1-12 CLEAR ACTION TABLE SCREEN 173
FIGURE 12.4.3.4.4.1-13 CLOSE SCREEN 173
FIGURE 12.4.3.4.4.1-14 OPERATIONS SCREEN 174
FIGURE 12.4.3.4.4.1-15 DIRECT CONTROL SCREEN 174
FIGURE 12.4.3.4.4.1-16 CLEAR CONFIGURATION SCREEN 1 175
FIGURE 12.4.3.4.4.1-17 CLEAR CONFIGURATION SCREEN 2 175
FIGURE 12.4.3.4.4.1-18 STATION CONFIGURATION SCREEN 176
FIGURE 12.4.3.4.4.1-19 ADVANCED OPERTIONS SCREEN 177
FIGURE 12.4.3.4.4.1-20 FIRMWARE VERSION SCREEN 178
FIGURE 12.4.3.4.4.1-21 LOAD NOW SCREEN 178
12-10
USAF TO 35C2-3-518-1
USA TM 9-6115-484-14
FIGURE 12.4.3.4.4.1-22 LOADING PROGRESSION SCREEN 179

FIGURE 12.4.3.4.4.1-23 UPGRADE FIRMWARE SCREEN 179
FIGURE 12.4.3.4.4.1-24 DIRECT CONNECT SCREEN 180
FIGURE 12.4.3.4.4.1-25 SELECT FIRMWARE SCREEN 180
FIGURE 12.4.3.4.4.1-26 LOADING FIRMWARE SCREEN 181
FIGURE 12.4.3.4.4.1-27 FIRMWARE LOAD COMPLETE SCREEN 181
FIGURE 12.4.3.4.4.1-28 CONFIGURE STATION SCREEN 182
FIGURE 12.4.3.4.4.1-29 ADVANCED TAB SCREEN 183
FIGURE 12.4.3.4.4.1-30 ASSIGN RESOURCES SCREEN 183
FIGURE 12.4.3.4.4.1-31 SET MEMORY SCREEN 184
FIGURE 12.4.3.4.4.1-32 RESOURCE ALLOCATION SCREEN 185
FIGURE 12.4.3.4.4.1-33 OPERATION/LINK SCREEN 186
FIGURE 12.4.3.4.4.1-34 LINKING INSTRUCTION SCREEN 186
FIGURE 12.4.3.4.4.1-35 MODULES ASSIGNED SCREEN 187
FIGURE 12.4.3.4.4.1-36 MODULE PROGRESSION SCREEN 187
FIGURE 12.4.3.4.4.1-37 LINKING COMPLETE SCREEN 1 188
FIGURE 12.4.3.4.4.1-38 LINKING COMPLETE SCREEN 2 188
FIGURE 12.4.3.4.4.1-39 FILE OPERATIONS SCREEN 189
FIGURE 12.4.3.4.4.1-40 LOAD ISAGRAF SCREEN 189
FIGURE 12.4.3.4.4.1-41 ISAGRAF PROGRAM SCREEN 190
FIGURE 12.4.3.4.4.1-42 APPLI.X6M FILE SCREEN 190
FIGURE 12.4.3.4.4.1-43 LOADING APPLI.X6M FILE SCREEN 191
FIGURE 12.4.3.4.4.1-44 APPLI.X6M FILE COMPLETE SCREEN 191
FIGURE 12.4.3.5-1 MODULAR DIN RAIL I/O DIM 1, DIM 2, DIM 3, DOM 1, DOM 2 193
FIGURE 12.4.3.5-2 MODULAR DIN RAIL I/O BASE 193
FIGURE 12.4.3.6-1 HUB 197
FIGURE 12.4.3.7-1 PCM LOCATION 200
FIGURE 12.4.3.8-1 CUSTOMER COMMUNICATION MODULE 203
FIGURE 12.4.3.9.1-1 POWER CONVERTER (P15) 206
FIGURE 12.4.3.10-1 TRANSDUCER LOCATION 210
FIGURE 12.4.3.10.3-1 TRANSDUCER (XD) CONFIGURATION 212
FIGURE 12.4.3.10.5-1 OPENING THE TRANSDUCER 213
FIGURE 12.4.3.10.5-2 SETTING THE DIP SWITCHES 213
FIGURE 12.4.3.11-1 AC TRANSFORMER BOX (ATB) 214
12-11
USAF TO 35C2-3-518-1
USA TM 9-6115-484-14
LIST OF TABLES
CHAPTER TITLE PAGE

TABLE 12.4.2.1.3.2-1 GENERATOR AND FEEDER BREAKER CONTROL SWITCHES 67
TABLE 12.4.2.1.4.2-1 ENGINE CONTROL SWITCH (ECS) 71
TABLE 12.4.2.1.5.2-1 EMERGENCY STOP PUSHBUTTON (ESPB) 75
TABLE 12.4.2.1.7-1 AVR FAULT AND ALARM CODES 80
TABLE 12.4.2.2.4.2-1 TIE BREAKER CONTROL SWITCH (BCST) 102
TABLE 12.4.2.2.5.2-1 SYSTEM MODE SWITCH (SMS) 106
TABLE 12.4.2.2.6.2-1 SYSTEM SYNCHRONIZING SWITCH (SSS) 110
TABLE 12.4.2.2.7.2-1 GENERATOR MODE SWITCH (GMS) 114
TABLE 12.4.2.2.8.2-1 MASTER SYSTEM ENABLE SWITCH (MSES) 117
TABLE 12.4.2.2.9.2-1 BATTLESHORT SWITCH (BSS) 120
TABLE 12.4.2.2.10.2-1 AUTOMATIC VOLTAGE REGULATOR SWITCH (AVRS) 123
TABLE 12.4.2.2.11.2-1 USS CONTACT TARGET TABLE 126
TABLE 12.4.2.2.13.2-1 BUZZER SILENCE PUSHBUTTON (SIL) 133
TABLE 12.4.2.2.17-1 FAULT MATRIX 148
TABLE 12.4.2.2.17-2 ALARMS MATRIX 148
TABLE 12.4.3.1.2-1 FREQUENCY SELECTOR SWITCH (FSS) 155
TABLE 12.4.3.4.2-1 RTU MAINTENANCE INFORMATION 164
TABLE 12.4.3.5.2-1 I/O MAINTENANCE INFORMATION 194
12-12
USAF TO 35C2-3-518-1
USA TM 9-6115-484-14
12.0 CONTROLS AND INSTRUMENTS REPAIR
12.1 SAFETY INSTRUCTIONS
a. Safety precautions must be observed while any maintenance is being performed. Safety
precautions must be observed to ensure that the operator/technician cannot have contact with the
following:
• Hot engine parts

• Hot engine fluids
• Medium Voltage AC electricity
• Low Voltage AC electricity
• Low Voltage DC electricity
• Rotating Parts
• High noise levels
b. Minor troubleshooting can be performed while both engines are running as long as safety
precautions are taken.
c. Minor maintenance can be performed while one generator set is running and the other
generator set has been shutdown. Some examples of this maintenance are:
• Lubrication System – Oil and Filter Change.

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

(b) Push to OPEN the Emergency Stop Switch.
(c) Place the Engine Control Switch (ECS) in the OFF position.
(d) Place a DO NOT OPERATE tag on the generator control panel.
(e) Turn the Battery Bank Parallel Switch to the OFF position.
(f) De-energize the Battery Charger.
(g) Disconnect the negative and positive cables from the Battery Bank for the engine
due maintenance.
(h) Place a DO NOT OPERATE tag on the Battery Bank.
(i) Place the generator Circuit Breaker in the LOCK OUT position.
(j) Disconnect the 7P1 and 7P2 Connectors located on the inside panel of the PDC.
(k) Close and Lock the generator set control panel.
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d. Major maintenance or service requires that the PU MUST be shutdown, isolated from any
power plant electrical bus or utility connection, isolated from any power plant control
system, and rendered unable to start. This is accomplished by performing the following:

(2) Isolate the PU from any power plant or utility connection in accordance with Section
5.9.6.15, Unit Isolation Procedure with PSC. See Note 1 and 2.
(5) Push to OPEN both Emergency Stop Switches.
NOTE 1: Also the PU must be completely electrically isolated from the power distribution bus and
any other electrical source that can back feed into the PU. All medium voltage cables need to
be placed on the standoff insulators by use of hot sticks and other safety gear.
NOTE 2: Ensure cables are not energized by opening the circuit breaker of the Primary Switching
Center (PSC), then disconnect Load Cables (Using the proper safety gear) on the PU and
place them on the Parking Stands.
12.2 BRIEF DESCRIPTION
This Section covers the Engine and PDC controls and instrument Inspect, Test (if applicable), Remove,
Repair and Service (if applicable). The engine controls and instruments sense engine parameters and
send these parameters to the GSC+ and Engine Control Module (ECM), which control the way each
engine runs. The PDC controls and instruments provide control over generator control, multi-PU plant
control (through a network) and medium distribution system control and protection.
12.3 SERVICE REQUIREMENTS
There is no Engine/PDC System maintenance requirement. Each device that has a specific service
requirement has that service is listed with that device.
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12.4 COMPONENT REPAIR PROCEDURES
12.4.1 ENGINE CONTROL DEVICES
NOTE: Additional reference material required for maintenance is Caterpillar Manual RENR2227-01
or later version, Troubleshooting 3406E Generator Set Engine.
a. Sensors and Electrical Components Description
• The engine is equipped with various optional engine features and controls. This section
discusses the general information about these engine control devices and the operation of
these devices.
b. Alarm Switches
• The Engine is equipped with alarms in order to alert the operator when undesirable operating
conditions occur. When an alarm is activated, corrective measures must be made before the
situation becomes an emergency.
• Alarm systems are electrically operated. The operations of all electric alarms use
components that actuate switches in a sensing unit. Alarms are set at critical operating
temperatures, operating pressures, operating levels, or operating speeds.
• A history of all of the engine faults is maintained in the Electronic Control Module (ECM).
These faults can be either Active Codes or Logged Codes. Refer to the Caterpillar Systems
Operation, Testing, and Adjusting; RENR1200-01 or later version, for the definitions of the
codes.
• The Battle Short switch bypasses all alarms except Overspeed and Short Circuit (50),
Ground Fault (50N) and Emergency Stop. Ensure that the Battle Short switch is reset after
repairs have been made.
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12.4.1.1 COOLANT TEMPERATURE SENSOR
The following maintenance procedures are provided for the Coolant Temperature Sensor:
Inspect
Test
Remove
Install
FIGURE 12.4.1.1-1 COOLANT TEMPERATURE SENSOR
12.4.1.1.1 INSPECT COOLANT TEMPERATURE SENSOR
Inspect the Coolant Temperature Sensor for the following:
a. Inspect for proper mounting.
b. Inspect for loose connections, leaks.
c. Inspect for physical and heat damage.
12.4.1.1.2 TEST COOLANT TEMPERATURE SENSOR
To test the Coolant Temperature Sensor, proceed as follows:
a. See Caterpillar Manual RENR2227-01 or latest version, Section P – 516 Coolant Temperature
Sensor, for the latest testing instructions.
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b. This sensor monitors engine coolant temperature. This feature is used for engine system
diagnostics with an output from the Electronic Control Module (ECM). The output of the ECM can
indicate a high coolant temperature through a relay or a lamp. In addition, the sensor activates
the Cold Start Strategy in Section 12.4.1.5, which improves the starting ability of the engine.
c. The minimum coolant temperature that will activate the alarm is 216°F (104°C). The switch
opens as the coolant cools. A resetting procedure is not required.
• At 225°F the Generator Breaker will open.
d. Failure of the Coolant Temperature Sensor: If one of the following conditions exists, a failure of
the coolant temperature sensor may have occurred:
• Sensor output is open.

• Sensor output is shorted to ground or supply
• Measured reading of the coolant temperature is out of specification.
e. The ECM will detect a failure of the coolant temperature sensor. The diagnostic code will warn the
operator about the status of the coolant temperature sensor. Strategies that are related to the
coolant temperature will be disabled. A failure of the coolant temperature sensor will not cause a
shutdown of the engine or any horsepower change.
12.4.1.1.3 REMOVE COOLANT TEMPERATURE SENSOR
WARNING

WARNING

WARNING
WHEN POWER GENERATION EQUIPMENT MUST BE IN OPERATION TO MAKE

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

To replace the Coolant Temperature Sensor, proceed as follows:
(1) Shutdown the PU in accordance with chapter 5.1.6.1 Shutdown Generators.

b. Disconnect the wiring harness J21/P21.
c. Drain coolant low enough so that coolant does not come out of the coolant sensor well.
d. Unscrew the Coolant Temperature Sensor using a wrench. Screw in a counter-clock-wise

direction until it comes free.
12.4.1.1.4 INSTALL COOLANT TEMPERATURE SENSOR
To install the Coolant Temperature Sensor, proceed as follows:
rerouted to the next PU. See procedures and warnings in paragraph 12.4.1.1.3.
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b. Reinstall new Coolant Temperature Sensor and with a wrench. Screw the sensor in a clock-
wise direction until it is tight.
c. Reinstall the wiring harness J21/P21.
d. Refill the coolant system.
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12.4.1.2 COOLANT LEVEL SENSOR
The following maintenance procedures are provided for the Coolant Level Sensor:
Inspect
Test
Remove
Install
G1 COOLANT LEVEL SENSOR
G2 COOLANT LEVEL SENSOR
J34
FIGURE 12.4.1.2-1 COOLANT LEVEL SENSORS
12.4.1.2.1 INSPECT COOLANT LEVEL SENSOR
Inspect the Coolant Level Sensor for the following:
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12.4.1.2.2 TEST COOLANT LEVEL SENSOR
To test the Coolant Level Sensor, proceed as follows:
a. See Caterpillar Manual RENR2227-01 or latest version, Section P – 525 Coolant Level Sensor for
the latest testing instructions.
b. The coolant level sensor monitors the engine coolant level in order to detect a low coolant level
condition. The coolant level sensor provides information to the GSC+. The output from the
GSC+ indicates a low coolant level indicator lamp. Coolant must be added to the cooling system
in order to correct the condition.
c. Coolant Level Sensor Failure.
• When the coolant level sensor output is open, shorted to ground or shorted to supply, a
coolant level sensor failure may have occurred.
• The coolant level sensor failure will not cause a shutdown of the engine or any horsepower
change.
12.4.1.2.3 REMOVE COOLANT LEVEL SENSOR
WARNING

WARNING

WARNING

USER.
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CAUTION

To remove the Coolant Level Sensor, proceed as follows:

c. Drain coolant low enough so that coolant does not come out of the coolant sensor well.
d. Unscrew the Coolant Level Sensor using a wrench. Screw in a counter-clock-wise direction until
it comes loose.
12.4.1.2.4 INSTALL COOLANT LEVEL SENSOR
To install the Coolant Level Sensor, proceed as follows:
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FIGURE 12.4.1.2.4-1 COOLANT SYSTEM AIR BLEED VALVE
b. Reinstall new Coolant Level Sensor and with a wrench. Screw the sensor in a clock-wise
direction until it is tight.
d. Refill the coolant system.
e. Open the Coolant System Air Bleed Valve during the refill process. Close the Coolant System
Air Bleed Valve when a steady stream of coolant is observed. Refer to Figure 12.4.1.2.4-1 for
reference.
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12.4.1.3 FILTERED ENGINE OIL PRESSURE SENSOR
The following maintenance procedures are provided for the Filtered Engine Oil Pressure Sensor:
Inspect
Test
Remove
Install
FILTERED
ENGINE OIL
PRESSURE
SENSOR
ATMOSPHERIC
PRESSURE
SENSOR
FIGURE 12.4.1.3-1 FILTERED ENGINE OIL PRESSURE SENSOR
12.4.1.3.1 INSPECT FILTERED ENGINE OIL PRESSURE SENSOR
Inspect the Filtered Engine Oil Pressure Sensor for the following:
c. Inspect for physical and heat damage (discolored insulation and or bare conductor).
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12.4.1.3.2 TEST FILTERED ENGINE OIL PRESSURE SENSOR
To test the Filtered Engine Oil Pressure Sensor, proceed as follows:
a. See Caterpillar Manual RENR2227-01 or latest version, Section P – 520 Filtered Engine Oil
Sensor for the latest testing instructions.
b. Low Oil Pressure Warning: The set point is dependent upon the engine rpm. The fault will be
active and logged only if the engine has been running for more than 15 seconds.
NOTE: The low oil pressure switches may close at 7 to 9 PSI (48 to 62 kPa) below the actual trip
point.
c. Failure Of The Engine Oil Pressure Sensor: If one of the following conditions occurs, a failure of
the engine oil pressure sensor may have occurred:
• Sensor output is open.

• Sensor output is shorted to ground or supply
• Measured reading of the oil pressure is out of specification.
d. The ECM will detect a failure of the engine oil pressure sensor. The diagnostic code warns the
user about the status of the engine oil pressure sensor. The alarms that are related to oil
pressure will be disabled. A failure of the engine oil pressure sensor will not cause a shutdown of
the engine or any horsepower change.
e. The engine oil pressure sensor can detect engine oil pressure for diagnostic purposes. The
engine oil pressure sensor sends a signal to the Electronic Control Module (ECM).
12.4.1.3.3 REMOVE FILTERED ENGINE OIL PRESSURE SENSOR
WARNING

WARNING

WARNING

USER.
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CAUTION

To remove the Filtered Engine Oil Pressure Sensor, proceed as follows:

c. Unscrew the sensor using a wrench. Screw in a counter-clock-wise direction until it comes
loose.
12.4.1.3.4 INSTALL FILTERED ENGINE OIL PRESSURE SENSOR
b. Reinstall the Filtered Engine Oil Pressure Sensor and with a wrench. Screw the sensor in a
clock-wise direction until it is tight.
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12.4.1.4 FLYWHEEL MOUNTED ENGINE SPEED SENSOR (MPU)
The following maintenance procedures are provided for the Flywheel Mounted Engine Speed Sensor,
sometimes referred to as the Magnetic Pick-Up (MPU):
Inspect
Test
Remove
Install
FIGURE 12.4.1.4-1 FLYWHEEL MOUNTED ENGINE SPEED SENSOR

(MAGNETIC PICK-UP)
12.4.1.4.1 INSPECT FLYWHEEL MOUNTED ENGINE SPEED SENSOR
NOTE: Engine Over-speed protection is provided by the EMCP II+ control. The flywheel housing
mounted Engine Speed Sensor is the input for engine speed to the EMCPII+ for this function.
NOTE: For additional reference, refer to SEBU7163-01 or later version, SMCS CODE: 1907-040;
7400-040; 7400-070.
a. Speed Sensing Loss Alarm:
• The speed-timing sensor output has opened.
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• The speed-timing sensor is shorted to ground.
• The speed-timing sensor is shorted to supply.
• The speed-timing sensor is missing pulses.
• The speed-timing sensor has extra pulses.
b. Intermittent failure causes erratic engine control. The electronic control system will detect a
failure of the flywheel mounted speed-timing sensor. The operator will be warned through the
“DIAGNOSTIC” lamp.
c. If flywheel mounted speed-timing sensor (1) cannot sense engine speed, the “DIAGNOSTIC”
lamp will indicate a diagnostic fault code, which will be logged in the Electronic Control Module
memory.
Inspect the Flywheel Mounted Engine Speed Sensor for the following:
b. Inspect for loose connections.
d. Inspect for debris.
To inspect the Flywheel Mounted Engine Speed Sensor, proceed as follows:
a. Remove access cover to expose flywheel and speed sensor.
b. Clean any debris from tip of sensor with clean lint-free cloth as necessary.
c. Re-install access cover.
12.4.1.4.2 REMOVE FLYWHEEL MOUNTED ENGINE SPEED SENSOR
WARNING

WARNING

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WARNING

USER.
CAUTION

To remove the Flywheel Mounted Engine Speed Sensor, proceed as follows:

maintenance the Communication Cable must be routed to the next PU in order to reestablish
the communication network.
loose.
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12.4.1.4.3 INSTALL FLYWHEEL MOUNTED ENGINE SPEED SENSOR
To install the Flywheel Mounted Engine Speed Sensor, proceed as follows:
(A) Air Gap, (1) Speed Sensor (2) Locknut
FIGURE 12.4.1.4.4-1 FLYWHEEL MOUNTED ENGINE SPEED SENSOR DIAGRAM
b. Use the Flywheel Mounted Engine Speed Sensor Diagram illustrated in Figure 12.4.1.4.4-1 to
make adjustments. The Flywheel Mounted Engine Speed Sensor must be adjusted after it is
installed and prior to use. The following instructions need to be followed for this procedure:
(1) Remove all debris from the tip of the speed sensor. Align a ring gear tooth directly in the
center of the threaded sensor opening.
(2) By hand, screw the speed sensor (1) into the hole until the end of the sensor contacts the
gear tooth.
(3) Turn the sensor (1) in the counterclockwise direction through 270 degrees (three-fourths
turn).
(4) Tighten locknut (2) to 18 + 4 Ft-Lbs (25 + 5 Nm).
NOTE: Do not allow speed sensor (1) to turn as locknut (2) is tightened.
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12.4.1.5 COLD START STRATEGY
The cold start strategy utilizes the input of the coolant temperature sensor. The cold start strategy helps
to provide the following features: quicker cold starts, white smoke cleanup, decreased deep cycling of the
battery, and extended engine life. When the coolant temperature is below 63°F (17°C), the cold start
strategy is activated. The cold mode deactivates because of the following items:
• The coolant temperature reaches 82°F (28°C).

• The engine has run for 12 minutes.
12.4.1.6 ENGINE SPEED GOVERNING
a. See Caterpillar Manual RENR7163-01 or latest version, SMCS CODE 1000; 1900; 1901; and
1902.
b. The engine speed governor monitors the throttle position and the actual engine rpm in order to
help control the following items: engine rpm, response, torque output, and smoke limiting. The
engine speed governor also helps to maintain constant engine rpm. Governing the fuel injection
duration to the cylinders through the electronic unit injectors controls the engine rpm. Throttle
input is used to calculate the engine rpm that is desired.
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12.4.1.7 PASSIVE SPEED/TIMING SENSORS
The following maintenance procedures are provided for the Passive Speed/Timing Sensors:
Inspect
Test
Remove
Install
UPPER
SPEED/TIMING
SENSOR
LOWER
SPEED/TIMING
SENSOR
Speed/Timing Sensor close-up

With harness disconnected
Engine Front (Left side): Upper and Lower Speed/Timing Sensors.
FIGURE 12.4.1.7-1 ELECTRONIC TIMING SENSOR
12.4.1.7.1 INSPECT PASSIVE SPEED/TIMING SENSORS
Inspect the Passive Speed/Timing Sensors for the following:
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d. Disconnect the speed/timing connectors “P44/J44 Upper Speed/Timing Sensor & J20/P20 -
Lower Speed/Timing Sensor” and disconnect the harness “pigtail” ends of the sensor harness (2).
Inspect the connectors for the following conditions (Tag the harness connections before
disconnecting to ensure proper reconnection of the Speed/Timing Sensor harness connectors).
• Corrosion
• Bent pins
• Missing pins
• Damaged sockets
• Mismating
• Broken wires
12.4.1.7.2 TEST PASSIVE SPEED/TIMING SENSORS
To test the Passive Speed/Timing Sensors, proceed as follows:
a. See Caterpillar Manual RENR2227-01 or latest version, Section P – 514 Passive Speed/Timing
b. An Over-speed condition is detected by the primary speed/timing sensor, when the engine rpm
exceeds 2500 RPM, the Electronic Control Module (ECM) will shut off the electronic unit injectors.
The electronic unit injectors will be shut off until the engine speed drops below 2500 RPM. A
diagnostic fault code will be logged into the ECM memory and the “DIAGNOSTIC” lamp will
indicate a diagnostic fault code.
12.4.1.7.3 REMOVE PASSIVE SPEED/TIMING SENSORS
WARNING

WARNING

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WARNING

USER.
CAUTION

To remove the Passive Speed/Timing Sensors, proceed as follows:

b. Disconnect the wiring harness J44/P44 for the upper speed/timing sensor. Disconnect the
wiring harness J20/P20 for the lower speed/timing sensor.
c. Unscrew the retaining clamp bolt that holds each sensor in place, using a wrench, in a counter-
clock-wise direction until it comes loose. Pull the sensor free from the engine.
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12.4.1.7.4 INSTALL PASSIVE SPEED/TIMING SENSORS
To install the Passive Speed/Timing Sensors, proceed as follows:
b. While installing the Passive Speed/Timing Sensors:
• The Top and Bottom Speed/Timing Sensors must be serviced as a pair. The two
sensors are not interchangeable and must have correct placement on the engine.
• Lubricate the O-rings with oil.
• Inspect to ensure both sensors have connector face seals inside the connector body. If a
seal is damaged or missing, use a 126-5011 replacement seal.
• Inspect to ensure both sensors are fully seated and the seal is in place before tightening the
bracket bolt.
• Inspect to ensure the connector is properly latched.
• Inspect to ensure the harness is attached to the engine harness clip.
c. Reinstall speed-timing sensor into place, then the retaining clamp. With a wrench tighten the
sensor retaining clamp bolt to18 + 3 Ft-Lbs (24 + 4 Nm).
d. Reinstall the wiring harness J44/P44 for the upper speed/timing sensor. Reinstall the wiring
harness J20/P20 for the lower speed/timing sensor.
e. The speed/timing sensors do not need to be Calibrated after they have been installed. See
Caterpillar Manual RENR2227-01 or latest version, Section P – 614 Passive Speed/Timing
Calibration for the latest instructions. Engine Timing Calibration is only required if the ECM is
replaced or if repairs have been made to the engine front drive train.
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12.4.1.8 INLET MANIFOLD AIR TEMPERATURE SENSOR
The following maintenance procedures are provided for the Inlet Manifold Air Temperature Sensor:
Inspect
Test
Remove
Install
FIGURE 12.4.1.8-1 AIR INLET TEMPERATURE SENSOR
12.4.1.8.1 INSPECT INLET MANIFOLD AIR TEMPERATURE SENSOR
Inspect the Inlet Manifold Air Temperature Sensor for the following:
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12.4.1.8.2 TEST INLET MANIFOLD AIR TEMPERATURE SENSOR
To test the Inlet Manifold Air Temperature Sensor, proceed as follows:
a. See Caterpillar Manual RENR2227-01 or latest version, Section P – 5100 Inlet Air Temperature
NOTE: The conducted heat from the inlet manifold air will affect the inlet manifold air temperature
sensor when the engine is idling, and after the engine is shut off. This warm-up is due to the
lack of coolant circulation through the engine. The reading from the inlet manifold air
temperature sensor may be significantly higher than the actual temperature of the air inside
the inlet manifold until the inlet manifold cools.
b. The inlet manifold air temperature sensor measures the temperature of the inlet manifold air. The
Electronic Control Module (ECM) monitors the inlet manifold air temperature sensor signal. The
output of the ECM can indicate high inlet manifold air temperature through a relay or a lamp. The
inlet manifold air temperature sensor will not cause a shutdown of the engine or any horsepower
change.
12.4.1.8.3 REMOVE INLET MANIFOLD AIR TEMPERATURE SENSOR
WARNING

WARNING

WARNING

EQUIPMENT MAY FAIL AND PRESENT A HIGH VOLTAGE SHOCK HAZARD TO
ITS USER.
CAUTION

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To remove the Inlet Manifold Air Temperature Sensor, proceed as follows:

loose.
12.4.1.8.4 INSTALL INLET MANIFOLD AIR TEMPERATURE SENSOR
To install the Inlet Manifold Air Temperature Sensor, proceed as follows:
b. Reinstall Inlet Manifold Air Temperature Sensor and with a wrench. Screw the sensor in a clock-
wise direction until it is tight.
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12.4.1.9 TURBOCHARGER COMPRESSOR OUTLET PRESSURE SENSOR
The following maintenance procedures are provided for the Turbocharger Compressor Outlet Pressure
Sensor:
Inspect
Test
Remove
Install
TURBOCHARGER OUTLET PRESSURE SENSOR
FIGURE 12.4.1.9-1 TURBOCHARGER COMMPRESSOR OUTLET PRESSURE SENSOR
12.4.1.9.1 INSPECT TURBOCHARGER COMPRESSOR OUTLET PRESSURE SENSOR
Inspect the Turbocharger Compressor Outlet Pressure Sensor for the following:
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12.4.1.9.2 TEST TURBOCHARGER COMPRESSOR OUTLET PRESSURE SENSOR
To test the Turbocharger Compressor Outlet Pressure Sensor, proceed as follows:
a. See Caterpillar Manual RENR2227-01 or latest version, Section P – 517 Turbocharger

Compressor Outlet Pressure Sensor for the latest testing instructions.
b. The air/fuel ratio control utilizes actual engine speed and actual boost pressure (inlet manifold air
pressure) in order to control the transient smoke level. When the throttle is increased and when
the engine demands more fuel, the fuel limit is controlled in order to reduce overall smoke levels
of the engine exhaust.
c. If the timing and the duration of the 90-volt signal are controlled, the Electronic Control Module
(ECM) can control injection timing and the amount of fuel that is injected.
NOTE: The Turbocharger Compressor Outlet Pressure Sensor is located on the top left side of the
engine.
d. The boost pressure is determined from the difference in pressure between the Turbocharger
Compressor Outlet Pressure Sensor (See Figure 12.4.1.9-1) and the Atmospheric Pressure
Sensor (See Figure 12.4.1.10-1).
e. Turbocharger Compressor Outlet Pressure Sensor Failure:
(1) A Turbocharger Compressor Outlet Pressure Sensor failure may have occurred if any of the
following conditions are present:
• The output of the Turbocharger Compressor Outlet Pressure Sensor is open.
• The output of the Turbocharger Compressor Outlet Pressure Sensor is shorted to ground
or to supply.
• The reading of the Turbocharger Compressor Outlet Pressure Sensor is out of

specification.
(2) The ECM will detect the Turbocharger Compressor Outlet Pressure Sensor failure. The
operator will be warned of the problem through the EMCP II+ panel. Turbocharger
Compressor Outlet Pressure Sensor failure will not cause a shutdown of the engine. The
engine may de-rate in power due to a failure of the Turbocharger Compressor Outlet
Pressure Sensor.
12.4.1.9.3 REMOVE TURBOCHARGER COMPRESSOR OUTLET PRESSURE SENSOR
WARNING

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WARNING

WARNING

USER.
CAUTION

To remove the Turbocharger Compressor Outlet Pressure Sensor, proceed as follows:

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loose.
12.4.1.9.4 INSTALL TURBOCHARGER COMPRESSOR OUTLET PRESSURE SENSOR
To install the Turbocharger Compressor Outlet Pressure Sensor, proceed as follows:
b. Reinstall Turbocharger Compressor Outlet Pressure Sensor and with a wrench screw the
sensor in a clock-wise direction until it is tight.
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12.4.1.10 ATMOSPHERIC PRESSURE SENSOR
The following maintenance procedures are provided for the Atmospheric Pressure Sensor:
Inspect
Test
Remove
Install
FILTERED
ENGINE OIL
PRESSURE
SENSOR
ATMOSPHERIC
PRESSURE
SENSOR
FIGURE 12.4.1.10-1 ATMOSPHERIC PRESSURE SENSOR CONNECTOR
12.4.1.10.1 INSPECT ATMOSPHERIC PRESSURE SENSOR
Inspect the Atmospheric Pressure Sensor for the following:
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12.4.1.10.2 TEST ATMOSPHERIC PRESSURE SENSOR
To test the Atmospheric Pressure Sensor, proceed as follows:
a. See Caterpillar Manual RENR2227-01 or latest version, Section P – 519 Atmospheric Pressure
b. The Atmospheric Pressure Sensor measures the atmospheric pressure in the crankcase. A
signal is sent to the Electronic Control Module (ECM).
c. The Atmospheric Pressure Sensor is an absolute pressure sensor measuring crankcase

pressure. Both the Boost Pressure and Oil Pressure communicated to service tools and over the
data link are calculated by subtracting the Atmospheric Pressure Sensor reading. The
Atmospheric Pressure Sensor measures pressure from 0 PSI (0 kPa) to 16.8 PSI (116 kPa)
absolute. The ECM uses the Atmospheric Pressure Sensor as a reference to perform an
automatic calibration of other pressure sensors. The ECM with 5VDC supplies the sensor.
Failure of the Atmospheric Pressure Sensor could affect engine speed, power or shutdown could
occur.
12.4.1.10.3 REMOVE ATMOSPHERIC PRESSURE SENSOR
WARNING

WARNING

WARNING

USER.
CAUTION

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To remove the Atmospheric Pressure Sensor, proceed as follows:

loose.
12.4.1.10.4 INSTALL ATMOSPHERIC PRESSURE SENSOR
To install the Atmospheric Pressure Sensor, proceed as follows:
b. Reinstall Atmospheric Pressure Sensor and with a wrench. Screw the sensor in a clock-wise
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12.4.1.11 FUEL TEMPERATURE SENSOR
The following maintenance procedures are provided for the Fuel Temperature Sensor:
Inspect
Test
Remove
Install
FUEL TEMPERATURE SENSOR
FIGURE 12.4.1.11-1 FUEL TEMPERATURE SENSOR
12.4.1.11.1 INSPECT FUEL TEMPERATURE SENSOR
Inspect the Fuel Temperature Sensor for the following:
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12.4.1.11.2 TEST FUEL TEMPERATURE SENSOR
To test the Fuel Temperature Sensor, proceed as follows:
a. A full range of testing procedures for the temperature sensor is located in RENR2227-01,
Troubleshooting, 3406E Generator Set Engines, section P-548.
b. The Fuel Temperature Sensor provides a fuel temperature signal to the ECM. The ECM adjusts
Engine-Operating parameters to compensate for changes in fuel temperature.
12.4.1.11.3 REMOVE FUEL TEMPERATURE SENSOR
WARNING

WARNING

WARNING

USER.
CAUTION

To remove the Fuel Temperature Sensor, proceed as follows:
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loose.
12.4.1.11.4 INSTALL FUEL TEMPERATURE SENSOR
To install the Fuel Temperature Sensor, proceed as follows:
b. Reinstall Fuel Temperature Sensor and with a wrench. Screw the sensor in a clock-wise
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12.4.1.12 ENGINE DIAGNOSTICS
12.4.1.12.1 SELF-DIAGNOSTICS
Caterpillar Electronic Engines have the capability to perform a self-diagnostic test. When the system
detects a problem, the GSC+ display “DIAG” is activated. Diagnostic codes will be stored in permanent
memory in the Electronic Control Module (ECM). Using the following components can retrieve the
diagnostic codes:
• Caterpillar electronic service tools. (ET Tool).

• GSC+ Upper Display.
a. Active codes represent problems that currently exist. These problems should be investigated
first. If a code is active, the “DIAG” will flash on GSC+ display.
b. Logged codes represent the following items:
• Intermittent Problems
• Recorded Events
• Performance History
c. The problems may have been repaired since the logging of the code. These codes do not
indicate that a repair is needed. The codes are guides or signals when a situation exists. Codes
may be helpful to troubleshoot problems.
12.4.1.12.2 PERMANENT FAULT LOGGING
The system provides the capability of Permanent Fault Logging. When the Electronic Control Module
(ECM) generates a diagnostic code, the code will be logged in the permanent memory. The logged
codes can then be retrieved using Caterpillar electronic service tools (CAT ET Tool).
12.4.1.12.3 ENGINE OPERATION WITH ACTIVE DIAGNOSTIC CODES
a. If the EMCP+ starts to flash codes during normal engine operation, the system has identified a
situation that is not within the specification. Check the following conditions:
• Engine oil pressure

• Coolant temperature
b. Use the GSC+ to retrieve the active codes or use the Electronic Technician Tool to retrieve the
active diagnostic code. Refer to the Chapter 5 and Chapter 6 for the following actions of the
operator:
• Shutdown the engine.

• Service the engine.
• Schedule service for the engine.
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c. The active diagnostic code should be investigated. The cause of the problem should be
corrected as soon as possible. If the cause of the active diagnostic code is repaired and there is
only one active diagnostic code, the active diagnostic code will turn off.
d. Operation of the engine and performance of the engine can be limited as a result of the active
diagnostic code that is generated. Acceleration rates may be significantly slower. Refer to the
Operation and Maintenance Manual for more information on the relationship between these
active diagnostic codes and engine performance.
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12.4.1.13 FILTER MONITORING PANEL
The following Maintenance procedures are provided for the Filter Monitoring Panel:
Inspect
Remove
Install
Service
FIGURE 12.4.1.13-1 FILTER MONITORING PANEL
The alarm setpoints are determined by the position of the needle/pointer within each gauge except for the
radiator circuit and air-vent gauges.
When the gauge setpoints have been reached; an alarm in the Auxiliary Alarm Panel illuminates and ORT
sounds an audible alarm, alerting the operator of a problem.
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12.4.1.13.1 INSPECT FILTER MONITORING PANEL
Inspect the Filter Monitoring Panel for the following conditions:
a. Inspect the gauge range; the Air Filter Element shall be set at 25 inches of water.
b. Inspect the gauge range; the Oil Differential Pressure shall be set at 30 PSID.
c. Inspect the gauge range; Primary Fuel Filter Differential Pressure Separator / Filter shall be set
at 5 PSID.
d. Inspect the gauge range; the Secondary Fuel Filter Differential Pressure shall be set at 30 PSID.
e. Inspect the Hydraulic System Gauge ranges:
(1) The Radiator Circuit pressure gauge operates between 2,100 and 3,100 PSI (While
Running).
(2) The Air-Vent pressure gauge operates between 2,300 and 3,100 PSI (While Running).
f. Inspect for proper operation.
g. Inspect for dents, cracks, breaks, leaks or other physical damage.
h. Inspect for security of attachment.
i. Inspect for missing Hardware.
12.4.1.13.2 REMOVE FILTER MONITORING PANEL
WARNING

AND OR DEATH.
WARNING

WARNING

ILLNESS.
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CAUTION

To remove the Filter Monitoring Panel, proceed as follows:

b. Unplug electrical harness connector on side of panel.
c. Tag and disconnect hoses. Cap both ends to prevent dirt from entering.
d. Remove four bolts and washers from outer vibration mounts.
e. With a slight pressure, push gauge bracket until vibration mount studs clear mounting bracket
and remove assembly.
12.4.1.13.3 INSTALL FILTER MONITORING PANEL
To install the Filter Monitoring Panel, proceed as follows:
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b. Reinstall the vibration mount studs into the bottom of the bracket. With a slight pressure, push
gauge bracket until vibration mount studs clear the mounting bracket and align with holes and
release.
c. Reinstall bracket with four nuts and washers on vibration mounts.
d. Remove caps and reinstall hoses. Remove tags.
e. Reinstall electrical wire harness into receptacle.
12.4.1.13.4 SERVICE FILTER MONITORING PANEL
To service the Filter Monitoring Panel, proceed as follows:
b. Using the proper adjusting tool, carefully adjust the needle/pointer to the following setpoints:
• Oil Differential Pressure – 30 PSID.

• Primary Fuel Filter Differential Pressure Separator / Filter – 5 PSID.
• Secondary Fuel Filter Differential Pressure – 30 PSID.
• Air Cleaner / Filter – 25 inches of water.
NOTE: Do not over-adjust the needle / pointer.
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12.4.2 PDC CONTROLS AND INSTRUMENTS
FIGURE 12.4.2-1 PDC LOCAL CONTROL PANEL (LCP)
a. This section will describe the maintenance procedures for the PDC controls and instruments in
the following sequence:
• Covers controls and instruments located on the interior and exterior doors of the Generator
Control Panels (GCP).
• Covers controls and instruments located on the interior and exterior door of the Master
Control Panel (MCP).
• Covers controls and instruments within the interior of cabinet A, B, and C.
b. Generator set controls and instruments that are panel-mounted in the PDC mounted on the rear
of the PU. These three main control panels are:
• The Panel, generator number 1 control panel, located on the outer left of the Power Unit
(GCP1).
• The Panel, generator number 2 control panel, located on the outer right of the Power Unit
(GCP2).
• The Master Control Panel located in the outer center panel of the Power Unit (MCP).
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12.4.2.1 GENERATOR CONTROL PANEL CONTROLS AND INSTRUMENTS
1. System In Battle Short Mode Light (SBL) 12. Feeder Breaker Control Switch (BCSF1/F2)
2. Primary Fuel Filter High Differential Pressure
13. Generator Over Current Relay (50/51G1/G2)
Alarm Light (HPFFDPL)
3. Secondary Fuel Filter High Differential Pressure
14. Feeder Over Current Relay (50/51F1/F2)
Alarm Light (HSFFDPL)
4. Primary Fuel Filter High Water Level Alarm
15. Emergency Stop Push Button (ESPB)
Light (PFFHWLL)
5. Oil Filter High Differential Pressure Alarm Light
16. Engine Control Switch (ECS)
(HOFDPL)
6. Air Filter High Differential Pressure Alarm Light
17. Panel Light Switch (PLS)
(HAFDPL)
7. Fuel Tank High Level Alarm Light (HFTLL) 18. Frequency Adjust Rheostat (FAR)
8. Fuel Tank Low Level Alarm Light (LFTLL) 19. Voltage Adjust Rheostat (VAR)
9. Hydraulic Tank Low Level Shutdown Light
20. Red Breaker Closed LED
(HTLLL)
10. Generator Set Control (GSC+)
21. Green Breaker Closed LED
11. Generator Breaker Control Switch (BCSG1/G2)
FIGURE 12.4.2.1-1 GENERATOR CONTROL PANEL CONTROLS / INSTRUMENTS
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12.4.2.1.1 GENERATOR SET CONTROLLER (GSC+)
The following maintenance procedures are provided for the Generator Set Controller:
Inspect
Test
Remove
Install
GSC+ Set Points
FIGURE 12.4.2.1.1-1 GENERATOR SET CONTROLLER (GSC+)
The Caterpillar GSC+ provides the local metering for its associated generator set. All metering
parameters are available from the GSC+.
a. The main component of the EMCPII+ system is the Generator Set Control (GSC+). The GSC+ is
designed to operate when powered by 24VDC battery systems. The GSC+ monitors and controls
many of the generator set functions. The Display of the GSC+ is seen in Figure 12.4.2.1.1-1. The
functions and features of the GSC+ are:
• Provides generator output information including power metering.

• Controls normal starting and stopping of the engine.
• Shows engine conditions and generator output information on two displays. The displays
also show fault codes and GSC+ programming information.
• Monitors the system for faults. If a fault occurs, the GSC+ performs a controlled fault
shutdown or provides a fault alarm annunciation. The GSC+ uses indicators and displays to
describe the fault to the operator or service technician.
• Contains programmable features for certain applications or customer requirements.
b. Primary Function: The primary function of upper display is to show AC voltage, current and
frequency information of the generator output. There are several options available on the upper
display for AC metering. These options can be viewed one at a time by pressing the AC Meter
key on the keypad. The options are:
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• Voltage (average), generator frequency, current (total).

• Voltage (line-line), generator frequency, current (line) for any one phase.
• Voltage (line-line) for all three phases at once.
• Current (line) for all three phases at once.
• Voltage (line-neutral) for all three phases at once.
c. Upper display is also used to show the various fault codes for system faults.
12.4.2.1.1.1 INSPECT GENERATOR SET CONTROLLER (GSC+)
Inspect the Generator Set Controller GSC+ for the following:
12.4.2.1.1.2 TEST GENERATOR SET CONTROLLER (GSC+)
See Caterpillar Manual RENR1200-01 or latest version, for the latest testing instructions.
12.4.2.1.1.3 REMOVE GENERATOR SET CONTROLLER (GSC+)

(13) Close and Lock the generator set control panels that will not be worked on.
b. Open the door of the GSC+ to be replaced in order to gain access to the rear of the GSC+.
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c. Disconnect the 40-pin connecter at the GSC+, using the appropriate Allen wrench.
d. Tag and disconnect all terminated wiring to the terminals on the GSC+.
e. Remove the six (6) retaining nuts holding the GSC+ in place on the door.
NOTE: Be careful to restrain the GSC+ from falling when removing the last nut.
12.4.2.1.1.4 INSTALL GENERATOR SET CONTROLLER (GSC+)
NOTE: The Caterpillar GSC+ must have software flashed into its memory, specific to DPGDS. The
CUSTOMER Version ET Tool supplied with the DPGDS equipment does not contain the
software required to perform this task. When ordering a replacement GSC+, ensure that it is
the appropriate GSC+ for the DPGDS system. If a commercial GSC+ is installed, a CAT
dealer must flash the correct software.
rerouted to the next PU. See procedures in paragraph 12.4.2.1.1.3.
b. Reinstall the GSC+ into the opening, insuring the gasket is in place to provide proper sealing.
c. Reinstall the retaining nuts while holding the GSC+ in place.
d. Reinstall the retaining nuts to seal the GSC+ in place.
e. Reinstall all terminated wiring to their respective points on the GSC+ terminal board using FO-15
as a reference. Remove all wire tags.
f. Reinstall the 40-pin connector and tighten it in place using the appropriate allen-wrench.
g. Energize the GSC+ by pushing in the DC Control Breaker.
h. Reinstall in the ATB bar code numbers into the GSC+ using the EMCP+ service Manual
(SENR5827) for programming OP8 parameters.
i. Program the necessary setpoints into the GSC+, using DPGDS GSC+ Programmable Setpoints
in Annex B.
j. Perform pre-operation checks, according to Section 5.1.3.5, to verify operation on the generator.
12.4.2.1.1.5 GSC+ SET POINTS
GSC+ Set Points are contained in Annex B.
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12.4.2.1.2 GENERATOR / FEEDER OVERCURRENT RELAY
The following maintenance procedures are provided for the Generator / Feeder Overcurrent Relay:
Inspect
Test
Remove
Install
Generator / Feeder Overcurrent Relay Set Points
FIGURE 12.4.2.1.2-1 GENERATOR AND FEEDER OVERCURRENT RELAY
There is one Basler BE1-851 Overcurrent relay for each Generator, Feeder, and Tie Circuit Breaker. The
LCD display on each over current relay provides a display of the current flow through each phase of the
associated breaker. The display also shows the total current flow through that breaker. Additionally, the
display may be used to monitor and/or program the relay see Figure 12.4.2.1-1 Generator Control Panel
for reference.
a. Front Panel Display:
(1) The Front Panel: Human-machine interface (HMI) for a BE1-851 Overcurrent Relay in an
FT-11 Case Configuration, see Figure 12.4.2.1.2-1 for reference.
(2) Two line by 16-character LCD display with backlighting: Is the Primary source for
receiving information from the relay or when locally programming settings to the relay.
Displays active logic scheme name, targets, metering values, demand values,
communications parameters, diagnostic information, and the menu tree steps or branches.
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(3) Power LED: When this LED is ON, indicates operating power is applied to the relay.
(4) Relay Trouble LED: When this LED is ON, indicates that the relay is off-line due to start-up
condition or a relay failure alarm.
(5) Minor Alarm LED: Not used in this application.
(6) Major Alarm LED: Not used in this application.
(7) Trip LED: When this LED is flashing ON, indicates that a protective element is picked up.
When this LED is ON continuously, indicates that a trip output is closed. The LED is sealed-in
if a protective trip has occurred and there are targets being displayed.
(8) Communications Port 0: RS-232 serial communications port. A computer terminal or PC

running a terminal emulation program such as Windows TM Terminal can be connected to
this port so that the user may send commands to the relay or receive reports from the relay.
Communication with the relay uses a simple ASCII command language.
(9) Reset Pushbutton Switch: Resets report data including: sealed-in Trip targets, Trip LED,
peak demand currents, and alarms.
(10) Scrolling Pushbuttons (keys): Scrolls UP/DOWN/LEFT/RIGHT through the menu tree or
when in the Edit mode, the LEFT/RIGHT scrolling pushbuttons select the variable to change
and the UP/DOWN scrolling pushbuttons change the variable.
(11) Edit Pushbutton Switch: Enables settings changes. When the Edit pushbutton is first
pushed, an LED on the pushbutton turns ON to indicate the edit mode is active. When
changes are complete (using the scrolling pushbuttons) and the Edit pushbutton is pushed
again, the LED turns OFF indicating that the changes are saved. If changes are not
completed and saved within five minutes, the edit mode is exited without saving changes.
(12) Identification Plate: Shows sensing input current range, power supply type, and serial
number.
(13) MENU TREE: The menu tree has six branches. These branches are:
• REPORT STATUS: Display and resetting of general status information such as

targets, and alarms status, etc.
• CONTROL: Operation of control functions such as controlling virtual switches,
selection of active setting group, etc.
• METERING: Display of real time metering values.
• REPORTS: Display and resetting of report information such as time and date,
demand registers, breaker duty statistics, etc.
• PROTECTION LOGIC: Display and setting of protective function setting parameters
such as pickups, time delays, etc.
• GENERAL SETTINGS: Display and setting of non-protective function setting
parameters such as communication.
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(14) Each screen in the menu tree is numbered in the upper left hand corner of the screen. This
number indicates the current branch and level in the menu tree structure so that you do not
loose track of where you are when you have left the top level of the menu tree. You scroll
through each level of the menu tree by using the right and left scrolling keys. To go to a level
of greater detail, you use the down scrolling key. Each time you go to a lower level in the
menu tree, another number is added to the screen number separated by a period.
12.4.2.1.2.1 INSPECT GENERATOR / FEEDER OVERCURRENT RELAY
Inspect the Generator / Feeder Overcurrent Relay for the following:
12.4.2.1.2.2 TEST GENERATOR / FEEDER OVERCURRENT RELAY
To test the Generator / Feeder Overcurrent Relay, proceed as follows:
a. Testing is performed by internal diagnostics during start up.
b. Refer to Basler Publication 9-2899-00-990, Section 13 Testing and Maintenance, for reference.
12.4.2.1.2.3 REMOVE GENERATOR / FEEDER OVERCURRENT RELAY
WARNING

WARNING

WARNING

USER.
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To remove the Generator / Feeder Overcurrent Relay, proceed as follows:

b. Remove the two front mounting screws located on the front lower corner of the relay.
c. Slide the Generator / Feeder Overcurrent Relay towards you and pull it from its mounting case.
12.4.2.1.2.4 INSTALL GENERATOR / FEEDER OVERCURRENT RELAY
To install the Generator / Feeder Overcurrent Relay, proceed as follows:
rerouted to the next PU. See procedures and warnings in paragraph 12.4.2.1.2.3.
b. Reinstall the Generator / Feeder Overcurrent Relay carefully, insuring that the circuit board goes
into the proper grove; push forward to replace the relay into its mounting case.
c. Reinstall the relay’s mounting screws.
12.4.2.1.2.5 SERVICE GENERATOR / FEEDER OVERCURRENT RELAY
Setting Overcurrent Relay: In order make changes to the Basler Overcurrent Relay use the following
instructions:
a. Connect the ORT Control Cable to the Basler Relay.
b. Start the ORT.
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c. At the “Windows” logon screen, Enter “Administrator” as username , Press “Tab”, Enter
Small Case “dpgds” as the password.
d. Click the “Ok” button or Press “Enter”.e. On the desktop, Left Click twice on the
“BESTCOMS” Icon. Wait for the program to open.
f. If it is a New Basler Overcurrent Relay, perform the following:
(1) Left click on “File”.

(2) Left click on “Open”. Left click on “FDR” for the preset feeder settings or “GEN” for
preset generator settings. Left click on the setting required, then left click on “Select”.
(3) Left click on “Communications”.
(4) Left click on “Upload Settings to Relay”.
(5) At “Password” screen press “Enter”.
(6) Left click on “Yes”.
(7) Left click on “OK”. At this time the relay has been properly setup for service.
g. If the relay needs to have it’s setting changed, perform the following:
(1) Left Click on “Communications”.

(2) Left click on “Download Settings from Relay”.
(3) Wait until the transfer is complete.
(4) Left click on “Screens”.
(5) Left Click on “Overcurrent”.
(6) There are three screens. On the 51 Time Overcurrent screen, click on the “Pickup” and
change to “Pri.Amps”.
(7) Make changes according to Annex C
(8) Left Click “File”.
(9) Press “Save As”.
(10) Name the File and click “save”.
(11) Left click “Communications”.
(12) Left click “Upload Settings to Relay”.
(13) At Password screen press “Enter”.
12.4.2.1.2.6 OVERCURRENT RELAY SET POINTS
Generator / Feeder Overcurrent Relay Set Points are contained in Annex D.
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12.4.2.1.3 GENERATOR AND FEEDER BREAKER CONTROL SWITCHES (BCS)
The following maintenance procedures are provided for the Generator and Feeder Control Switches:
Inspect
Test
Remove
Install
FIGURE 12.4.2.1.3-1 BREAKER CONTROL SWITCHES
a. There are Breaker Control Switches for each breaker mounted in the MEP-PU-810, these are:
• Generator 1 (G1) Breaker Control Switch (BCSG1)
• Generator 2 (G2) Breaker Control Switch (BCSG2)
• Feeder 1 (F1) Breaker Control Switch (BCSF1)
• Feeder 2 (F2) Breaker Control Switch (BCSF2)
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b. These switches have two momentary positions (Trip and Close), and two maintained positions
(Center and Lockout). There is also a target to indicate the last operation performed by the
switch. These switches are used for local operation of the breakers, setting up the breakers for
automatic operation, and disabling breaker operation.
12.4.2.1.3.1 INSPECT GENERATOR AND FEEDER BREAKER CONTROL SWITCHES
Inspect the Generator and Feeder Control Switches (BCS), for the following:
12.4.2.1.3.2 TEST GENERATOR AND FEEDER BREAKER CONTROL SWITCHES
WARNING

WARNING

WARNING

USER.
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To test the Generator and Feeder Control Switches (BCS), proceed as follows:
TABLE 12.4.2.1.3.2-1 GENERATOR AND FEEDER BREAKER CONTROL SWITCHES

POSITION
NAT NAC
DECK CONTACTS TRIP TRIP (NORMAL (NORMAL CLOSE
(LOCKOUT) (MOMENTARY) AFTER AFTER (MOMENTARY)
TRIP) CLOSE)
12 & 13 X
1
16 & 17 X
21 & 26 X
2
24 & 25 X
33 & 34 X
3
37 & 38 X
41 & 42 X X
4
45 & 46 X X
52 & 53 X X
5
56 & 57 X X
61 & 62 X X
6
65 & 66 X X

b. Remove Breaker Control Switch (BCS), in accordance with Section 12.4.2.1.3.3.
c. Using a multimeter set to OHMS (Ω) Rx1 scale, test for contact continuity in switch positions
specified. Multimeter should indicate zero ohms at points marked in chart as shown in Table
12.4.2.1.3.2-1.
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d. Multimeter should indicate infinite ohms at all open contacts in chart as shown in Table
12.4.2.1.3.2-1.
NOTE: An integral spring return mechanism returns handle to normal-vertical position except in pull-
to-lock position. Slip contacts are incorporated to maintain contact closure in last commanded
position.
e. Target window opening on face of switch plate should show green when last command operation
was TRIP.
f. Target window should show red when last command operation was CLOSE.
g. Switch handle should always return to normal vertical position following either command
operation, TRIP or CLOSE.
h. Replace Generator and Feeder Control Switches (BCS) if any fail any of the above requirements.
12.4.2.1.3.3 REMOVE GENERATOR AND FEEDER BREAKER CONTROL SWITCHES
To remove Generator and Feeder Control Switches (BCS), proceed as follows:
b. Remove screw from center of handle and slide handle from switch.
c. Remove the three retaining screws securing the Breaker Control Switch (BCS) to the generator
control panel.
d. Remove the Breaker Control Switch (BCS) from rear of panel.
e. Tag and disconnect wiring (do not remove jumpers) from Breaker Control Switch (BCS).
12.4.2.1.3.4 INSTALL GENERATOR AND FEEDER BREAKER CONTROL SWITCHES
To install the Generator and Feeder Breaker Control Switch (BCS), proceed as follows:
b. Reinstall wiring to the Breaker Control Switch (BCS) and discard tags.
c. Reinstall the Breaker Control Switch (BCS) and secure with three screws.
d. Reinstall the handle on the switch and secure with retaining screw.
e. Close control panel door and tighten captive screws (1).
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12.4.2.1.4 ENGINE CONTROL SWITCH (ECS)
The following maintenance procedures are provided for the Engine Control Switch (ECS):
Inspect
Test
Remove
Install
ENGINE CONTROL SWITCH (ECS)
FIGURE 12.4.2.1.4-1 ENGINE CONTROL SWITCH (ECS)
There is a switch for each generator set mounted in the MEP-PU-810. These rotary snap switches have
four maintained positions. The switch may be rotated 360° in either direction. The switch is used for local
operation of the generator, setting up the generator for automatic operation, and disabling generator
operation.
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12.4.2.1.4.1 INSPECT ENGINE CONTROL SWITCH (ECS)
Inspect the Engine Control Switch (ECS) for the following:
12.4.2.1.4.2 TEST ENGINE CONTROL SWITCH (ECS)
WARNING

WARNING

WARNING

USER.
To test the Engine Control Switch (ECS), proceed as follows:

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b. Using a multimeter set to OHMS (Ω) Rx1 scale, test for contact continuity in switch positions
specified. Multimeter should indicate zero ohm at points marked in chart as shown in Table
12.4.2.1.4.2-1.
c. Multimeter should indicate infinite ohms at all open contacts in chart as shown in Table
12.4.2.1.4.2-1.
d. Replace Engine Control Switch (ECS) if it fails any of the above requirements.
TABLE 12.4.2.1.4.2-1 ENGINE CONTROL SWITCH (ECS)

CONTACT 0° 90° 180° 270°
OFF/RESET AUTOMATIC MANUAL START COOLDOWN/STOP
1 X X X X
2 X
3 X
4 X
5 X
6 X
7 X
8 X
9 X
10 X
12.4.2.1.4.3 REMOVE ENGINE CONTROL SWITCH (ECS)
To remove the Engine Control Switch (ECS), proceed as follows:
b. Remove screw from center of handle and slide handle from switch.
c. Remove 4 retaining screws that hold the Engine Control Switch (ECS) to the control panel.
d. Remove the Engine Control Switch (ECS) from rear of panel.
e. Tag and disconnect the Engine Control Switch (ECS).
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12.4.2.1.4.4 INSTALL ENGINE CONTROL SWITCH (ECS)
To install the Engine Control Switch (ECS), proceed as follows:
b. Reinstall Engine Control Switch (ECS) from rear of the control panel, and secure it with the four
retaining screws.
c. Reinstall the handle and secure it with the mounting screw.
d. Reinstall the wiring to Engine Control Switch (ECS) and discard tags.
e. Close the control panel door.
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12.4.2.1.5 EMERGENCY STOP PUSHBUTTON (ESPB)
The following maintenance procedures are provided for the Emergency Stop Pushbutton (ESPB):
Inspect
Test
Remove
Install
FIGURE 12.4.2.1.5-1 EMERGENCY STOP PUSHBUTTON (ESPB)
There is a pushbutton for each generator mounted in the Generator Control Panel of the PU. The
Emergency Stop Pushbutton (ESPB) has two maintained positions.
12.4.2.1.5.1 INSPECT EMERGENCY STOP PUSHBUTTON (ESPB)
Inspect the Emergency Stop Pushbutton (ESPB) for the following:
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12.4.2.1.5.2 TEST EMERGENCY STOP PUSHBUTTON (ESPB)
WARNING

WARNING

WARNING

USER.
To test Emergency Stop Pushbutton (ESPB), proceed as follows:

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12.4.2.1.5.2-1.
12.4.2.1.5.2-1.
d. Replace Emergency Stop Pushbutton (ESPB) if it fails any of the above requirements.
TABLE 12.4.2.1.5.2-1 EMERGENCY STOP PUSHBUTTON (ESPB)

EMERGENCY STOP PUSHBUTTON (ESPB)
WIRE NUMBER
SWITCH POSITION
R18B & 4B ESPB & 30 16B & 12B
NORMAL - OUT X X
PUSHED-IN X
e. Using a multimeter set to OHMS (Ω) Rx1 scale, test for contact continuity in switch positions
12.4.2.1.5.2-1.
f. Multimeter should indicate infinite ohms at all open contacts in chart as shown in Table
12.4.2.1.5.2-1.
12.4.2.1.5.3 REMOVE EMERGENCY STOP PUSHBUTTON (ESPB)
To remove the Emergency Stop Pushbutton (ESPB), proceed as follows:
b. Twist red handle to the left until it comes off.
c. Twist black retaining nut to the left until it comes off.
d. Remove Emergency Stop Pushbutton (ESPB) from rear of panel.
e. Tag and disconnect wires on the Emergency Stop Pushbutton (ESPB).
12.4.2.1.5.4 INSTALL EMERGENCY STOP PUSHBUTTON (ESPB)
To install the Emergency Stop Pushbutton (ESPB), proceed as follows
rerouted to the next PU. See procedures and warnings in paragraph 12.4.2.1.5.2
b. Reinstall the Emergency Stop Pushbutton (ESPB) from rear of the control panel, and secure
retaining nut.
c. Reinstall wiring to Emergency Stop Pushbutton (ESPB) and discard tags.
d. Close control panel door and tighten captive screws.
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12.4.2.1.6 EMERGENCY STOP ACTUATOR (ESA)
The following maintenance procedures are provided for the Emergency Stop Actuator (ESA):
Inspect
Test
Remove
Install
FIGURE 12.4.2.1.6-1 EMERGENCY STOP ACTUATOR (ESA)
There is a emergency stop actuator pushbutton for each generator mounted in the generator control
panel of the MEP-PU-810. The pushbutton is momentary operated. Depressing the pushbutton will
cause it to operate the associated generators (ESPB). Although the actuator is only momentary, the
(ESPB) must be manually reset (pulled-out) by opening the associated generator control panel door.
12.4.2.1.6.1 INSPECT EMERGENCY STOP ACTUATOR (ESA)
Inspect the Emergency Stop Actuator (ESA) for the following:
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12.4.2.1.6.2 TEST EMERGENCY STOP ACTUATOR (ESA)
WARNING

WARNING

WARNING

ITS USER.
To test, the Emergency Stop Actuator (ESA), proceed as follows:

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b. Push the Emergency Stop Actuator (ESA) in. The Emergency Stop Pushbutton (ESPB) should
be in the Pushed in Position.
c. Adjust the Emergency Stop Actuator (ESA) (Screw-in or Screw-out) until Emergency Stop
Pushbutton (ESPB) closes fully (Pushed-in), when the ESA is pressed.
12.4.2.1.6.3 REMOVE EMERGENCY STOP ACTUATOR (ESA)
To remove, the Emergency Stop Actuator (ESA), proceed as follows:
b. Twist red handle to the left until it comes off.
c. Twist black retaining nut to the left until it comes off.
d. Remove Emergency Stop Actuator (ESA) from rear of panel.
12.4.2.1.6.4 INSTALL EMERGENCY STOP ACTUATOR (ESA)
To install the Emergency Stop Actuator (ESA), proceed as follows:
b. Reinstall the Emergency Stop Actuator (ESA) from rear of the control panel, and reinstall the
retaining nut.
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12.4.2.1.7 AUTOMATIC VOLTAGE REGULATOR (AVR)
The following maintenance procedures are provided for the Automatic Voltage Regulator (AVR):
Inspect
Test
Remove
Install
Service
FIGURE 12.4.2.1.7-1 AUTOMATIC VOLTAGE REGULATOR (AVR)
The Automatic Voltage Regulator is a microprocessor based voltage regulator. The main purpose of the
Automatic Voltage Regulator is to regulate output voltage of a generator used with an engine generator
set. Service personnel can modify (program) certain regulation characteristics. This will allow the engine
generator set to function in the most efficient manner. The Automatic Voltage Regulator can also
integrate into one package many options that were previously panel mounted; such as KVAR/PF
controller, over-excitation protection, fault detection, over voltage protection, under voltage protection,
diode monitor, reverse power relay and system parameter monitoring. Refer to Table for 12.4.2.1.7-1 for
AVR Fault and Alarm codes.
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a. The programmable parameters of the Automatic Voltage Regulator are:
• Voltage verses frequency (V/Hz) characteristic, two slope ranges adjustable from 1 to 10
V/Hz for optimum performance.
• Droop adjustment (up to 10% at 0.8 pf).
• Over voltage trip point (105% to 140% of nominal) with adjustable trip time.
• Under voltage trip point (60% to 95% of nominal) with adjustable trip time.
• Gain (0-10% of nominal).
• Single-phase or three-phase true RMS sensing.
• Under frequency trip point (15 to 40 Hz).
• Knee frequency (45 to 65 Hz).
b. The protective functions that the Automatic Voltage Regulator provides are:
• Over voltage protection, under voltage protection, Loss of sensing.

• Rotating diode monitor (monitors the status of the rotating diodes and operates the alarm
relay in the event of failure of one or more of the diodes), Over-excitation protection.
• Loss of excitation (monitors excitation and will initiate a shutdown of the unit if excitation is
lost).
• Under frequency protection to avoid overheating of the rotor.
• Instantaneous field over current trip to protect the Automatic Voltage Regulator in the event of
output short circuit or improper connections.
• Optional reverse power relay (monitors generator output power and initiates a shutdown of
the unit if a reverse power condition is detected.
TABLE 12.4.2.1.7-1 AVR FAULT AND ALARM CODES

ACTIVE SHUTDOWN FAULTS (PARAMETER :92)
FAULT CODE DESCRIPTION CLASSIFICATION (1)
0000 No Fault Present -
701 Under Voltage Resettable Shutdown Fault
702 Over Voltage Resettable Shutdown Fault
703 Over Excitation Resettable Shutdown Fault
704 Reverse VAR(2) Resettable Shutdown Fault
705 Reverse Power Resettable Shutdown Fault
801 Instantaneous Trip Non-Resettable Shutdown Fault
802 Loss of Sensing Non-Resettable Shutdown Fault
803 Loss of Frequency Non-Resettable Shutdown Fault
ALARM FAULTS (PARAMETER :95)
FAULT CODE DESCRIPTION CLASSIFICATION (3)
0000 No Fault Present -
601 Internal Memory Failure Alarm Fault
602 Internal Watchdog Failure Alarm Fault
603 Rotating Diode Fault Alarm Fault
604 Reverse VAR(2) Alarm Fault
(1) Resettable shutdown faults are reset by selecting parameter :96 (shutdown fault reset) on the
display and pressing the function key. Non-resettable shutdown faults are reset by opening the
DC Control Power Circuit Breaker (CBCP).
(2) The AVR looks for 0.4 and greater leading power factor for shutdown.
(3) Alarm faults are cleared by selecting parameter :94 (fault clear) on the display and pressing the
function key.
For additional information refer to SENR5833-02 or later version, SMCS CODE: 4467
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c. Automatic Voltage Regulator Components:
(1) Display (2) KeyPad (3) J1 Connector (4) Screw Terminals
FIGURE 12.4.2.1.7-2 AUTOMATIC VOLTAGE REGULATOR (AVR)
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(1) Display (2) KeyPad (5) Function Key (6) ScrolL-Down Key (7) Scroll-Up Key
FIGURE 12.4.2.1.7-3 AUTOMATIC VOLTAGE REGULATOR KEY PAD
• Display (1) of the Automatic Voltage Regulator, shows numbers that represent the different
parameters of the Automatic Voltage Regulator system. Keypad (2) is used to change the
information that is shown on display (1). J1 connector (3) is used to join the Automatic
Voltage Regulator to a personal computer. Screw terminals (4) are used to join the
Automatic Voltage Regulator to the generator and various customer options.
• Display (1) and keypad (2) are used to select and manipulate parameter values that control
the operation of the Automatic Voltage Regulator. Display (1) of the Automatic Voltage
Regulator has four digits. A colon in the display indicates that the number showing is a
parameter code. If a colon is not present, then the number showing is a parameter value. A
decimal point in the display is used to indicate the precision of the parameter value.
• Keypad (2) has three keys. The keys are: function key (5), scroll down key (6) and scroll
up key (7).
• Display (1) has two modes, parameter code mode and parameter value mode. Function
key (5) is used to toggle back and forth between the two modes. Scroll down key (6) and
scroll up key (7) are used to decrease and increase the parameter number or value number
that is showing on display (1).
• The operation of display (1) and keypad (2) can be described as a table. Pressing
function key (5) toggles the display back and forth between the two columns of the table
(parameter code and parameter value). If a colon is present, the display is in parameter code
mode. If a colon is not present, the display is in parameter value mode.
• Pressing a scroll up key (7) or scroll down key (6) will increase or decrease the display to
the next number within a column. Use of the scroll keys cannot cause the display to change
columns of the table.
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12.4.2.1.7.1 INSPECT AUTOMATIC VOLTAGE REGULATOR (AVR)
Inspect the Automatic Voltage Regulator (AVR) for the following:
12.4.2.1.7.2 TEST AUTOMATIC VOLTAGE REGULATOR (AVR)
To test the Automatic Voltage Regulator (AVR), proceed as follows:
Refer to Caterpillar Manual SENR5833-02 or later version, SMCS CODE: 4467 for reference.
12.4.2.1.7.3 REMOVE AUTOMATIC VOLTAGE REGULATOR (AVR)
WARNING

WARNING

WARNING

USER.
To remove the Automatic Voltage Regulator (AVR), proceed as follows:

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b. Tag and disconnect wires from the Automatic Voltage Regulator (AVR).
c. Remove 4 retaining nuts and washers that hold the Automatic Voltage Regulator (AVR) to the
door panel.
d. Remove the Automatic Voltage Regulator (AVR) from rear of panel.
12.4.2.1.7.4 INSTALL AUTOMATIC VOLTAGE REGULATOR (AVR)
To install the Automatic Voltage Regulator (AVR), proceed as follows:
b. Place the Automatic Voltage Regulator (AVR) back into place on the door panel, and secure it
with the four retaining washers and nuts.
c. Connect the wiring to Automatic Voltage Regulator (AVR) and discard tags.
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12.4.2.1.7.5 SERVICE AUTOMATIC VOLTAGE REGULATOR (AVR)
(1) Display (2) KeyPad (5) Function Key (6) ScrolL-Down Key (7) Scroll-Up Key
FIGURE 12.4.2.1.7-4 AUTOMATIC VOLTAGE REGULATOR KEY PAD
a. Changing Parameter Codes.
b. To program a parameter code (change the value):
• Select the desired parameter code by pressing the scroll down key (6) or scroll up key
(7).
• Access the parameter value by pressing the function key (5).
• Select the desired parameter value by pressing the scroll down key (6) or scroll up key
(7).
• Enter the chosen value into the memory of the Automatic Voltage Regulator by pressing the
function key (5).
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12.4.2.2 MASTER CONTROL PANEL
. Synchroscope / Synchcheck Relay (SC/25M) 11. Breaker Control Switch, Tie (BCST)
2. Phase Rotation Test Light (PRL) 12. Master Start Enable Switch (MSES)
3. Tie Over current Relay (50/51T) 13. System Status Light (SSL)
4. Tie Breaker Open (Green) LED (TOL) 14. Buzzer Silence Push Button (BSPB)
5. Tie Breaker Closed (Red) LED (TCL) 15. Generator Overload Indicator Lights
6. Bus Voltage/Frequency Meter (BVFM) 16. Battle Short Switch (BSS)
7. 50/60 Hertz Status Lights (50L/60L) 17. System Synchronizing Switch (SSS)
8. DC Control Power Breaker (CBCP) 18. Panel Lights Switch (PLS)
9. Generator Mode Switch (GMS) 19. System Mode Switch (SMS)
10. Automatic Voltage Regulator Switch (AVRS) 20. Unit Selector Switch (USS)
21. Unit Selector Indicators (USI)
FIGURE 12.4.2.2-1 MASTER CONTROL PANEL (MCP)
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12.4.2.2.1 SYNCHROSCOPE / SYNCH-CHECK RELAY (SC/25M)
The following maintenance procedures are provided for the Synchroscope / Synch-Check Relay
(SC/25M):
Inspect
Test
Remove
Install
FIGURE 12.4.2.2.1-1 SYNCHROSCOPE / SYNCH-CHECK RELAY (SC/25M)
This meter provides a digital representation of a Synchroscope during manual synchronizing sequences.
There are 24 red LED’s arranged in a ring simulating the traditional 360° movement of an analog
Synchroscope. Only one LED is lit at a time indicating the phase difference between the incoming and
running signals. The display will “rotate” clockwise or counter clockwise and fast or slow depending on
the frequency difference between incoming and running. Once the incoming and running are
synchronized, the ring LED’s will go out and the green triangular LED’s will be lit. The green LED’s at 3
o’clock and at 9 o’clock indicate the status of the voltage. Red is out of allowed synchronizing range and
green is in range.
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12.4.2.2.1.1 INSPECT SYNCHROSCOPE / SYNCH-CHECK RELAY (SC/25M)
Inspect the Synchroscope / Synch-Check Relay (SC/25M) for the following:
12.4.2.2.1.2 TEST SYNCHROSCOPE / SYNCH-CHECK RELAY (SC/25M)
To test Synchroscope / Synch-Check Relay (SC/25M), proceed as follows:
This is no field-testing for this device.
NOTE: There are NO field adjustments for this device. It comes preset from the manufacturer.
12.4.2.2.1.3 REMOVE SYNCHROSCOPE / SYNCH-CHECK RELAY (SC/25M)
WARNING

WARNING

WARNING

USER.
To remove Synchroscope / Synch-Check Relay (SC/25M), proceed as follows:
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b. Remove the four front retaining screws and remove the cover.
c. Remove the four-meter retaining bolts and nuts.
d. Tag and remove the wires and remove the meter.
12.4.2.2.1.4 INSTALL SYNCHROSCOPE / SYNCH-CHECK RELAY (SC/25M)
To install Synchroscope / Synch-Check Relay (SC/25M), proceed as follows:
b. Reinstall the meter and the four retaining bolts and nuts.
c. Reinstall the front cover and the four front retaining screws.
d. Reinstall the wires and remove the Tags.
e. Close the Master Control Panel (MCP) door.
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12.4.2.2.2 TIE OVERCURRENT RELAY
The following maintenance procedures are provided for the Tie Overcurrent Relay:
Inspect
Test
Remove
Install
Service
Tie Overcurrent Relay Set Points
FIGURE 12.4.2.2.2-1 TIE OVERCURRENT RELAY
There is one Basler BE1-851 Overcurrent Relay for the Tie Circuit Breaker. The LCD display on each
overcurrent relay provides a display of the current flow through each phase of the associated breaker.
The display also shows the total current flow through that breaker. Additionally, the display may be used
to monitor and/or program the relay. (See Figure 12.4.2.2.2-1)
a. Front Panel Display:
(1) The front panel human-machine interface (HMI) for a BE1-851 Overcurrent Relay in an
FT-11 Case configuration. See Figure 12.4.2.2.2-1 for reference.
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(2) Two line by 16-character LCD display with backlighting: Is the primary source for
receiving information from the relay or when locally programming settings to the relay.
Displays active logic scheme name, targets, metering values, demand values,
communications parameters, diagnostic information, and the menu tree steps or
branches.
(3) Power LED: When this LED is ON, indicates operating power is applied to the relay.
(4) Relay Trouble LED: When this LED is ON, indicates that the relay is off-line due to
start-up condition or a relay failure alarm.
(5) Minor Alarm LED: Not used in this application.
(6) Major Alarm LED: Not used in this application.
(7) Trip LED: When this LED is flashing ON, indicates that a protective element is picked
up. When this LED is ON continuously, indicates that a trip output is closed. The LED is
sealed-in if a protective trip has occurred and there are targets being displayed.
(8) Communications Port 0. RS-232 Serial Communications Port: A computer terminal

or PC running a terminal emulation program such as Windows TM Terminal can be
connected to this port so that the user may send commands to the relay or receive
reports from the relay. Communication with the relay uses a simple ASCII command
language.
(9) Reset pushbutton switch: Resets report data including: Sealed-in Trip targets, Trip
LED, peak demand currents, and alarms.
(10) Scrolling pushbuttons (keys): Scrolls UP/DOWN/LEFT/RIGHT through the menu tree
or when in the Edit mode, the LEFT/RIGHT scrolling pushbuttons select the variable to
change and the UP/DOWN scrolling pushbuttons change the variable.
(11) Edit Pushbutton Switch: Enables settings changes. When the Edit pushbutton is first
pushed, an LED on the pushbutton turns ON to indicate the edit mode is active. When
changes are complete (using the scrolling pushbuttons) and the Edit pushbutton is
pushed again, the LED turns OFF indicating that the changes are saved. If changes are
not completed and saved within five minutes, the edit mode is exited without saving
changes.
(12) Identification plate showing sensing input current range, power supply type, and serial
number.
(13) MENU TREE: The menu tree has six branches. These branches are:
• REPORT STATUS: Display and resetting of general status information such as

targets, and alarms status, etc.
• CONTROL: Operation of control functions such as controlling virtual switches,
selection of active setting group, etc.
• METERING: Display of real time metering values.
• REPORTS: Display and resetting of report information such as time and date,
demand registers, breaker duty statistics, etc.
• PROTECTION LOGIC: Display and setting of protective function setting parameters
such as pickups, time delays, etc.
• GENERAL SETTINGS: Display and setting of non-protective function setting
parameters such as communication.
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(14) Each screen in the menu tree is numbered in the upper left hand corner of the screen.
This number indicates the current branch and level in the menu tree structure so that you
do not loose track of where you are when you have left the top level of the menu tree.
You scroll through each level of the menu tree by using the right and left scrolling keys.
To go to a level of greater detail, you use the down scrolling key. Each time you go to a
lower level in the menu tree, another number is added to the screen number separated
by a period.
12.4.2.2.2.1 INSPECT TIE OVERCURRENT RELAY
Inspect the Tie Overcurrent Relay for the following:
12.4.2.2.2.2 TEST TIE OVERCURRENT RELAY
To test the Load Tie Overcurrent Relay, proceed as follows:
a. Testing is performed by internal diagnostics during start up.
b. Refer to Basler Publication 9-2899-00-990, Section 13 Testing and Maintenance, for reference.
12.4.2.2.2.3 REMOVE TIE OVERCURRENT RELAY
WARNING

WARNING

WARNING

ITS USER.
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To remove the Tie Overcurrent Relay, proceed as follows:

NOTE 1: When the DC Control Breaker is in the (OFF) position (Pulled – Out), all control power is
turned off to the PU. This will cause the HUB to stop functioning. This causes the network to
not see the equipment shutdown and all PU’s after it. When pulling major maintenance the
(A) (B) Communication Cable must be routed to the next PU in order to reestablish the
communication network.
b. Remove the two front mounting screws located on the front lower corner of the relay.
c. Slide the relay towards you and remove the relay from its mounting case.
12.4.2.2.2.4 INSTALL TIE OVERCURRENT RELAY
To install the Tie Overcurrent Relay, proceed as follows:
b. Reinstall the Tie Overcurrent Relay carefully, ensuring that the circuit board goes into the proper
grove; forward to Reinstall the relay into its mounting case.
c. Reinstall the relay mounting screws.
d. Close the Master Control Panel (MCP) door.
12.4.2.2.2.5 SERVICE TIE OVERCURRENT RELAY
Setting Overcurrent Relay: In order make changes to the Basler Overcurrent Relay use the following
instructions:
a. Connect the ORT Control Cable to the Basler Overcurrent Relay.
b. Start the ORT.
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c. At the “Windows” log on screen, Enter “Administrator” as username, Press “Tab”, Enter lower
case “dpgds” for the password.
d. Click in the “Ok” button or Press “Enter”.
e. On the “Windows” desktop, Left Click twice on the “BESTCOMS” Icon. Wait for the program to
open.
f. If it is a New Basler Overcurrent Relay, perform the following:
(1) Left click on “File”.

(2) Left click on “Open”. Left click on “TIE” for the preset Load Tie settings. Left click on
the setting required, then left click on “Select”.
(3) Left click on “Communications”.
(4) Left click on “Upload Settings to Relay”.
(5) At “Password” screen press “Enter”.
g. If the relay needs to have it’s setting changed, perform the following:
(1) Left Click on “Communications”.

(2) Left click on “Download Settings from Relay”.
(3) Wait until the transfer is complete.
(4) Left click on “Screens”.
(5) Left Click on “Overcurrent”.
(6) There are three screens. On the 51 Time Overcurrent screen, click on the “Pickup” and
change to “Pri.Amps”.
(7) Make changes according to Annex C
(8) Left Click “File”.
(9) Press “Save As”.
(10) Name the File and click “save”.
(11) Left click “Communications”.
(12) Left click “Upload Settings to Relay”.
(13) At Password screen press “Enter”.
12.4.2.2.2.6 OVERCURRENT RELAY SET POINTS
Tie Overcurrent Relay Set Points are contained in Annex D.
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12.4.2.2.3 BUS VOLT / FREQUENCY METER
The following maintenance procedures are provided for the Bus Volt / Frequency Meter:
Inspect
Test
Remove
Install
Service
FIGURE 12.4.2.2.3-1 BUS VOLT / FREQUENCY METER
This meter provides a digital display of the system bus during manual synchronizing sequences. The
upper display shows bus voltage while the lower display shows bus frequency. See Figure 12.4.2.2.3-1.
12.4.2.2.3.1 INSPECT BUS VOLT / FREQUENCY METER
Inspect the Bus Volt / Frequency Meter for the following:
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12.4.2.2.3.2 TEST BUS VOLT / FREQUENCY METER
To test the Bus Volt / Frequency Meter, proceed as follows:
There are no field tests that can be performed on this device.
12.4.2.2.3.3 REMOVE BUS VOLT/FREQUENCY METER
WARNING

WARNING

WARNING

ITS USER.
To remove the Bus Volt / Frequency Meter, proceed as follows:

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b. Remove the four front retaining screws and remove the cover.
c. Remove the four-meter retaining bolts and nuts.
d. Tag and remove the wires and remove the meter.
12.4.2.2.3.4 INSTALL BUS VOLT / FREQUENCY METER
To install the Bus Volt / Frequency Meter, proceed as follows:
b. Reinstall the meter and the four retaining bolts and nuts.
c. Reinstall the front cover and the four front retaining screws.
d. Reinstall the wires and remove the tags.
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12.4.2.2.3.5 SERVICE BUS VOLT/FREQUENCY METER
1
2 3 4
(1) Mode Key (2) Right Key (3) Up Key (4) Enter Key
FIGURE 12.4.2.2.3.5-1 BUS VOLT/FREQUENCY METER (WITH FRONT COVER REMOVED)
a. Listed below are the Bus Volt/Frequency Meter adjustment procedures, refer to Figure
12.4.2.2.3.5-1 for reference.
b. Setting the PT ratio for voltage display:

(1) Remove the front faceplate by removing the four (4) screws recessed in the corners of
the meter.
(2) Press the “Mode” key. The meter will display “SET”.
(3) Press the “En” key. The upper display shows “PT”.
(4) Press the “En” key. The upper display shows “PT P”.
(5) Press the “En” key. The upper display shows the current primary setting and the left-
most digit is flashing.
(6) Using the “f” key change the left digit to 3.
(7) Press the “d” key to select the next digit.
(8) Using the “f” key change the digit to 5.
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(13) Press the “En” key. An LED will flash.
(14) Use the “f” key to move the decimal point so the reading is 35.50.
(15) Press the “En” key. The new primary ratio, decimal point and LED will flash.
(16) Press the “En” key to save the change.
(17) Press the “Mode” key twice to return to the voltage display.
For further information on configuring the meter see the Yokogawa instruction booklet (IM2492VF-1).
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12.4.2.2.4 TIE BREAKER CONTROL SWITCH (BCST)
The following maintenance procedures are provided for the Tie Breaker Control Switch (BCST):
Inspect
Test
Remove
Install
FIGURE 12.4.2.2.4-1 TIE BREAKER CONTROL SWITCH (BCST)
This switch has two momentary positions (Trip and Close), and two maintained positions (Center and
Lockout). There is also a target to indicate the last operation performed by the switch. This switch is
used for local operation of the breakers, setting up the breaker for automatic operation, and disabling
breaker operation.
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12.4.2.2.4.1 INSPECT TIE BREAKER CONTROL SWITCH (BCST)
Inspect the Tie Breaker Control Switch (BCST) for the following:
12.4.2.2.4.2 TEST TIE BREAKER CONTROL SWITCH (BCST)
WARNING

WARNING

WARNING

ITS USER.
To test the Tie Breaker Control Switch (BCST), proceed as follows:

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b. Remove Tie Breaker Control Switch (BCST).
TABLE 12.4.2.2.4.2-1 TIE BREAKER CONTROL SWITCH (BCST)

POSITION
NAT NAC
DECK CONTACTS TRIP TRIP (NORMAL (NORMAL CLOSE
(LOCKOUT) (MOMENTARY) AFTER AFTER (MOMENTARY)
TRIP) CLOSE)
12 & 13 X
1
16 & 17 X
21 & 26 X
2
24 & 25 X
33 & 34 X
3
37 & 38 X
41 & 42 X X
4
45 & 46 X X
52 & 53 X X
5
56 & 57 X X
61 & 62 X X
6
65 & 66 X X
c. Using a multimeter set to OHMS (Ω) Rx1 scale, test for contact continuity in switch positions
12.4.2.2.4.2-1.
d. Multimeter should indicate infinite ohms at all open contacts in chart as shown in Table
12.4.2.2.4.2-1.
NOTE: An integral spring return mechanism returns handle to normal-vertical position except in pull-
to-lock position. Slip contacts are incorporated to maintain contact closure in last commanded
position.
e. Target window opening on face of switch plate should show green when last command operation
was TRIP.
f. Target window should show red when last command operation was CLOSE.
g. Switch handle should always return to normal vertical position following either command
operation, TRIP or CLOSE.
h. Replace the Tie Breaker Control Switch (BCST) if it fails any of the above requirements.
i. If the Tie Breaker Control Switch (BCST) meets above requirements, install in accordance step d.
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12.4.2.2.4.3 REMOVE TIE BREAKER CONTROL SWITCH (BCST)
To remove the Tie Breaker Control Switch (BCST), proceed as follows:
b. Remove retaining screw from center of handle and slide handle from switch.
c. Remove the three retaining screws securing the Tie Breaker Control Switch (BCST) to the
generator control panel.
d. Remove the Tie Breaker Control Switch (BCST) from rear of panel.
e. Tag and disconnect wiring (do not remove jumpers) from Tie Breaker Control Switch (BCST).
12.4.2.2.4.4 INSTALL TIE BREAKER CONTROL SWITCH (BCST)
To install the Tie Breaker Control Switch (BCST), proceed as follows:
b. Reinstall wiring to the Tie Breaker Control Switch (BCST) and discard tags.
c. Reinstall the Tie Breaker Control Switch (BCST) and secure with three screws
d. Reinstall the handle on switch and secure with retaining screw
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12.4.2.2.5 SYSTEM MODE SWITCH (SMS)
The following maintenance procedures are provided for the System Mode Switch (SMS):
Inspect
Test
Remove
Install
FIGURE 12.4.2.2.5-1 SYSTEM MODE SWITCH (SMS)
This switch is located on the Master Control Panel. It is a maintained, three-position switch. This switch
is used to determine the PU mode of operation.
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12.4.2.2.5.1 INSPECT SYSTEM MODE SWITCH (SMS)
Inspect the System Mode Switch (SMS) for the following:
12.4.2.2.5.2 TEST SYSTEM MODE SWITCH (SMS)
WARNING

WARNING

WARNING

USER.
To test the System Mode Switch (SMS), proceed as follows:

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12.4.2.2.5.2-1.
12.4.2.2.5.2-1.
d. Replace the System Mode Switch (SMS) if it fails any of the above requirements.
TABLE 12.4.2.2.5.2-1 SYSTEM MODE SWITCH (SMS)

SYSTEM MODE SWITCH (SMS)
SWITCH COMMON TERMINALS
POSITION TERMINALS 13 14 17 18 23 24 27 28
11 & 12 X
15 & 16 X
MAN
21 & 22 X
25 & 26 X
11 & 12
15 & 16
OFF
21 & 22
25 & 26
11 & 12 X
15 & 16 X
AUTO
21 & 22 X
25 & 26 X
12.4.2.2.5.3 REMOVE SYSTEM MODE SWITCH (SMS)
To remove the System Mode Switch (SMS), proceed as follows:
b. Remove the handle retaining screw.
c. Remove the 3 retaining screws from the front of the switch.
d. Remove the System Mode Switch (SMS) from rear of panel.
e. Tag and disconnect the System Mode Switch (SMS).
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12.4.2.2.5.4 INSTALL SYSTEM MODE SWITCH (SMS)
To install the System Mode Switch (SMS), proceed as follows
b. Reinstall the System Mode Switch (SMS) from rear of the control panel, and secure with 3
retaining screws.
c. Reinstall the handle with mounting screw.
d. Reinstall wiring to the System Mode Switch (SMS) and discard tags.
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12.4.2.2.6 SYSTEM SYNCHRONIZING SWITCH (SSS)
The following maintenance procedures are provided for the System Synchronizing Switch (SSS):
Inspect
Test
Remove
Install
FIGURE 12.4.2.2.6-1 SYSTEM SYNCHRONIZING SWITCH (SSS)
This switch is located on the center door control section. It is a maintained, three-position switch. This
switch is used to determine which generator is to be manually synchronized to the system bus.
12.4.2.2.6.1 INSPECT SYSTEM SYNCHRONIZING SWITCH (SSS)
Inspect the System Synchronizing Switch (SSS) for the following:
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12.4.2.2.6.2 TEST SYSTEM SYNCHRONIZING SWITCH (SSS)
WARNING

WARNING

WARNING

USER.
To test the System Synchronizing Switch (SSS), proceed as follows:

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12.4.2.2.6.2-1. Leave jumpers in place during the test.
12.4.2.2.6.2-1.
d. Replace the System Synchronizing Switch (SSS) if it fails any of the above requirements.
TABLE 12.4.2.2.6.2-1 SYSTEM SYNCHRONIZING SWITCH (SSS)

POSITION
DECK CONTACTS
GEN 1 OFF GEN 2 TIE
11 & 12 X
1 11 & 18 X
11 & 13 X
21 & 22 X
2 21 & 28 X
21 & 23 X
31 & 32 X
3 31 & 38 X
31 & 33 X
41 & 42 X
4 41 & 48 X
41 & 43 X
51 & 52 X
5 51 & 58 X
51 & 53 X
61 & 62 X
6 61 & 68 X
61 & 63 X
1. Using a multimeter set to OHMS (Ω) Rx1 scale, test for contact continuity in switch positions
specified. Multimeter should indicate zero ohm at points marked in chart as shown in Figure
12.4.2.2.6.2-1.
2. Multimeter should indicate infinite ohms at all open contacts in chart as shown in Figure
12.4.2.2.6.2-1.
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12.4.2.2.6.3 REMOVE SYSTEM SYNCHRONIZING SWITCH (SSS)
To remove the System Synchronizing Switch (SSS), proceed as follows
b. Remove handle-retaining screw.
c. Remove the 3 front mounting screws.
d. Remove the System Synchronizing Switch (SSS) from the rear of the Master Control Panel.
e. Tag and disconnect the System Synchronizing Switch (SSS).
12.4.2.2.6.4 INSTALL SYSTEM SYNCHRONIZING SWITCH (SSS)
To install the System Synchronizing Switch (SSS), proceed as follows
b. Reinstall the System Synchronizing Switch (SSS) from rear of the control panel, and secure
retaining nut.
c. Reinstall wiring to the System Synchronizing Switch (SSS) and discard tags.
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12.4.2.2.7 GENERATOR MODE SWITCH (GMS)
The following maintenance procedures are provided for the Generator Mode Switch (GMS):
Inspect
Test
Remove
Install
FIGURE 12.4.2.2.7-1 GENERATOR MODE SWITCH (GMS)
This switch is located on the center door control section. It is a maintained, two-position switch. This
switch is used to determine generator load sharing method of operation.
12.4.2.2.7.1 INSPECT GENERATOR MODE SWITCH (GMS)
Inspect the Generator Mode Switch (GMS) for the following:
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12.4.2.2.7.2 TEST GENERATOR MODE SWITCH (GMS)
WARNING

WARNING

WARNING

ITS USER.
To test the Generator Mode Switch (GMS), proceed as follows:

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12.4.2.2.7.2-1.
12.4.2.2.7.2-1.
d. Replace the Generator Mode Switch (GMS) if it fails any of the above requirements.
TABLE 12.4.2.2.7.2-1 GENERATOR MODE SWITCH (GMS)

GENERATOR MODE SWITCH (GMS)
SWITCH POSITION TERMINALS 1 & 2
UTILITY POWER X
PRIME POWER
12.4.2.2.7.3 REMOVE GENERATOR MODE SWITCH (GMS)
To remove the Generator Mode Switch (GMS), proceed as follows:
b. From the rear of the switch turn the open tab until the switch releases.
c. Tag and disconnect the Generator Mode Switch (GMS).
d. Remove the Generator Mode Switch (GMS) from rear of panel.
12.4.2.2.7.4 INSTALL GENERATOR MODE SWITCH (GMS)
To install the Generator Mode Switch (GMS), proceed as follows:
b. Reinstall the Generator Mode Switch (GMS) from rear of the control panel, and secure retaining
nut.
c. Reinstall wiring to the Generator Mode Switch (GMS) and discard tags.
d. Close control panel door and tighten captive screws.
e. Ensure all equipment is not energized prior to reconnecting cables.
f. Reinstall Tie and Load cables to the Output Terminals.
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12.4.2.2.8 MASTER SYSTEM ENABLE SWITCH (MSES)
The following maintenance procedures are provided for the Master System Enable Switch (MSES):
Inspect
Test
Remove
Install
FIGURE 12.4.2.2.8-1 MASTER SYSTEM ENABLE SWITCH (MSES)
This switch is located on the center door control section. It is a momentary, three position spring-loaded
switch. The Master System Enable Switch (MSES), switch enables the system to function in Automatic.
• By toggling the Master System Enable Switch (MSES) it will start any idle engine on the PU.
• Can be used as a local start switch.
• Used to clear lockouts as indicated by the red light on the System Status Light being on.
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12.4.2.2.8.1 INSPECT MASTER SYSTEM ENABLE SWITCH (MSES)
Inspect the Master System Enable Switch (MSES) for the following:
12.4.2.2.8.2 TEST MASTER SYSTEM ENABLE SWITCH (MSES)
WARNING

WARNING

WARNING

USER.
To test the Master System Enable Switch (MSES), proceed as follows:

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12.4.2.2.8.2-1.
12.4.2.2.8.2-1.
d. Replace the Master System Enable Switch (MSES) if it fails any of the above requirements.
TABLE 12.4.2.2.8.2-1 MASTER SYSTEM ENABLE SWITCH (MSES)

MASTER SYSTEM ENABLE SWITCH (MSES)
ENABLE (MOMENTARY LEFT) X
CENTER
ENABLE (MOMENTARY RIGHT)
12.4.2.2.8.3 REMOVE MASTER SYSTEM ENABLE SWITCH (MSES)
To remove the Master System Enable Switch (MSES), proceed as follows
b. From the rear of the switch move the Open Tab to the left and remove the switch.
c. Tag and disconnect Master System Enable Switch (MSES).
d. Remove Master System Enable Switch (MSES) from rear of panel.
12.4.2.2.8.4 INSTALL MASTER SYSTEM ENABLE SWITCH (MSES)
To install the Master System Enable Switch (MSES), proceed as follows:
b. Reinstall the MSES from rear of the Master Control Panel, push until it clicks into place.
c. Reinstall wiring to the Master System Enable Switch (MSES) and discard tags.
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12.4.2.2.9 BATTLESHORT SWITCH (BSS)
The following maintenance procedures are provided for the Battleshort Switch (BSS):
Inspect
Test
Remove
Install
FIGURE 12.4.2.2.9-1 BATTLESHORT SWITCH (BSS)
This switch is located on the center door control section. It is a maintained, two-position toggle switch.
This switch has a flip cover that will return the BSS to OFF when it is closed.
12.4.2.2.9.1 INSPECT BATTLESHORT SWITCH (BSS)
Inspect the Battleshort Switch (BSS) for the following:
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12.4.2.2.9.2 TEST BATTLESHORT SWITCH (BSS)
WARNING
REMOVE ALL RING, NECKLACES, JEWELERY AND LOOSE CLOTHING. FAILURE

TO DO SO COULD CAUSE SEVERE INJURY OR DEATH.
WARNING

WARNING

USER.
To test the Battleshort Switch (BSS), proceed as follows:

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12.4.2.2.9.2-1.
12.4.2.2.9.2-1.
d. Replace the Battleshort Switch (BSS) if it fails any of the above requirements.
TABLE 12.4.2.2.9.2-1 BATTLESHORT SWITCH (BSS)

BATTLESHORT SWITCH (BSS)
SWITCH TERMINALS
POSITION 1 2 3 4 5
NORMAL X X X X
BATTLESHORT X X X
12.4.2.2.9.3 REMOVE BATTLESHORT SWITCH (BSS)
To remove the Battleshort Switch (BSS), proceed as follows:
b. Remove the front Battleshort Switch (BSS) retaining nut.
c. Remove the Battleshort Switch (BSS) from rear of panel.
d. Tag and disconnect the Battleshort Switch (BSS). Do not remove the Jumpers.
12.4.2.2.9.4 INSTALL BATTLESHORT SWITCH (BSS)
To install the Battleshort Switch (BSS), proceed as follows:
b. Reinstall the Battleshort Switch (BSS) from rear of the control panel, and reinstall the retaining
nut.
c. Reinstall wiring to Battleshort Switch (BSS) and discard tags.
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12.4.2.2.10 AUTOMATIC VOLTAGE REGULATOR SWITCH (AVRS)
The following maintenance procedures are provided for the Automatic Voltage Regulator Switch (AVRS):
Inspect
Test
Remove
Install
Service
FIGURE 12.4.2.2.10-1 AUTOMATIC VOLTAGE REGULATOR SWITCH (AVRS)
This switch is located on the center door control section. It is a maintained, two-position switch. This
switch is used to determine which method of voltage control the automatic voltage regulator is in.
12.4.2.2.10.1 INSPECT AUTOMATIC VOLTAGE REGULATOR SWITCH (AVRS)
Inspect the Automatic Voltage Regulator Switch (AVRS) for the following:
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12.4.2.2.10.2 TEST AUTOMATIC VOLTAGE REGULATOR SWITCH (AVRS)
WARNING

WARNING

WARNING

USER.
To test the Automatic Voltage Regulator Switch (AVRS), proceed as follows:

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12.4.2.2.10.2-1.
12.4.2.2.10.2-1.
d. Replace the Automatic Voltage Regulator Switch (AVRS) if it fails any of the above requirements.
TABLE 12.4.2.2.10.2-1 AUTOMATIC VOLTAGE REGULATOR SWITCH (AVRS)

AUTOMATIC VOLTAGE REGULATOR SWITCH (AVRS)
UTILITY PARALLEL X
PRIME POWER
12.4.2.2.10.3 REMOVE AUTOMATIC VOLTAGE REGULATOR SWITCH (AVRS)
To remove the Automatic Voltage Regulator Switch (AVRS), proceed as follows:
b. From rear of the Master Control Panel move the Open retaining tab to the left until the switch
disconnects.
c. Remove the Automatic Voltage Regulator Switch (AVRS) from rear of the panel.
d. Tag and disconnect the Automatic Voltage Regulator Switch (AVRS).
12.4.2.2.10.4 INSTALL AUTOMATIC VOLTAGE REGULATOR SWITCH (AVRS)
To install the Automatic Voltage Regulator Switch (AVRS), proceed as follows:
b. Reinstall the Automatic Voltage Regulator Switch (AVRS) from rear of the Master Control panel,
and push the switch into the socket until it clicks into place.
c. Reinstall wiring to Automatic Voltage Regulator Switch (AVRS) and discard tags.
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12.4.2.2.11 UNIT SELECTOR SWITCH (USS)
The following maintenance procedures are provided for the Unit Selector Switch (USS):
Inspect
Test
Remove
Install
FIGURE 12.4.2.2.11-1 UNIT SELECTOR SWITCH (USS), UNIT SELECTOR INDICATORS

(USI)
This switch is located on the Master Control Panel (MCP). It is a maintained, four-position switch. This
switch is used in conjunction with the MSES to select the identifier for multiple PU and automatic
operation.
WARNING
ONLY ONE PU MAY BE SELECTED TO ANY ONE USS POSITION DURING

MULTIPLE PU OPERATIONS. OPERATING WITH MORE THAN ONE UNIT AT THE
SAME ID MAY CAUSE UNSAFE AND ERRATIC OPERATIONAL CONDITIONS.
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“A” This position selects the PU to be identified as PU ‘A’. This designates this PU as the master
unit. It coordinates the operation of the other online Units. In single unit operation this is the
position required for the PU to operate properly in automatic. In multiple PU lineups this should
be the left most PU.
“B” This position selects the PU to be identified as PU ‘B’. This designates this PU a slave unit. It
operates independently except during the generator economizing and dead bus closure when it
requires commands or permission from the ‘A’ PU. This PU should be the second PU from the
left in the physical lineup.
“C” This position selects the PU to be identified as PU ‘C’. This designates this PU a slave unit. It
requires commands or permission from the ‘A’ PU. This PU should be the third PU from the left
in the physical lineup.
“D” This position selects the PU to be identified as PU ‘D’. This designates this PU a slave unit. It
requires commands or permission from the ‘A’ PU. This PU should be the fourth and last PU
from the left in the physical lineup.
12.4.2.2.11.1 INSPECT UNIT SELECTOR SWITCH (USS)
Inspect the Unit Selector Switch (USS) for the following:
12.4.2.2.11.2 TEST UNIT SELECTOR SWITCH (USS)
WARNING

WARNING

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WARNING

USER.
To test the Unit Selector Switch (USS), proceed as follows:

b. Using a multimeter set on OHMS (Ω) Rx1 scale; measure the resistance across the switch
contacts. The resistance should be less than 1-ohm when closed and infinite when open. Use
Table 12.4.2.2.11.2-1 to determine which contacts are closed in each position.
TABLE 12.4.2.2.11.2-1 USS CONTACT TARGET TABLE

SWITCH POSITION
DECK CONTACTS
A B C D
1 – 2 (NC) X
A (1)
3 – 4 (NO) X
1 – 2 (NC) X
B (2)
3 – 4 (NO) X
c. If any of the contact block tests fail, replace that contact block with one of the same type.
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12.4.2.2.11.3 REMOVE UNIT SELECTOR SWITCH (USS)
To remove the Unit Selector Switch (USS), proceed as follows:
b. Remove the contact assembly; disconnect wires from the terminals on the contact block to
remove.
c. Release the contact assembly’s locking tangs with a small flathead screwdriver and remove.
d. Remove the Operator; disconnect the contact block from the operator by pushing the locking
lever slightly forward and to the right. This releases the contact block from the operator.
e. From the front of the door, carefully loosen the lock-ring from the rest of the operator.
f. Slide the operator out through the back of the door.
12.4.2.2.11.4 INSTALL UNIT SELECTOR SWITCH (USS)
To install the Unit Selector Switch (USS), proceed as follows:
a. Reinstall the contact assembly; snap the contact assembly into the appropriate slot and verify it
is firmly locked in.
b. Reinstall the wiring harness to the appropriate terminals based on the associated wiring
drawing(s).
c. Reinstall the Operator; reinstall the Operator through the hole in the door.
d. Reinstall the lock-ring onto the operator and tighten it so that the operator is tight and aligned
with the position indications when operated.
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12.4.2.2.12 UNIT SELECTOR INDICATORS (USI)
The following maintenance procedures are provided for the Unit Selector Indicators (USI):
Inspect
Test
Remove
Install
Use Figure 12.4.2.2.11-1 for reference. These four white indicators reflect the set selection of the PU
during operation. The indicators are off whenever the unit’s network ID has not been set. Depending on
the position of the Unit Selector Switch (USS) when the Master System Enable Switch (MSES) is cycled,
the associated LED will energize. These indicators provide positive indication that the control system has
energized the current setup parameters and the unit is starting operation. Note: in MANUAL mode the
indicators only reflect that the unit’s ID has been set; in AUTO mode, the control system will also proceed
with a normal startup. Whenever the System Mode Switch (SMS) has been in the OFF position for 3 or
more seconds the unit ID is cleared and the indicator is de-energized until the SMS is placed in MANUAL
or AUTO and the MSES is cycled.
12.4.2.2.12.1 INSPECT UNIT SELECTOR INDICATORS (USI)
Inspect the Unit Selector Indicators (USI) for the following:
12.4.2.2.12.2 TEST UNIT SELECTOR INDICATORS (USI)
WARNING

To test the Unit Selector Indicators (USI), proceed as follows:
a. Ensure the PU is isolated from other PU’s by disconnecting both (A) (B) communication cables.
b. Turn on the DC control power by pushing-in the DC-Control Power Breaker.
c. Place both Engine Control Switches ECS in the OFF position.
d. Place the System Mode Switch in OFF and ensure there are no Unit Selector Indicators on.
e. Place the SMS in MANUAL.
f. Place the USS in position A and cycle the Master System Enable Switch (MSES).
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g. Verify the “A” USI energizes.
h. Place the SMS in OFF for a minimum of 3 seconds and observe the ‘A” USI de-energizes.
i. Repeat steps “e” through “g” for positions ‘B, ‘C’, and ‘D’ USI’s, substituting the position testing
for ‘A’ position.
NOTE: When the DC Control Power Circuit Breaker is in the (OFF) position (Pulled – Out), all control
12.4.2.2.12.3 REMOVE UNIT SELECTOR INDICATORS (USI)
To remove the Unit Selector Indicators (USI), proceed as follows:
WARNING

WARNING

WARNING

USER.

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b. Remove the indicator’s lens cap by unscrewing it in a counter-clockwise direction.
c. Disconnect wiring from the indicator base.
d. Remove the indicator LED by carefully unscrewing it in a counter-clockwise direction.
12.4.2.2.12.4 INSTALL UNIT SELECTOR INDICATORS (USI)
To install the Unit Selector Indicators (USI), proceed as follows:
b. Reinstall the replacement LED by screwing it into the socket in a clockwise direction.
c. Reinstall the indicator wiring per the associated wiring diagram.
d. Reinstall the lens cap by screwing it onto the socket in a clockwise direction.
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12.4.2.2.13 BUZZER SILENCE PUSHBUTTON (SIL)
The following maintenance procedures are provided for the Buzzer Silence Pushbutton (SIL):
Inspect
Test
Remove
Install
FIGURE 12.4.2.2.13-1 BUZZER SILENCE PUSHBUTTON (SIL)
This pushbutton is located on Master Control Panel (MCP). The pushbutton is used to silence the
audible buzzer whenever an alarm or fault signal is activated. The pushbutton will only acknowledge one
alarm or fault at a time. Multiple alarms and faults require the operator to press the pushbutton for each
active alarm or fault. The operator cannot press the button beyond the number of active alarms and
faults. The buzzer works in conjunction with the System Status Lights. Whenever the amber or red light
is flashing the buzzer is activated. Once the alarm is silenced the buzzer de-energizes and the amber or
red light stay on solid until the condition clears. The pushbutton also silences the ORT buzzer if there are
no other active alarms or faults on other PUs on the ORT network.
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12.4.2.2.13.1 INSPECT BUZZER SILENCE PUSHBUTTON (SIL)
Inspect the Buzzer Silence Pushbutton (SIL) for the following:
12.4.2.2.13.2 TEST BUZZER SILENCE PUSHBUTTON (SIL)
WARNING

WARNING

WARNING

USER.
To test the Buzzer Silence Pushbutton (SIL), proceed as follows:

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specified. Multimeter should indicate zero ohm at points marked in chart as shown in Figure
12.4.2.2.13.2-1.
c. Multimeter should indicate infinite ohms at all open contacts in chart as shown in Figure
12.4.2.2.13.2-1.
d. Replace Buzzer Silence Pushbutton (SIL) if it fails any of the above requirements.
TABLE 12.4.2.2.13.2-1 BUZZER SILENCE PUSHBUTTON (SIL)

BUZZER SILENCE PUSHBUTTON (SIL)
WIRE NUMBER
SWITCH POSITION
100 & 160
NORMAL - OUT
PUSHED-IN X
e. Using a multimeter set to OHMS (Ω) Rx1 scale, test for contact continuity in switch positions
specified. Multimeter should indicate zero ohms at points marked in chart as shown in Figure
12.4.2.2.13.2-1.
f. Multimeter should indicate infinite ohms at all open contacts in chart as shown in Figure
12.4.2.2.13.2-1.
12.4.2.2.13.3 REMOVE BUZZER SILENCE PUSHBUTTON (SIL)
To remove the Buzzer Silence Pushbutton (SIL), proceed as follows:
b. Twist the pushbutton retaining ring to the left until it comes off.
c. Unscrew the contact block from the operator.
d. Remove the Buzzer Silence Pushbutton (SIL) from rear of panel.
e. Tag and disconnect Buzzer Silence Pushbutton (SIL).
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12.4.2.2.13.4 INSTALL BUZZER SILENCE PUSHBUTTON (SIL)
To install the Buzzer Silence Pushbutton (SIL), proceed as follows:
b. Reinstall the Buzzer Silence Pushbutton (SIL) from rear of the control panel, secure retaining
nut, and Reinstall contact block.
c. Reinstall wiring to the Buzzer Silence Pushbutton (SIL) and discard tags.
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12.4.2.2.14 SYSTEM STATUS LIGHT (SSL)
The following maintenance procedures are provided for the System Status Light (SSL):
Inspect
Test
Remove
Install
FIGURE 12.4.2.2.14-1 SYSTEM STATUS LIGHT (SSL)
This indicator consists of four individual lights, integrated into a single cluster housing. The individually
colored LEDs are arranged red, green, amber, and green starting with the upper LED.
• Amber – Located at the lower position on the cluster. This LED indicates the presence of an
alarm condition. The LED flashing indicates a new un-silenced alarm. Once the alarm has been
silenced, the LED remains on solid. After the alarm condition clears the LED extinguishes. Used
in conjunction with the green LED’s, the operator can determine which associated generator has
the active alarm and/or fault.
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• Red – Located at the upper position on the cluster. This LED indicates the presence of a
fault/shutdown condition. The LED flashing indicates a new un-silenced alarm. Once the alarm
has been silenced, the LED remains on solid. After the alarm condition clears the LED
extinguishes. Used in conjunction with the green LED’s, the operator can determine which
associated generator has the active alarm and/or fault.
• Green – Located at the left and right positions on the cluster. These LED’s indicates the status of
their respective generators (left for Gen. 1, right for Gen. 2). An on-solid LED indicates that that
generator is ready for operation and has no active alarms or faults. A flashing LED indicates that
that generator has an active alarm or fault condition. Used in conjunction with the amber and red
LED’s, the operator can determine whether the associated generator has an active alarm and/or
fault.
12.4.2.2.14.1 INSPECT SYSTEM STATUS LIGHT (SSL)
Inspect the System Status Light (SSL) for the following:
12.4.2.2.14.2 TEST SYSTEM STATUS LIGHT (SSL)
WARNING

WARNING

WARNING

USER.
To test the System Status Light (SSL), proceed as follows:
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b. Remove the LED lens cap.
c. Carefully slide out the LED in question from the lens cap.
d. Using an ohmmeter check the LED. With the leads connected one way to the LED there should
be high resistance, reversing the leads there should be no resistance on a good LED. Replace
any LEDs that are high resistance both ways (Open) or low resistance both ways (Shorted).
12.4.2.2.14.3 REMOVE SYSTEM STATUS LIGHT (SSL)
To replace the System Status Light (SSL), proceed as follows:
b. Disconnect all wiring to the back of the light fixture
c. Remove the lens cap from the base by unscrewing it counter-clockwise.
d. Carefully remove the base assembly from the door by unscrewing the locknut from the front of
the door.
e. Slide the base assembly out of the door.
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12.4.2.2.14.4 INSTALL SYSTEM STATUS LIGHT (SSL)
To install the System Status Light (SSL), proceed as follows:
b. Reinstall the base assembly through the door from the back of the door.
c. Reinstall the lock nut positioning the base assembly so the terminals are on the sides.
d. Reinstall the lens cap lining up the lenses so the red lens is at the top. If the cap will not seat
properly, the base assembly is upside down. Loosen the locknut and invert it.
e. Reinstall the wiring to the base assembly. Remove Tags.
f. Close the Master Control Panel (MCP) door.
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12.4.2.2.15 50/60 HERTZ INDICATOR LIGHTS
The following maintenance procedures are provided for the 50/60 Hertz Indicator Lights:
Inspect
Test
Remove
Install
FIGURE 12.4.2.2.15-1 50/60 HERTZ INDICATOR LIGHTS
These two indicators reflect the current frequency that the control system expects. This is independent of
the setups required to configure both the AVR’s and GSC’s. The 50/60HZ lights reflect the Frequency
Selector Switch position while there are no Unit Selection Indicators (USI) on. Once a USI light is on the
FSS has no effect on the 50/60Hz lights. The selected light is set whenever the MSES is cycled to set
the USI lights or the System Mode Switch (SMS) is not in the off position.
12.4.2.2.15.1 INSPECT 50/60 HERTZ INDICATOR LIGHTS
Inspect the 50/60 Hertz Indicator Lights for the following:
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12.4.2.2.15.2 TEST 50/60 HERTZ INDICATOR LIGHTS
WARNING

To test the 50/60 Hertz Indicator Lights, proceed as follows:
a. Ensure the PU is isolated from other PU’s by disconnecting both (A) (B) communication cables.
b. Turn on the DC control power by pushing-in the DC-Power Switch.
c. Place both Engine Control Switches (ECS) in the OFF position.
d. Place the SMS in OFF. Observe any lit USI’s de-energize.
e. Open the Master Control Panel (MCP) door.
f. Check the position of the Frequency Selector Switch (FSS). It should match the current lit
Frequency Indicator.
g. Change the position of the FSS. Observe the Frequency Indicator lit also changes.
NOTE: When the DC Control Power Circuit Breaker is in the (OFF) position (Pulled – Out), all control
12.4.2.2.15.3 REMOVE 50/60 HERTZ INDICATOR LIGHTS
To remove the 50/60 Hertz Indicator Lights, proceed as follows:
b. Remove the indicator’s lens cap by unscrewing it in a counter-clockwise direction.
c. Remove the indicator LED by carefully unscrewing it in a counter-clockwise direction.
d. Tag and Disconnect the wiring from the base of the indicator.
e. Remove the base locknut from the front of the base and slide the base out to the back of the
door.
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12.4.2.2.15.4 INSTALL 50/60 HERTZ INDICATOR LIGHTS
To install the 50/60 Hertz Indicator Lights, proceed as follows:
b. Reinstall the replacement base from the back of the door and tighten the locknut.
c. Reinstall the wiring to the base of the indicator. Remove Tags.
d. Reinstall the LED by screwing it into the socket in a clockwise direction.
e. Reinstall the lens cap by screwing it onto the socket in a clockwise direction.
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12.4.2.2.16 PHASE ROTATION TEST LIGHTS (PRL)
The following maintenance procedures are provided for the Phase Rotation Test Lights (PRL):
Inspect
Test
Remove
Install
FIGURE 12.4.2.2.16-1 PHASE ROTATION TEST LIGHTS (PRL)
The Phase Rotation Test Lights indicate the phase rotation of the system bus. There are two
independent indicators. One indicates an A-B-C sequence and the other indicates an A-C-B sequence.
Under normal operating conditions the A-B-C sequence is proper. These indicators are used to verify all
sources are operating on the same phase sequence, which is required for parallel operation. The
indicators work along with an internally mounted phase sequence relay (device-47). The system bus
must be energized from only one source at a time for the check to work properly.
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12.4.2.2.16.1 INSPECT PHASE ROTATION TEST LIGHTS (PRL)
WARNING

WARNING

WARNING

USER.
Inspect the Phase Rotation Test Lights (PRL) for the following:
d. When the PU is connected to a live bus, and the Tie Breaker in the open position, push the test
switch to the test position and check the Phase Rotation Test Lights to see if ABC or CBA lights.
12.4.2.2.16.2 TEST PHASE ROTATION TEST LIGHTS (PRL)
WARNING

WARNING

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WARNING

USER.
To test the Phase Rotation Test Lights (PRL), proceed as follows:
a. This maintenance requires that the PU be connected to a live bus through the Load Tie Breaker.
The Load Tie breaker must be in the OPEN position to perform this test.
b. When the PU is connected to a live bus, and the Tie Breaker in the open position, push the test
switch to the test position and check the Phase Rotation Lights to see if ABC or CBA lights.
c. If neither ABC nor CBA light illuminates, inspect both bulbs by:
(1) Remove the lens cap by unscrewing it in the counter-clockwise direction.
(2) Remove the light bulb by unscrewing it in the counter-clockwise direction.
(3) Visually inspect the filament of the light bulb to see if it is broken. If necessary check the
bulbs with a multimeter set on OHMS, and check for an (Open) circuit.
(4) Replace the bulb if it is found to be defective.
d. If neither bulb is defective, check for 24VDC with a multimeter set in the DC range, at the back of
the test switch, with the switch in the OFF position.
e. With the test leads still connected, push the test switch into the TEST position. If there is still
24VDC at the switch in the test position, replace the defective switch.
12.4.2.2.16.3 REMOVE PHASE ROTATION TEST LIGHTS (PRL)
WARNING

WARNING

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WARNING

USER.
To remove the Phase Rotation Test Lights (PRL), proceed as follows:

b. Remove the lock ring and loosen the locknut on the back of the door.
c. Remove the lens by screwing it in a counterclockwise direction.
d. Remove the bulb by screwing it on in a counterclockwise direction.
e. Remove the base from the rear of the door.
f. Remove and Tag the wiring from the base.
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12.4.2.2.16.4 INSTALL PHASE ROTATION TEST LIGHTS (PRL)
To install the Phase Rotation Test Lights (PRL), proceed as follows:
b. Reinstall the base from the rear of the door.
c. Reinstall the lock ring and tighten the locknut on the back of the door.
d. Reinstall the replacement bulb by screwing it in a clockwise direction.
e. Reinstall the lens cap by screwing it on in a clockwise direction.
f. Reinstall the locknut so there is just sufficient threads to allow the lens cap to be firmly screwed
onto the base.
g. Reinstall the wiring to the base. Remove Tags.
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12.4.2.2.17 ALARM / FAULT BUZZER
The following maintenance procedures are provided for the Alarm / Fault Buzzer:
Inspect
Test
Remove
Install
FIGURE 12.4.2.2.17-1 ALARM / FAULT BUZZER
a. The buzzer is located at the top center of the Master Control Section. The buzzer actuates
whenever the control system sees a new alarm or fault activated. The buzzer will remain on as
long as there is an un-silenced alarm or fault. Pressing the Silence pushbutton for each active
alarm or fault silences the buzzer. The buzzer may also be silenced from a networked ORT.
b. Table 12.4.2.2.17-1 and Table 12.4.2.2.17-2 presents the Alarms and Fault matrix that activate
the buzzer during a fault.
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TABLE 12.4.2.2.17-1 FAULT MATRIX
FAULTS ACTIVATING BUZZER

High Coolant Temperature
Emergency Stop
Low Oil Pressure
Overcrank
Overspeed
Under Frequency
Over Frequency
Under Voltage
Over Voltage
Reverse Power
Frequency Sensing
Low Fuel Level
Neutral Ground Resistor (NGR)
Phase Time Overcurrent
Phase Instantaneous Overcurrent (Short Circuit)
Ground Time Overcurrent
Ground Instantaneous Overcurrent (Ground Fault)
ORT Immediate Stop
Generator Overload
TABLE 12.4.2.2.17-2 ALARMS MATRIX

ALARMS ACTIVATING BUZZER
High Coolant Temperature
Low Coolant Temperature
Low Oil Pressure
ECM Control
Low Battery Voltage
Under Frequency
Over Frequency
Under Voltage
Over Voltage
Reverse Power
Frequency Sensing
Low Fuel Level
Generator Overload
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12.4.2.2.17.1 INSPECT ALARM/FAULT BUZZER
WARNING

WARNING

WARNING

USER.
Inspect the Alarm/Fault Buzzer for the following:
a. Check the interior wire connections for loose connections.
b. Verify both setscrews are tight.
c. Check gasket for leaks by loosening the setscrews and removing the buzzer from its base.
12.4.2.2.17.2 TEST ALARM/FAULT BUZZER
WARNING

WARNING

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WARNING

ITS USER.
To test the Alarm/Fault Buzzer, proceed as follows:
a. This maintenance requires that the PU be set in Manual Mode Mode, and not running.
b. Turn on DC control power by pushing in the DC Power breaker.
c. Place one (ECS) in the STOP/COOLDOWN position.
d. Press in that engines local Emergency - Stop pushbutton.
e. Observe the EMCP II+ for the Emergency - Stop LED illuminates.
f. Observe that the alarm buzzer energizes.
g. Press the Silence Pushbutton to silence the buzzer; this may take 2 actions on the pushbutton.
h. Pull the Emergency - Stop button back out.
I. Place the (ECS) in OFF/RESET.
12.4.2.2.17.3 REMOVE ALARM/FAULT BUZZER
WARNING

WARNING

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WARNING

USER.
To remove the alarm/Fault Buzzer, proceed as follows:

b. Loosen both setscrews on the external sides of the buzzer.
c. Carefully pull out the buzzer assembly.
d. Remove and Tag the wires from the terminals inside the door.
e. Remove the conduit lock ring from the inside of the door.
f. Remove the mounting screws from the base of the buzzer.
g. Remove the buzzer from the door.
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12.4.2.2.17.4 INSTALL ALARM/FAULT BUZZER
To install the alarm/Fault Buzzer, proceed as follows:
b. Reinstall the conduit fitting to the base.
c. Reinstall the Alarm / Fault Buzzer in the door by tightening its mounting screws.
d. Reinstall the conduit to the door by tightening its lock nut from the inside of the door.
e. Reinstall the wiring to the base terminals and Remove tags.
f. Loosen the setscrews on the sides of the base.
g. Reinstall the Alarm / Fault Buzzer assembly into the base insuring proper alignment.
h. Tighten both setscrews.
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12.4.3 CONTROLS AND INSTRUMENTS WITHIN CABINET A, B, AND C
12.4.3.1 FREQUENCY SELECTOR SWITCH (FSS)
The following maintenance procedures are provided for the Frequency Selector Switch (FSS):
Inspect
Test
Remove
Install
FIGURE 12.4.3.1-1 FREQUENCY SELECTOR SWITCH (FSS)
This switch is located on the inside of the center door. It is a maintained, two-position, lever-lock toggle
switch. The lever-lock feature provides the switch with a positive position lock. This switch is only
functional while the PU status indicators are flashing. For the RTU to recognize a change, place the
(SMS) in off until the PU status indicators flash, then select MAN or AUTO and cycle the (MSS).
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12.4.3.1.1 INSPECT FREQUENCY SELECTOR SWITCH (FSS)
Inspect the Frequency Selector Switch (FSS) for the following:
12.4.3.1.2 TEST FREQUENCY SELECTOR SWITCH (FSS)

WARNING

WARNING

WARNING

USER.
To test the Frequency Selector Switch (FSS), proceed as follows:

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b. Using a multimeter set to OHMS (Ω) Rx1 scale, test for continuity in switch positions specified.
Multimeter should indicate zero ohms at points marked in chart as shown in Table 12.4.3.1.2-1.
c. Multimeter should indicate infinite ohms at all open contacts as shown in Table 12.4.3.1.2-1.
d. Replace the Frequency Selector Switch (FSS) if it fails any of the above requirements.
TABLE 12.4.3.1.2-1 FREQUENCY SELECTOR SWITCH (FSS)

FREQUENCY SELECTOR SWITCH (FSS)
60 HERTZ
50 HERTZ X
12.4.3.1.3 REMOVE FREQUENCY SELECTOR SWITCH (FSS)
To remove the Frequency Selector Switch (FSS), proceed as follows
b. Remove the 2-switch bracket retaining screws.
c. Remove the front switch-retaining nut.
d. Remove the Frequency Selector Switch (FSS) from rear of the bracket.
e. Tag and disconnect wires on the Frequency Selector Switch (FSS).
12.4.3.1.4 INSTALL FREQUENCY SELECTOR SWITCH (FSS)
To install the Frequency Selector Switch (FSS), proceed as follows
b. Reinstall the FSS from rear of the mounting bracket, and secure with the retaining nut.
c. Reinstall wiring to the Frequency Selector Switch (FSS) and discard tags.
d. Reinstall the mounting bracket with 2 retaining screws.
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12.4.3.2 AUTOMATIC SYNCHRONIZER (SPMA)
The following maintenance procedures are provided for the Automatic Synchronizer (SPMA):
Inspect
Test
Remove
Install
FIGURE 12.4.3.2-1 AUTOMATIC SYNCHRONIZER (SPMA)
This solid-state device provides the automatic speed-matching synchronizing of its associated generator.
The Automatic Synchronizer (SPMA) will either increase the engine speed or decrease engine speed in
order to speed-match with the bus. There are two units provided, one for each generator. They are
installed on the insider of the center door.
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12.4.3.2.1 INSPECT AUTOMATIC SYNCHRONIZER (SPMA)
Inspect the Automatic Synchronizer (SPMA) for the following:
12.4.3.2.2 TEST AUTOMATIC SYNCHRONIZER (SPMA)
To test the Automatic Synchronizer (SPMA), proceed as follows:
Refer to the Woodard SPM-A Synchronizer Manual, 82384R, Chapter 4, Calibration and checkout
procedures.
12.4.3.2.3 REMOVE AUTOMATIC SYNCHRONIZER (SPMA)
WARNING

WARNING

WARNING

USER.
To remove the Automatic Synchronizer (SPMA), proceed as follows

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b. Tag and disconnect the wiring from the Automatic Synchronizer (SPMA). Refer to FO-18.
c. Remove the four mounting bolts and remove the Automatic Synchronizer (SPMA) from the
cabinet.
12.4.3.2.4 INSTALL AUTOMATIC SYNCHRONIZER (SPMA)
To install the Automatic Synchronizer (SPMA), proceed as follows:
b. Reinstall the Automatic Synchronizer (SPMA) from rear of the control panel, and secure with
retaining nuts.
c. Reinstall wiring to the Automatic Synchronizer (SPMA) and discard tags.
d. Calibrate the Automatic Synchronizer (SPMA) using instructions found in the Woodard SPM-A
Synchronizer Manual, 82384R for Chapter 4, Calibration and checkout procedures.
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12.4.3.3 LOAD SHARING MODULE (LSM)
The following maintenance procedures are provided for the Load Sharing Module (LSM):
Inspect
Test
Remove
Install
FIGURE 12.4.3.3-1 LOAD SHARING MODULE
There are two units provided, one for each generator. They are installed on the inside of the center door.
The load-sharing module receives input from current transformers (CT) and potential transformers (PT),
to calculate power from the generator, assuming constant voltage. It generates an output that biases the
speed reference of the speed control. The load-sharing module uses paralleling lines to ensure
proportional load sharing with other generators that are isochronously paralleled. Refer to FO-18 for LSM
wiring diagram.
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12.4.3.3.1 INSPECT LOAD SHARING MODULE (LSM)
Inspect the Load Sharing Module (LSM) for the following:
12.4.3.3.2 TEST LOAD SHARING MODULE (LSM)
To test the Load Sharing Module (LSM), proceed as follows:
See Caterpillar SENR6565-02, SMCS Code: 4490-035, or later version for the most current procedures.
NOTE: SENR6565-02 is broken into two separate manuals. For this LSM refer to RENR2471-01.
12.4.3.3.3 REMOVE LOAD SHARING MODULE (LSM)
WARNING

WARNING

WARNING

USER.
To remove the Load Sharing Module (LSM), proceed as follows

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b. Tag and disconnect the wiring from the Load Sharing Module (LSM). Refer to FO-18.
c. Remove the four mounting bolts and remove the Load Sharing Module (LSM) from the cabinet.
12.4.3.3.4 INSTALL LOAD SHARING MODULE (LSM)
To install the Load Sharing Module (LSM), proceed as follows
b. Reinstall the Load Sharing Module (LSM) from rear of the control panel, and secure with
retaining nuts.
c. Reinstall wiring to the Load Sharing Module (LSM) and discard tags.
d. Calibrate the Load Sharing Module (LSM) using instructions found in See Caterpillar SENR6565-
02, SMCS Code: 4490, or later version for the most current procedures.
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12.4.3.4 REMOTE TERMINAL UNIT (RTU)
The following maintenance procedures are provided for the Remote Terminal Unit (RTU):
Inspect
Test
Remove
Install:
• RTU
• RTU Software
FIGURE 12.4.3.4-1 REMOTE TERMINAL UNIT (RTU)
This microprocessor based controller and its associated input/output modules are located on the center
section swing out sub panel. The Remote Terminal Unit (RTU) provides the control logic for automatic
operation. Additionally, it retrieves all operating parameters from both GSC + modules on the PU and
provides the networked controlling between MEP-PU-810s. During Manual operations the Remote
Terminal Unit (RTU) only provides monitoring capability. During automatic operations, however, the
Remote Terminal Unit (RTU) provides all the control algorithms for the various control routines within the
PU system. It also allows the ORT to function with the PU(s).
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• Each Remote Terminal Unit (RTU) has a Power LED, and a status LED that indicates
configuration and communication status by blinking in different ways.
• Every on-board discrete I/O channel is isolated from logic circuitry and from any expansion I/O
modules for fault-free operation.
WARNING
EXPLOSION HAZARD – WHEN IN HAZARDOUS LOCATIONS, DISCONNECT

POWER BEFORE REPLACING OR WIRING MODULES.
12.4.3.4.1 INSPECT REMOTE TERMINAL UNIT (RTU)
Inspect the Remote Terminal Unit (RTU) for the following:
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12.4.3.4.2 TEST REMOTE TERMINAL UNIT (RTU)
To test the Remote Terminal Unit (RTU), proceed as follows:
Refer to Table 12.4.3.4.2-1 and Sixnet, Versa TRAK, Remote Terminal Units, Installation and
Maintenance Manual, Section 10, Dated September 1998 or later.
TABLE 12.4.3.4.2-1 RTU MAINTENANCE INFORMATION

MAINTENANCE INFORMATION
DIAGNOSTICS INFORMATION
Local diagnostics can be performed through any available port while the
LOCAL versatrak is responding to messages from other ports.
DIAGNOSTICS Diagnostic software, such as Ioview and I/O TOOLKIT,
can be used to display the status of the I/O registers.
VERATRAK The “Status” LED on a Versa TRAK should be ON continuously within 3
STATUS LED seconds of power up.
SIXTRAK I/O The “Status” LED on each SIXTRAK expansion I/O module may be observed
STATUS LED in one of five states:
ON The module is configured properly and communicating with the RTU.
There is no power to the module, or the status LED is being turned off
OFF
intentionally by Plant Floor during the module linking operation.
Long blinking indicates one of two conditions. Either the module has lost
LONG BLINK its communication with the RTU for more than 10 seconds, or the module
.75 SECONDS ON, has not received configuration data from the RTU. Upon initial system
.25 SECONDS OFF startup (no configuration in the RTU) this should be the observed LED state
on each module,
SHORT BLINK
.25 SECONDS ON, Short blinking indicates a failure of the module self test upon power up.
.75 SECONDS OFF
WINKING A Status LED may be winked by the Plant Floor utility to bring attention to
10 the module. This winking occurs during module linking procedure. Refer
BLINKS/SECOND to the online help in Plant Floor for more information.
The Versa TRAK RTU has nonvolatile (battery-free) memory for storing
configuration data from the Plant Floor utility. They also have battery-
backed memory for storage of program variables and logged data. The
RTU MEMORY battery is a rechargeable lithium cell that is kept fresh by the power circuitry
in the RTU. The memory retention time will be shorter at higher
temperatures. The life expectancy of the lithium battery is approximately 10
years.
The RTU battery will remain charged for no longer than 1 year while in
storage. To ensure battery-backed memory storage of programmed
RTU BATTERY
variables the battery must be recharged periodically. See service
procedures in Chapter 6.
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12.4.3.4.3 REMOVE REMOTE TERMINAL UNIT (RTU)
WARNING

WARNING

WARNING

USER.
To remove the Remote Terminal Unit (RTU), proceed as follows:

b. Tag and disconnect the wiring from the Remote Terminal Unit (RTU).
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c. Remove the four mounting screws and remove the Remote Terminal Unit (RTU) from the
cabinet.
12.4.3.4.4 INSTALL REMOTE TERMINAL UNIT (RTU)
To install the Remote Terminal Unit (RTU), proceed as follows:
b. Reinstall the Remote Terminal Unit (RTU) on the control panel, and secure with retaining
screws..
c. Reinstall wiring to the Remote Terminal Unit (RTU) and discard tags.
d. Place DC Control Power Circuit Breaker to ON.
e. Reinstall the RTU software. Follow the procedures listed in Section 12.4.3.4.4.1:
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12.4.3.4.4.1 INSTALL RTU SOFTWARE (NEW INSTALL)
To install the RTU software, proceed as follows:
This maintenance requires that the PU MUST be shutdown, rendered unable to start, cool enough for
the maintenance to be performed, and Communication Cable (A) and (B) rerouted to the next PU.
This is accomplished by performing the following:
1. Shutdown the PU in accordance with Section 5.1.6.1 Shutdown Generators.

2. Isolate the PU from any power plant control system.
3. Place both Engine Control Switches (ECS) in the OFF position.
4. Place a DO NOT OPERATE tag on both generator control panels.
5. Turn the Battery Bank Parallel Switch to the OFF position.
6. Place all Circuit Breakers in the LOCK OUT position.
7 The (A) (B) Communication Cable must be routed to the next PU in order to reestablish the
communication network.
8. Turn “ON” the ORT.
9. At the login enter the following:
a. Username: Administrator
b. Password: dpgds (case sensitive)
10. Start IO Toolkit by double-clicking on the IO Toolkit icon. Refer to Figure 12.4.3.4.4.1-1 for
reference.
FIGURE 12.4.3.4.4.1-1 IO TOOLKIT ICON
a. From the Main Menu select “Device”, then “Select”.
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FIGURE 12.4.3.4.4.1-2 DEVICE SCREEN
b. Select the “Use comm port” radio button. This sets up the ORT to communicate with the
RTU via the serial port.
FIGURE 12.4.3.4.4.1-3 USE COMM PORT SCREEN
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11. Prepare PDC

a. Place SMS switch in the OFF position.
b. Place both ECS switches in the OFF/RESET position.
c. Turn on DC power on the PDC.
12. Connect the computer to the RTU
a. Connect the Null Modem/Gender Changer (located in the ORT case) into the male end of the
DB9 connector of the serial cable located in the ORT case (See Figure 12.4.3.4.4.1-5).
b. Plug one end of the serial cable to the computer’s serial port and the other into the RTU’s
Plant Floor port (See location in Figure 12.4.3.4-1).
13. Delete existing files
a. Select “pdc1” from the Station Names on the Stations tab of the main window.
FIGURE 12.4.3.4.4.1-4 PDC 1 SCREEN
b. From the Main Menu select “Operations”, then “File Operations”.
FIGURE 12.4.3.4.4.1-5 NULL MODEM/GENDER CHANGER
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FIGURE 12.4.3.4.4.1-6 FILE OPERATIONS SCREEN
c. Observe window displaying file contents of RTU.
FIGURE 12.4.3.4.4.1-7 RTU CONTENTS SCREEN
d. Select the “isa11.x6m” file.
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FIGURE 12.4.3.4.4.1-8 ISA11.X6M SCREEN
e. Click the “Delete” button to delete the file.

f. Acknowledge “Yes” when prompted.
FIGURE 12.4.3.4.4.1-9 DELETE FILE SCREEN
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g. Observe the isa.x6m file is deleted.
FIGURE 12.4.3.4.4.1-10 FILE DELETED SCREEN
h. When the files clears from the window, select the “Action.6TL” file.
FIGURE 12.4.3.4.4.1-11 ACTION. 6TL SCREEN
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i. Click the “Clear” button to clear the file.

j. Acknowledge “Yes” when prompted.
FIGURE 12.4.3.4.4.1-12 CLEAR ACTION TABLE SCREEN
k. When the file size is 0, click “Close”.
FIGURE 12.4.3.4.4.1-13 CLOSE SCREEN
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l. From the Main Menu select “Operations”, then “Advanced Operations”, “Clear Configuration”.
FIGURE 12.4.3.4.4.1-14 OPERATIONS SCREEN
m. Acknowledge Yes on the “Direct Control” pop-up.
FIGURE 12.4.3.4.4.1-15 DIRECT CONTROL SCREEN
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n. Acknowledge Yes on the “Clear Configuration” pop-up.
FIGURE 12.4.3.4.4.1-16 CLEAR CONFIGURATION SCREEN 1
o. Observe the “Clear Configuration” status pop-up.
FIGURE 12.4.3.4.4.1-17 CLEAR CONFIGURATION SCREEN 2
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p. Observe the proper completion of the Station Configuration cleared as indicated in the IO
Toolkit status window (lower left hand corner of the screen).
FIGURE 12.4.3.4.4.1-18 STATION CONFIGURATION SCREEN
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14. Firmware Update

a. From the Main Menu select “Operations”, then “Advanced Operations”, then “Read Firmware
Version”.
FIGURE 12.4.3.4.4.1-19 ADVANCED OPERTIONS SCREEN
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b. If version is 2.23X, then skip to step 15 – Configuration Update, otherwise continue.
FIGURE 12.4.3.4.4.1-20 FIRMWARE VERSION SCREEN
c. From the Main Menu select “Operations”, then “Load”, “Load Now”.
FIGURE 12.4.3.4.4.1-21 LOAD NOW SCREEN
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d. Observe the loading progression.
FIGURE 12.4.3.4.4.1-22 LOADING PROGRESSION SCREEN
e. From the Main Menu select “Operations”, then “Advanced Operations”, “Upgrade Firmware”.
FIGURE 12.4.3.4.4.1-23 UPGRADE FIRMWARE SCREEN
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f. Acknowledge “Yes” on the Direct Connect screen.
FIGURE 12.4.3.4.4.1-24 DIRECT CONNECT SCREEN
g. Navigate to C:\....\PLC_Files, select the “STPR223X.6FW” file.
FIGURE 12.4.3.4.4.1-25 SELECT FIRMWARE SCREEN
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h. Click “OK”.
i. Observe progression (approx. 5 minutes).
FIGURE 12.4.3.4.4.1-26 LOADING FIRMWARE SCREEN
j. Observe the “Firmware load complete” in the lower status window.
FIGURE 12.4.3.4.4.1-27 FIRMWARE LOAD COMPLETE SCREEN
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15. Configuration Update

a. From the Main Menu select “Configure”, then “Configure Station/Module”.
FIGURE 12.4.3.4.4.1-28 CONFIGURE STATION SCREEN
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b. Select the “Advanced” tab.
FIGURE 12.4.3.4.4.1-29 ADVANCED TAB SCREEN
c. Click on “Assign Resources” button.
FIGURE 12.4.3.4.4.1-30 ASSIGN RESOURCES SCREEN
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d. Verify the File System memory allocation is 512 Kbytes.

e. Click on “Set Memory”
FIGURE 12.4.3.4.4.1-31 SET MEMORY SCREEN
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f. Acknowledge “OK” to any pop-up windows.

g. Verify you receive a “Memory matches” message in green text beneath the action buttons.
FIGURE 12.4.3.4.4.1-32 RESOURCE ALLOCATION SCREEN
h. Click “OK” once completed to close window.

i. Click “OK” to close “Sixtrak/VERSAtrak Configuration” window.
16. Load new files
a. From the Main Menu select “Operations”, then “Link”.
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FIGURE 12.4.3.4.4.1-33 OPERATION/LINK SCREEN
b. Follow the linking instructions on the screen to link the input and output modules.
FIGURE 12.4.3.4.4.1-34 LINKING INSTRUCTION SCREEN
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c. When all modules have been assigned, click the “Apply” button.
FIGURE 12.4.3.4.4.1-35 MODULES ASSIGNED SCREEN
d. Observe the progression.
FIGURE 12.4.3.4.4.1-36 MODULE PROGRESSION SCREEN
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e. Click the “Close” button.
FIGURE 12.4.3.4.4.1-37 LINKING COMPLETE SCREEN 1
f. Click “OK”.
FIGURE 12.4.3.4.4.1-38 LINKING COMPLETE SCREEN 2
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g. From the Main Menu select “Operations”, then “File Operations”.
FIGURE 12.4.3.4.4.1-39 FILE OPERATIONS SCREEN
h. Click the “Load Isagraf” button.
FIGURE 12.4.3.4.4.1-40 LOAD ISAGRAF SCREEN
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i. Acknowledge “Yes” when prompted.
FIGURE 12.4.3.4.4.1-41 ISAGRAF PROGRAM SCREEN
j. Select the “Appli.X6M” file.
FIGURE 12.4.3.4.4.1-42 APPLI.X6M FILE SCREEN
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k. Click the “Open” button.

l. Observe the progression.
FIGURE 12.4.3.4.4.1-43 LOADING APPLI.X6M FILE SCREEN
m. Click the “Close” button.
FIGURE 12.4.3.4.4.1-44 APPLI.X6M FILE COMPLETE SCREEN
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n. Close IO Toolkit, do not save changes.
17. Check RTU loading

a. Cycle DC power.
b. Insure SMS switch is in the OFF position.
c. Place both ECS switches in the AUTO position.
d. “Red flag” both generator BCS switches.
e. Place the SMS switch in the AUTO position.
f. Observe both green ready lights on SSL energize.
g. Return the SMS to the OFF position.
h. Return both ECS switches to the OFF/RESET position.
i. Turn off DC power.
j. Disconnect the serial cable from the RTU.
k. Place the RTU software/firmware sticker horizontally on the lower right side of the RTU.
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12.4.3.5 MODULAR DIN RAIL (I/O)
The following maintenance procedures are provided for the Modular DIN Rail (I/O):
Inspect
Test
Remove
Install
FIGURE 12.4.3.5-1 MODULAR DIN RAIL I/O DIM 1, DIM 2, DIM 3, DOM 1, DOM 2
MODULAR DIN RAIL I/O BASE
FIGURE 12.4.3.5-2 MODULAR DIN RAIL I/O BASE
See Figure 12.4.3.5-1 and Figure 12.4.3.5-2 for reference. The DIM and DOM modules provide direct
wiring to all devices within the PU controlled by the microprocessor based controller (RTU).
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12.4.3.5.1 INSPECT MODULAR DIN RAIL (I/O)
Inspect the Modular DIN Rail (I/O) for the following:
12.4.3.5.2 TEST MODULAR DIN RAIL (I/O)
To test the Modular DIN Rail (I/O), proceed as follows:
Refer to the Sixnet, SixTrak, Modular DIN Rail I/O, Installation and Maintenance Manual, Section 10,
Dated September 1998 or later.
TABLE 12.4.3.5.2-1 I/O MAINTENANCE INFORMATION

MAINTENANCE INFORMATION
DIAGNOSTICS INFORMATION
Local Diagnostics can be performed through any available port while the
LOCAL RTU is responding to messages from the other port.
DIAGNOSTICS Diagnostic software, such as I/Oview and I/O Toolkit, can
be used to display the status of the I/O registers.
The “Status” LED on each module may be observed in one of five states:
ON: The module is configured properly and communicating with the RTU.
OFF: There is no power to the module, or the status LED is being turned off
intentionally by I/O Toolkit during the module linking operation.
LONG BLINK .75 SECONDS ON, .25 SECONDS OFF: Long blinking indicates
one of two conditions. Either the module has lost its communication with the
STATUS LED RTU for more than 10 seconds, or the module has not received configuration
data from the RTU. Upon initial system startup (no configuration in the RTU)
this should be the observed LED state on each module,
SHORT BLINK .25 SECONDS ON, .75 SECONDS OFF: Short blinking indicates
a failure of the module self test upon power up.
WINKING 10 BLINKS/SECOND: A Status LED may be winked by the I/O Toolkit

utility to bring attention to the module. This winking occurs during module
linking procedure. Refer to the online help in I/O Toolkit for more information.
HOT SWAP I/O modules may be unplugged from their bases, even in live systems. SixTrak I/O
FEATURE modules automatically self-configure from system memory.
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12.4.3.5.3 REMOVE MODULAR DIN RAIL (I/O)
WARNING

WARNING

WARNING

USER.
To remove the Modular DIN Rail (I/O), proceed as follows:

b. Squeeze the center of the Modular DIN Rail I/O and pull the relay free of the base.
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12.4.3.5.4 INSTALL MODULAR DIN RAIL (I/O)
To install the Modular DIN Rail (I/O), proceed as follows:
Squeeze the center of the Modular DIN Rail I/O and Reinstall the relay into of the base. This can be
performed while the DC Control circuit breaker is on.
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12.4.3.6 HUB
The following maintenance procedures are provided for the HUB:
Inspect
Test
Remove
Install
FIGURE 12.4.3.6-1 HUB
See Figure 12.4.3.6-1 for reference. These micro-hubs provide the networking capability used by the
th
PU’s and the ORT. The hubs can be either a 9-port unit with the 5 port being used for up linking to
another PU or a five-port unit. This device is located in the center section on the swing out sub panel.
12.4.3.6.1 INSPECT HUB
Inspect the HUB for the following:
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12.4.3.6.2 TEST HUB
a. There is no field-testing on the HUB.
b. The HUB performs internal diagnostics during start up.
c. Ensure that the power light is on.
d. Check power supply to the HUB, if there is 24VDC present and the green power light is not
illuminated, replace the HUB. Refer to FO-23 for reference.
12.4.3.6.3 REMOVE HUB
WARNING

WARNING

WARNING

ITS USER.
To remove the HUB, proceed as follows:

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b. Tag and disconnect the wiring from the HUB.
c. Release the latch on the bottom of the hub with a small screwdriver by pushing down and then
pulling the hub up and out from the Modular Din Rail.
12.4.3.6.4 INSTALL HUB
To install the (HUB), proceed as follows:
b. Reinstall the HUB into the control panel by sliding into the Modular Din Rail and pushing down to
engage the locking tab.
c. Reinstall wiring to the HUB. Remove tags.
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12.4.3.7 PROTOCOL COMMUNICATION MODULE (PCM)
The following maintenance procedures are provided for the Protocol Communication Module (PCM):
Inspect
Test
Remove
Install
PROTOCOL COMMUNICATION MODULE (PCM)
FIGURE 12.4.3.7-1 PCM LOCATION
This micro-controller constantly polls the Caterpillar CCM for the parameters required by the control
system. These parameters are then converted from their Caterpillar M5X protocol to Modbus addresses
and stored on board for access by the RTU. This device is located in the center section swingout
subpan. It is installed below the CCM.
12.4.3.7.1 INSPECT PROTOCOL COMMUNICATION MODULE (PCM)
Inspect the Protocol Communication Module (PCM) for the following:
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12.4.3.7.2 TEST PROTOCOL COMMUNICATION MODULE (PCM)
To test the Protocol Communication Module (PCM), proceed as follows:
a. Check that the Uplink Port LEDS “ACT/LNK – 10/100” are flashing on the RTU.
b. Check with a multi-meter on the VDC scale, at pins J2 “DCIN” and “GRD” for 15VDC. Refer to
FO-21 more information.
c. The Protocol Communication Module (PCM) translates the M5X CAT protocol that is transferred
by the Customer Communication Module (CCM) through the DB25 connector, into MODBUS PLC
Language.
d. Check that both LED’s “4” and “6” of the Customer Communication Module are flashing,
indicating that data is being transmitted and received by the Protocol Communication Module
(PCM). Refer to Illustration 3, SMCS Code 1926 “Display Description”, of the “Operation Section”
in the Operation and Maintenance Manual “SEBU6874-04”, March 2000, for more information.
e. The Remote Terminal Unit (RTU) receives the MODBUS PLC Language from the Customer
Communication Module (CCM) through the DB9 connector that is connected to the RTU’s main
port connector.
NOTE 1: The PCM battery is not utilized for this configuration. However, if the battery has a short, the
PCM will cease to function.
12.4.3.7.3 REMOVE PROTOCOL COMMUNICATION MODULE (PCM)
WARNING

WARNING

WARNING

USER.
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To remove the Protocol Communication Module (PCM), proceed as follows:

b. Tag and disconnect the wiring from the PCM.
c. Remove the mounting bolts and remove the PCM from the cabinet.
12.4.3.7.4 INSTALL PROTOCOL COMMUNICATION MODULE (PCM)
To install the Protocol Communication Module (PCM), proceed as follows:
b. Reinstall the Protocol Communication Module (PCM) from the control panel, and secure with
retaining nuts.
c. Reinstall wiring to the Protocol Communication Module (PCM) and discard tags.
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12.4.3.8 CUSTOMER COMMUNICATION MODULE (CCM)
The following maintenance procedures are provided for the Customer Communication Module (CCM):
Inspect
Test
Remove
Install
Service
CUSTOMER COMMUNICATION MODULE (CCM)
FIGURE 12.4.3.8-1 CUSTOMER COMMUNICATION MODULE
This Caterpillar device provides a two-way communication link between the electronic controller
(generator set) and a host device (PCM). This component is installed on the center section swing-out sub
panel (See Figure 12.4.3.7-1 and Figure 12.4.3.8-1).
12.4.3.8.1 INSPECT CUSTOMER COMMUNICATION MODULE (CCM)
Inspect the Customer Communication Module (CCM) for the following:
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12.4.3.8.2 TEST CUSTOMER COMMUNICATION MODULE (CCM)
To test the Customer Communication Module (CCM), proceed as follows:
a. This device performs a self-diagnostic test each time it is energized.
b. For troubleshooting instructions, see SEBU6874-04 or later version, SCMS CODE: 1926.
12.4.3.8.3 REMOVE CUSTOMER COMMUNICATION MODULE (CCM)
WARNING

WARNING

WARNING

USER.
To remove the Customer Communication Module (CCM), proceed as follows:

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b. Tag and disconnect the wiring from the Customer Communication Module (CCM).
c. Remove the mounting bolts and remove the Customer Communication Module (CCM) from the
cabinet.
12.4.3.8.4 INSTALL CUSTOMER COMMUNICATION MODULE (CCM)
To install the Customer Communication Module (CCM), proceed as follows:
b. Reinstall the Customer Communication Module (CCM) from the control panel, and secure with
retaining nuts.
c. Reinstall wiring to the Customer Communication Module (CCM) and discard tags.
12.4.3.8.5 SERVICE CUSTOMER COMMUNICATION MODULE (CCM)
a. The CCM contains a 101-1 785 Battery that supplies power for internal memory whenever the
CCM is powered-down. In single unit installations, the CCM power is OFF whenever the GSC+
power is OFF. The battery has an expected life of five years. The battery is mounted to the
inside of the front plate of the CCM behind the three-digit display.
b. Replacing the CCM Battery
(1) Remove the four screws securing the front plate to the housing.
(2) The battery is held in place by two small tabs on the upper and lower side of the battery.
A tie-wrap provides additional support.
(3) Remove the tie-wrap.
(4) With a small screwdriver, carefully pry one tab and lift that side of the battery slightly.
(5) Repeat for the other tabs and remove the battery.
(6) Carefully press the replacement battery into holder until tabs are securing the battery.
(7) The battery has one corner that is angled to make sure proper polarity is maintained
during installation.
(8) Make sure the battery pins are entering the sockets of the holder properly.
(9) Install the new tie-wrap.
(10) Reinstall the front plate of the CCM.
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12.4.3.9 POWER CONVERTER
12.4.3.9.1 POWER CONVERTER (P15)
The following maintenance procedures are provided for the Power Converter (P15):
Inspect
Test
Remove
Install
FIGURE 12.4.3.9.1-1 POWER CONVERTER (P15)
This device converts 24VDC to 15VDC for use by the micro-hub. It is located on the center section swing
out sub panel.
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12.4.3.9.1.1 INSPECT POWER CONVERTER (P15)
Inspect the Power Converter (P15) for the following:
12.4.3.9.1.2 TEST POWER CONVERTER P15
To test the Power Converter (P15), proceed as follows:

b. With a multimeter in the VDC mode, check the Input and Output voltage terminals. Input should
read 24VDC and the output should read 15VDC.
12.4.3.9.1.3 REMOVE POWER CONVERTER (P15)
WARNING

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WARNING

WARNING

USER.
To remove the Power Converter P15, proceed as follows:

b. Tag and disconnect the wiring from the (P15).
c. Release the locking tab on the bottom of the Power Converter with a small screwdriver, push up
and remove the assembly from the Modular Din Rail.
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12.4.3.9.1.4 INSTALL POWER CONVERTER P15
To install the Power Converter (P15), proceed as follows:
rerouted to the next PU.
b. Reinstall the Power Converter (P15) on the control panel by sliding into the Modular Din Rail and
pushing down to engage the locking tab.
c. Reinstall wiring to the Power Converter (P15), and discard tags.
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THIS PAGE INTENTIONALLY BLANK

SECTION TITLE PAGE

11.1 SAFETY INSTRUCTIONS 5

11.2 FUEL SYSTEM DESCRIPTION 7

11.2.1 FUEL INJECTION 8

11.2.2 THE UNIT INJECTOR MECHANISM 10

11.2.3 SYSTEM MAINTENANCE 11

11.3 SERVICE REQUIREMENTS OF THE FUEL SYSTEM 12

11.3.1 PRIMARY FUEL FILTER 12

11.3.1.1 INSPECT THE PRIMARY FUEL FILTER 12

11.3.1.2 SERVICE THE PRIMARY FUEL FILTER 13

11.3.2 SECONDARY FUEL FILTER 16

11.3.2.1 INSPECT THE SECONDARY FUEL FILTER 16

11.3.2.2 SERVICE THE SECONDARY FUEL FILTER 17

11.3.3 FUEL STRAINER 18

11.3.3.1 INSPECT THE FUEL STRAINER 18

11.3.3.2 SERVICE THE FUEL STRAINER 19

11.3.4 ETHER INJECTION 21

11.3.4.1 INSPECT THE ETHER INJECTION ASSEMBLY 21

11.3.4.2 SERVICE THE ETHER INJECTION ASSEMBLY 21

11.3.5 FUEL SYSTEM PRIMING PROCEDURE 23

11.4 COMPONENT REPAIR PROCEDURES 26

11.4.1 FUEL SOLENOID VALVE (L3) 26

11.4.1.1 INSPECT THE FUEL SOLENOID VALVE (L3) 27

SECTION TITLE PAGE

11.4.1.3 INSTALL THE FUEL SOLENOID VALVE (L3) 28

11.4.2 EXTERNAL FUEL TRANSFER PUMP ASSEMBLY 30

11.4.2.1 INSPECT THE EXTERNAL FUEL TRANSFER PUMP ASSEMBLY 31

11.4.2.2 TEST THE EXTERNAL FUEL TRANSFER PUMP ASSEMBLY 31

11.4.2.3 REMOVE THE EXTERNAL FUEL TRANSFER PUMP ASSEMBLY 31

11.4.2.4 INSTALL THE EXTERNAL FUEL TRANSFER PUMP ASSEMBLY 33

11.4.3 FUEL PRIMER PUMP 34

11.4.3.1 INSPECT THE FUEL PRIMER PUMP 34

11.4.3.2 REMOVE THE FUEL PRIMER PUMP 35

11.4.3.3 INSTALL THE FUEL PRIMER PUMP 36

11.4.4 ENGINE MOUNTED FUEL PUMP 37

11.4.4.1 INSPECT THE ENGINE MOUNTED FUEL PUMP 37

11.4.4.2 REMOVE THE ENGINE MOUNTED FUEL PUMP 38

11.4.4.3 INSTALL THE ENGINE MOUNTED FUEL PUMP 39

11.4.5 FUEL FLOAT SWITCH ASSEMBLY 40

11.4.5.1 INSPECT THE FUEL FLOAT SWITCH ASSEMBLY 41

11.4.5.2 TEST THE FUEL FLOAT SWITCH ASSEMBLY 41

11.4.5.3 REMOVE THE FUEL FLOAT SWITCH ASSEMBLY 42

11.4.5.4 INSTALL THE FUEL FLOAT SWITCH ASSEMBLY 43

FIGURE TITLE PAGE

FIGURE 11.2.1-1 UNIT INJECTOR MECHANISM 9

FIGURE 11.2.2-1 UNIT INJECTOR COMPONENTS 10

FIGURE 11.3.1-1 PRIMARY FUEL FILTER 12

FIGURE 11.3.1.2-1 PRIMARY FUEL FILTER DRAIN VALVE 15

FIGURE 11.3.2-1 SECONDARY FUEL FILTER 16

FIGURE 11.3.3-1 FUEL STRAINER ASSEMBLY 18

FIGURE 11.3.4-1 ETHER INJECTION ASSEMBLY 21

FIGURE 11.3.5-1 CYLINDER HEAD AIR BLEED CAP 24

FIGURE 11.3.5-2 FUEL PRIMING PUMP 24

FIGURE 11.3.5-3 FUEL SYSTEM AIR BLEED PLUG 25

FIGURE 11.4.1-1 FUEL SOLENOID VALVE (L3) 26

FIGURE 11.4.2-1 FUEL TRANSFER PUMP 30

FIGURE 11.4.3-1 FUEL PRIMER PUMP 34

FIGURE 11.4.4-1 ENGINE MOUNTED FUEL PUMP 37

FIGURE 11.4.5-1 FUEL FLOAT SWITCHES 40

TABLE TITLE PAGE