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1. Ascended the pole if necessary Wore the correct PPE Installed the mounting bracket on the pole Mounted the lighting fixture and ballast onto the bracket oN O o A OO N Ensured that the mounted equipment was secured to the pole for safety purposes Ko Installed the distribution and control wiring 10 Closed out lockout and tagout procedures by removing locking and tagging devices 11 Energized the circuit 12 Verified that the lamp illuminated the designated area 13 Adjusted the lamp to illuminate the designated area if necessary 14 Ensured that the items listed in the conditions were properly cleaned and stored Evaluation Guidance Score the Soldier GO if all measures are passed P Score the Soldier NO GO if any measure is failed F If the Soldier fails any measure show him how to do it correctly 31 March 2009 STP 5 21P2 SM TG 3 273 Chapter 3 References Required LCH 3 274 Related AEH EM 385 1 1 ER 385 1 31 FM 5 125 FM 5 412 NEC HANDBOOK TM 5 682 TM 5 684 TM 5 811 1 TM 5 811 3 STP 5 21P2 SM TG 31 March 2009 MOS Skill Level Tasks Install Distribution Equipment De energized 052 204 1122 Conditions As a power line distribution specialist in a tactical or nontactical environment when distribution equipment needs to be installed or replaced de energized you
2. STP 5 21P2 SM TG 31 March 2009 Performance Measures 9 10 11 12 13 14 15 16 17 Cleaned all surfaces using an approved solvent to remove any carbon dust or residue Replaced the high voltage insulation layer as specified in the manufacturer s literature Applied a semiconductive layer as specified in the manufacturer s literature Recreated a shield layer as specified in the manufacturer s literature Attached a ground as specified in the manufacturer s literature and left it long enough to reach the grounding point Applied a high voltage insulation layer as specified in the manufacturer s literature Applied an outer jacket to prevent moisture from entering the power cable as specified in the manufacturer s literature Tested the splice to ensure that it met the rating of the cable Closed out lockout and tagout procedures by removing locking and tagging devices MOS Skill Level Tasks Evaluation Guidance Score the Soldier GO if all measures are passed P Score the Soldier NO GO if any measure is failed F If the Soldier fails any measure show him how to do it correctly References Required Related EM 385 1 1 FM 3 34 480 FM 5 412 LCH NESC TM 5 682 TM 5 684 TM 5 686 TM 5 811 1 TM 5 811 3 31 March 2009 STP 5 21P2 SM TG Chapter 3 Rescue a Victim From a Nonaerial Electrical Conductor 052 244 2105 Conditions As a power plant operator in a tactical or nontact
3. ee eccceeceeeeeeeeeeeeeeeneeeeeeeeeeeseeaeeeseeatens 3 39 052 244 2123 Operate a Multiunit Power Plant cccccceccececeeeeeceneeeceeeeeeeseceeeaaeeeeeeeeeeeesnaeees 3 40 052 244 2124 Install a Nonorganic Generator ce ccececeeeeeeeeeeeeeeseeeeeeeeeeeaeeeseeeaeeeeseeaeeesenaeees 3 43 052 244 2125 Operate a Nonorganic Generator ee eceeceeeeeeeneeeeseeeeeeeeeeeeeeeeseeeaeeeseeeaeeeeeeaaeees 3 46 052 244 2127 Identify the Hazards of a Power Generation and Distribution System 0 3 48 052 244 2128 Troubleshoot a Direct Current DC Voltage System ecceeeeeeeeeeteeeeeneees 3 50 052 244 2129 Troubleshoot an Alternating Current AC Control Voltage Circuit ee 3 52 Distribution Restriction Approved for public release distribution is unlimited This publication supersedes STP 5 21P2 SM TG 3 March 2006 31 March 2009 STP 5 21P2 SM TG i Contents 052 244 2130 Perform a Load ASSESSMENT uu eeeceeeceenteeeeeeeeeeeeeeeeeeeceeeeeeeseeeeaeeeseeeaeeeteeaeeeeeeaatees 3 54 052 244 2131 Troubleshoot an Engine Failure to Crank cceceeeeeeeceeeeeeceeeeeeeeeeeeeeeaeeeseeatees 3 59 052 244 2133 Troubleshoot an Engine Failure to Accelerate and or Maintain a Rated Speedin or anren dt tien asle ee Sabet a a r Seok tatn Sond Hae hold Aceh te eee aes 3 61 052 244 2135 Troubleshoot a Generator s Improper Voltage Output cccceececeeeteeeeeeeteees 3 63 052 244 2136 Install Low Voltage Organic E
4. revolutions per minute Tested relays associated with the alternator 3 64 STP 5 21P2 SM TG 31 March 2009 MOS Skill Level Tasks Performance Measures GO NO GO 12 Tested the rotating rectifier 13 Replaced faulty components parts 14 Closed out the lockout and tagout procedures by removing locking and tagging devices 15 Tested the system to ensure that faults were corrected 16 Returned the generator to operation 17 Recorded actions taken on the maintenance logbook 18 Ensured that the items listed in the conditions were properly cleaned and stored Evaluation Guidance Score the Soldier GO if all measures are passed P Score the Soldier NO GO if any measure is failed F If the Soldier fails any measure show him how to do it correctly References Required Related FM 3 34 480 31 March 2009 STP 5 21P2 SM TG 3 65 Chapter 3 Install Low Voltage Organic Equipment 052 244 2136 Conditions As a power plant operator in a tactical or nontactical environment when tasked to provide low voltage power you are given a general mechanic s tool box electronic tool kit electrical construction prints wiring diagrams manufacturer s literature and appropriate technical manuals DANGER 1 THIS TASK SHOULD ONLY BE PERFORMED BY QUALIFIED PERSONNEL WHO ARE KNOWLEDGEABLE IN THE INSTALLATION AND MAINTENANCE OF ELECTRICAL EQUIPMENT AND ITS
5. 12 Cycled each valve fully opened and closed to ensure proper operation 13 Primed the fuel system to eliminate air 14 Closed out lockout and tagout procedures by removing locking and tagging devices 15 Started the diesel engine and observed the fuel system for leaks 16 Recorded actions taken on DA Form 2404 or DA Form 5988 E and maintenance logbooks 17 Ensured that items the listed in the conditions were properly cleaned and stored Evaluation Guidance Score the Soldier GO if all measures are passed P Score the Soldier NO GO if any measure is failed F If the Soldier fails any measure show him how to do it correctly References Required Related DA FORM 2404 EM 385 1 1 DA FORM 5988 E FM 10 67 1 TM 5 6115 456 34P TM 5 6115 593 12 TM 5 6115 593 34 31 March 2009 STP 5 21P2 SM TG 3 175 Chapter 3 Service an External Fuel System for a Diesel Engine 052 205 2127 Conditions As a power station mechanic in a tactical or nontactical environment during maintenance you are given a lockout and tagout kit a general mechanic s tool box Environmental Protection Agency EPA guidelines the applicable manufacturer s literature maintenance logbooks and DA Form 2404 Equipment Inspection and Maintenance Worksheet or DA Form 5988 E Equipment Inspection Maintenance Worksheet DANGER 1 THIS TASK SHOULD ONLY BE PERFORMED BY QUALIFIED PERSONNEL WHO AR
6. Tested the system Buried the cable if required oN O oO A OO N Ensured that the items listed in the conditions were properly cleaned and stored Evaluation Guidance Score the Soldier GO if all measures are passed P Score the Soldier NO GO if any measure is failed F If the Soldier fails any measure show him how to do it correctly References Required Related FM 3 34 480 31 March 2009 STP 5 21P2 SM TG 3 107 Chapter 3 Service an Induction Disk and or Electromagnetic Relay 052 207 2118 Conditions As a power station instrument technician in a tactical or nontactical environment during routine scheduled maintenance or when the relay device suspected of being defective you are given an SR 90 or Pulsar relay test set with instruction manual a Westinghouse type or General Electric GE type relay test block an EPS 1000 electronic phase shifter with instruction manual an instruction booklet for the specific relay being serviced an electronic tool kit a burnishing tool a calculator wiring diagrams maintenance logbooks and the applicable manufacturer s literature with schematics DANGER 1 REMOVE RINGS NECKLACES OTHER JEWELRY AND LOOSE CLOTHING FAILURE TO COMPLY MAY CAUSE PERMANENT INJURY OR DEATH 2 TERMINALS INSIDE THE SWITCHGEAR COMPARTMENT WILL REMAIN ENERGIZED AFTER REMOVING THE RELAY FROM SERVICE CONTACT WITH THE EXPOSED CONNECTION MAY CAUSE PERMANENT INJURY OR DE
7. 1 Identified the characteristics of ferrous components and materials 2 Prepared the welding area and the items to be welded 3 Inspected the welding machine to ensure that protective guards covers and insulators were in the proper position and good material condition 4 Selected the proper welding electrode type and size 5 Selected the proper current AC or DC and the proper current polarity DC negative electrode or DC positive electrode 6 Determined the approximate welding amperage required 31 March 2009 STP 5 21P2 SM TG 3 139 Chapter 3 Performance Measures GO NO GO 7 Energized the welding machine and adjusted the amperage 8 Performed one or more SMAW weld types depending on the items to be welded 9 Inspected the weld for proper penetration 10 Shut down and properly stored the welding equipment Evaluation Guidance Score the Soldier GO if all measures are passed P Score the Soldier NO GO if any measure is failed F If the Soldier fails any measure show him how to do it correctly References Required Related EM 385 1 1 TC 9 510 3 140 STP 5 21P2 SM TG 31 March 2009 MOS Skill Level Tasks Perform Oxyfuel Cutting 052 205 2105 Conditions As a power station mechanic in a nontactical environment when the oxyfuel cutting method must be used you are given the applicable manufacturer s literature an o
8. Check the governor speed control system Check the hydraulic system Check the pneumatic system Check the alternating current AC control system Check the direct current DC control system 7a anao0om Perform lockout and tagout procedures Inspect test clean repair or replace system components parts according to the manufacturer s literature Perform a functions check on serviced systems 9 10 11 12 Close out lockout and tagout procedures by removing all locking and tagging devices Put the system back into service Record faults and repairs in the maintenance logbook Ensure that the items listed in the conditions are properly cleaned and stored Evaluation Preparation Setup Provide the Soldier with the items listed in the conditions Give the Soldier a safety briefing before starting the test and ensure that safety precautions are followed Prepare the testing area and equipment in advance to ensure that task standards can be met Brief Soldier Direct the Soldier to service a nonorganic prime mover Performance Measures GO NO GO 1 2 N O oO fF OQ Reviewed danger warning and caution notices _ Reviewed the appropriate technical manuals construction prints wiring diagrams manufacturer s literature or industry standards maintenance logbook and historical data pertaining to the equipment Ensured that the PPE was correctly tested and was ful
9. Performed preoperational checks on the test equipment according to the manufacturer s literature Connected the test set to the cable Located the underground cable by tracing it from the source to the load Marked the path of the cable with flags Performed a preoperational check on the test equipment according to the manufacturer s literature Connected the fault locator to the cable being tested 10 11 Set up the fault locator for surge tracing Operated the surge detector and followed the marked cable path until a thump indicated the location of the fault Located the fault by tracing it from the source to the fault location Repaired the fault in the cable Tested the repairs Marked the cable location from the source to the load Removed the test equipment from the circuit being tested Closed out lockout and tagout procedures by removing locking and tagging devices Evaluation Guidance Score the Soldier GO if all measures are passed P Score the Soldier NO GO if any measure is failed F If the Soldier fails any measure show him how to do it correctly References Required Related EM 385 1 1 ER 385 1 31 3 302 STP 5 21P2 SM TG 31 March 2009 MOS Skill Level Tasks References Required Related FM 3 34 480 FM 5 412 LCH TM 5 682 TM 5 684 TM 5 811 1 TM 5 811 3 31 March 2009 STP 5 21P2 SM TG 3 303 Chapter 3 Perform Live Line Testing 052 204 2214 Conditions As a po
10. 14 15 16 17 Remove the high voltage insulation layer using the distance indicated in the manufacturer s literature Install the termination lug using the correct compression tool a Place two crimps on the lug and rotate it approximately 90 between each crimp b Remove sharp edges Clean surfaces using an approved solvent to remove carbon dust and residue Replace the high voltage insulation layer according to the manufacturer s literature Apply a semiconductive layer according to the manufacturer s literature Recreate a shield layer according to the manufacturer s literature Attach a ground according to the manufacturer s literature and ensure that it is long enough to reach the grounding point Apply a high voltage insulation layer according to the manufacturer s literature Apply an outer jacket to prevent moisture from entering the power cable according to the manufacturer s literature Test the splice to ensure that it meets the cable rating Close out lockout and tagout procedures by removing locking and tagging devices Evaluation Preparation Setup Provide the Soldier with the items listed in the conditions Give the Soldier a safety briefing before starting the test and ensure that safety precautions are followed Prepare the testing area and equipment in advance to ensure that task standards can be met Brief Soldier Direct the Soldier to terminate a medium voltage power cable Performance Mea
11. 2 EQUIPMENT WITH A CLASS III LEAK SHOULD NOT BE OPERATED AND MUST BE REPAIRED OR SENT FOR REPAIR IMMEDIATELY FAILURE TO COMPLY MAY CAUSE EQUIPMENT DAMAGE THAT MAY CAUSE LONG TERM FAILURE NOTES 1 All equipment is not the same and may function differently depending on the make model or manufacturer Troubleshooting steps are similar but may vary Always consult the applicable manufacturer s literature for each piece of equipment 2 Tests should be conducted as specified in the manufacturer s literature when available Use industry standards when the manufacturer s literature cannot be obtained 3 Defective equipment should be repaired or replaced immediately and not used until correctly repaired or replaced Standards Repair a diesel engine lube oil system by verifying repairing and replacing defective components parts Performance Steps 1 Review the TMs manufacturer s literature or industry standards maintenance logbooks and historical data pertaining to the equipment malfunction 2 Ensure that PPE is correctly tested and fully mission capable 3 188 STP 5 21P2 SM TG 31 March 2009 MOS Skill Level Tasks Performance Steps 7 8 9 10 Inspect tools and testing equipment for serviceability 3 4 5 6 Perform lockout and tagout procedures Verify the defective components parts Repair or replace the defective components parts using the applicable TM applicable manufacturer s literatu
12. Brief Soldier Direct the Soldier to troubleshoot the cause of an unexpected shutdown of a diesel engine Performance Measures GO NO GO 1 Reviewed maintenance logbooks manufacturer s literature and historical data pertaining to the equipment 2 Identified the cause of the diesel engine shutdown 3 Performed on site corrections when possible 4 Recorded actions taken on DA Form 2404 or DA Form 5988 E and maintenance logbooks 5 Ensured that the items listed in the conditions were properly cleaned and stored Evaluation Guidance Score the Soldier GO if all measures are passed P Score the Soldier NO GO if any measure is failed F If the Soldier fails any measure show him how to do it correctly References Required Related DA FORM 2404 EM 385 1 1 DA FORM 5988 E 3 158 STP 5 21P2 SM TG 31 March 2009 MOS Skill Level Tasks Troubleshoot an Engine Failure to Start 052 205 2118 Conditions As a power station mechanic in a tactical or nontactical environment when a diesel engine fails to start you are given the applicable manufacturer s literature a general mechanic s tool box a multimeter a Caterpillar electronic technician ET tool maintenance logbooks DA Form 2404 Equipment Inspection and Maintenance Worksheet or DA Form 5988 E Equipment Inspection Maintenance Worksheet and a lockout and tagout kit DANGER 1 REMOVE RINGS NECKLACES OTHER JEWELRY AND L
13. Performed during operation checks according to the manufacturer s literature and recorded operational and maintenance data 5 Conducted unit shutdown operations 6 Performed after operation checks Evaluation Guidance Score the Soldier GO if all measures are passed P Score the Soldier NO GO if any measure is failed F If the Soldier fails any measure show him how to do it correctly References Required Related DA FORM 2404 FM 3 34 480 DA FORM 5988 E 31 March 2009 STP 5 21P2 SM TG 3 47 Chapter 3 Identify the Hazards of a Power Generation and Distribution System 052 244 2127 Conditions As a power plant operator in a tactical or nontactical environment you are given FM 5 19 National Fire Protection Association 70E EM 385 1 1 TM 5 682 and material safety data sheets MSDSs DANGER 1 THIS TASK SHOULD ONLY BE PERFORMED BY QUALIFIED PERSONNEL WHO ARE KNOWLEDGEABLE IN THE INSTALLATION OPERATION AND MAINTENANCE OF ELECTRICAL POWER GENERATION EQUIPMENT AND ITS ASSOCIATED HAZARDS FAILURE TO COMPLY MAY CAUSE PERMANENT INJURY OR DEATH 2 ALWAYS WEAR THE PERSONAL PROTECTIVE EQUIPMENT REQUIRED FOR INSPECTIONS IN HAZARDOUS AREAS FAILURE TO COMPLY MAY CAUSE PERMANENT INJURY OR DEATH 3 REMOVE RINGS NECKLACES OTHER JEWELRY AND LOOSE CLOTHING FAILURE TO COMPLY MAY CAUSE PERMANENT INJURY OR DEATH Standards Identify hazards associated with a power generation and distribution syste
14. according to operation instructions provided with the test set 11 Kept a record of the test results 12 Determined the status of the insulation by interpreting the test 13 Reconnected and torqued cables as necessary 14 Removed safety grounds 15 Closed out lockout and tagout procedures by removing locking and tagging devices 16 Reenergized the equipment 17 Ensured that the items listed in the conditions were properly cleaned and stored Evaluation Guidance Score the Soldier GO if all measures are passed P Score the Soldier NO GO if any measure is failed F If the Soldier fails any measure show him how to do it correctly References Required Related EM 385 1 1 ER 385 1 31 FM 3 34 480 FM 5 412 LCH TM 5 682 TM 5 684 TM 5 811 1 TM 5 811 3 31 March 2009 STP 5 21P2 SM TG 3 249 Chapter 3 Subject Area 5 U4 Power Line Distribution Tasks Inspect Safety Equipment 052 204 1108 Conditions As a power line distribution specialist in a tactical or nontactical dry well lit environment during scheduled or unscheduled maintenance and when safety equipment needs to be inspected you are given the applicable equipment technical manuals TMs the applicable manufacturer s literature DA Form 2404 Equipment Inspection and Maintenance Worksheet or DA Form 5988 E Equipment Inspection and Maintenance Worksheet and the applicable safety standing operating pr
15. ce eeecceeeeeeeenneeeeeeeeeeeeeaeeeeeeeaeeeeeenaeeeeeeneeeeeeaes 3 309 052 204 2218 Supervise the Installation of Underground Cable ee cceseeeeeereeeeeteeeeeeenaees 3 311 052 204 2219 Supervise the Loading and Unloading of Utility Poles 0 ee eeeeeeeeeees 3 314 052 204 2220 Supervise the Mechanical Erection of a Utility Pole eeeeeeeeeeeteeeeeneees 3 316 Subject Area 6 S3 and E5 Combined Tasks 052 264 2106 Service a Potential Transformer eee ceccceeeeeeeeeeneeeeeeeneeeseeeaeeeeeeaeeeeeeeteeeeeeaes 3 319 052 264 2107 Service a Current Transformer CT ccceeseeeeeeeeeeeeeeeeneeeeeeneeeeeeeneeeeeeneeeeeeaes 3 321 052 264 2108 Solder an Electrical or Electronic Component ccccccceeeeeeeceeeeeeeeeeseeseeaeees 3 324 052 264 2109 Perform Advanced Electrical Troubleshooting Procedures 3 326 052 264 2110 Determine the Transformer Polarity 0 ccccccceeeeeeeeeeeneeeeeeeeeeeeeeaaeeeeeeneeeeeeaaes 3 328 052 264 2112 Service an Automatic Transfer Switch ATS eee ceeeeeeeeeeeeeneeeeeeneeeeeeseeeeeeeaes 3 331 052 264 2113 Service a Voltage REQUIAtOr 00 cece eeeeneeeeeeeaeeeeeeaeeeeeeaaaeeeeeeaeeeeeenaeeeeseaaes 3 334 052 264 2114 Service an Uninterruptible Power Supply UPS cc cceeeeeeeeeeeneeeeeeeteeeeeeeaaes 3 337 Subject Area 7 S3 and S2 Combined Tasks 052 264 2105 Service an Electronic GOVErNOM ceceeeceeeeeeeeeeeeneeeeeeneeeeeenaeeeeeeeaaeeeeeeneeeeneaes 3 339 052 264 211
16. 1 Reviewed the appropriate TMs applicable manufacturer s literature or industry standards maintenance logbooks and historical data pertaining to the equipment malfunction Ensured that PPE was correctly tested and fully mission capable Inspected tools and testing equipment for serviceability Performed lockout and tagout procedures Verified the defective components parts O oa A W N Repaired or replaced the defective components parts using the appropriate TM applicable manufacturer s literature or industry standards 7 Closed out lockout and tagout procedures by removing locking and tagging devices 8 Performed a functions check on the diesel engine air intake and or exhaust system 9 Recorded actions taken on DA Form 2404 or DA Form 5988 E and maintenance logbooks 10 Ensured that the items listed in the conditions were properly cleaned and stored Evaluation Guidance Score the Soldier GO if all measures are passed P Score the Soldier NO GO if any measure is failed F If the Soldier fails any measure show him how to do it correctly References Required Related DA FORM 2404 EM 385 1 1 DA FORM 5988 E 3 194 STP 5 21P2 SM TG 31 March 2009 MOS Skill Level Tasks Subject Area 4 S3 Electrical Equipment Maintenance Power Station Tasks Service a Low Voltage Circuit Breaker 052 206 2100 Conditions A
17. 15 16 17 Removed the meter and tagged attached leads Inspected the meter for physical damage Tested the meter according to the manufacturer s literature Compared the results with the manufacturer s specifications and took appropriate action by calibrating or replacing the meter Tested the circuit for voltage presence 12 Tagged the equipment with the appropriate calibration sticker including the name and testing date Reinstalled the meter Closed out lockout and tagout procedures by removing locking and tagging devices Energized the circuit and checked for proper meter operation Kept a record of results and actions taken Ensured that the items listed in the conditions were properly cleaned and stored Evaluation Guidance Score the Soldier GO if all measures are passed P Score the Soldier NO GO if any measure is failed F If the Soldier fails any measure show him how to do it correctly 3 126 STP 5 21P2 SM TG 31 March 2009 MOS Skill Level Tasks Produce an Electronic Schematic 052 207 2126 Conditions As a power station instrument technician in a tactical or nontactical environment tasked to produce an electronic schematic for an electronic system you are given an electronic system Standards Produce an electronic schematic that accurately depicts an electronic system Performance Steps 1 Determine which electronic system needs the electronic schematic 2 Identify electronic co
18. 4 Damage protection c Check for the proper operation of transfer pumps and the security of the mounting d Check the fuel for algae or water contamination e Check for fuel warmer proper operation f Inspect valves for signs of 1 Leakage 2 Damage 3 Deterioration 4 Operability 10 Ensure that connection points are properly tightened NOTE The fuel system may need to be primed before putting it back into operation 11 Close out lockout and tagout procedures by removing locking and tagging devices 12 Start the diesel engine and observe the fuel system for leaks 13 Record actions taken on DA Form 2404 or DA Form 5988 E and maintenance logbooks 14 Ensure that the items listed in the conditions are properly cleaned and stored Evaluation Preparation Setup Provide the Soldier with the items listed in the conditions Give the Soldier a safety briefing before starting the test and ensure that safety precautions are followed Prepare the testing area and equipment in advance to ensure that task standards can be met Brief Soldier Direct the Soldier to service an external fuel system for a diesel engine Performance Measures GO NO GO 1 Reviewed maintenance logbooks and historical data pertaining to the equipment to verify that the external fuel system needed to be serviced 2 Performed lockout and tagout procedures 3 Shut off fuel supply lines 4 Depressurized and drained th
19. Ensured that PPE was correctly tested and fully mission capable Inspected tools and testing equipment for serviceability Performed lockout and tagout procedures a A O N Identified fault locations by checking the equipment fault indicator panel or the engine cooling system for obvious malfunctions O Conducted further testing to identify specific defective components if necessary 7 Recorded actions taken on DA Form 2404 or DA Form 5988 E and maintenance logbooks 8 Ensured that the items listed in the conditions were properly cleaned and stored Evaluation Guidance Score the Soldier GO if all measures are passed P Score the Soldier NO GO if any measure is failed F If the Soldier fails any measure show him how to do it correctly References Required Related DA FORM 2404 EM 385 1 1 DA FORM 5988 E 31 March 2009 STP 5 21P2 SM TG 3 185 Chapter 3 Troubleshoot a Diesel Engine Air Intake and or Exhaust System 052 205 2131 Conditions As a power station mechanic in a nontactical environment when a diesel engine air intake and or exhaust system malfunctions you are given a lockout and tagout kit a general mechanic s tool box the applicable technical manual TMs the applicable manufacturer s literature or industry standards maintenance logbooks DA Form 2404 Equipment Inspection and Maintenance Worksheet or DA Form 5988 E Equipment Ins
20. Performance Measures GO NO GO 4 Recorded actions taken on DA Form 2404 or DA Form 5988 E and maintenance logbooks 5 Ensured that the items listed in the conditions were properly cleaned and stored Evaluation Guidance Score the Soldier GO if all measures are passed P Score the Soldier NO GO if any measure is failed F If the Soldier fails any measure show him how to do it correctly References Required Related DA FORM 2404 TM 9 6115 604 12 DA FORM 5988 E 31 March 2009 STP 5 21P2 SM TG 3 129 Chapter 3 Troubleshoot a Diesel Engine for Loss of Power 052 205 2034 Conditions As a power station mechanic in a tactical or nontactical environment when a diesel engine cannot reach or maintain the desired revolutions per minute you are given a lockout and tagout kit maintenance logbooks DA Form 2404 Equipment Inspection and Maintenance Worksheet or DA Form 5988 E Equipment Inspection Maintenance Worksheet a general mechanic s tool box and the applicable manufacturer s literature DANGER 1 ENSURE THAT BATTERIES ARE DISCONNECTED BEFORE SERVICING APPLY SAFE CLEARANCE PROCEDURES TO ASSOCIATED CIRCUITS FAILURE TO COMPLY MAY CAUSE PERSONAL INJURY OR DEATH 2 ENSURE THAT EQUIPMENT IS PROPERLY LOCKED OUT AND TAGGED OUT FAILURE TO COMPLY MAY CAUSE PERMANENT INJURY OR DEATH 3 REMOVE RINGS NECKLACES OTHER JEWELRY AND LOOSE CLOTHING FAILURE TO COMPLY MAY CAUSE PERMANENT INJURY OR DEATH WA
21. Verify that the equipment grounding is correct Verify the presence of transformer surge arresters Measure the insulation resistance of each winding at the designated tap position Remove a sample of insulating liquid according to ASTM D923 and test the sample for the 1 Dielectric breakdown voltage specified in ASTM D877 or ASTM D1816 2 Acid neutralization number specified in ASTM D974 3 Interfacial tension specified in ASTM D971 4 Color specified in ASTM D1500 5 Visual condition specified in ASTM D1524 k Remove a sample of insulating liquid and have a dissolved gas analysis performed according to ASTM D3612 ao uu O OD 6 Perform electrical tests a Perform resistance measurements on the bolted connections using a low resistance ohmmeter b Perform insulation resistance tests winding to winding and winding to ground on each phase and ensure that the test values at 1 minute meet the manufacturer s specifications If not stated compare the results by voltage to the NETA Maintenance Testing Specifications for Electrical Power Distribution Equipment and Systems c Perform a turn to turn ratio test on each tap setting and ensure that the test results do not deviate more than 1 2 percent from the adjacent coils or calculated ratio d Perform power factor and dissipation factor tests on the bushings using the ambient temperature and ensure that the maximum power factor is corrected to 20 C according to th
22. 1 Park the truck as close as possible to the location of the work being performed 2 Perform the work on the uphill side of the truck if it is parked on a slope b Prepare the truck for operation 1 Engage the emergency brake 2 Engage the power take off 3 Transfer the controls from the truck to the machine 4 Lower the outriggers 5 Free the boom for movement 6 Don the proper safety gear 2 Operate the truck boom using the primary and secondary controls while paying close attention to the hand and arm signals of the ground guide a Raise the boom to a height of 30 feet b Rotate the boom to the left c Rotate the boom to the right d Lower the boom and place it back in the cradle 3 Operate the line truck boom while paying close attention to the hand and arm signals of the ground guide WARNING WHEN EXTENDING THE SECOND STAGE OF THE BOOM OR WHEN WINCHING UP ENSURE THAT THE WINCH HOOK DOES NOT GET PULLED INTO THE WINCH LINE GUIDE FAILURE TO COMPLY MAY CAUSE IMMEDIATE PERSONAL INJURY OR EQUIPMENT DAMAGE a Raise the boom straight up ensuring that it does not exceed an 80 angle above the horizontal position b Rotate the boom so that it is in line with the desired location of the winch hook 3 84 STP 5 21P2 SM TG 31 March 2009 MOS Skill Level Tasks Performance Steps c Extend the second stage of the boom so that the hook will fall within 1 foot of the desired area when the winch is lowered d Lower the
23. Evaluation Preparation Setup Provide the Soldier with the items listed in the conditions Give the Soldier a safety briefing before starting the test and ensure that safety precautions are followed Prepare the testing area and equipment in advance to ensure that task standards can be met Brief Soldier Direct the Soldier to improve grounding electrode resistance Performance Measures GO NO GO 1 2 3 10 Determined the soil condition Assembled multiple rods to lengthen the earth electrode Aligned the electrode at an oblique angle that did not exceed 45 and drove the rod a minimum of 8 feet deep in contact with the soil Performed a ground resistance test If the resistance exceeded the required resistance levels proceeded to step 5 7 and or 8 Placed multiple rods Performed a ground resistance test If the resistance exceeded the required resistance levels proceeded to step 7 Treated the soil with a chemical treatment Used chemical methods to reduce the soil resistivity Performed a ground resistance test If the resistance exceeded the required resistance levels proceeded to step 10 Applied any combination of the above methods to achieve the required resistance levels 31 March 2009 STP 5 21P2 SM TG 3 73 Chapter 3 Performance Measures GO NO GO 11 Performed a ground resistance test If the r
24. Score the Soldier NO GO if any measure is failed F If the Soldier fails any measure show him how to do it correctly 3 222 STP 5 21P2 SM TG 31 March 2009 MOS Skill Level Tasks References Required Related DA FORM 2404 NESC TM 5 684 31 March 2009 STP 5 21P2 SM TG 3 223 Chapter 3 Service a Switchgear Enclosure 052 206 2122 Conditions As a power plant electrician in a tactical or nontactical environment during maintenance intervals you are given DA Form 2404 Equipment Inspection and Maintenance Worksheet a vacuum cleaner or cleaning brush an external light source a general mechanic s tool box electrical construction prints wiring diagrams a high voltage detector a lockout and tagout kit and the applicable manufacturer s literature with schematics DANGER 1 THIS TASK SHOULD ONLY BE PERFORMED BY QUALIFIED PERSONNEL WHO ARE KNOWLEDGEABLE IN THE SERVICING AND MAINTENANCE OF SWITCHGEAR ENCLOSURES AND THEIR ASSOCIATED HAZARDS FAILURE TO COMPLY MAY CAUSE PERMANENT INJURY OR DEATH 2 DO NOT TOUCH EXPOSED ELECTRICAL CONNECTIONS WHILE A POWER SOURCE IS CONNECTED TO THE SWITCHGEAR FAILURE TO COMPLY MAY CAUSE PERMANENT INJURY OR DEATH 3 USE THE PROPER TEST EQUIPMENT TO TEST FOR VOLTAGE BEFORE OPENING THE SWITCHGEAR ENCLOSURE FAILURE TO COMPLY MAY CAUSE PERMANENT INJURY OR DEATH 4 REMOVE RINGS NECKLACES OTHER JEWELRY AND LOOSE CLOTHING FAILURE TO COMPLY MAY CAUSE PERMANENT INJURY OR DEATH WARNING
25. investigate the values that deviate from adjacent poles or similar breakers by more than 50 percent of the lowest value 1 Review danger warning and caution notices 2 Review the manufacturer s literature electrical construction prints and wiring diagrams 3 Perform lockout and tagout procedures 4 Inspect the circuit breaker to ensure that the mechanical functions operate smoothly and that there is no physical damage Clean the breaker before testing unless as found and as left tests are required Operate the circuit breaker to ensure smooth operation Inspect the case for cracks or other defects Inspect the bolted electrical connections for high resistance Inspect the mechanism contacts and arc chutes in the unsealed units Dango 5 Perform resistance measurements through the bolted connections using a low resistance ohmmeter 6 Perform insulation resistance tests pole to pole pole to ground and across the open contacts of 31 March 2009 STP 5 21P2 SM TG 3 195 Chapter 3 Performance Steps 10 11 12 13 14 15 16 each phase Perform an insulation resistance test on the control wiring Perform longtime delay time current characteristic tests by passing 300 percent of the rated current through each pole separately unless series testing is required to defeat the ground fault functions Ensure that the circuit breaker trip times fall within the guidelines specified in the man
26. 19 20 Tested the circuit for voltage presence Removed the timing relay from the base according to the manufacturer s literature Identified relay contacts Determined time delay types Tested the relay for proper pickup time delay Tested the relay for proper dropout time delay Compared test results with the manufacturer s specifications and took appropriate action Calibrated reinstalled or replaced the timing relay Tested the circuit for voltage presence Tagged the timing relay with the appropriate calibration sticker to include the name and testing date Reinstalled the timing relay Closed out lockout and tagout procedures by removing locking and tagging devices Energized the circuit and checked for proper timing relay operation Kept a record of results and actions taken Ensured that the items listed in the conditions statement properly cleaned and stored Evaluation Guidance Score the Soldier GO if all measures are passed P Score the Soldier NO GO if any measure is failed F If the Soldier fails any measure show him how to do it correctly References Required Related DA FORM 2404 3 102 STP 5 21P2 SM TG 31 March 2009 MOS Skill Level Tasks Service a Current Boost Module 052 207 2113 Conditions As a power station instrument technician in a tactical or nontactical environment during scheduled maintenance or if the current boost module is suspected of being defective you are g
27. 2 20460 1 10200 0 98400 0 73800 Ounces Pounds Short tons Long tons Foot pounds Kilopascals STP 5 21P2 SM TG Pounds per square inch 31 March 2009 Appendix B Wire Gauge Size Conversion Chart This appendix contains wire gauge size conversions Table B 1 is a wire gauge size conversion chart Table B 1 Wire Gauge Size Conversion Chart Diameter Cross Section Area AWG ras miimetere SARS eaa a ovnchitts 0000 0 460000 11 6800 0 16620000 107 20000 211600 000 0 000161 000 0 409600 10 4000 0 13180000 85 03000 167800 000 0 000203 00 0 364800 9 2660 0 10450000 67 43000 133100 000 0 000256 O 0 324900 8 2520 0 08289000 53 48000 105500 000 0 000323 1 0 289300 7 3480 0 06573000 42 41000 83690 000 0 000407 2 0 257600 6 5430 0 05123000 33 63000 66370 000 0 000513 3 0 229400 5 8270 0 04134000 26 27000 52630 000 0 000647 4 0 204300 5 1890 0 03278000 21 15000 41740 000 0 000815 5 0 187900 4 6200 0 02600000 16 77000 33100 000 0 001030 6 0 162000 4 1150 0 02062000 13 30000 26250 000 0 001300 7 0 144300 3 6650 0 01635000 10 55000 20820 000 0 001630 8 0 128500 3 2640 0 01297000 8 36600 16510 000 0 002060 9 0 114400 2 9060 0 01028000 6 63400 13090 000 0 002600 10 0 101900 2 5880 0 00815600 5 26100 10380 000 0 003280 11 0 090740 2 3050 0 00646700 4 17200 8234 000 0 004130 12
28. 50 percent of the remaining 10 000 watts 5 000 watts 12 500 5 000 17 500 watts 1 Expect the power demands on the system to increase in the future 14 Consider other factors on the load survey a The total load b Limit the load calculations to the identified critical loads c Special considerations d Allow for growth 1 Expect the power demands on the system to increase in the future 2 Allow for a growth of 50 percent of the initial load depending on the type of load and the circumstances e A site map f Calculate power assessments using power factor ratings when possible g Consider the effects of harmonic loads where applicable NOTE Steps 15 through 18 are for conducting an emergency generation load assessment only and should not be used to calculate a load for permanent or semipermanent usage 15 Calculate the emergency generation load a Locate and identify the facility feeder transformer and use it to determine the size of the power generation equipment needed to power the facility b Use the facility main circuit breaker or other service disconnection means to calculate the emergency power generation requirements if the facility transformer size cannot be determined or if it powers multiple facilities NOTE If the main circuit breaker or service disconnect size cannot be determined the incoming load cables from the feeder transformer or service disconnect can be used as the facility ampacity when calculat
29. AND LOOSE CLOTHING FAILURE TO COMPLY MAY CAUSE PERMANENT INJURY OR DEATH 5 DIESEL FUEL IS FLAMMABLE AND MODERATELY TOXIC TO THE EYES SKIN AND RESPIRATORY TRACT SKIN AND EYE PROTECTION ARE REQUIRED AVOID REPEATED OR PROLONGED CONTACT WITH DIESEL FUEL AND USE IT IN A WELL VENTILATED AREA FAILURE TO COMPLY MAY CAUSE PERMANENT INJURY OR DEATH CAUTION NOISE LEVELS IN EXCESS OF 85 DECIBELS EXIST WITHIN A 50 FOOT RADIUS OF OPERATING EQUIPMENT ALWAYS WEAR SINGLE HEARING PROTECTION WITHIN A 50 FOOT RADIUS FAILURE TO COMPLY MAY CAUSE PERSONAL INJURY Standards Install the generator to meet the load requirements so that the system parameters are met and the generator can be safely operated within its capacity Performance Steps 1 Ensure that the generator set meets the load requirements 2 Prepare the engine a Conduct a thorough walk around inspection checking for obvious faults in the mechanical and electrical operating systems b Check the engine for leaks or damage c Check the coolant level and add coolant if needed d Check the oil level and add oil if needed e Ensure that air filters are present and serviceable 3 Ground the generator unit a Determine the soil resistance b Emplace the appropriate number of ground rods based on the soil resistance 31 March 2009 STP 5 21P2 SM TG 3 43 Chapter 3 Performance Steps N O On A ee 11 12 13 c Make the connections d Test the ground At
30. Direct the Soldier to service an AC generator assembly Performance Measures GO NO GO 1 O N O Oa A W N _ 11 12 Reviewed danger warning and caution notices Reviewed the manufacturer s literature and wiring diagrams Reviewed maintenance logbooks and historical data pertaining to the equipment Performed lockout and tagout procedures Grounded the generator leads Inspected the generator Disconnected and tagged the generator leads Tested the main stator to ensure that ohm values were more than 5 16 megohms Tested the main rotor to ensure that ohm values were more than 2 megohms Tested the exciter rotor assembly to ensure that ohm values were more than 1 megohm Tested the exciter stator to ensure that ohm values were more than 1 megohm Tested the rotating rectifier 3 234 STP 5 21P2 SM TG 31 March 2009 MOS Skill Level Tasks Performance Measures GO NO GO 13 Replaced bolted lead wires on rectifiers at the terminal studs 14 Closed out lockout and tagout procedures by removing locking and tagging devices 15 Ensured that the items listed in the conditions were properly cleaned and stored Evaluation Guidance Score the Soldier GO if all measures are passed P Score the Soldier NO GO if any measure is failed F If the Soldier fails any measure
31. Performance Steps 7 8 9 10 11 12 13 14 15 16 17 18 Remove the controller and tag the leads Inspect the controller for damage Connect the handheld programming device to the diagnostic and service port Perform testing and calibration according to the DSLC operations and calibration manual Compare the results with the manufacturer s specifications and take appropriate action a Reinstall the controller b Reprogram the controller c Replace the controller Test the circuit for voltage presence a Proceed to step 13 if there is no voltage present b Stop if there is voltage present and perform the following checks until voltage is no longer present 1 Check the schematics for proper circuit identification 2 Check for back fed circuits 3 Check for the proper use of safe clearance procedures Tag the controller with the appropriate calibration sticker including the name and testing date Reinstall the controller a Attach tagged leads b Verify connections using the schematics Close out lockout and tagout procedures by removing locking and tagging devices Energize the circuit and ensure that it is operating properly Keep a record of results and actions taken Ensure that the items listed in the conditions are properly cleaned and stored Evaluation Preparation Setup Provide the Soldier with the items listed in the conditions Give the Soldier a safety briefing before starting
32. Repair or replace the cylinder head depending on the test results 6 7 8 9 Reinstall the cylinder head according to the manufacturer s literature sequence Close out lockout and tagout procedures by removing locking and tagging devices Start the unit and observe it for proper operation Inspect the cylinder head by measuring and inspecting it according to the manufacturer s literature Refer to the manufacturer s literature for proper torque specifications and the correct torque Record actions taken on DA Form 2404 or DA Form 5988 E and maintenance logbooks Ensure that the items listed in the conditions are properly cleaned and stored Evaluation Preparation Setup Provide the Soldier with the items listed in the conditions Give the Soldier a safety briefing before starting the test and ensure that safety precautions are followed Prepare the testing area and equipment in advance to ensure that task standards can be met Brief Soldier Direct the Soldier to service a diesel engine cylinder head Performance Measures 1 O oa A W N N 10 11 12 13 Reviewed maintenance logbooks and historical data for the equipment to verify that the diesel engine cylinder head needed to be serviced Performed lockout and tagout procedures Visually inspected the exterior of the cylinder head for obvious faults Removed the cylinder head according to the manufacturer s literature Cleaned the cylinde
33. T T T IT IT IT IT AN 2 2 4 STP 5 21P2 SM TG 31 March 2009 Trainer s Guide Table 2 1 MOS 21P2 Critical Tasks continued Location Tng Tng SL Freq 22216 secese m m n 052 206 2122 Service a SwitchosarEnosue m amw 052 206 2128 Perform a Power Factor and Dissipation Factor Test at an 2 052 206 2124 Service an AirMagnetic Cirout Breer ar mn 052 206 2125 Service an Atemating Current AC GeneratorAssemby AIT an 2 052 206 2127 Service a Sulfur Hexafuorde SF6 Circuit Breaker Aat an 2 052 206 2183 identify Electrical Faults Using an Infrared R Camera At an 2 052 206 2184 Service a SulfurHexafuoride SF6 Swich ar an 2 052 206 2135 Service a Vacuum Gircut Breer m amw 052 206 2136 Performan insulation Resistance Tet am wn Subject Area 5 U4 Power Line Distribution Tasks 052 204 1118 Maintain Climbing and Rigging Equipment ASI SD 052 204 1119 Perform Operator Preventive Maintenance Checks and ASI SD Services PMCS on a Line Truck With Auxiliary NINININI MIM MIM NM NM Equipment 052 204 1120 Install a Grounding Set ASI SD 052 204 1121 Install High Intensity Lights and Ballasts ASI SD 052 204 1122 Install Distribution Equipment De energized ASI SD 052 204 1123 Secure Conductor to Insulator De energized ASI SD 052 204 1124 Climb a Utility Pole ASI SD 052 204 1126 Perform a Crossarm Change Out ASI SD NTMI NMI N
34. and a secure mounting 8 Inspected radiator fans 9 Inspected the fan belt for tension and signs of excessive wear glazing dry rotting fraying 10 Inspected the radiator 11 Checked the coolant for the proper antifreeze level and added coolant or additives as needed 12 Closed out lockout and tagout procedures by removing locking and tagging devices 3 152 STP 5 21P2 SM TG 31 March 2009 MOS Skill Level Tasks Performance Measures GO NO GO 13 Started the unit and observed it for proper operation 14 Recorded actions taken on DA Form 2404 or DA Form 5988 E and maintenance logbooks 15 Ensured that the items listed in the conditions were properly cleaned and stored Evaluation Guidance Score the Soldier GO if all measures are passed P Score the Soldier NO GO if any measure is failed F If the Soldier fails any measure show him how to do it correctly References Required Related DA FORM 2404 TM 9 6115 604 12 DA FORM 5988 E 31 March 2009 STP 5 21P2 SM TG 3 153 Chapter 3 Service an Engine Air Intake and or Exhaust System 052 205 2113 Conditions As a power station mechanic in a tactical or nontactical environment when a engine air intake and or exhaust system is identified for service or symptoms of air intake and or exhaust system faults occur you are given a lockout and tagout kit a general mechanic s tool box the
35. and rotate it approximately 90 between each crimp Clean surfaces with an approved solvent to remove carbon dust or residue Replace the high voltage layer according to the manufacturer s literature Apply a semiconductive layer from the edge of the shielding tape to the edge of the opposing shield according to the manufacturer s literature Recreate a shield layer across the splice connector according to the manufacturer s literature Attach a ground to a shield according to the manufacturer s literature Leave the ground long enough to reach the grounding point Apply an outer jacket to the cable according to the manufacturer s literature to prevent moisture from entering the cable Test the splice to ensure that it meets the rating of the cable Close out lockout and tagout procedures by removing locking and tagging devices Evaluation Preparation Setup Provide the Soldier with the items listed in the conditions Give the Soldier a safety briefing before starting the test and ensure that safety precautions are followed Prepare the testing area and equipment in advance to ensure that task standards can be met Brief Soldier Direct the Soldier to splice a medium voltage power cable Performance Measures GO NO GO 1 2 3 4 Performed lockout and tagout procedures Inspected the splice kit Prepared the cable and spliced it according to the manufacturer s literature Aligned cables so that
36. ensure that Pins 2 and 6 are opposite b Cut off the old connector c Strip the outer jacket back about 1 inch d Lay out the conductors 1 Lay out the straight through and crossover cable pin configuration for End A in the following order a White striped green Green White striped orange Blue White striped brown Brown White striped orange Orange White striped green Blue h Brown e Cut back the conductors to within 1 2 inch of the outer jacket f Crimp the new connector end 5 Reconnect the cable 3 106 STP 5 21P2 SM TG 31 March 2009 MOS Skill Level Tasks Performance Steps 6 Test the system 7 Bury the cable if required 8 Ensure that the items listed in the conditions are properly cleaned and stored Evaluation Preparation Setup Provide the Soldier with the items listed in the conditions Give the Soldier a safety briefing before starting the test and ensure that safety precautions are followed Prepare the testing area and equipment in advance to ensure that task standards can be met Brief Soldier Direct the Soldier to service a signal transmission circuit Performance Measures GO NO GO 1 Reviewed danger warning and caution notices before proceeding Reviewed the manufacturer s literature with schematics and wiring diagrams Inspected the cable for serviceability Repaired the cable as needed Reconnected the cable
37. show him how to do it correctly References Required Related DA FORM 2404 NESC TM 5 682 TM 9 6115 604 12 31 March 2009 STP 5 21P2 SM TG 3 235 Chapter 3 Service a Sulfur Hexafluoride SF6 Circuit Breaker 052 206 2127 Conditions As a power plant electrician in a tactical or nontactical environment during maintenance you are given safety standing operating procedures a general mechanic s tool box a digital low resistance ohmmeter a megohmmeter a high potential test set a power factor test set wiring diagrams grounding equipment and the applicable manufacturer s literature with schematics DANGER 1 THIS TASK SHOULD ONLY BE PERFORMED BY QUALIFIED PERSONNEL WHO ARE KNOWLEDGEABLE IN THE INSTALLATION AND MAINTENANCE OF CIRCUIT BREAKERS AND POWER EQUIPMENT AND THEIR ASSOCIATED HAZARDS FAILURE TO COMPLY MAY CAUSE PERMANENT INJURY OR DEATH 2 DO NOT TOUCH EXPOSED ELECTRICAL CONNECTIONS WHILE A POWER SOURCE IS CONNECTED TO THE CIRCUIT BREAKER FAILURE TO COMPLY MAY CAUSE PERMANENT INJURY OR DEATH 3 REMOVE RINGS NECKLACES OTHER JEWELRY AND LOOSE CLOTHING FAILURE TO COMPLY MAY CAUSE PERMANENT INJURY OR DEATH 4 DO NOT EXCEED THE MAXIMUM VOLTAGE STIPULATED FOR THIS TEST FAILURE TO COMPLY COULD CAUSE THE SF6 BOTTLES TO EXPLODE AND MAY RESULT IN PERMANENT INJURY OR DEATH Standards Safely service an SF6 circuit breaker by inspecting and testing it Test the SF6 circuit breaker according to the manufacturer s lit
38. stopping and reporting future hazards and unsafe actions Evaluation Preparation Setup Provide the Soldier with the items listed in the conditions Brief Soldier Direct the Soldier to conduct a safety briefing Performance Measures GO NO GO 1 Performed an initial walk through of the jobsite 2 Noted possible hazards and associated risks 3 Informed personnel verbally of possible hazards and associated risks 4 Reminded personnel that everyone at the jobsite was a safety officer who had the responsibility of stopping and reporting future hazards and unsafe actions Evaluation Guidance Score the Soldier GO if all measures are passed P Score the Soldier NO GO if any measure is failed F If the Soldier fails any measure show him how to do it correctly References Required Related FM 5 19 AR 385 10 EM 385 1 1 ER 385 1 31 LCH TM 5 682 TM 5 684 31 March 2009 STP 5 21P2 SM TG 3 295 Chapter 3 Conduct a Safety Inspection 052 204 2208 Conditions As a power line distribution supervisor in a tactical or nontactical environment before or during work on a jobsite you are given a safety checklist a detailed job description and applicable safety standing operating procedures SOPs DANGER ALWAYS WEAR THE PERSONAL PROTECTIVE EQUIPMENT REQUIRED FOR INSPECTIONS IN HAZARDOUS AREAS FAILURE TO COMPLY MAY CAUSE IMMEDIATE DEATH OR PERMANENT INJURY Standards Conduct a safety inspe
39. 1 Proceed to the next step if the results are acceptable 2 Reduce the ground resistance by using additional or longer ground rods treating the soil or using a combination of each if the results are unacceptable b Perform point to point tests between the main grounding system and the major electrical equipment frames lightning rods and system neutrals 31 March 2009 STP 5 21P2 SM TG 3 207 Chapter 3 Performance Steps 1 Proceed to the next step if the results are acceptable 2 Test individual sections identify deficiencies and then correct them if the results are unacceptable 8 Improve ground electrode resistance as needed see task 052 244 2107 9 Keep a record of the test results 10 Reconnect the power to the system 11 Ensure that the items listed in the conditions are properly cleaned and stored Evaluation Preparation Setup Provide the Soldier with the items listed in the conditions Give the Soldier a safety briefing before starting the test and ensure that safety precautions are followed Prepare the testing area and equipment in advance to ensure that task standards can be met Brief Soldier Direct the Soldier to service a system ground Performance Measures GO NO GO 1 Reviewed danger warning and caution notices 2 Reviewed the manufacturer s literature electrical construction prints and wiring diagrams 3 Identified the correct resistance level according to Section
40. 1 Set up a safety zone with at least a 10 foot radius from the pole base 2 Inspect the climbing and rigging equipment tools and handlines for defects 3 Observe and assist the lineman from the ground as he performs his tasks 4 Communicate properly with the lineman during each task performed 5 Ensure that the items listed in the conditions are properly cleaned and stored Evaluation Preparation Setup Provide the Soldier with the items listed in the conditions Give the Soldier a safety briefing before starting the test and ensure that safety precautions are followed Prepare the testing area and equipment in advance to ensure that the task standards can be met Brief Soldier Direct the Soldier to perform groundman duties Performance Measures GO NO GO 1 Set up a safety zone with at least a 10 foot radius from the pole base 2 Inspected the climbing and rigging equipment tools and handlines for defects 3 Observed and assisted the lineman from the ground as he performed his tasks 4 Communicated properly with the lineman during each task performed 5 Ensured that the items listed in the conditions were properly cleaned and stored Evaluation Guidance Score the Soldier GO if all measures are passed P Score the Soldier NO GO if any measure is failed F If the Soldier fails any measure show him how to do it correctly References Required Related EM 385 1 1 FM 5 125 31 Ma
41. 11 Add fuel as needed during MEP 029 generator operation 12 Inspect the exhaust system after MEP 029 generator operation a Check the mufflers for serviceability b Ensure that the rain caps move freely c Check the turbocharger assembly for leaks and damage 13 Inspect the fuel system after MEP 029 generator operation 14 Record actions taken on DA Form 2404 or DA Form 5988 E and the maintenance logbook Evaluation Preparation Setup Provide the Soldier with the items listed in the conditions Give the Soldier a safety briefing before starting the test and ensure that safety precautions are followed Prepare 31 March 2009 STP 5 21P2 SM TG 3 81 Chapter 3 the testing area and equipment in advance to ensure that task standards can be met Brief Soldier Direct the Soldier to perform PMCS on an MEP 029 Generator Performance Measures 1 oO ON DO Oa FP W ND a ee Gee A o a Aa OO N gt O Inspected the battery compartment Inspected the exhaust system Inspected the ground terminals for tight connections Inspected the controls and instruments on the engine panel Inspected the air cleaner to ensure that the service indicator was not red Inspected the radiator assembly Inspected the fuel system Inspected the muffler and exhaust during MEP 029 generator operation Inspected the engine panel controls and instruments during MEP 029 generator operation Inspected the generator panel durin
42. 2009 Chapter 2 Trainer s Guide 2 1 General The trainer s guide TG identifies the essential components of a unit training plan for individual training Units have different training needs and requirements based on differences in environment location equipment dispersion and similar factors Therefore the TG should be used as a guide for conducting unit training and not a rigid standard It provides information necessary for planning training requirements for the MOS The TG Identifies subject areas in which Soldiers must be trained Identifies individual tasks for each subject area Specifies where Soldiers are initially trained on each task e Recommends how often to train each task to sustain proficiency 2 2 MOS 21P2 Critical Tasks This list identifies by general subject areas the critical tasks to be trained in an MOS and the type of training required resident integration or sustainment Task number column This column lists the task numbers for all tasks included in the subject area Title column This column lists the task title for each task in the subject area Training location column This column identifies the training location where the task is first trained to STP standards If the task is first trained to standard in the unit the word Unit will be in this column If the task is first trained to standard in the resident course it will be identified by brevity code Figure 2 1 con
43. 3 References Required DA FORM 2404 DA FORM 5988 E 3 156 Related STP 5 21P2 SM TG 31 March 2009 MOS Skill Level Tasks Troubleshoot the Cause of an Unexpected Shutdown of a Diesel Engine 052 205 2116 Conditions As a power station mechanic in a tactical or nontactical environment when an unexpected shutdown of a diesel engine occurs you are given the applicable manufacturer s literature a general mechanic s tool box maintenance logbooks DA Form 2404 Equipment Inspection and Maintenance Worksheet or DA Form 5988 E Equipment Inspection Maintenance Worksheet and a lockout and tagout kit DANGER 1 ENSURE THAT EQUIPMENT IS PROPERLY LOCKED OUT AND TAGGED OUT FAILURE TO COMPLY MAY CAUSE PERMANENT INJURY OR DEATH 2 REMOVE RINGS NECKLACES OTHER JEWELRY AND LOOSE CLOTHING FAILURE TO COMPLY MAY CAUSE PERMANENT INJURY OR DEATH CAUTION NOISE LEVELS IN EXCESS OF 85 DECIBELS EXIST WITHIN A 50 FOOT RADIUS OF OPERATING EQUIPMENT PERSONNEL MUST WEAR SINGLE HEARING PROTECTION WITHIN A 50 FOOT RADIUS FAILURE TO COMPLY MAY CAUSE PERSONAL INJURY Standards Troubleshoot a diesel engine for an unexpected shutdown by identifying the cause testing the engine according to the applicable manufacturer s literature and annotating the problem Performance Steps NOTE This task follows the assumption that all relays and fuses are in good working condition 1 Review maintenance logbooks manufacturer s literature and histo
44. 31 March 2009 STP 5 21P2 SM TG 3 259 Chapter 3 Brief Soldier Direct the Soldier to rescue an injured victim from an aerial bucket truck Performance Measures GO NO GO 1 Evaluated the situation by calling to the victim 2 Ensured your own protection 3 Lowered the bucket until it was 1 foot off the ground 4 Removed the victim from the bucket and lowered him to the ground 5 Continued administering first aid until qualified medical personnel arrived Evaluation Guidance Score the Soldier GO if all measures are passed P Score the Soldier NO GO if any measure is failed F If the Soldier fails any measure show him how to do it correctly References Required Related EM 385 1 1 FM 4 25 11 LCH TM 5 682 TM 5 684 3 260 STP 5 21P2 SM TG 31 March 2009 MOS Skill Level Tasks Inspect Hot Line Equipment 052 204 1117 Conditions As a power line distribution specialist in a tactical or nontactical dry well lit environment during scheduled or unscheduled maintenance when hot line equipment needs to be inspected you are given the applicable manufacturer s literature with maintenance instructions DA Form 2404 Equipment Inspection and Maintenance Worksheet and the applicable safety standing operating procedures SOPs DANGER HOT LINE EQUIPMENT WHETHER OR NOT SPECIFICALLY ADDRESSED IN THIS TASK MUST BE MAINTAINED AS SPECIFIED IN THE APPLICABLE MANUFACTURER S MAINTENANCE INSTR
45. 5 21P2 SM TG 31 March 2009 MOS Skill Level Tasks Service an Alternating Current AC Generator Assembly 052 206 2125 Conditions As a power station electrician in a tactical or nontactical environment during maintenance you are given a multimeter wire markers a general mechanic s tool box an air gap feeler gauge a high voltage detector a lockout and tagout kit a 5 kilovolt direct current DC megohmmeter high voltage gloves a grounding stick wiring diagrams maintenance logbooks safety clearance standing operating procedures and the applicable manufacturer s literature with schematics DANGER 1 REMOVE RINGS NECKLACES OTHER JEWELRY AND LOOSE CLOTHING FAILURE TO COMPLY MAY CAUSE PERMANENT INJURY OR DEATH 2 ENSURE THAT LOAD CABLES ARE INSTALLED ON PARKING STANDS FAILURE TO COMPLY MAY CAUSE PERMANENT INJURY OR DEATH 3 USE THE PROPER TEST EQUIPMENT TO TEST FOR VOLTAGE BEFORE CONTACTING COMPONENTS PARTS FAILURE TO COMPLY MAY CAUSE PERMANENT INJURY OR DEATH WARNING COMPRESSED AIR USED FOR CLEANING OR DRYING MAY CREATE AIRBORNE PARTICLES THAT COULD ENTER THE EYES PRESSURE SHOULD NOT EXCEED 30 POUNDS PER SQUARE INCH WEARING OF GOGGLES IS REQUIRED FAILURE TO COMPLY MAY CAUSE IMMEDIATE PERSONAL INJURY OR EQUIPMENT DAMAGE Standards Safely service an AC generator assembly to make it operational Accurately inspect and test the generator assembly and repair or replace faulty components parts Performance Steps
46. 5 21P2 SM TG 3 323 Chapter 3 Solder an Electrical or Electronic Component 052 264 2108 Conditions As a power station instrument technician or a power station electrician in a tactical or nontactical environment when producing a new electronic circuit or repairing an existing electronic circuit you are given a soldering iron solder and rosin flux a multimeter an electronic tool kit appropriate technical manuals or bulletins and the applicable manufacturer s literature with schematics DANGER REMOVE RINGS NECKLACES OTHER JEWELRY AND LOOSE CLOTHING FAILURE TO COMPLY MAY CAUSE PERMANENT INJURY OR DEATH WARNING THE SOLDERING IRON IS VERY HOT DURING OPERATION USE CAUTION TO AVOID SETTING YOURSELF OR THE WORKPLACE ON FIRE FAILURE TO COMPLY MAY CAUSE IMMEDIATE PERSONAL INJURY OR EQUIPMENT DAMAGE NOTE KEEP THE WORK AREA NEAT AND ORGANIZED AND THE METER AND EQUIPMENT STABLE WHILE PERFORMING THIS TASK FAILURE TO COMPLY MAY LEAD TO UNRELIABLE TEST READINGS Standards Solder an electrical or electronic component to complete a new or existing circuit so that the resistance measures 0 ohms Performance Steps 1 Identify components parts to be soldered 2 Inspect components parts for damage and serviceability 3 Prepare components parts to be soldered a Clean surfaces to be soldered b Apply rosin flux to surfaces to be soldered c Insert each electronic component part individually into its proper position d Ensure tha
47. ARE NORMALLY PERFORMED WITH THE SUSPECTED EQUIPMENT ENERGIZED AND IN OPERATION FAILURE TO OBSERVE SAFETY MEASURES MAY CAUSE PERMANENT INJURY OR DEATH 2 REMOVE RINGS NECKLACES OTHER JEWELRY AND LOOSE CLOTHING FAILURE TO COMPLY MAY CAUSE PERMANENT INJURY OR DEATH Standards Perform electronic troubleshooting procedures using systematic procedures Safely troubleshoot the electronic or control circuit and identify the cause of system malfunction Performance Steps 1 Review danger warning and caution notices before proceeding 2 Review the manufacturer s literature with schematics electrical construction prints and wiring diagrams 3 Review maintenance logbooks and historical data pertaining to the equipment 4 Check for obvious malfunctions a De energize the inoperative system b Test the system for voltage presence 1 Proceed to step 4b 2 c if there is no voltage present 2 Stop if there is voltage present and perform the following checks until voltage is no longer present a Check schematics for proper circuit identification b Check for back fed circuits c Check for the proper use of safe clearance procedures c Visually inspect for obvious damage d Check fuses e Ensure that control switches are positioned correctly f Check for indications of burning wires or components via sight and smell g Check for wire continuity in the involved circuit 5 Ensure that the power is on a Energize the sy
48. ASSOCIATED HAZARDS FAILURE TO COMPLY MAY CAUSE PERMANENT INJURY OR DEATH 2 DO NOT TOUCH EXPOSED ELECTRICAL CONNECTIONS WHEN A POWER SOURCE IS CONNECTED TO THE EQUIPMENT FAILURE TO COMPLY MAY CAUSE PERMANENT INJURY OR DEATH WARNING 1 REMOVE RINGS NECKLACES OTHER JEWELRY AND LOOSE CLOTHING FAILURE TO COMPLY MAY CAUSE INJURY 2 ENSURE THAT THE POWER IS REMOVED FROM THE PRIMARY POWER CABLES BEFORE TOUCHING THEM FAILURE TO COMPLY MAY CAUSE INJURY Standards Install low voltage organic equipment without causing injury or equipment damage and ensure that the equipment is able to run and supply power to the connected equipment Performance Steps NOTE Installation should be conducted according to the manufacturer s literature when available 1 Review danger warning and caution notices 2 Review the manufacturer s literature electrical construction prints and wiring diagrams 3 Inventory equipment 4 Position equipment a Review the site layout 1 Verify that the ground is level 2 Ensure that the site is not in a flood plan 3 Verify that the proposed location is not a high traffic zone b Place equipment with proper spacing and orientation according to the application specifications 5 Perform preventive maintenance checks and services PMCS on equipment 6 Install ground rods WARNING ENSURE THAT THE POWER IS REMOVED FROM THE PRIMARY POWER CABLES BEFORE TOUCHING THEM FAILURE TO COMPLY MAY CAUSE IM
49. AVOID CONTACT WITH HEATERS IN THE ENCLOSURE EVEN AFTER THE POWER HAS BEEN REMOVED FAILURE TO COMPLY MAY CAUSE IMMEDIATE PERSONAL INJURY Standards Service the switchgear enclosure by cleaning and inspecting it to ensure that nothing infringes upon the safe operation of the switchgear assembly Performance Steps 1 Review danger warning and caution notices 2 Review the manufacturer s literature electrical construction prints and wiring diagrams 3 Perform lockout and tagout procedures 4 Conduct voltage tests with the appropriate voltage detector in the order listed in the substeps a Check an energized circuit to ensure that the voltage detector is working properly b Check for the presence of voltage on the de energized circuit 1 Replace the cover immediately and trace the incoming power circuits if there is voltage present 2 Remove the power and verify that there is no voltage present c Check the energized circuit again to verify that the voltage detector is working properly 5 Inspect the exterior of the switchgear enclosure a Check for dents cracks and holes on the outer walls b Check for the integrity of panels including the top and bottom c Check for proper hinge and door operation d Check for the integrity of welds e Check for broken bolts and missing or loose bolts nuts and washers f Check for grounding connection quality 3 224 STP 5 21P2 SM TG 31 March 2009 MOS Skill Level Tasks Pe
50. As a power line distribution specialist in a tactical or nontactical environment when an individual is responsive or unresponsive and unable to exit the manhole on his own you are given a two way radio or telephone communication equipment an extraction system for confined space entry and rescue a safety harness and the applicable personal protective equipment PPE DANGER TIME IS EXTREMELY CRITICAL THROUGHOUT THIS TASK FAILURE TO RESCUE A VICTIM IN A TIMELY MANNER MAY RESULT IN PERMANENT INJURY OR DEATH WARNING CARE SHOULD BE TAKEN WHEN RAISING THE VICTIM OUT OF THE MANHOLE ENSURE THAT YOU DO NOT INCREASE OR CAUSE FURTHER INJURIES TO THE VICTIM FAILURE TO COMPLY MAY CAUSE IMMEDIATE PERSONAL INJURY Standards Rescue an injured victim from a manhole by raising the victim up and out of the manhole using an extraction system for confined space entry and rescue Administer first aid until he is in stable condition or qualified medical personnel arrive Performance Steps 1 Evaluate the situation by calling to the victim a Determine the victim s level of injury or illness before rescuing the victim from the manhole if the victim is conscious and responds in an understanding voice b Prepare to rescue the victim from a manhole and provide aid if he is unconscious does not respond or appears to be stunned or dazed 2 Ensure your own protection a Contact emergency response personnel b De energize the circuit if necessary or pract
51. COMPLY MAY CAUSE IMMEDIATE PERSONAL INJURY OR EQUIPMENT DAMAGE Standards Manage a power line crew by ensuring that the power line crew adheres to work and safety requirements of the applicable manufacturer s literature safety SOPs and the LCH Performance Steps 1 Review danger warning and caution notices Ensure that the PPE has been correctly tested and is fully operable Ensure that DA Form 2702 Bill of Materials includes all items necessary to perform the task Inspect tools and climbing and rigging equipment for serviceability Develop a plan for obtaining nonorganic tools and equipment necessary to perform any mission O oa A W N Issue a safety briefing that highlights safety precautions and the concept of the operation 31 March 2009 STP 5 21P2 SM TG 3 309 Chapter 3 Performance Steps 7 Assign personnel positions and ensure that they understand roles 8 Supervise the operation of a line truck with auxiliary equipment 9 Ensure that tasks are performed to standard and that safety procedures are followed 10 Ensure that PPE climbing and rigging equipment and tools are correctly cleaned and stored Evaluation Preparation Setup Provide the Soldier with the items listed in the conditions Give the Soldier a safety briefing before starting the test and ensure that safety precautions are followed Prepare the testing area and equipment in advance to ensure that task standards can be met Brief Sold
52. D923 ASTM D971 ASTM D974 NETA 3 220 STP 5 21P2 SM TG 31 March 2009 MOS Skill Level Tasks Service Bus Bars 052 206 2116 Conditions As a power station electrician in a tactical or nontactical environment during maintenance you are given safety standing operating procedures a lockout and tagout kit a general mechanic s tool box an electrician s tool kit a grounding cluster conductive grease a crocus cloth a nonabrasive wiping cloth a vacuum cleaner a brush broom a wire brush the required torque wrenches electrical construction prints wiring diagrams a digital low resistance ohmmeter an infrared IR camera and the applicable manufacturer s literature with schematics DANGER 1 THIS TASK SHOULD ONLY BE PERFORMED BY QUALIFIED PERSONNEL WHO ARE KNOWLEDGEABLE IN THE INSTALLATION AND MAINTENANCE OF SWITCHGEAR BUS WORK AND POWER EQUIPMENT AND THEIR ASSOCIATED HAZARDS FAILURE TO COMPLY MAY CAUSE PERMANENT INJURY OR DEATH 2 REMOVE RINGS NECKLACES OTHER JEWELRY AND LOOSE CLOTHING FAILURE TO COMPLY MAY CAUSE PERMANENT INJURY OR DEATH 3 DO NOT TOUCH EXPOSED ELECTRICAL CONNECTIONS WHILE A POWER SOURCE IS CONNECTED TO THE BUS WORK FAILURE TO COMPLY MAY CAUSE PERMANENT INJURY OR DEATH Standards Service bus bars by cleaning and inspecting them to ensure that they are capable of carrying a rated load safely Performance Steps 1 Review danger warning and caution notices 2 Review the manufacturer s literatur
53. Diagram 052 244 2121 Conditions You are a power plant operator in a tactical or nontactical environment where there is a fault in the system Scheduled services are due or an upgrade to the system is needed or proposed You are given an electrical one line diagram for an electrical system Standards Read and interpret information from an electrical one line diagram by identifying electrical flow and electrical symbols and their relationships Performance Steps 1 Identify the correct electrical one line diagram for an electrical system 2 Identify lines and symbols on the diagram 3 Determine the function of the symbols on the one line diagram and the relationships between the electrical devices 4 Identify possible electrical paths depending on switchgear positioning Evaluation Preparation Provide the Soldier with the items listed in the conditions Give the Soldier a safety briefing before starting the test and ensure that safety precautions are followed Prepare the testing area and equipment in advance to ensure that task standards can be met Brief Soldier Direct the Soldier to read an electrical one line diagram Performance Measures GO NO GO 1 Identified the correct electrical one line diagram for an electrical system 2 Identified lines and symbols on the diagram 3 Determined the function of the symbols on the one line diagram and the relationships between the electrical devices 4
54. Dissolved in Electrical Insulating Oil by Gas Chromatography 10 October 2002 lt http www astm org Standards D3612 htm gt Standard Test Method for Dielectric Breakdown Voltage of Insulating Liquids Using Disk Electrodes 10 October 2002 lt http www astm org Standards D877 htm gt Standard Practices for Sampling Electrical Insulating Liquids 10 October 1997 lt http Awww astm org Standards D923 htm gt Standard Test Method for Interfacial Tension of Oil Against Water by the Ring Method 1 October 2004 lt http www astm org Standards D971 htm gt Standard Test Method for Acid and Base Number by Color Indicator Titration 1 November 2004 lt hitp Awww astm org Standards D974 htm gt STP 5 21P2 SM TG References 1 References DA LABEL 80 EM 385 1 1 ENG FORM 1925 ENG FORM 1927 R ENG FORM 2198 ER 385 1 31 IEEE GREEN BOOK LCH NEC HANDBOOK NETA NFPA 70E OSHA REG 1910 147 UGLYS Soldier Training Publications STP 21 1 SMCT STP 21 24 SMCT Technical Bulletins TB 43 180 Technical Manuals TM 5 551K TM 5 6115 593 12 TM 5 682 TM 5 704 TM 5 811 1 TM 9 6115 604 12 References 2 US Army Calibrated Instrument 1 December 1977 Safety and Health Requirements 3 November 2003 lt http 140 194 76 129 publications eng manuals em385 1 1 2003 English toc htm gt Danger Main Hold Card lt http 140 194 76 129 publications forms gt Safe Clearance Request lt http 140 194 76 129 publ
55. FAILURE TO COMPLY MAY CAUSE PERMANENT INJURY OR DEATH Standards Repair a low voltage control cable so that it carries the rated current or signal of the original cable and does not cause injury or equipment damage Replace the cable if it cannot be repaired to meet these requirements Performance Steps 1 Review danger warning and caution notices 2 Review the manufacturer s literature electrical construction prints and wiring diagrams 3 Ensure that personal protective equipment has been properly tested and is fully operable a Test the cable for continuity b Perform an insulation resistance test at no higher than 500 volts NOTE Do not perform step 3b on the unshielded twisted pair UTP cable 4 Perform lockout and tagout procedures 5 Prepare an as found wiring diagram to ensure the correct reinstallation of the cable 6 Ensure that no voltage is present by using a voltage detector and voltmeter 7 Disconnect the damaged cable from the equipment to perform repairs as necessary 8 Repair the damaged cable using the splice mechanical type connector or termination method NOTE A damaged UTP cable should be replaced unless it is repairable at the ends 9 Reinstall the cable using the as found wiring diagram 10 Test the cable 11 Close out lockout and tagout procedures by removing locking and tagging devices 12 Ensure that voltage is present by using a voltage detector and voltmeter 13 Ensure that the items
56. IEEE RED BOOK INTRO CIRCUIT ANALYSIS NESC S AND C HANDBOOK Technical Bulletins TB 385 4 TB SIG 222 Technical Manuals TM 5 315 TM 5 6115 456 34P 31 March 2009 The Army Safety Program RAR 001 2008 11 07 23 August 2007 Concepts and Equipment of Petroleum Operations 2 April 1998 Plumbing Pipe Fitting and Sewerage 31 August 2001 Engineer Prime Power Operations 4 April 2007 First Aid NTRP 4 02 1 1 AFMAN 44 163 1 MCRP 3 02G 23 December 2002 Recovery and Battle Damage Assessment and Repair MCRP 4 11 4A 19 September 2006 Rigging Techniques Procedures and Applications 3 October 1995 Project Management 13 June 1994 Introduction to Marine Electricity 1 September 1994 American Electricians Handbook 14th Edition McGraw Hill 2002 IEEE Red Book Standard 141 IEEE Recommended Practice for Electric Power Distribution for Industrial Plants 1993 Introductory Circuit Analysis 10th Edition Prentice Hall 4 March 2002 National Electrical Safety Code 2007 lt htip standards ieee org nesc gt Switchgear and Control Handbook 3rd Edition McGraw Hill 1998 Safety Requirements for Maintenance of Electrical and Electronic Equipment 1 July 2008 Solder and Soldering 5 March 1985 Firefighting and Rescue Procedures in Theaters of Operations 20 April 1971 Direct Support and General Support Maintenance Repair Parts and Special Tools List Including Depot Maintenance Repair Parts and Special Tools E
57. Identified possible electrical paths depending on switchgear positioning Evaluation Guidance Score the Soldier GO if all measures are passed P Score the Soldier NO GO if any measure is failed F If the Soldier fails any measure show him how to do it correctly References Required Related EM 385 1 1 FM 3 34 480 FM 5 412 LCH TM 5 684 TM 5 686 TM 5 811 1 TM 5 811 3 31 March 2009 STP 5 21P2 SM TG 3 39 Chapter 3 Operate a Multiunit Power Plant 052 244 2123 Conditions As a power plant operator in a tactical or nontactical environment after a multiunit power plant has been successfully installed and tested and preventive maintenance checks and services PMCS have been completed you are given technical manuals TMs the standing operating procedure SOP an operator s logbook and personal protective equipment DANGER 1 THIS TASK SHOULD ONLY BE PERFORMED BY QUALIFIED PERSONNEL WHO ARE KNOWLEDGEABLE IN THE INSTALLATION OPERATION AND MAINTENANCE OF MEDIUM VOLTAGE ELECTRICAL POWER GENERATION EQUIPMENT AND ITS ASSOCIATED HAZARDS FAILURE TO COMPLY MAY CAUSE PERMANENT INJURY OR DEATH 2 DO NOT OPERATE THE GENERATOR SET UNLESS IT HAS BEEN PROPERLY GROUNDED FAILURE TO COMPLY MAY CAUSE PERMANENT INJURY OR DEATH 3 REMOVE RINGS NECKLACES OTHER JEWELRY AND LOOSE CLOTHING FAILURE TO COMPLY MAY CAUSE PERMANENT INJURY OR DEATH CAUTION NOISE LEVELS IN EXCESS OF 85 DECIBELS EXIST WITHIN A 50 FOOT RADIUS OF OPE
58. NECKLACES OTHER JEWELRY AND LOOSE CLOTHING FAILURE TO COMPLY MAY CAUSE PERMANENT INJURY OR DEATH Standards Service the system ground by inspecting the ground grid to check for continuity throughout the system and to determine if the minimum ohm level has been met Repair or correct deficiencies Performance Steps NOTE Service the equipment if the equipment ground fault or the operation of the neutral overcurrent protective device has been erratic due to suspected ground resistance charges 1 Review danger warning and caution notices 2 Review the manufacturer s literature electrical construction prints and wiring diagrams 3 Identify the correct resistance level according to Section 250 56 of the NEC Handbook 4 Disconnect the power to the system if possible 5 Conduct a visual inspection a Locate the major components parts of the system 1 Identify the equipment enclosures 2 Identify the structural members 3 Identify the fencing 4 Identify the lightning rods 5 Identify the system neutrals b Inspect the connection points for common faults 1 Check for corrosion 2 Check for loose connections 3 Check for broken connections 4 Check for overheating 6 Service the connection points by repairing replacing or cleaning them 7 Conduct electrical tests a Perform a fall of potential test according to the IEEE Green Book and the test set instructions on the main grounding electrode or system
59. NESC NEC HANDBOOK UGLYS 3 58 STP 5 21P2 SM TG 31 March 2009 MOS Skill Level Tasks Troubleshoot an Engine Failure to Crank 052 244 2131 Conditions As a power plant operator in a tactical or nontactical environment when an engine fails to crank you are given an engine appropriate technical manuals a maintenance logbook a general mechanic s tool box a multimeter and a lockout and tagout kit DANGER 1 ENSURE THAT THE PRIME MOVER IS PROPERLY LOCKED OUT AND TAGGED OUT FAILURE TO COMPLY MAY CAUSE PERMANENT INJURY OR DEATH 2 THIS TASK SHOULD ONLY BE PERFORMED BY QUALIFIED PERSONNEL WHO ARE KNOWLEDGEABLE IN THE OPERATION AND MAINTENANCE OF ELECTRICAL POWER GENERATION EQUIPMENT AND ITS ASSOCIATED HAZARDS FAILURE TO COMPLY MAY CAUSE PERMANENT INJURY OR DEATH 3 REMOVE ALL RINGS NECKLACES OTHER JEWELRY AND LOOSE CLOTHING FAILURE TO COMPLY MAY CAUSE PERMANENT INJURY OR DEATH Standards Troubleshoot an engine that fails to crank by identifying the fault testing the fault to verify that it is the cause of the malfunction and annotating the cause of the malfunction and the corrective actions taken Performance Steps 1 Review danger warning and caution notices 2 Review the manufacturer s literature electrical construction prints and wiring diagrams 3 Review the maintenance logbook and historical data pertaining to the equipment 4 Ensure that the generator prime mover is locked out and tagged out 5 C
60. NOTE The procedures below should be used in conjunction with the manufacturer s literature 1 Review danger warning and caution notices Review the manufacturer s literature and wiring diagrams Review maintenance logbooks and historical data pertaining to the equipment Perform lockout and tagout procedures Ground the generator leads O oa A W N Inspect the generator a Check for excessive contamination dust dirt debris b Check for excessive operating temperatures c Check for fractured parts d Check for loose or missing parts e Check for lubrication contamination f Check for stator insulation deterioration 7 Disconnect and tag the generator leads WARNING BEFORE TESTING THE MAIN OR EXCITER ROTOR WITH AN INSULATION RESISTANCE TESTER TERMINAL LEADS SHOULD BE DISCONNECTED FROM THE ROTATING RECTIFIER FAILURE TO COMPLY MAY CAUSE EQUIPMENT DAMAGE 8 Test the main stator to ensure that ohm values are more than 5 16 megohms a Apply 5 kilovolts for 60 seconds using a megohmmeter b Keep a record of the readings c Perform preventive measures cleaning drying repairing replacing 31 March 2009 STP 5 21P2 SM TG 3 233 Chapter 3 Performance Steps 9 10 11 12 13 14 15 Test the main rotor to ensure that ohm values are more than 2 megohms a Apply the manufacturer s recommended voltage for 60 seconds using the megohmmeter b Keep a record of the readings Test the ex
61. OF ROTATING ENGINE COMPONENTS FAILURE TO COMPLY MAY CAUSE PERMANENT INJURY OR DEATH 3 ALWAYS WEAR PPE AS REQUIRED FOR INSPECTIONS IN HAZARDOUS AREAS FAILURE TO COMPLY MAY CAUSE PERMANENT INJURY OR DEATH WARNING ENGINE OIL IS VERY HOT DURING OPERATION DO NOT REMOVE OIL OR LUBE OIL COMPONENTS UNTIL THE ENGINE HAS COOLED FAILURE TO COMPLY MAY CAUSE IMMEDIATE PERSONAL INJURY CAUTION 1 EQUIPMENT WITH A CLASS III LEAK SHOULD NOT BE OPERATED AND MUST BE REPAIRED OR SENT FOR REPAIR IMMEDIATELY FAILURE TO COMPLY MAY RESULT IN EQUIPMENT DAMAGE THAT MAY CAUSE LONG TERM FAILURE 2 NOISE LEVELS IN EXCESS OF 85 DECIBELS EXIST WITHIN A 50 FOOT RADIUS OF OPERATING EQUIPMENT PERSONNEL MUST WEAR SINGLE HEARING PROTECTION WITHIN A 50 FOOT RADIUS FAILURE TO COMPLY MAY CAUSE INJURY NOTES 1 All equipment is not the same and may function differently depending on the make model and manufacturer Troubleshooting steps are similar but may vary Always consult the applicable manufacturer s literature for each piece of equipment 2 Tests should be conducted as specified in the manufacturer s literature when available Use industry standards when the manufacturer s literature cannot be obtained 3 Defective equipment should not be used it should be repaired or replaced immediately Standards Troubleshoot a diesel engine lube oil system through inspection fault identification and fault testing to identify the cause of malfunction Perf
62. OR DEATH 2 REMOVE RINGS NECKLACES OTHER JEWELRY AND LOOSE CLOTHING FAILURE TO COMPLY MAY CAUSE PERMANENT INJURY OR DEATH Standards Perform advanced electrical troubleshooting procedures using systematic procedures Safely troubleshoot the electrical circuit or distribution system by identifying the possible cause of the malfunction testing to verify the cause of the malfunction and making repairs if possible to correct the malfunction Performance Steps 1 Review danger warning and caution notices Review the manufacturer s literature electrical construction prints and wiring diagrams Review maintenance logbooks and historical data pertaining to the equipment Identify portions of the circuit or system that are without power or have improper voltage levels Check and reset tripped protective devices circuit breakers fuses protective relays O oa A OO N Check voltage levels a Check for indications of shorts or opens from phase to neutral b Check for indications of shorts or opens from phase to phase c Check for indications of shorts or opens from phase to ground d Check for indications of shorts or opens from ground to neutral e Check for indications of shorts or opens from phase and line voltages of three phase systems 7 Check conductor ends a Check for proper termination b Check for a solid electrical connection c Check for loose connections 8 Check conductors electrically for shorts
63. OR DEATH WARNING THE ENGINE COOLANT GETS VERY HOT DURING OPERATION DO NOT REMOVE ANY COOLING SYSTEM COMPONENTS UNTIL THE ENGINE HAS COOLED FAILURE TO COMPLY MAY CAUSE IMMEDIATE PERSONAL INJURY CAUTION 1 NOISE LEVELS IN EXCESS OF 85 DECIBELS EXIST WITHIN A 50 FOOT RADIUS OF OPERATING EQUIPMENT PERSONNEL MUST WEAR SINGLE HEARING PROTECTION WITHIN A 50 FOOT RADIUS FAILURE TO COMPLY MAY CAUSE INJURY 2 EQUIPMENT WITH A CLASS III LEAK SHOULD NOT BE OPERATED AND MUST BE REPAIRED OR SENT FOR REPAIR IMMEDIATELY FAILURE TO COMPLY MAY RESULT IN EQUIPMENT DAMAGE THAT MAY CAUSE LONG TERM FAILURE NOTES 1 All equipment is not the same and may function differently depending on the make model or manufacturer Troubleshooting steps are similar but may vary Always consult the applicable manufacturer s literature for each piece of equipment 2 All tests should be conducted as specified in the manufacturer s literature when available Use industry standards when the manufacturer s literature cannot be obtained 3 Defective equipment should be repaired or replaced immediately and not used until correctly repaired or replaced 3 190 STP 5 21P2 SM TG 31 March 2009 MOS Skill Level Tasks Standards Repair a diesel engine cooling system by verifying repairing and replacing the defective components parts Performance Steps 1 O oa A W N N Review the appropriate TMs applicable manufacturer s literature or industry standard
64. REMOVE COOLING SYSTEM COMPONENTS UNTIL THE ENGINE HAS COOLED FAILURE TO COMPLY MAY CAUSE PERMANENT INJURY CAUTION 1 EQUIPMENT WITH A CLASS III LEAK SHOULD NOT BE OPERATED AND MUST BE REPAIRED OR SENT FOR REPAIR IMMEDIATELY FAILURE TO COMPLY MAY RESULT IN EQUIPMENT DAMAGE THAT MAY CAUSE LONG TERM FAILURE 2 NOISE LEVELS IN EXCESS OF 85 DECIBELS EXIST WITHIN A 50 FOOT RADIUS OF OPERATING EQUIPMENT PERSONNEL MUST WEAR SINGLE HEARING PROTECTION WITHIN A 50 FOOT RADIUS FAILURE TO COMPLY MAY CAUSE INJURY NOTE 1 All equipment is not the same and may function differently depending on the make model and manufacturer Troubleshooting steps are similar but may vary Always consult the applicable manufacturer s literature for each piece of equipment 2 Tests should be conducted as specified in the manufacturer s literature or industry standards 3 Defective equipment should be repaired or replaced immediately and not used until correctly repaired or replaced Standards Troubleshoot a diesel engine cooling system through inspection fault identification and fault testing to verify the cause of malfunction Performance Steps 1 Review TMs manufacturer s literature or industry standards maintenance logbooks and historical data pertaining to the equipment 2 Ensure that PPE is correctly tested and fully mission capable 3 184 STP 5 21P2 SM TG 31 March 2009 MOS Skill Level Tasks Performance Steps 3 Inspect tools and
65. TG 3 279 Chapter 3 Climb a Utility Pole 052 204 1124 Conditions As a power line distribution specialist in a tactical or nontactical environment when installation maintenance or repairs to an overhead distribution system are needed at a minimum height of 25 feet you are given applicable climbing and rigging equipment a 2 pound hammer a brace and a 3 8 inch bit a 3 8 inch wooden dowel 1 foot long a shovel and the applicable personal protective equipment PPE WARNING 1 IF A POLE IS FOUND TO BE DEFECTIVE IT SHOULD BE SCHEDULED FOR REPLACEMENT AS SOON AS POSSIBLE FAILURE TO COMPLY MAY CAUSE IMMEDIATE PERSONAL INJURY OR EQUIPMENT DAMAGE 2 WHEN POSSIBLE INDIVIDUALS NOT ASCENDING THE POLE MUST MAINTAIN A MINIMUM DISTANCE OF 10 FEET FROM THE POLE BASE TO ENSURE THAT THEY ARE NOT STRUCK BY DROPPED OBJECTS FAILURE TO COMPLY MAY CAUSE IMMEDIATE PERSONAL INJURY 3 USE PROPER CLIMBING TECHNIQUES TO AVOID SLIPPING OR FALLING WEAR LONG SLEEVES AND GLOVES TO AVOID SPLINTERS WEAR PROTECTIVE EYEWEAR WHENEVER METAL IS USED TO STRIKE METAL FAILURE TO COMPLY MAY CAUSE IMMEDIATE PERSONAL INJURY Standards Climb a utility pole to a minimum height of 35 feet belt in hitchhike down 5 feet hitchhike back up to eye level circle right and assume a good working position circle left and assume a good working position hitchhike down 5 feet unbelt and descend the pole without falling Performance Steps 1 Perform a utility pole
66. TO COMPLY MAY CAUSE IMMEDIATE PERSONAL INJURY OR EQUIPMENT DAMAGE NOTE There are several different types of splicing kits available for use with medium voltage power cables Each kit contains specific instructions on how to make the splice Always follow the manufacturer s procedures for the specific kit used Standards Splice a medium voltage power cable to ensure that the splice meets the rating of the original cable and does not cause an electrical hazard to personnel or equipment Ensure that the cable is able to transmit the maximum electrical load without undue heating and is at the full mechanical strength of the conductors Performance Steps 1 Perform lockout and tagout procedures NOTES 1 If the two cables do not have enough length to be spliced an additional length of cable will be needed 2 This task covers a 5 to 35 kilovolt single conductor shielded power cable that is made of polyethylene cross linked polyethylene butyl or other rubberlike insulation with a polyvinyl chloride PVC or neoprene jacket 3 The insulation resistance value should exceed 80 percent of the cable s insulation rating 2 Inspect the splice kit a Ensure that the correct splice kit for the cable is being used b Inventory the kit to ensure that all components parts are present 3 Prepare the cable and splice it according to the manufacturer s literature a Measure and mark the cable b Inspect the cable for carbon particles
67. USE TAGOUT PROCEDURES FAILURE TO COMPLY MAY CAUSE PERMANENT INJURY OR DEATH Standards Perform lockout and tagout procedures according to OSHA regulations to ensure the safe isolation of energized circuits and mechanical hazards Performance Steps NOTES 1 Authorized personnel applying lockout and tagout devices are also responsible for ensuring the control of residual energy and for placing tagging and removing protective grounds 2 Safe clearances must be used for electrical work performed on de energized lines and for equipment operating over 600 volts 1 Notify the project supervisor of the work areas requiring lockout and tagout procedures 2 Initiate a safe clearance request a Fill out Eng Form 1927 R b Annotate the safe clearance in the power station operation log Eng Form 2198 3 Review the schematics and prints of the system a Identify all energy isolating devices and disconnectors b Identify where the system can be isolated by 1 Shutting down the system 2 Isolating the system 3 Blocking the system 4 Securing the system 4 Isolate systems operated by remote controlled power sources 5 Create a list of energy isolating devices and disconnecting equipment to be locked and tagged a Identify the primary means of isolation 31 March 2009 STP 5 21P2 SM TG 3 19 Chapter 3 Performance Steps b Identify the secondary means of isolation 6 Review other work areas to identify possible ex
68. add acetylene and oxygen until the acetylene valve no longer increases flame size d Make a final torch adjustment using the oxygen valve nearest to the cutting tip to adjust the preheat flame and adjust the oxygen flow to remove the blue feather flame leaving only the small blue tips of the flame at the torch tip e Depress the oxygen lever to ensure that the oxygen lance flow does not disrupt the preheat flame 5 Cut the material using the correct cutting techniques 6 Shut down and properly store the cutting equipment a Close the torch oxygen valve first and then close the torch acetylene valve b Shut off tank supply valves c Bleed the oxygen from the hose by opening both oxygen torch valves and then closing both oxygen torch valves d Bleed the acetylene from the hose by opening the torch acetylene valve and then closing the acetylene valve e Back out the oxygen and acetylene regulator pressure setscrews counterclockwise until no resistance is felt f Place the torch in a secure location to prevent damage Evaluation Preparation Setup Provide the Soldier with the items listed in the conditions Give the Soldier a safety briefing before starting the test and ensure that safety precautions are followed Prepare the testing area and equipment in advance to ensure that task standards can be met Brief Soldier Direct the Soldier to perform oxyfuel cutting 31 March 2009 STP 5 21P2 SM TG 3 143 Chapter 3 Perfo
69. appropriate depth and according to cable ratings in the safety SOPs the applicable manufacturer s literature and the LCH Performance Steps 1 Review danger warning and caution notices before proceeding Review the manufacturer s literature electrical construction prints and wiring diagrams Ensure that PPE is correctly tested and fully mission capable Complete DA Form 2702 for the tools and equipment necessary to perform this task Inspect tools and rigging equipment for serviceability Develop a plan for obtaining nonorganic tools and the equipment necessary to perform the mission Issue a safety briefing that highlights safety precautions and the concept of the operation oN O oO A W N Assign personnel positions and ensure that they understand their role in accomplishing this task 9 Determine if the mobile or stationary reel method of reeling out the conductors will be used NOTE Conductors should never be removed from a nonrotating reel or coil Failure to rotate the reel or coil will cause the conductors to twist and kink resulting in their damage 10 Inspect conductors to ensure that they were not damaged during reeling out 11 Ensure that conductors are placed on conductor support devices in the proper sequence 31 March 2009 STP 5 21P2 SM TG 3 311 Chapter 3 Performance Steps 12 Ensure that the underground cable is installed according to electrical construction prints 13 Ensure that the items
70. cccceeeeeeeeeeeeneeeeetneeeeeetiieeeertieeeeeeee 3 4 052 244 2103 Terminate a Medium Voltage Power Cable 00 ccceccceeeeeeeteeeeeeeneeeeeteieeeeeetneeeeeeae 3 7 052 244 2105 Rescue a Victim From a Nonaerial Electrical Conductor ee eeeeeeeeeeeeeeneees 3 10 052 244 2106 Perform Preventive Maintenance on Safety Equipment cccececesteeeeeeees 3 12 052 244 2109 Perform Operator Preventive Maintenance Checks and Services PMCS on Test Measurement and Diagnostic Equipment TMDE ccceeeeeeeeeeeees 3 15 052 244 2111 Troubleshoot an Engine Failure to Stop eeeeeeceeeeeeeeeeneeeeeseeneeeeeeenaeereeeaees 3 17 052 244 2112 Perform Lockout and Tagout Procedures cceceeeeeeeeeeeneeeeeseeeeeeteenaeeeeeeaeees 3 19 052 244 2114 Operate a Mobile Electric Power MEP 810A or B Generator c ccceeeees 3 24 052 244 2115 Operate a Mobile Electric Power MEP 012 or 208 Generator 3 27 052 244 2116 Operate a Mobile Electric Power MEP 029 Generator cceeseeeeeeeeeeeneeees 3 30 052 244 2117 Perform Preventive Maintenance Checks and Services PMCS on a Mobile Electric Power MEP 810A or B Generator sssssssesrsesssrnneeennannsnnnneeennannnnnnaeennaa 3 33 052 244 2118 Perform Preventive Maintenance Checks and Services PMCS on a Mobile Electric Power MEP 012 or 208 Generator eessesessrrsseernanrsnnnnrennannnnannaeennaa 3 37 052 244 2121 Read an Electrical One Line Diagram
71. components parts Performed an overpotential test on each pole with the switch closed and ensured that the insulation could withstand the applied test voltage Closed out lockout and tagout procedures by removing locking and tagging devices Reenergized the oil switch Ensured that the oil switch operated as designed Ensured that the items listed in the conditions were properly cleaned and stored Evaluation Guidance Score the Soldier GO if all measures are passed P Score the Soldier NO GO if any measure is failed F If the Soldier fails any measure show him how to do it correctly References Required Related FM 3 34 480 LCH NESC NETA 31 March 2009 STP 5 21P2 SM TG 3 203 Chapter 3 Service a Vacuum Switch 052 206 2103 Conditions As a power station electrician in a tactical or nontactical environment during maintenance you are given a vacuum switch safety standing operating procedures a general mechanic s tool box a digital low resistance ohmmeter a megohmmeter a high potential test set and or a vacuum bottle test set grounding equipment and the applicable manufacturer s literature DANGER 1 THIS TASK SHOULD ONLY BE PERFORMED BY QUALIFIED PERSONNEL WHO ARE KNOWLEDGEABLE IN THE INSTALLATION AND MAINTENANCE OF VACUUM SWITCHES AND POWER EQUIPMENT AND THEIR ASSOCIATED HAZARDS FAILURE TO COMPLY MAY CAUSE PERMANENT INJURY OR DEATH 2 DO NOT TOUCH EXPOSED ELECTRICAL CONNECTIONS WHILE A POWER SO
72. cylinder 3 Determine what caused the malfunction NOTE This list is meant to be a guideline and is not all inclusive Check for the most obvious and easily corrected problems first Check for contaminated fuel at the misfiring cylinder or injector Check for air restriction at the cylinder air inlet Check for low compression on the misfiring cylinder Check for incorrect injector timing Check for low fuel or oil pressure at the misfiring cylinder Check for incorrect exhaust valve adjustment and timing Check for incorrect power assembly components Check for a damaged power pack TO 9QAQ00M 4 Record actions taken on DA Form 2404 or DA Form 5988 E and maintenance logbooks 5 Ensure that the items listed in the conditions are properly cleaned and stored Evaluation Preparation Setup Provide the Soldier with the items listed in the conditions Give the Soldier a safety briefing before starting the test and ensure that safety precautions are followed Prepare the testing area and equipment in advance to ensure that task standards can be met Brief Soldier Direct the Soldier to troubleshoot a diesel engine for a misfiring cylinder Performance Measures GO NO GO 1 Reviewed maintenance logbooks and historical data pertaining to the equipment 2 Identified the misfiring cylinder 3 Determined what caused the malfunction 3 128 STP 5 21P2 SM TG 31 March 2009 MOS Skill Level Tasks
73. depending on the make model or manufacturer Installation steps are similar but may vary Always consult the applicable manufacturer s literature for each piece of equipment Standards Install distribution equipment de energized as specified in the applicable manufacturer s literature Ensure that hardware is mechanically tight and electrically connected Performance Steps 1 Review danger warning and caution notices before proceeding Review the manufacturer s literature electrical construction prints and wiring diagrams Ensure that PPE is properly tested and fully mission capable Inspect tools and climbing and rigging equipment for serviceability Perform lockout and tagout procedures Ascend the pole to the desired height if necessary Test phases to ensure that there is no voltage present oN O oO A W N Install personal protective grounds 31 March 2009 STP 5 21P2 SM TG 3 275 Chapter 3 Performance Steps 9 Install rigging equipment as necessary 10 Raise and position safely the distribution equipment to be installed 11 Install mounting hardware as stated in the applicable manufacturer s literature 12 Remove rigging equipment 13 Connect the distribution equipment electrically according to the applicable manufacturer s literature 14 Verify the correct phase sequence 15 Position or sag conductors to the appropriate clearance according to the applicable manufacturer s literature 16 Remove
74. drop values should not exceed high levels of the normal range as indicated in the manufacturer s literature If the manufacturer s literature is not available investigate the values that deviate from adjacent poles or similar breakers by more than 50 percent of the lowest value a Clean the circuit breaker before testing it unless as found and as left tests are required b Inspect for 1 Anchorage 2 Alignment 3 Grounding 4 Arc chutes 3 230 STP 5 21P2 SM TG 31 March 2009 MOS Skill Level Tasks Performance Steps 10 11 12 13 14 15 5 Condition wear and alignment of moving and stationary contacts 6 Puffer operation c Verify that 1 Maintenance devices are available for servicing and operating the circuit breaker 2 Primary and secondary contact wipes are specified according to the manufacturer s literature Proper cell fit and element alignment are present Moving current carrying parts have appropriate contact lubrications Moving sliding surfaces have the correct amount of appropriate lubrications Perform mechanical operator and contact alignment tests for the circuit breaker and operating mechanism Perform resistance measurements through the bolted connections using a low resistance ohmmeter and compare contact resistances of electrical connections to the values of similar connections if the manufacturer s literature is not available Perform insulation resistance tes
75. dry area 11 Maintain the block and tackle a Check the rope and blocks 1 Check for cuts 2 Check for frays 3 Check for breaks 4 Check for cracks 5 Check for continuous smooth movement of the rope through the block sheaves b Wipe the wooden parts with linseed oil c Wipe the metal parts with machine oil d Hang the chain hoist in a clean dry area 12 Maintain the chain hoist a Check the chain hoist 1 Check for a slipping brake mechanism 2 Check for cracks Check for chemical damage Check for deformation Check for a worn chain Check for proper lubrication Check for free movement of the hooks b Wipe the chain hoist with a light coat of machine oil c Hang the chain hoist in a clean dry area 3 4 5 6 7 13 Ensure that the items listed in the conditions are properly cleaned and stored Evaluation Preparation Setup Provide the Soldier with the items listed in the conditions Give the Soldier a safety briefing before starting the test and ensure that safety precautions are followed Prepare the testing area and equipment in advance to ensure that task standards can be met Brief Soldier Give the Soldier a requirement to maintain climbing and rigging equipment Performance Measures GO NO GO 1 Inventoried the climbing and rigging equipment Ensured that all items were included in the inventory Inspected leather products Inspected metal
76. electronic media engineer manual enlisted member engineer Environmental Protection Agency evasion plan of action Enlisted Personnel Management System electronic phase shifter evaluation report engineer regulation electronic technician electronic tool endotracheal engineering test Fahrenheit fail failed frequency full full load amperes field manual flare multiunit force module frequency modulated frequency modulation frequency general engineering General Electric general education development gasoline engine driven general generator Institute of Electrical and Electronics Engineers incident report information requirement infrared intelligence requirements Joint Oil Analysis Program kilo volt ampere Lineman s and Cableman s Handbook light combat helicopter light emitting diode STP 5 21P2 SM TG 31 March 2009 LRA MEP METL MIG MO MOS MSDS MSG NA NCO NCOES NEC NESC NETA NFPA OSHA pam PCB PFC PLC PLDC PMCS PN POL 31 March 2009 Glossary local reproduction authorized locked rotor amperes military environmental protection mobile electric power mission essential task list metal inert gas Missouri monthly month medical officer maintenance and operations military occupational specialty minimum operating strip minimal operational strip material safety data sheet mission specific data set message master sergeant
77. engine lube oil system Recorded actions taken on DA Form 2404 or DA Form 5988 E and maintenance logbooks Ensured that the items listed in the conditions were properly cleaned and stored Evaluation Guidance Score the Soldier GO if all measures are passed P Score the Soldier NO GO if any measure is failed F If the Soldier fails any measure show him how to do it correctly References Required Related DA FORM 2404 EM 385 1 1 DA FORM 5988 E 31 March 2009 STP 5 21P2 SM TG 3 189 Chapter 3 Repair a Diesel Engine Cooling System 052 205 2133 Conditions As a power station mechanic in a nontactical environment when a diesel engine cooling system needs repair you are given a lockout and tagout kit a general mechanic s tool box the applicable technical manuals TMs the applicable manufacturer s literature or industry standards maintenance logbooks DA Form 2404 Equipment Inspection and Maintenance Worksheet or DA Form 5988 E Equipment Inspection Maintenance Worksheet and applicable personal protective equipment PPE DANGER 1 REMOVE RINGS NECKLACES OTHER JEWELRY AND LOOSE CLOTHING FAILURE TO COMPLY MAY CAUSE PERMANENT INJURY OR DEATH 2 EXERCISE EXTREME CAUTION WHEN WORKING IN THE AREA OF ROTATING ENGINE COMPONENTS FAILURE TO COMPLY MAY CAUSE PERMANENT INJURY OR DEATH 3 ALWAYS WEAR PPE AS REQUIRED FOR INSPECTIONS IN HAZARDOUS AREAS FAILURE TO COMPLY MAY CAUSE PERMANENT INJURY
78. environment when an underground cable needs to be installed you are given electrical construction prints applicable electrical distribution equipment as specified in the electrical construction prints wiring diagrams a line truck with a cable trailer applicable digging or trenching equipment a voltage detector a lockout and tagout kit grounding equipment safety standing operating procedures SOPs the applicable manufacturer s literature the Lineman s and Cableman s Handbook LCH the applicable personal protective equipment PPE and DA Form 2702 Bill of Materials DANGER 1 THIS TASK SHOULD ONLY BE PERFORMED BY QUALIFIED PERSONNEL KNOWLEDGEABLE IN THE INSTALLATION AND MAINTENANCE OF ELECTRICAL DISTRIBUTION SYSTEMS AND POWER EQUIPMENT AND THE ASSOCIATED HAZARDS FAILURE TO COMPLY MAY CAUSE PERMANENT INJURY OR DEATH 2 A VOLTAGE DETECTOR SHOULD BE USED TO ENSURE THAT CABLES ARE NOT ENERGIZED MATERIAL SUCH AS A LEAD SHEATH THAT ACTS AS A SHIELD MUST NOT BE BETWEEN THE VOLTAGE DETECTOR AND THE CONDUCTORS OF THE CIRCUIT BEING TESTED FAILURE TO TEST CABLES MAY CAUSE PERMANENT INJURY OR DEATH 3 NEVER POSITION YOURSELF UNDER A SUSPENDED LOAD FAILURE TO COMPLY MAY CAUSE OR PERMANENT INJURY OR DEATH 4 REMOVE RINGS NECKLACES OTHER JEWELRY AND LOOSE CLOTHING FAILURE TO COMPLY MAY CAUSE PERMANENT INJURY OR DEATH Standards Supervise the installation of underground cable by ensuring that the cable is safely installed at the
79. equipment in advance to ensure that task standards can be met Brief Soldier Direct the Soldier to service optoelectronic equipment Performance Measures GO NO GO 1 A WO N O OO N QOQ A 11 Reviewed danger warning and caution notices before proceeding Reviewed the manufacturer s literature with schematics and wiring diagrams Reviewed maintenance logbooks and historical data pertaining to the equipment Identified the circuit connected to the optoelectronic equipment by using the schematics Performed lockout and tagout procedures Tested the circuit for voltage presence Removed the equipment and tagged the leads Inspected the equipment for damage Tested the equipment according to the manufacturer s literature Compared the results with the manufacturer s specifications and took appropriate action Reinstalled or replaced the equipment 3 116 STP 5 21P2 SM TG 31 March 2009 MOS Skill Level Tasks Performance Measures GO NO GO 12 Tested the circuit for voltage presence 13 Tagged the equipment with the appropriate calibration sticker including the name and testing date 14 Reinstalled the equipment 15 Closed out lockout and tagout procedures by removing locking and tagging devices 16 Energized the circuit and ensured that it was operating pr
80. followed Prepare the testing area and equipment in advance to ensure that task standards can be met Brief Soldier Direct the Soldier to replace a diesel engine piston assembly Performance Measures 1 O OoOo N O o A W N _ Performed lockout and tagout procedures Removed the cylinder head Removed inspection covers Removed the piston assembly Disassembled the piston and connecting rod Removed connecting rod bearings Removed main bearings Removed the cylinder liner and seals Inspected the piston and connecting rod assembly Inspected connecting rod bearings 3 162 STP 5 21P2 SM TG 31 March 2009 MOS Skill Level Tasks Performance Measures GO NO GO 11 Inspected the crankshaft journal 12 Inspected main bearings 13 Inspected the cylinder liner and seals 14 Repaired defective parts 15 Replaced parts that could not be repaired 16 Reassembled the piston and connecting rod 17 Closed out lockout and tagout procedures by removing locking and tagging devices 18 Operated the prime mover and checked for proper operation 19 Recorded actions taken on DA Form 2404 or DA Form 5988 E and maintenance logbooks 20 Ensured that the items listed in the conditions were properly cleaned and stored Evaluation Guidance Score the Soldier GO if all measures are passed P Score the Soldie
81. found in TB 43 180 3 Ensure that a valid DA Label 80 is attached to TMDE requiring calibration 4 Ensure that a valid DA Label 80 stamped with Calibration Not Required is attached to the test equipment not requiring calibration on Place a valid DA Label 80 stamped with Calibrate Before Use on the TMDE that has not been calibrated Submit defective and delinquent equipment for calibration or repair Clean test equipment as necessary 6 7 8 Perform PMCS on electrical mechanical and instrumentation TMDE 9 Record actions taken on DA Form 2404 or DA Form 5988 E 10 Ensure that the items listed in the conditions are properly cleaned and stored Evaluation Preparation Setup Provide the Soldier with the items listed in the conditions Give the Soldier a safety briefing before starting the test and ensure that safety precautions are followed Prepare the testing area and equipment in advance to ensure that task standards can be met Brief Soldier Direct the Soldier to perform operator PMCS on TMDE Performance Measures GO NO GO 1 Ensured that TMDE requiring calibration was listed in TB 43 180 2 Completed DA Form 3758 R for the items requiring calibration that were not found in TB 43 180 3 Ensured that a valid DA Label 80 was attached to TMDE requiring calibration 31 March 2009 STP 5 21P2 SM TG 3 15 Chapter 3 Performance Measures GO NO GO 4 Ensured tha
82. him how to do it correctly References Required DA FORM 2404 Related LCH NESC STP 5 21P2 SM TG 31 March 2009 MOS Skill Level Tasks Perform Operator Preventive Maintenance Checks and Services PMCS on Test Measurement and Diagnostic Equipment TMDE 052 244 2109 Conditions As a power plant operator in a tactical or nontactical environment during scheduled or unscheduled maintenance of test equipment you are given the manufacturer s literature technical manuals TB 43 180 cleaning materials electrician tools the equipment stated in the manufacturer s maintenance instructions standing operating procedures DA Form 2404 Equipment Inspection and Maintenance Worksheet DA Form 3758 R Calibration and Repair Requirements Worksheet DA Form 5988 E Equipment Inspection Maintenance Worksheet and DA Label 80 U S Army Calibrated Instrument DANGER ALL TMDE MUST BE MAINTAINED ACCORDING TO MANUFACTURER SPECIFICATIONS FAILURE TO COMPLY MAY CAUSE EQUIPMENT DAMAGE PERMANENT INJURY OR DEATH Standards Perform PMCS on TMDE as indicated in the manufacturer s literature Performance Steps NOTE All TMDE regardless of whether it is mentioned in this publication will be inspected and maintained as specified in the technical manual the manufacturer s literature and TB 43 180 1 Ensure that TMDE requiring calibration is listed in TB 43 180 2 Complete DA Form 3758 R for the items requiring calibration that are not
83. it according to the manufacturer s literature Repair or replace the motor based on the test results Performance Steps 1 Review danger warning and caution notices 2 Review the manufacturer s literature and wiring diagrams 3 Review maintenance logbooks and historical data pertaining to the equipment 4 Record critical data from the motor manufacturer s data plate 5 Perform a visual inspection of the motor a Inspect the outer casing b Inspect the connections c Inspect the mounting hardware d Inspect the ventilation NOTE Electric motor windings cannot be wet keep the motor dry or dry the motor before conducting tests 6 Start the motor to perform checks a Check for data plate voltage b Check for current draw c Check for the correct temperature d Check for abnormal noise 3 342 STP 5 21P2 SM TG 31 March 2009 MOS Skill Level Tasks Performance Steps 7 Disconnect the motor leads and ensure that they are isolated and marked 8 Disassemble the motor and label the bell ends 9 Clean the motor 10 Identify the type of electric motor series shunt compound 11 Test motor components parts 12 Reassemble the motor 13 Adjust and lubricate the motor as needed 14 Return the motor to operation testing it for proper operating parameters according to the manufacturer s literature 15 Ensure that the items listed in the conditions are properly cleaned and stored Evaluation Preparation S
84. it correctly References Required Related DA FORM 2404 EM 385 1 1 DA FORM 5988 E 31 March 2009 STP 5 21P2 SM TG 3 187 Chapter 3 Repair a Diesel Engine Lube Oil System 052 205 2132 Conditions As a power station mechanic in a nontactical environment when a diesel engine lube oil system needs repair you are given a lockout and tagout kit a general mechanic s tool box the applicable technical manuals TMs the applicable manufacturer s literature or industry standards maintenance logbooks DA Form 2404 Equipment Inspection and Maintenance Worksheet or DA Form 5988 E Equipment Inspection Maintenance Worksheet and applicable personal protective equipment PPE DANGER 1 REMOVE RINGS NECKLACES OTHER JEWELRY AND LOOSE CLOTHING FAILURE TO COMPLY MAY CAUSE PERMANENT INJURY OR DEATH 2 EXERCISE EXTREME CARE WHEN WORKING IN THE AREA OF ROTATING ENGINE COMPONENTS FAILURE TO COMPLY MAY CAUSE PERMANENT INJURY OR DEATH 3 ALWAYS WEAR PPE AS REQUIRED FOR INSPECTIONS IN HAZARDOUS AREAS FAILURE TO COMPLY MAY CAUSE PERMANENT INJURY OR DEATH WARNING ENGINE OIL GETS VERY HOT DURING OPERATION DO NOT REMOVE OIL OR LUBE OIL COMPONENTS UNTIL THE ENGINE HAS COOLED FAILURE TO COMPLY MAY CAUSE IMMEDIATE PERSONAL INJURY CAUTION 1 NOISE LEVELS IN EXCESS OF 85 DECIBELS EXIST WITHIN A 50 FOOT RADIUS OF OPERATING EQUIPMENT PERSONNEL MUST WEAR SINGLE HEARING PROTECTION WITHIN A 50 FOOT RADIUS FAILURE TO COMPLY MAY CAUSE INJURY
85. its normal running watts for starting As a rule of thumb most motors require four times as much power to start as they do to run and the power load should be sized accordingly 31 March 2009 STP 5 21P2 SM TG 3 55 Chapter 3 Performance Steps 11 Calculate the total load per building a Identify the connected load for each area b Add the totals together for the total connected load to the building 12 Determine the maximum demand a Determine if the total possible power load may be connected at the same time 1 Determine the demand or the amount of power that must be available on the power supply 2 Determine if the total possible power load is equal to the demand load b Determine the maximum demand of the building the set point at some arbitrary figure below the possible total connected load 13 Calculate the demand factor NOTE When specifications are not provided refer to the standard loads for branch circuits and feeder and demand factors for feeders table in FM 5 424 a Determine the demand factor percentage by taking a ratio of maximum demand to the total connected load in the building b Calculate the building loads by using the standard demand factors found in FM 5 424 EXAMPLE Calculate the demand factor for a 90 000 square foot warehouse using a factor of 0 25 watts per square foot given a total connected load of 22 500 90 000 x 0 25 22 500 FORMULA 100 percent of the first 12 500 watts 12 500 watts
86. listed in the conditions Give the Soldier a safety briefing before starting the test and ensure that safety precautions are followed Prepare the testing area and equipment in advance to ensure that task standards can be met Brief Soldier Direct the Soldier to perform preventive maintenance on safety equipment Performance Measures GO NO GO 1 Inspected the hot sticks Inspected the grounding sticks Inspected the ground clusters 2 3 4 5 Maintained the rubber gloves Maintained the rubber sleeves 31 March 2009 STP 5 21P2 SM TG 3 13 Chapter 3 Performance Measures 6 7 8 9 10 11 12 13 14 15 16 17 18 19 Maintained the rubber blankets and mats Inspected the flash suits Maintained the hard hats Inspected the safety glasses and face shields Inspected the antislip floor mats Maintained the petroleum spill kits Maintained the lighted exit signs Maintained the safety board Inspected the fire extinguishers Inspected the eyewash stations Maintained the emergency lights Maintained the smoke detectors Recorded actions taken on DA Form 2404 Ensured that all cleaning material electrician tools and safety equipment were properly cleaned and stored Evaluation Guidance Score the Soldier GO if all measures are passed P Score the Soldier NO GO if any measure is failed F If the Soldier fails any measure show
87. maintenance repair or new installation is needed for an overhead or underground electrical distribution system you are given a line truck with auxiliary equipment the appropriate technical or service manual ground guides a safety harness and personal protective equipment DANGER NEVER LIFT OBJECTS WITHOUT TWO GROUND GUIDES ONE TO ASSIST IN FINDING LOCATIONS OF ITEMS BEING LIFTED AND ANOTHER TO HELP ENSURE THAT THE OBJECT BEING LIFTED DOES NOT BEGIN TO SWAY OUT OF CONTROL FAILURE TO COMPLY MAY CAUSE PERMANENT INJURY OR DEATH WARNING BEFORE MOVING A BUCKET OR LINE TRUCK YOU MUST PERFORM PREVENTIVE MAINTENANCE CHECKS AND SERVICES YOU MUST ALSO BE LICENSED ON THE EQUIPMENT OR BE ACCOMPANIED BY A LICENSED DRIVER IN THE VEHICLE CAB TO ENSURE THAT CORRECT OPERATING PROCEDURES ARE FOLLOWED FAILURE TO COMPLY MAY CAUSE IMMEDIATE PERSONAL INJURY OR EQUIPMENT DAMAGE Standards Operate a line truck with auxiliary equipment by using the primary and secondary controls to move the bucket winch line and auger to predetermined areas and by operating the auxiliary equipment according to the applicable technical or service manual Performance Steps 1 Prepare a line truck for operation NOTE Consult the applicable technical or service manual for each bucket and line truck to obtain guidance on the correct operation of controls Before using a bucket or line truck near energized lines ground the truck chassis for safety a Position the truck
88. major sergeant signal skill level side lap switch locator slow curing asphalt Soldier s manual service member shielded metal arc welding Soldier s manual of common tasks standing operating procedure specialist standard printing color staff sergeant Soldier training publication sustainment technical bulletin STP 5 21P2 SM TG 31 March 2009 Glossary TC TG tm TM TMDE tng TRADOC UPS USAR USASMA UTP VA WK Section Il Terms bus technical coordinator training circular track commander tank commander trainer s guide team technical manual theater missile trademark test measurement and diagnostic equipment training United States Army Training and Doctrine Command universal polar stereographic uninterruptible power supply United States Army Reserve United States Army Sergeants Major Academy unshielded twisted pair vertical angle Virginia volt ampere vulnerability assessment week weekly A fixed assembly of conductors or bars for connecting power generating equipment and associated electrical equipment to a grid or cubicles 31 March 2009 STP 5 21P2 SM TG Glossary 5 This page is intentionally left blank References Required Publications Required publications are sources that users must read in order to understand or to comply with this publication Army Regulations AR 614 200 Department of Army Forms Enlisted Assignments and Utilization Management 27 Jun
89. more system faults you are given a prime mover a lockout and tagout kit grounding equipment safety standing operating procedures the appropriate technical manuals construction prints wiring diagrams the manufacturer s literature or industry standards a maintenance logbook a general mechanic s tool box a multimeter and personal protective equipment PPE DANGER 1 THIS TASK SHOULD ONLY BE PERFORMED BY QUALIFIED PERSONNEL WHO ARE KNOWLEDGEABLE IN THE INSTALLATION AND MAINTENANCE OF ELECTRICAL DISTRIBUTION SYSTEMS AND POWER EQUIPMENT AND THEIR ASSOCIATED HAZARDS FAILURE TO COMPLY MAY CAUSE PERMANENT INJURY OR DEATH 2 REMOVE RINGS NECKLACES OTHER JEWELRY AND LOOSE CLOTHING FAILURE TO COMPLY MAY CAUSE PERMANENT INJURY OR DEATH 3 EXERCISE EXTREME CARE WHEN WORKING AROUND ROTATING ENGINE COMPONENTS PARTS FAILURE TO COMPLY MAY CAUSE PERMANENT INJURY OR DEATH 4 ALWAYS WEAR THE PPE REQUIRED FOR INSPECTIONS IN HAZARDOUS AREAS FAILURE TO COMPLY MAY CAUSE PERMANENT INJURY OR DEATH 5 ISOLATION VERIFICATION AND SYSTEM DE ENERGIZING MUST BE ACCOMPLISHED BY ATTEMPTING TO OPERATE THE ENERGY ISOLATING DEVICES AND DISCONNECTING MEANS FAILURE TO COMPLY MAY CAUSE PERMANENT INJURY OR DEATH CAUTION 1 NOISE LEVELS IN EXCESS OF 85 DECIBELS EXIST WITHIN A 50 FOOT RADIUS OF OPERATING EQUIPMENT PERSONNEL MUST WEAR SINGLE HEARING PROTECTION WITHIN A 50 FOOT RADIUS FAILURE TO COMPLY MAY CAUSE PERSONAL INJURY 2 EQUIPMENT WITH A CLAS
90. of the CT visually and manually to ensure that mechanical functions operate smoothly and that there is no physical damage 7 Perform a continuity check on the transformer winding to ensure that the winding resistance is consistent with the manufacturer s specifications 8 Verify the CT ratio 31 March 2009 STP 5 21P2 SM TG 3 321 Chapter 3 Performance Steps 9 10 11 12 13 14 Perform an insulation resistance test on the transformer and connect a megohmmeter across the lead terminal or a to ground terminal at a test voltage specified in the manufacturer s literature to ensure that insulation resistance readings are a minimum of 100 megohms Reconnect the isolated equipment Close out lockout and tagout procedures by removing locking and tagging devices Ensure that the equipment is operating as designed Keep a record of the test results and actions taken Ensure that the items listed in the conditions are properly cleaned and stored Evaluation Preparation Setup Provide the Soldier with the items listed in the conditions Give the Soldier a safety briefing before starting the test and ensure that safety precautions are followed Prepare the testing area and equipment in advance to ensure that task standards can be met Brief Soldier Direct the Soldier to service a CT Performance Measures 1 O oa A W N 10 11 12 13 14 Reviewed danger warning and caution notices Reviewed the ma
91. percent of the lowest value 5 Color as specified in ASTM D 1500 6 Visual condition as specified in ASTM D 1524 5 Service a liquid filled power transformer a Inspect the condition of the transformer visually and mechanically 1 Verify that the control alarm and trip settings on the temperature indicators are correct according to the manufacturer s literature 2 Verify that the cooling fans and pumps operate correctly 3 Inspect the bolted electrical connections for high resistance and compare the resistances to the values of similar connections 4 Verify that the bolt torque levels are correct according to the manufacturer s literature b Perform insulation resistance tests winding to winding and winding to ground on each phase Ensure that the test values at 1 minute met the manufacturer s specifications and if not stated the results should be compared by voltage to the InterNational Electrical Test Association NETA Maintenance Testing Specifications for Electrical Power Distribution Equipment and Systems Verify that the liquid levels in the tanks and bushings are correct Perform turn ratio test on each tap setting and ensure that the test results did not deviate more than one half percent from either the adjacent coils or the calculated ratio Verify that positive pressures are maintained on nitrogen blanketed transformers Perform specific inspections and mechanical tests recommended by the manufacturer
92. position Remove splash guards Check fuel hydraulic and radiator fill tanks for leaks and damage Check fuel levels with the built in dipstick coolant levels through the coolant sight glass and hydraulic fluid levels through the hydraulic fluid sight glass Check the fuel transfer pump assembly for secure mounting and leaks a Place the fuel transfer mode switch in automatic mode Position A b Place the fuel transfer pump power switch in the G1 position Check the condition of the batteries a Check for cleanliness and signs of damage b Check electrical connections for tightness and signs of corrosion Ensure that the battery isolation switch is in the OFF position Use a flashlight to check between the generators for leaks loose hardware and other potential problems Ensure that tie output cables are properly connected and that concentric neutrals are connected to the ground Ensure that the tie output cover is locked Check the PU equipment grounds for proper connection Ensure that the PU interconnect control cable is properly connected Inspect the exterior fuel system for proper connection leaks and fuel availability Open the three primary distribution center doors and check for damage loose connections and foreign objects Position the selector switch in the proper mode based on location 50 or 60 hertz Secure side access doors Record actions taken on DA Form 2404 or DA Form 5988 E Ensure that th
93. s Handbook LCH and personal protective equipment PPE DANGER 1 ALWAYS WEAR THE PPE REQUIRED FOR INSPECTIONS IN HAZARDOUS AREAS FAILURE TO COMPLY MAY CAUSE PERMANENT INJURY OR DEATH 2 THIS TASK SHOULD ONLY BE PERFORMED BY QUALIFIED PERSONNEL WHO ARE KNOWLEDGEABLE IN THE INSTALLATION AND MAINTENANCE OF ELECTRONICS AND CONTROL INSTRUMENTATION AND THEIR ASSOCIATED HAZARDS FAILURE TO COMPLY MAY CAUSE PERMANENT INJURY OR DEATH 3 REMOVE RINGS NECKLACES OTHER JEWELRY AND LOOSE CLOTHING FAILURE TO COMPLY MAY CAUSE PERMANENT INJURY OR DEATH 4 IT IS VITAL FOR EACH INDIVIDUAL TO UNDERSTAND THE ASSIGNMENT AND TO CARRY IT OUT WITHOUT HESITATION WHEN THE SUPERVISOR GIVES A COMMAND FAILURE TO COMPLY MAY CAUSE IMMEDIATE DEATH OR PERMANENT INJURY 5 NEVER LIFT OBJECTS WITHOUT A GROUND GUIDE TO ASSIST OR WITHOUT ANOTHER INDIVIDUAL TO HELP ENSURE THAT THE OBJECT DOES NOT BEGIN TO SWAY OUT OF CONTROL FAILURE TO COMPLY MAY CAUSE PERMANENT INJURY OR DEATH WARNING 1 BEFORE MOVING A LINE TRUCK YOU MUST PERFORM PREVENTIVE MAINTENANCE CHECKS AND SERVICES YOU MUST ALSO BE LICENSED ON THE EQUIPMENT OR BE ACCOMPANIED BY A LICENSED DRIVER IN THE VEHICLE CAB TO ENSURE THAT CORRECT OPERATING PROCEDURES ARE FOLLOWED FAILURE TO COMPLY MAY CAUSE IMMEDIATE PERSONAL INJURY OR EQUIPMENT DAMAGE 2 WHEN EXTENDING THE SECOND STAGE OF THE BOOM OR WHEN WINCHING UP ENSURE THAT THE WINCH HOOK DOES NOT GET PULLED INTO THE WINCH LINE GUIDE FAILURE TO
94. s Responsibilities Each Soldier is responsible for performing individual tasks that the first line supervisor identifies based on the unit mission essential task list METL The Soldier must perform each task to the standards listed in the Soldier s manual SM If a Soldier has a question about how to do a task or which tasks in this manual he must perform it is his responsibility to ask the first line supervisor for clarification The first line supervisor knows how to perform each task or can direct the Soldier to the appropriate training materials 1 6 Noncommissioned Officer Self Development and the Soldier s Manual Self development is one of the key components of the leader development program It is a planned progressive and sequential program followed by leaders to enhance and sustain their military competency It consists of individual study research professional reading practice and self assessment Under the self development concept the noncommissioned officer NCO as an Army professional has the responsibility to remain current in all phases of the MOS The SM is the primary source for the NCO to use in maintaining MOS proficiency 1 7 Unit Learning Centers Unit learning centers are valuable resources for planning self development programs They can help access enlisted career maps training support products and extension training materials 1 8 Training Support a This manual includes the following appendixes and in
95. s guidelines for the particular kit used Standards Terminate a medium voltage power cable so that the termination meets the rating of the original cable and does not cause an electrical hazard to personnel or damage to equipment The cable must be able to transmit the maximum electrical load without undue heating and it must be at the full mechanical load strength of the conductors Performance Steps 1 Perform lockout and tagout procedures NOTE Some performance steps will be omitted when terminating an overhead medium voltage cable 2 Inspect the termination kit a Use the correct termination kit for the cable b Inventory the kit to ensure that all components parts are present 3 Prepare the cable and termination according to the manufacturer s literature a Measure and mark the cable b Inspect the cable for carbon particles and remove those that are found c Inspect the primary cable insulation and remove those that are found d Cut the cable to the proper length 4 Remove the jacket using the distance indicated in the manufacturer s literature and ensure that the length required for the lug is added to the measure back distance 5 Remove the shield using the distance indicated in the manufacturer s literature 6 Remove the semiconductor using the distance indicated in the manufacturer s literature 3 292 STP 5 21P2 SM TG 31 March 2009 MOS Skill Level Tasks Performance Steps 7 9 10 11 12 13
96. situation by calling to the victim a Determine the level of injury or illness before attempting rescue procedures NOTE If the victim is conscious and responds in an understanding voice use self recovery procedures to talk him down b Prepare to perform an aerial bucket truck rescue if the victim is unconscious does not respond or appears to be stunned or dazed 2 Ensure your own protection a Contact emergency response personnel b De energize the circuit if necessary or practical 3 Lower the bucket until it is 1 foot off the ground a Leap onto the truck and ensure that no part of your body touches the truck and the ground at the same time b Switch the bucket control mode to the lower controls c Lower the bucket to the ground using the most direct route until it is 1 foot off the ground 4 Remove the victim from the bucket and lower him to the ground a Tilt the bucket to the side at approximately a 90 angle b Detach the victim s safety lanyard and remove him from the bucket c Pull the victim clear of hazards d Administer first aid as required 5 Continue administering first aid until qualified medical personnel arrive Evaluation Preparation Setup Provide the Soldier with the items listed in the conditions Give the Soldier a safety briefing before starting the test and ensure that safety precautions are followed Prepare the testing area and equipment in advance to ensure that task standards can be met
97. specified parameters Checked for proper battery charging Checked for proper inverter operation Serviced the batteries Returned the UPS and load to the incoming power supply Performed a functions check on the UPS 13 Ensured that the items listed in the conditions were properly cleaned and stored Evaluation Guidance Score the Soldier GO if all measures are passed P Score the Soldier NO GO if any measure is failed F If the Soldier fails any measure show him how to do it correctly 3 338 STP 5 21P2 SM TG 31 March 2009 MOS Skill Level Tasks Subject Area 7 S3 and S2 Combined Tasks Service an Electronic Governor 052 264 2105 Conditions As a power station mechanic or instrumentation technician in a tactical or nontactical environment during maintenance you are given an engine a lockout and tagout kit TM 5 6115 456 15 TM 9 6115 604 12 and TM 9 6115 604 34 or the manufacturer s literature with schematics maintenance logbooks and a general mechanic s tool box DANGER 1 REMOVE RINGS NECKLACES OTHER JEWELRY AND LOOSE CLOTHING FAILURE TO COMPLY MAY CAUSE PERMANENT INJURY OR DEATH 2 HAZARDOUS VOLTAGES APPEAR AT TERMINALS INSIDE THE HIGH VOLTAGE CABINET DURING GENERATOR SET OPERATION OBSERVE SAFETY PRECAUTIONS APPLICABLE TO MAINTENANCE ON HIGH VOLTAGE EQUIPMENT FAILURE TO COMPLY MAY CAUSE PERMANENT INJURY OR DEATH CAUTION NOISE LEVELS IN EXCESS OF 85 DECIBELS EXIST WITHIN A 50 FOO
98. tagging devices Test the system to ensure that faults are corrected Return the generator to operation Record actions taken on the maintenance logbook Ensure that the items listed in the conditions are properly cleaned and stored Evaluation Preparation Setup Provide the Soldier with the items listed in the conditions Give the Soldier a safety briefing before starting the test and ensure that safety precautions are followed Prepare the testing area and equipment in advance to ensure that task standards can be met Brief Soldier Direct the Soldier to troubleshoot a generator s improper voltage output Performance Measures GO NO GO 1 o oo N DO a FF Q 10 11 Reviewed danger warning and caution notices Reviewed the manufacturer s literature electrical construction prints and wiring diagrams Reviewed the maintenance logbook and historical data pertaining to equipment Performed lockout and tagout procedures Isolated the system and system circuits that needed troubleshooting Identified fault indicators Ensured that the voltage detector functioned properly Tested the voltage regulator for proper settings Ensured that the voltage regulator was receiving the proper amount of voltage from the power transformers and current transformers Ensured that the prime mover of the generator was operating at the proper
99. the conditions are properly cleaned and stored Evaluation Preparation Setup Provide the Soldier with the items listed in the conditions Give the Soldier a safety briefing before starting the test and ensure that safety precautions are followed Prepare the testing area and equipment in advance to ensure that task standards can be met Brief Soldier Direct the Soldier to determine the transformer polarity Performance Measures GO NO GO 1 Reviewed danger warning and caution notices 2 Reviewed the manufacturer s literature electrical construction prints and wiring diagrams 3 Reviewed maintenance logbooks and historical data pertaining to the equipment 4 Performed lockout and tagout procedures 5 Grounded out residual voltage 31 March 2009 STP 5 21P2 SM TG 3 329 Chapter 3 Performance Measures 6 10 11 12 13 14 15 16 17 Kept a record of how the transformer was wired Disconnected the transformer 7 8 9 Applied grounds on the incoming and load cables Tested for polarity on a single phase power or potential transformer and proceeded to step 11 if the test was performed ona CT Marked the appropriate polarity on the transformer Tested for polarity on a CT using the current or inductive kick method Recorded the test results Marked the appropriate polarity on the CT Removed the grounds from incoming and load cables Re
100. the connection points by repairing replacing or cleaning them Conducted electrical tests point to point between the main grounding system connection point and the major electrical equipment frames and system neutrals to ensure a solid bond throughout the system Kept a record of the test results Closed out lockout and tagout procedures by removing locking and tagging devices Performed a functions check on the electrical equipment grounding system Ensured that the items listed in the conditions were properly cleaned and stored Evaluation Guidance Score the Soldier GO if all measures are passed P Score the Soldier NO GO if any measure is failed F If the Soldier fails any measure show him how to do it correctly References Required Related NEC HANDBOOK FM 3 34 480 NETA NFPA 1001 31 March 2009 STP 5 21P2 SM TG 3 213 Chapter 3 Service a Power Transformer 052 206 2114 Conditions As a power station electrician in a tactical or nontactical environment during maintenance you are given safety standing operating procedures a grounding cluster a general mechanic s tool box electrical construction prints wiring diagrams a digital low resistance ohmmeter a megohmmeter a transformer turn to turn ratio test set an oil test set a power factor test set ASTM D877 D923 D971 D974 D1500 D1524 D1816 D2285 D3612 and D3613 standards the InterNational Electrical Test Association NETA Maintena
101. the items listed in the conditions Give the Soldier a safety briefing before starting the test and ensure that safety precautions are followed Prepare the testing area and equipment in advance to ensure that task standards can be met Brief Soldier Direct the Soldier to service a distribution transformer Performance Measures GO NO GO 1 Reviewed danger warning and caution notices 2 Reviewed the manufacturer s literature electrical construction prints and wiring diagrams Performed lockout and tagout procedures Serviced a dry type distribution transformer Serviced a liquid filled distribution transformer Performed electrical tests Reconnected the isolated equipment oN O oO A O Closed out lockout and tagout procedures by removing locking and tagging devices Ko Reenergized the de energized equipment 10 Checked the primary and secondary sides of the transformer for the proper voltages listed on the equipment data plate 11 Ensured that the items listed in the conditions were properly cleaned and stored Evaluation Guidance Score the Soldier GO if all measures are passed P Score the Soldier NO GO if any measure is failed F If the Soldier fails any measure show him how to do it correctly References Required Related ASTM D1500 NESC ASTM D1524 TM 5 686 ASTM D1816 ASTM D3612 ASTM D877 ASTM
102. the start position 8 Circled to the left until he was positioned directly below the crossarm 9 Assumed a good working position that allowed him to reach the end of the crossarm and then returned to the start position 10 Hitchhiked down the pole 5 feet 11 Unbelted and descended the pole Evaluation Guidance Score the Soldier GO if all measures are passed P Score the Soldier NO GO if any measure is failed F If the Soldier fails any measure show him how to do it correctly References Required Related EM 385 1 1 FM 5 125 LCH TM 5 682 TM 5 684 3 282 STP 5 21P2 SM TG 31 March 2009 MOS Skill Level Tasks Perform a Crossarm Change Out 052 204 1126 Conditions As a power line distribution specialist in a tactical or nontactical environment when a crossarm needs to be replaced due to deterioration or upgrades you are given applicable climbing and rigging equipment a groundman the required hand tools the applicable personal protective equipment PPE and a lockout and tagout kit WARNING 1 WHEN POSSIBLE INDIVIDUALS NOT ACSENDING THE POLE MUST MAINTAIN A MINIMUM DISTANCE OF AT LEAST 10 FEET FROM THE BASE OF THE POLE TO ENSURE THAT THEY ARE NOT STRUCK BY DROPPED OBJECTS FAILURE TO COMPLY MAY CAUSE IMMEDIATE PERSONAL INJURY 2 USE PROPER CLIMBING TECHNIQUES TO AVOID SLIPPING OR FALLING WEAR LONG SLEEVES AND GLOVES TO AVOID SPLINTERS AND WEAR PROTECTIVE EYEWEAR WHEN USING M
103. the system to its full working pressure and perform a full system trace a Remove vault covers or piping protectors to gain visual access to the portions of the aboveground piping b Closely inspect connections c Closely inspect valves 1 Cycle each valve fully opened and closed 2 Adjust the stem packing to produce moderate resistance while turning it to ensure leak tightness around the stem 3 Tighten valve bonnets if any leakage is indicated on the valve body WARNING ENSURE THAT THE VALVE IS IN THE OPEN POSITION WITH THE VALVE SEALING FACE BACKED OFF ITS SEAT BEFORE TIGHTENING THE VALVE DAMAGE TO THE VALVE WILL RESULT IF THE BONNET IS TIGHTENED WITH THE VALVE SEATED IN THE CLOSED POSITION 12 Drain condensation from the volume tanks and in line water separators on compressed air systems 13 Verify that automated condensation drain systems are clean and working as designed 14 Replace inoperative drain systems 15 Clean filters and strainers on the incoming sides of pumps or compressors 16 Replace filters that cannot be cleaned 17 Record actions taken on DA Form 2404 or DA Form 5988 E and maintenance logbooks 18 Ensure that the items listed in the conditions are properly cleaned and stored Evaluation Preparation Setup Provide the Soldier with the items listed in the conditions Give the Soldier a safety briefing before starting the test and ensure that safety precautions are followed Prepare the testing area and eq
104. the test and ensure that safety precautions are followed Prepare the testing area and equipment in advance to ensure that task standards can be met Brief Soldier Direct the Soldier to service a DSLC Performance Measures GO NO GO 1 oN O oO A W N Reviewed danger warning and caution notices before proceeding Reviewed the manufacturer s literature with schematics and wiring diagrams Reviewed maintenance logbooks and historical data pertaining to the equipment Identified the circuit connected to the DSLC by using the schematics Performed lockout and tagout procedures Tested the circuit for voltage presence Removed the controller and tagged the leads Inspected the controller for damage 3 122 STP 5 21P2 SM TG 31 March 2009 MOS Skill Level Tasks Performance Measures GO NO GO 9 Connected the handheld programming device to the diagnostic and service port 10 Performed testing and calibration according to the DSLC operations and calibration manual 11 Compared the results with the manufacturer s specifications and took appropriate action 12 Tested the circuit for voltage presence 13 Tagged the controller with the appropriate calibration sticker including the name and testing date 14 Reinstalled the controller 15 Closed out lockout and tagout procedures by removing
105. tools d Inspect the handline 3 Lay out the handline and attach it to the body belt 4 Ascend the utility pole until you are eye level with the lag screw and then belt in NOTE When performing this task ensure that you use the proper climbing technique Start 6 inches above the ground with subsequent steps being 8 to 10 inches apart Your feet should not be directly above one another Maintain adequate spacing between your heels Your toes should be pointing up and out with your weight on your heels Use your legs to climb not your arms Keep your body straight and your knees away from the pole at all times Ensure that you use the inverted J method when inserting the gaff into the pole and always lock your weight supporting leg 5 Hitchhike down 5 feet and then hitchhike back up until you are eye level with the lag screw 6 Circle to the right until you are positioned directly below the crossarm 7 Assume a good working position that allows you to reach the end of the crossarm and then return to the start position 8 Circle to the left until you are positioned directly below the crossarm 9 Assume a good working position that allows you to reach the end of the crossarm and then return to the start position 10 Hitchhike down the pole 5 feet 11 Unbelt and descend the pole NOTE When descending the pole ensure that you follow Keep your body straight keep your knees away from the pole and lock your weight supporti
106. values of similar connections according to the manufacturer s literature Perform insulation resistance tests pole to pole pole to ground and across the open poles Ensure that the test values are not less than 1 000 megohms at a direct current DC test voltage of 2 500 volts minimum unless otherwise stated in the manufacturer s literature Perform an insulation resistance test on the control wiring at 1 000 volts DC minimum of 2 megohms according to the manufacturer s literature and follow the manufacturer s recommendations for units with solid state components parts Perform an overpotential test on each pole with the switch closed and ensure that the insulation can withstand the applied test voltage a Test each pole to ground with all other poles grounded b Ensure that the test voltage used is within the manufacturer s specifications Close out lockout and tagout procedures by removing locking and tagging devices Reenergize the oil switch Ensure that the oil switch operates as designed Ensure that the items listed in the conditions are properly cleaned and stored Evaluation Preparation Setup Provide the Soldier with the items listed in the conditions Give the Soldier a safety briefing before starting the test and ensure that safety precautions are followed Prepare the testing area and equipment in advance to ensure that task standards can be met Brief Soldier Direct the Soldier to service an oil switch
107. 0 080810 2 0530 0 00512900 3 30900 6530 000 0 005210 13 0 071960 1 8280 0 00406700 2 62400 5178 000 0 006570 14 0 064080 1 6280 0 00322500 2 08100 4107 000 0 008290 15 0 057070 1 4500 0 00255800 1 65000 3257 000 0 010400 16 0 050820 1 2910 0 00202800 1 30900 2583 000 0 013200 17 0 045260 1 1500 0 00160900 1 03800 2048 000 0 016600 18 0 04030 1 0240 0 00127600 0 82310 1600 000 0 020900 31 March 2009 STP 5 21P2 SM TG Appendix B Table B 1 Wire Gauge Size Conversion Chart continued Diameter Cross Section Area AWG inches Millimeters Square Square Circular Resistance Inches Millimeters Mills Ohm Meters 19 0 035890 0 9116 0 00101200 0 65270 1288 000 0 026400 20 0 031960 0 8118 0 00080230 0 51760 1022 000 0 033300 21 0 028460 0 7229 0 00063630 0 41050 810 100 0 042000 22 0 025350 0 6439 0 00050460 0 32560 642 400 0 053000 23 0 022570 0 5733 0 00040010 0 25820 509 500 0 066800 24 0 020100 0 5105 0 00031730 0 20470 404 000 0 084200 25 0 017900 0 4547 0 00025170 0 16240 320 400 0 106000 26 0 015840 0 4049 0 00019960 0 12880 254 100 0 134000 27 0 014200 0 3607 0 00015830 0 10210 201 500 0 169000 28 0 012640 0 3211 0 00012550 0 08098 159 800 0 213000 29 0 011260 0 2860 0 00009954 0 06422 126 700 0 268000 30 0 010030 0 2548 0 00007894 0 05093 100 500 0 339000 31 0 008928 0 2268 0 00006260 0 04039 79 700 0 427000 32 0 007950 0 201
108. 04 Equipment Inspection and Maintenance Worksheet or DA Form 5988 E Equipment Inspection Maintenance Worksheet and the applicable personal protective equipment PPE DANGER 1 REMOVE RINGS NECKLACES OTHER JEWELRY AND LOOSE CLOTHING FAILURE TO COMPLY MAY CAUSE PERMANENT INJURY OR DEATH 2 EXERCISE EXTREME CAUTION WHEN WORKING IN THE AREA OF ROTATING ENGINE COMPONENTS FAILURE TO COMPLY MAY CAUSE PERMANENT INJURY OR DEATH 3 ALWAYS WEAR PPE AS REQUIRED FOR INSPECTIONS IN HAZARDOUS AREAS FAILURE TO COMPLY MAY CAUSE PERMANENT INJURY OR DEATH WARNING ENGINE EXHAUST GETS VERY HOT DURING OPERATION DO NOT REMOVE EXHAUST SYSTEM COMPONENTS UNTIL THE ENGINE HAS COOLED FAILURE TO COMPLY MAY CAUSE IMMEDIATE PERSONAL INJURY CAUTION NOISE LEVELS IN EXCESS OF 85 DECIBELS EXIST WITHIN A 50 FOOT RADIUS OF OPERATING EQUIPMENT PERSONNEL MUST WEAR SINGLE HEARING PROTECTION WITHIN A 50 FOOT RADIUS FAILURE TO COMPLY MAY CAUSE INJURY NOTES 1 All equipment is not the same and may function differently depending on the make model or manufacturer Troubleshooting steps are similar but may vary Always consult the applicable manufacturer s literature for each piece of equipment 2 All tests should be conducted as specified in the manufacturer s literature when available Use industry standards when the manufacturer s literature cannot be obtained Standards Repair a diesel engine air intake and or exhaust system by verifying repairi
109. 08 052 204 1113 052 204 1114 052 204 1115 052 204 1116 052 204 1117 052 204 1118 052 204 1119 052 204 1120 052 204 1121 052 204 1122 052 204 1123 052 204 1124 052 204 1126 052 204 1127 052 204 1128 31 March 2009 Service a Low Voltage Circuit Breaker ccccceeceeeeeeetereeeeeeieeeeeteneeeeetneeeereae Install a Medium Voltage Nonaerial Air Switch 0 ceccccecceceeeeeeeeetceeeeeeeeeees SENEE an ON Switches veka nested ate a ate ae tet Service A VACUUM SWItCH irea eee aR n aE E ARTESA AEEA EAAS Service a Syster Ground spim ran iEnd i sah ee te ete Service a Nonaerial Air Switch asaassieesiiresesrresirrssrennesninnnentnnnesnnnaaniannasnannant Service an Electrical Equipment Grounding System 0 cccceeeeeeeeeteeeeeeenaes SELvice a Power Transformo escencia nE Na R deed Service a Distribution Transformer esiesrriesrrecirrerrrririerineisierrindirinistrirnerineneiens Sevice BUS BIS ioa AEE RENEE Service a Switchgear EnclosSure a ssesssseserrrnseirrcsrrrnsisnnsdinnanntnnndannannntannasnadannena Perform a Power Factor and Dissipation Factor Test ccceeeeseeeeeeeeeeees Service an Air Magnetic Circuit Breaker 0 c ce cecceeeeeeteeeeeenneeeeeetnaeeeeeeneeeeeeaas Service an Alternating Current AC Generator Assembly Service a Sulfur Hexafluoride SF6 Circuit Breaker eceeeeeeeeeeeeneeeeeeenes Identify Electrical Faults Using an Infrared IR Camera Service a Sulfur Hexa
110. 09 MOS Skill Level Tasks Performance Steps pure supply to the torch d Close both torch oxygen valves after 10 seconds of gas flow e Open the torch acetylene valve f Stand to the side of the regulator and slowly open the tank valve about one quarter to one half turn until the dial on the high pressure gauge moves indicating tank pressure WARNING THE ACETYLENE SHOULD ONLY BE OPENED ABOUT ONE QUARTER TO ONE HALF TURN TO ALLOW THE TANK TO BE SHUT OFF RAPIDLY IN THE EVENT OF A MALFUNCTION FAILURE TO COMPLY MAY CAUSE IMMEDIATE PERSONAL INJURY AND EQUIPMENT DAMAGE g Adjust the acetylene regulator working pressure as necessary for cutting NOTES 1 Acetylene gas will flow out of the torch tip while the working pressure is being adjusted The open flow will allow proper adjustment in the flowing condition and purge the acetylene hose to obtain a pure supply to the torch 2 Refer to the manufacturer s literature to determine the appropriate pressure for the cutting torch tip size being used The tip size is indicated on the side of the cutting tip h Shut off the torch acetylene valve after 10 seconds of gas flow i Monitor the low pressure regulator gauge for any sign of a malfunction 4 Light and adjust the torch flame a Open fully the oxygen valve that is nearest to the hose connection b Open only the acetylene torch valve and light the torch with the spark lighter Quickly cut in oxygen to reduce soot c Progressively
111. 100 Produce an Electronic Circuit ceeeceeeeeeeeeeeeeeeeeseeeeeeeeeeeeeeeseeeaeeeseeaeesseeaeeess 3 95 052 207 2101 Perform Electronic Troubleshooting Procedures 00 ccccceeseeeeeeeeeeeeteeneeeeeeenaeees 3 97 052 207 2106 Service a TIMING Relay aeeoeia a a Ea EEEE AES 3 100 052 207 2113 Service a Current Boost Module aseeisssceeriserirriserrreeriireeiernnaaiinneeenaaantnneeeinaenaa 3 103 052 207 2116 Service a Signal Transmission Circuit ceeeeeeeeeeeeeeeeeeeeeeeeeenaeeeeeeseeeeeeeaaes 3 106 052 207 2118 Service an Induction Disk and or Electromagnetic Relay cceceeseereeeeees 3 108 052 207 2119 Service a Programmable Logic Controller PLC eee ceeeeeceeeeenteeeeeenneeeeeenaaes 3 112 052 207 2120 Service Optoelectronic Equipment cccccceeeeeeeeceeceeeeeeesececeneeceeeeeeeeeesnaeees 3 115 052 207 2121 Service a Solid State Relay ce ceeeceeeeeeeeeeeeeneeeeeeeeeeeeeaeeeeeeaeeeeeeiaeeeeeeeaes 3 118 052 207 2123 Service a Digital Synchronizer and Load Controller DSLC eee 3 121 052220722125 Service a Moler aiaa ceeds devtantisesteeces wills siedadeisesinteas OR 3 124 052 207 2126 Produce an Electronic Schematic 20 0 0 eeceeeeeeeceeeeeeeeeenneeeeeeeeeeeeeaaeeeeeeneeeeeeaes 3 127 Subject Area 3 S2 Mechanical Equipment Maintenance Power Station Tasks 052 205 2032 Troubleshoot a Diesel Engine for a Misfiring Cylinder cc eeeeeeeeeesteeeeeneees 3 128 052 205 2034 Troubleshoot a D
112. 2 Reviewed the electrical one line diagrams electrical construction prints and manufacturer s literature 3 Requested permission from the project supervisor to energize the electrical distribution system 4 Performed an inspection with the project supervisor and personnel who performed work on the distribution system to ensure that all personnel were notified that the distribution system would soon be reenergized 5 Ensured that each lockout and tagout device was removed by the installer or designated representative if the installer was not available 6 Ensured that personnel PPE hot line equipment climbing and rigging equipment and tools were safely positioned or removed from the area to be reenergized 7 Reenergized the distribution system 8 Performed a functions check on the electrical distribution system Evaluation Guidance Score the Soldier GO if all measures are passed P Score the Soldier NO GO if any measure is failed F If the Soldier fails any measure show him how to do it correctly References Required Related LCH EM 385 1 1 ER 385 1 31 FM 3 34 480 FM 5 412 NESC TM 5 682 TM 5 684 TM 5 686 TM 5 811 1 TM 5 811 3 3 300 STP 5 21P2 SM TG 31 March 2009 MOS Skill Level Tasks Locate an Underground Cable and or a Fault 052 204 2213 Conditions As a power line distribution supervisor in a tactical or nontactical environment wh
113. 2 205 2128 Conditions As a power station mechanic in a nontactical environment when the diesel engine starting system needs serviced you are given the applicable manufacturer s literature a general mechanic s tool box maintenance logbooks and DA Form 2404 Equipment Inspection and Maintenance Worksheet or DA Form 5988 E Equipment Inspection Maintenance Worksheet DANGER 1 REMOVE RINGS NECKLACES OTHER JEWELRY AND LOOSE CLOTHING FAILURE TO COMPLY MAY CAUSE PERMANENT INJURY OR DEATH 2 ENSURE THAT EQUIPMENT IS PROPERLY LOCKED OUT AND TAGGED OUT FAILURE TO COMPLY MAY CAUSE PERMANENT INJURY OR DEATH Standards Service a diesel engine starting system by testing cleaning repairing or replacing starting system components parts Performance Steps 1 Review maintenance logbooks and historical data pertaining to the equipment to verify that the diesel engine starting system needs to be serviced 2 Inspect the starting system NOTE Only one of the following starting systems is inspected a Check the electric start system 1 Test for the correct direct current DC voltage at the starter 2 Inspect for loose or corroded battery terminals and connections 3 Test the battery electrolyte and alkaline level 4 Inspect starter connections 5 Check for starter malfunctions and misalignment b Check the air start system 1 Inspect air lines for too much moisture 2 Check for air compressor malfunction 3 Inspect
114. 2 SM TG Chapter 3 Performance Measures GO NO GO 29 Opened the three primary distribution center doors and checked for damage loose connections and foreign objects 30 Positioned the selector switch in the proper mode based on location 50 or 60 hertz 31 Secured side access doors 32 Recorded actions taken on DA Form 2404 or DA Form 5988 E 33 Ensured that the items listed in the conditions were properly cleaned and stored Evaluation Guidance Score the Soldier GO if all measures are passed P Score the Soldier NO GO if any measure is failed F If the Soldier fails any measure show him how to do it correctly References Required Related DA FORM 2404 DA FORM 5988 E 3 36 STP 5 21P2 SM TG 31 March 2009 MOS Skill Level Tasks Perform Preventive Maintenance Checks and Services PMCS on a Mobile Electric Power MEP 012 or 208 Generator 052 244 2118 Conditions As a power plant operator in a tactical or nontactical environment you are given an MEP 012 or 208 generator TM 5 6115 456 15 or TM 9 6115 604 12 DA Form 2404 Equipment Inspection and Maintenance Worksheet or DA Form 5988 E Equipment Inspection Maintenance Worksheet a pen a clipboard a general mechanic s tool box a wiping cloth and personal protective equipment DANGER 1 THIS TASK SHOULD ONLY BE PERFORMED BY QUALIFIED PERSONNEL WHO ARE KNOWLEDGEABLE IN THE INSTALLATION OPERATION AND MAINTE
115. 211 Conditions As a power line distribution supervisor in a tactical or nontactical environment when materials are needed for an electrical construction project you are given electrical construction prints TM 5 811 1 the Lineman s and Cableman s Handbook LCH paper pencils a calculator and DA Form 2702 Bill of Materials Standards Develop a BOM list that reflects the total materials required to complete an electrical construction project Materials must be the sizes and types specified in the electrical construction prints TM 5 811 1 and the LCH Record materials on DA Form 2702 Performance Steps 1 Review the electrical construction prints 2 Complete a BOM list a Record the stock or part number indicated on the electrical construction prints if applicable b Record the item name or description indicated on the electrical construction prints c Record the number of required pieces indicated on the electrical construction prints if applicable d Record the sizes and lengths of items indicated on the electrical construction prints if applicable e Record the unit of issue and indicate whether the item is a spool or a length or if the item is issued as each f Record the estimated waste of each item g Total the quantities needed based on the number of pieces units of issue required lengths and estimated wastes for each item h Record the total quantity of each item 3 Complete DA Form 2702 a Complete th
116. 250 56 of the NEC Handbook Disconnected the power to the system if possible Conducted a visual inspection Serviced the connection points by repairing replacing or cleaning them 4 5 6 7 Conducted electrical tests 8 Improved ground electrode resistance as needed see task 052 244 2107 9 Kept a record of the test results 0 Reconnected the power to the system 11 Ensured that the items listed in the conditions were properly cleaned and stored Evaluation Guidance Score the Soldier GO if all measures are passed P Score the Soldier NO GO if any measure is failed F If the Soldier fails any measure show him how to do it correctly References Required Related IEEE GREEN BOOK DA FORM 2404 NEC HANDBOOK NESC NETA TM 5 684 3 208 STP 5 21P2 SM TG 31 March 2009 MOS Skill Level Tasks Service a Nonaerial Air Switch 052 206 2105 Conditions As a power station electrician in a tactical or nontactical environment during maintenance you are given safety standing operating procedures a lockout and tagout kit a general mechanic s tool box an electrician s tool kit electrical construction prints wiring diagrams a low resistance ohmmeter a megohmmeter a torque wrench a grounding cluster conductive grease nonconductive grease and the applicable manufacturer s literature with schematics DANGER 1 THIS TASK SHO
117. 3 14 15 16 c Replace the sensing device Test the circuit for voltage a Proceed to step 11 if no voltage is present b Stop if voltage is present and do not proceed to step 11 until voltage is no longer present 1 Check the schematics for proper circuit identification 2 Check for possible back fed circuits 3 Check for the proper installation of safe clearances Reinstall the sensing device a Attach tagged leads b Verify connections Close out lockout and tagout procedures by removing locking and tagging devices Energize the circuit Perform a function check Keep a record of the test results and actions taken Ensure that the items listed in the conditions are properly cleaned and stored Evaluation Preparation Setup Provide the Soldier with the items listed in the conditions Give the Soldier a safety briefing before starting the test and ensure that safety precautions are followed Prepare the testing area and equipment in advance to ensure that task standards can be met Brief Soldier Direct the Soldier to service an auxiliary and or an instrumentation sensing device Performance Measures 1 A W N N O A 10 11 12 13 Reviewed danger warning and caution notices Reviewed the manufacturer s literature and wiring diagrams Reviewed maintenance logbooks and historical data pertaining to the equipment Used the schematics to identify the circuit of the sensing devi
118. 4 Completed DA Form 2702 and included the tools and equipment necessary to perform the task 5 Ensured that personnel were safely positioned or removed from the area to be tested 6 Performed an initial equipment self test 7 Tested each phase conductor or circuit part with adequately rated test equipment 8 Ensured that the items listed in the conditions were properly cleaned and stored Evaluation Guidance Score the Soldier GO if all measures are passed P Score the Soldier NO GO if any measure is failed F If the Soldier fails any measure show him how to do it correctly References Required Related DA FORM 2702 EM 385 1 1 LCH ER 385 1 31 FM 3 34 480 FM 5 412 TM 5 682 TM 5 684 TM 5 811 1 TM 5 811 3 31 March 2009 STP 5 21P2 SM TG 3 305 Chapter 3 Perform Maintenance on Electrical Distribution Equipment 052 204 2216 Conditions As a power line distribution supervisor in a tactical or nontactical environment when maintenance must be performed on electrical distribution equipment you are given electrical one line diagrams for the distribution equipment applicable climbing and rigging equipment hot line tools an electrician s tool kit a voltage detector a lockout and tagout kit grounding equipment safety standing operating procedures SOPs the applicable manufacturer s literature or industry standards the Lineman s and Cableman s Handbook LCH the applicable p
119. 4 Select equipment that is appropriate for the environment and weather when installing a switch outdoors 5 Follow specific guidelines when installing a switch indoors a Place the switch in a dry well ventilated room b Leave adequate space around the equipment for operation and maintenance c Do not use expulsion type fuses where loud noises could startle personnel working in the vicinity Select a switch that meets safety mission and load requirements De energize the circuit where the switch will be installed Isolate the equipment in the work area Perform lockout and tagout procedures O Oo N Q Install personal protective grounds 11 Place the switch on a level surface 12 Install the grounding for case and neutral grounds 13 Install the equipment to the load 3 198 STP 5 21P2 SM TG 31 March 2009 MOS Skill Level Tasks Performance Steps 14 Install the equipment to the power source 15 Verify the correct phase sequence 16 Remove personal protective grounds 17 Close out lockout and tagout procedures by removing locking and tagging devices 18 Perform a functions check on the switch 19 Ensure that the items listed in the conditions are properly cleaned and stored Evaluation Preparation Setup Provide the Soldier with the items listed in the conditions Give the Soldier a safety briefing before starting the test and ensure that safety precautions are followed Prepare the testing area and
120. 5 3 Identify the main circuit breakers 4 Identify the fire extinguishers b Disconnect the accessories c Store accessories d Secure accessories in appropriate shipping locations Prepare the basic initial issue a Inventory the generator and accessories b Inspect the generator and accessories c Load the generator and accessories d Secure the generator and accessories Inspect the tools and rigging and lifting equipment for serviceability Install the lifting rigging and positioning equipment as necessary Supervise the loading of the generator onto the transport vehicle Ensure that the items listed in the conditions are properly cleaned and stored Evaluation Preparation Setup Provide the Soldier with the items listed in the conditions Give the Soldier a safety briefing before starting the test and ensure that safety precautions are followed Prepare the testing area and equipment in advance to ensure that task standards can be met Brief Soldier Direct the Soldier to prepare a power plant for movement Performance Measures 1 O Oo N O oO KF QOQ A ee A A AA OO N Reviewed danger warning and caution notices Reviewed the manufacturer s literature electrical construction prints and wiring diagrams Contacted unit movement personnel to arrange for shipment of the power plant Shut down the power plant Applied safe clearance procedures to the power plant Isolated the power p
121. 5 1 1 FM 3 34 480 NETA 31 March 2009 STP 5 21P2 SM TG 3 197 Chapter 3 Install a Medium Voltage Nonaerial Air Switch 052 206 2101 Conditions As a power station electrician in a tactical or nontactical environment when a medium voltage nonaerial air switch needs to be installed or replaced you are given safety standing operating procedures a general mechanic s tool box a lockout and tagout kit grounding equipment electrical construction prints wiring diagrams and the applicable manufacturer s literature DANGER 1 THIS TASK SHOULD ONLY BE PERFORMED BY QUALIFIED PERSONNEL WHO ARE KNOWLEDGEABLE IN THE INSTALLATION AND MAINTENANCE OF SWITCHGEAR AND POWER EQUIPMENT AND THEIR ASSOCIATED HAZARDS FAILURE TO COMPLY MAY CAUSE PERMANENT INJURY OR DEATH 2 DO NOT TOUCH EXPOSED ELECTRICAL CONNECTIONS WHILE A POWER SOURCE IS CONNECTED TO THE SWITCH FAILURE TO COMPLY MAY CAUSE PERMANENT INJURY OR DEATH 3 REMOVE RINGS NECKLACES OTHER JEWELRY AND LOOSE CLOTHING FAILURE TO COMPLY MAY CAUSE PERMANENT INJURY OR DEATH Standards Safely install a medium voltage nonaerial air switch in a suitable location to meet mission requirements Performance Steps 1 Review danger warning and caution notices 2 Review the manufacturer s literature electrical construction prints and wiring diagrams 3 Identify the best location for the switch such as a secure area with minimal traffic to ensure easy access during emergencies
122. 5 Troubleshoot the Improper Operation of an Electrical Motor ceeeeee 3 342 Subject Area 8 S2 and E5 Combined Tasks 052 264 2104 Service an Auxiliary and or an Instrumentation Sensing Device eee 3 344 Appendix A Metric Conversion Chatt ccccccccesseeeeeceeeeeeeeeeeeeeeeeeeeensensseaeeeseeeseseesseaeeeeseseseseeeeeeneeeeeees A 1 Appendix B Wire Gauge Size Conversion Chart cccsceeeeeeeeeeeeeeeseeenee seen eeeeesseaeeeeeeeseeeeeseaneneeeeens B 1 GIOSSANY A E E T N E E N N estceny Glossary 1 Referent oS re A A IR AEA A OIRNE ARANE AREA a DIRANA EEREN References 1 iv STP 5 21P2 SM TG 31 March 2009 Preface This Soldier training publication STP contains standardized training objectives in the form of task summaries to train and evaluate Soldiers on critical tasks that support unit missions during wartime Trainers and leaders should actively plan for Soldiers holding this military occupational specialty MOS to have access to this publication This publication applies to the Active Army the Army National Guard ARNG Army National Guard of the United States ARNGUS and the U S Army Reserve USAR unless otherwise stated The proponent for this publication is the United States Army Training and Doctrine Command TRADOC Send comments and recommendations on Department of the Army DA Form 2028 Recommended Changes to Publications and Blank Forms directly to Commandant United States Arm
123. 7 1 FM 25 4 FM 25 5 and any related Combined Arms Training Strategies CATS and drills to establish effective training plans and programs that integrate individual and collective tasks 1 3 Task Summaries Task summaries contain information necessary to conduct training and evaluate Soldier proficiency on tasks critical to the MOS A separate task summary is provided for each critical task These task summaries are in effect standardized training objectives which ensure that Soldiers do not have to relearn a task on reassignment to a new unit The format for the task summaries included in this manual is as follows Task title The task title identifies the action to be performed Task number The 10 digit task number identifies each task or skill Include this task number and title in any correspondence relating to the task Conditions Task conditions identify the equipment tools references job aids and supporting personnel that the Soldier needs to perform the task in wartime This section identifies environmental conditions that could alter task performance visibility temperature wind This section also identifies specific cues or events chemical attack identification of a threat vehicle that trigger task performance Standards Task standards describe how well and to what level a task must be performed under wartime conditions Standards are typically described in terms of accuracy completeness and speed T
124. 8 Maintain climber gaffs a Use the TH slots on the gaff gauge to measure gaff thickness b Use the W slots on the gaff gauge to measure gaff width c Shape gaffs into the correct thickness according to the applicable manufacturer s literature if required 9 Test climber gaffs a Check climber gaffs using the plane test b Check climber gaffs using the cutout test 10 Maintain the handline a Uncoil the handline 1 Secure one end of the handline to a stationary object 2 Stretch the handline taut to remove twists and kinks and center the hook splice or knot at the free end of the rope b Check the handline 1 Check for cuts 2 Check for frays 3 Check for cracks 4 Continuous smooth movement of the rope through the block sheave c Recoil the handline for storage 1 Ensure that loops are the same length about 3 feet 2 Wrap the last 6 to 8 feet of rope around the coil a Place the coil of the rope around your wrist b Turn the coil with your arm held horizontally at your elbow away from your body 3 264 STP 5 21P2 SM TG 31 March 2009 MOS Skill Level Tasks Performance Steps c Guide the remaining rope around the coil until there is 2 feet remaining d Grasp the secured rope with your hand that is holding the coil and pull the rope through the coil making a loop e Give the loop a twist and place it over the top of the coil f Snug the loop around the coil g Hang the handline in a clean
125. 9 0 00004964 0 03023 63 210 0 538000 33 0 007080 0 1796 0 00003944 0 02545 50 220 0 679000 34 0 006305 0 1601 0 00003122 0 02014 39 750 0 856000 35 0 005615 0 1426 0 00002476 0 01597 31 520 1 080000 36 0 005000 0 1270 0 00001963 0 01267 25 000 1 360000 37 0 004453 0 1131 0 00001557 0 01005 19 830 1 720000 38 0 003965 0 1007 0 00001235 0 00797 15 720 2 160000 39 0 003531 0 0897 0 00000979 0 00632 12 470 2 730000 40 0 003145 0 0799 0 00000777 0 00501 9 888 3 440000 41 0 002800 0 0711 0 00000616 0 00397 7 842 42 0 002494 0 0633 0 00000488 0 00315 6 219 43 0 002221 0 0564 0 00000387 0 00250 4 932 B 2 STP 5 21P2 SM TG 31 March 2009 Wire Gauge Size Conversion Chart Table B 1 Wire Gauge Size Conversion Chart continued AWG Diameter Cross Section Area inches Mitimetors Saue awe Caan Genin 44 0 001978 0 0502 0 00000307 0 00198 3 911 45 0 001761 0 0447 0 00000244 0 00157 3 102 46 0 001568 0 0398 0 00000193 0 00125 2 460 47 0 001397 0 0355 0 00000153 0 00099 1 951 48 0 001244 0 0316 0 00000122 0 00078 1 547 49 0 001107 0 0281 0 00000096 0 00062 1 227 50 0 000986 0 0251 0 00000076 0 00049 0 973 31 March 2009 STP 5 21P2 SM TG B 3 This page is intentionally left blank Section Acronyms amp Abbreviations R 1SG AC ACCP AEH AIT AN ANCOC AR ARNG ARNGUS ASI ASTM ATS attn AWG BA BDAR BNCOC BOM B
126. A FORM 2404 TM 9 6115 604 12 DA FORM 5988 E 3 134 STP 5 21P2 SM TG 31 March 2009 MOS Skill Level Tasks Service a Diesel Engine Cylinder Head 052 205 2100 Conditions As a power station mechanic in a nontactical environment when a diesel engine cylinder head has been identified for service or symptoms of cylinder head faults occur you are given a lockout and tagout kit a general mechanic s tool box torque wrenches special tools applicable technical manuals TMs the applicable manufacturer s literature maintenance logbooks and DA Form 2404 Equipment Inspection and Maintenance Worksheet or DA Form 5988 E Equipment Inspection Maintenance Worksheet DANGER 1 ENSURE THAT EQUIPMENT IS PROPERLY LOCKED OUT AND TAGGED OUT FAILURE TO COMPLY MAY CAUSE PERMANENT INJURY OR DEATH 2 REMOVE RINGS NECKLACES OTHER JEWELRY AND LOOSE CLOTHING FAILURE TO COMPLY MAY CAUSE PERMANENT INJURY OR DEATH WARNING 1 WHEN DISCONNECTING BATTERY CABLES ALWAYS DISCONNECT THE NEGATIVE TERMINAL FIRST WHEN RECONNECTING CONNECT THE POSITIVE TERMINAL FIRST FAILURE TO COMPLY MAY RESULT IN SPARKING OR BATTERY EXPLOSION AND MAY CAUSE IMMEDIATE PERSONAL INJURY OR EQUIPMENT DAMAGE 2 ENGINE SYSTEMS SHOULD BE ALLOWED TO COOL COMPLETELY BEFORE ATTEMPTING TO SERVICE THE INTERNAL COMPONENTS FAILURE TO COMPLY MAY CAUSE IMMEDIATE PERSONAL INJURY AND EQUIPMENT DAMAGE CAUTION NOISE LEVELS IN EXCESS OF 85 DECIBELS EXIST WITHIN A 50 FOOT RADIUS
127. AND EQUIPMENT DAMAGE Standards Perform electric arc welding in a manner that will safely fuse the metal together to provide enough strength to match or exceed the original tensile strength of the base metal or original configuration Performance Steps NOTE This task is to be performed with SMAW equipment not metal inert gas MIG or tungsten inert gas TIG welding equipment 1 Identify the characteristics of ferrous components and materials 2 Prepare the welding area and the items to be welded a Inspect the welding area for readily combustible material and clear the area of combustible material b Position the material or item to be welded in a safe location 1 Ensure that no material is placed directly on concrete or asphalt floors or near flammable materials 2 Ensure that only the items to be welded receive the arc 3 Ensure that sparks and other hot items are diverted away from potential hazards 3 138 STP 5 21P2 SM TG 31 March 2009 MOS Skill Level Tasks Performance Steps 3 Inspect the welding machine to ensure that protective guards covers and insulators are in the proper position and in good material condition 4 Select the proper welding electrode type and size a Consider the nature of the base metal b Consider the position to be welded c Consider the type of welding machine available 5 Select the proper current alternating current AC or direct current DC and the proper current polar
128. ATH WARNING 1 NOT ALL RELAYS ARE THE DRAW OUT TYPE ALWAYS REFER TO THE MANUFACTURER S LITERATURE TO ENSURE THAT CURRENT TRANSFORMER CONTACTS ARE SHORTED BEFORE REMOVING THE RELAY FROM SERVICE FAILURE TO COMPLY MAY CAUSE IMMEDIATE PERSONAL INJURY AND SEVERE DAMAGE TO EQUIPMENT 2 EXTREME CARE SHOULD BE TAKEN WHEN REMOVING THE RELAY DEVICE FROM SERVICE DO NOT CAUSE THE CIRCUIT THAT THE RELAY IS PROTECTING TO TRIP FAILURE TO COMPLY MAY CAUSE DAMAGE TO EQUIPMENT NOTE Keep the work area neat and organized Keep the meter and equipment stable while performing this task Failure to comply may lead to unreliable test readings Standards Service the relay device in question by testing it to determine if it meets the manufacturer s specifications Perform any necessary adjustments to bring the relay to serviceable condition when possible Replace the relay when it cannot be returned to the manufacturer s specifications Performance Steps 1 Review danger warning and caution notices before proceeding 2 Review the manufacturer s literature with schematics and wiring diagrams 3 Review maintenance logbooks and historical data pertaining to the equipment 4 Review the relay instruction booklet 5 Record the relay information Record the location Record the circuit identification Record the date Record the temperature Record the relay nameplate data Record one as found relay settings NOTE Use extreme ca
129. AY CAUSE PERMANENT INJURY OR DEATH 4 DO NOT EXCEED THE MAXIMUM VOLTAGE STIPULATED FOR THIS TEST FAILURE TO COMPLY MAY CAUSE PERMANENT INJURY OR DEATH WARNING 1 AN APPLICATION OF HIGH VOLTAGE ACROSS AN OPEN GAP IN A VACUUM CAN PRODUCE AN X RAY EMISSION THAT MAY CAUSE IMMEDIATE PERSONAL INJURY 2 SOME DIRECT CURRENT DC HIGH POTENTIAL TEST SETS ARE HALF WAVE RECTIFIED AND MAY PRODUCE PEAK VOLTAGES IN EXCESS OF THE MANUFACTURER S RECOMMENDED MAXIMUM FOR THE SWITCH FAILURE TO FOLLOW TEST SET INSTRUCTIONS MAY CAUSE IMMEDIATE PERSONAL INJURY OR EQUIPMENT DAMAGE Standards Safely service a vacuum circuit breaker by inspecting and testing it Test the vacuum circuit breaker according to the manufacturer s literature Reinstall or repair the vacuum circuit breaker based on the test results Performance Steps NOTE Conduct tests according to the manufacturer s literature Use industry standards when the manufacturer s literature cannot be obtained 1 Review danger warning and caution notices 2 Review the manufacturer s literature and wiring diagrams 3 Review maintenance logbooks and historical data pertaining to the equipment 4 Perform lockout and tagout procedures 5 Inspect the condition of the vacuum circuit breaker visually and manually NOTE Microhm or millivolt drop values should not exceed the high levels of the normal range as indicated in the manufacturer s literature If the manufacturer s literature is not availab
130. Bring the units online and off line as directed by a supervisor or loading schedule 4 ODA200 uu 7 Determine the proper number of generators required to handle the assessed load 8 Operate the generators in different modes of operation Operate the generator in automatic mode Operate the generator in manual mode Operate the generator in economize on Operate the generator in economize off Operate the generator in load sharing aooo 9 Parallel the generators on and off the bus as directed by a shift supervisor or as needed 10 Maintain the operator s logbook according to the SOP a Perform initial assessment of the power plant and individual generators b Make appropriate logbook entries when significant events happen 11 Monitor engine and generator indicators to ensure continued operation through various load changes 12 Maintain an hourly reading log detailing the engine and electrical parameters of the equipment online and off line 13 Perform during operation PMCS according to the TM 14 Conduct unit shutdown operations 15 Conduct postoperation PMCS according to the TM Evaluation Preparation Setup Provide the Soldier with the items listed in the conditions Give the Soldier a safety briefing before starting the test and ensure that safety precautions are followed Prepare the testing area and equipment in advance to ensure that task standards can be met Brief Soldier Direct the So
131. CLES WITH A CLASS III LEAK SHOULD NOT BE OPERATED AND MUST BE SENT FOR REPAIR IMMEDIATELY FAILURE TO COMPLY MAY RESULT IN EQUIPMENT DAMAGE THAT MAY CAUSE LONG TERM FAILURE NOTE For different line trucks consult the user s manual for correct PMCS Standards Perform operator PMCS on a line truck with auxiliary equipment before during and after operation or when directed to do so Performance Steps 1 Perform before operation PMCS a Inspect the vehicle exterior for damage and deficiencies checking for 1 A cracked or broken windshield 2 Cracked broken or inoperable windshield wipers 3 A cracked or damaged hood 4 Cracked broken or inoperable headlights 5 Cracked broken or inoperable marker and directional lights 6 Cracked broken or inoperable reverse lights and alarm 7 Cracked torn or missing hood latches 8 Leaks spills or drips underneath the vehicle 9 Cracked or broken side windows 0 Cracked or broken side mirrors 11 Cracked sliced or torn tires inside and outside 12 Broken handles dents or other damage on the side tool bin door that may prevent the bins from opening closing or locking properly 13 Cracked or frayed cable steps b Inspect the engine and engine components for damage and deficiencies 1 Check the following fluid levels a Engine oil b Coolant c Power steering fluid d Windshield washer fluid 2 Check for leaks or spills 3 Check wiring for cracks fra
132. Check for a faulty injector s Q 9A00fM 3 130 STP 5 21P2 SM TG 31 March 2009 MOS Skill Level Tasks Performance Steps i Check for a high lubricating oil level j Determine if the engine is operating above the recommended altitude k Check for engine overload Check the turbocharger operation m Check for airflow restriction 3 De energize the circuit before applying safe clearance procedures 4 Perform lockout and tagout procedures 5 Identify the malfunction 6 Repair or replace defective components parts when possible NOTE If adverse environmental conditions prevent fault correction refer to direct support for further repair 7 Close out lockout and tagout procedures by removing locking and tagging devices 8 Energize the circuit and ensure that it is operating properly 9 Record actions taken on DA Form 2404 or DA Form 5988 E and maintenance logbooks 10 Ensure that the items listed in the conditions are properly cleaned and stored Evaluation Preparation Setup Provide the Soldier with the items listed in the conditions Give the Soldier a safety briefing before starting the test and ensure that safety precautions are followed Prepare the testing area and equipment in advance to ensure that task standards can be met Brief Soldier Direct the Soldier to troubleshoot a diesel engine for loss of power Performance Measures GO NO GO 1 Reviewed maintenance logbooks and historical data pertaining to t
133. Check the hydraulic tank on the front of the unit Check the filter cap and bypass assembly Check the return line filter Check the differential pressure gauge Check the tank breather Check the sight glass Check the hydraulic tank supply shutoff valve Check the hydraulic system cooler Check the air to air aftercooler fan motor Check the radiator fan motor Check the hydraulic fan motor vent Check the pressure relief control box or hydraulic manifold Check hydraulic system pressure gauges Check the hydraulic pump 3533 x 5O Wan TD 6 Service filters when the unit reaches the required hours of service a Replace filters b Clean filter screens c Replace fluid 7 Reinstall panels 8 Perform a functions check on the hydraulic system NOTE For the next step keep the unit isolated from the rest of the power plant a Remove safety measures on the unit not the power plant b Start the unit c Operate the unit under no load for 3 to 5 minutes d Check gauges for proper pressure e Check hydraulic oil for the correct fluid level and ensure that it is not cloudy f Shut down the unit 9 Ensure that lockout and tagout procedures are closed out by removing locking and tagging devices 10 Record actions taken on DA Form 2404 or DA Form 5988 E and maintenance logbooks 11 Ensure that the items listed in the conditions are properly cleaned and stored Evaluation Preparation Setup Pro
134. Conditions As a power line distribution supervisor in a tactical or nontactical environment when a utility pole needs to be mechanically erected you are given a line truck tampers a shovel applicable guying equipment applicable pole grounding equipment a butt man a truck operator ground guides the Lineman s and Cableman s Handbook LCH wiring diagrams electrical construction prints safety standing operating procedures SOPs the applicable personal protective equipment PPE and DA Form 2702 Bill of Materials DANGER 1 THIS TASK SHOULD ONLY BE PERFORMED BY QUALIFIED PERSONNEL KNOWLEDGEABLE IN THE INSTALLATION AND MAINTENANCE OF ELECTRICAL DISTRIBUTION SYSTEMS AND POWER EQUIPMENT AND THE ASSOCIATED HAZARDS FAILURE TO COMPLY MAY CAUSE PERMANENT INJURY OR DEATH 2 NEVER POSITION YOURSELF UNDER A SUSPENDED LOAD FAILURE TO COMPLY MAY CAUSE PERMANENT INJURY OR DEATH Standards Supervise the mechanical erection of a utility pole by ensuring that the utility pole is facing the proper direction firmly embedded into the ground at the proper depth and rigged and raised in a safe manner Performance Steps 1 Review danger warning and caution notices before proceeding Review the manufacturer s literature electrical construction prints and wiring diagrams Ensure that PPE is correctly tested and fully mission capable Complete DA Form 2702 for the tools and equipment necessary to perform this task Inspect tools and rigg
135. D BY QUALIFIED PERSONNEL WHO ARE KNOWLEDGEABLE IN THE OPERATION AND MAINTENANCE OF MEDIUM VOLTAGE ELECTRICAL POWER GENERATION EQUIPMENT AND THE HAZARDS ASSOCIATED WITH IT FAILURE TO COMPLY MAY CAUSE PERMANENT INJURY OR DEATH 2 REMOVE RINGS NECKLACES OTHER JEWELRY AND LOOSE CLOTHING FAILURE TO COMPLY MAY CAUSE PERMANENT INJURY OR DEATH CAUTION NOISE LEVELS IN EXCESS OF 85 DECIBELS EXIST WITHIN A 50 FOOT RADIUS OF OPERATING EQUIPMENT ALWAYS WEAR SINGLE HEARING PROTECTION WITHIN A 50 FOOT RADIUS OF OPERATING EQUIPMENT FAILURE TO COMPLY MAY CAUSE INJURY Standards Troubleshoot an engine that fails to stop by identifying and verifying the cause of the engine failure Correct the fault if possible Performance Steps 1 Review danger warning and caution notices 2 Review the manufacturer s literature electrical construction prints and wiring diagrams 3 Review the maintenance logbook and historical data pertaining to the equipment 4 Check the system emergency STOP button a Ensure that the button functions properly b Verify the proper voltage at the emergency STOP button 5 Check the stop circuit Inspect the stop circuit for loose connections Check the stop circuit for defective wiring harnesses Verify that the engine run relays de energize Check for improper system voltage Check for unauthorized modifications D2DQaqnqna 6 Correct deficiencies if possible 7 Record faults in the maintenanc
136. D HAZARDS FAILURE TO COMPLY MAY CAUSE PERMANENT INJURY OR DEATH 2 ALWAYS WEAR THE PERSONAL PROTECTIVE EQUIPMENT REQUIRED FOR INSPECTIONS IN HAZARDOUS AREAS FAILURE TO COMPLY MAY CAUSE PERMANENT INJURY OR DEATH 3 REMOVE RINGS NECKLACES OTHER JEWELRY AND LOOSE CLOTHING FAILURE TO COMPLY MAY CAUSE PERMANENT INJURY OR DEATH Standards Troubleshoot a DC voltage system by identifying the cause s of the malfunction Safely and accurately locate and correct the malfunction in the DC voltage system without causing injury or equipment damage Performance Steps 1 Review danger warning and caution notices Review the manufacturer s literature electrical construction prints and wiring diagrams Review the maintenance logbook and historical data pertaining to equipment Isolate the system circuits that need troubleshooting Perform lockout and tagout procedures O a A W N Identify the symptoms of the problem a Check for unusual sounds b Identify physical abnormalities c Check for unusual smells 7 Review the references a Review technical manuals b Review the manufacturer s literature c Review electrical diagrams 8 Locate the fault or problem a Determine which portion s of the circuit are working correctly Eliminate circuits or portions of circuits that allow a look at a smaller more isolated area b Verify that circuit components parts function properly c Identify faulty components parts 9
137. D PERSONNEL WHO ARE KNOWLEDGEABLE IN THE INSTALLATION OPERATION AND MAINTENANCE OF ELECTRICAL POWER GENERATION EQUIPMENT AND ITS ASSOCIATED HAZARDS FAILURE TO COMPLY MAY CAUSE PERMANENT INJURY OR DEATH 2 DO NOT OPERATE THE GENERATOR UNLESS IT HAS BEEN PROPERLY GROUNDED FAILURE TO COMPLY MAY CAUSE PERMANENT INJURY OR DEATH 3 REMOVE RINGS NECKLACES OTHER JEWELRY AND LOOSE CLOTHING FAILURE TO COMPLY MAY CAUSE PERMANENT INJURY OR DEATH CAUTION NOISE LEVELS IN EXCESS OF 85 DECIBELS EXIST WITHIN A 50 FOOT RADIUS OF OPERATING EQUIPMENT PERSONNEL MUST WEAR SINGLE HEARING PROTECTION WITHIN A 50 FOOT RADIUS FAILURE TO COMPLY MAY CAUSE PERSONAL INJURY Standards Operate the generator according to the manufacturer s literature so that the system parameters are met without causing injury or equipment damage Operate the generator within its voltage amperage kilowatt and power factor limitations while maintaining the load Performance Steps 1 Perform before operation checks 2 Start the generator a Set a desired frequency b Set a desired voltage 3 Perform one of the following operating procedures a Perform isolated operating procedures 1 Ensure that there is no other generator online 2 Close the circuit breaker and assume the load 3 Maintain the frequency and voltage 4 Operate within the limits of the generator 5 Open the circuit breaker b Perform parallel operating procedures 1 Energize the synchro
138. E a Wear a hard hat b Wear leather work gloves c Wear insulated protective equipment if working near live circuits d Wear steel toed safety boots e Wear safety glasses Install the mounting bracket on the pole Mount the lighting fixture and ballast onto the bracket Ensure that the mounted equipment is secured to the pole for safety purposes Install the distribution and control wiring O O N QOQ Close out lockout and tagout procedures by removing locking and tagging devices 11 Energize the circuit 3 272 STP 5 21P2 SM TG 31 March 2009 MOS Skill Level Tasks Performance Steps 12 Verify that the lamp illuminates the designated area 13 Adjust the lamp to illuminate the designated area if necessary 14 Ensure that the items listed in the conditions are properly cleaned and stored Evaluation Preparation Setup Provide the Soldier with the items listed in the conditions Give the Soldier a safety briefing before starting the test and ensure that safety precautions are followed Prepare the testing area and equipment in advance to ensure that task standards can be met Brief Soldier Direct the Soldier to install high intensity lights and ballasts Performance Measures GO NO GO 1 Reviewed the applicable manufacturer s literature electrical construction prints and wiring diagrams Performed lockout and tagout procedures Ensured that personnel followed safety clearances
139. E KNOWLEDGEABLE IN THE INSTALLATION OPERATION AND MAINTENANCE OF ELECTRICAL POWER GENERATION EQUIPMENT AND THE ASSOCIATED HAZARDS FAILURE TO COMPLY MAY CAUSE PERMANENT INJURY OR DEATH 2 DO NOT TOUCH EXPOSED ELECTRICAL CONNECTIONS WHEN A POWER SOURCE SUCH AS UTILITY POWER OR ANOTHER GENERATOR SET IS CONNECTED TO THE LOAD TERMINALS FAILURE TO COMPLY MAY CAUSE PERMANENT INJURY OR DEATH 3 REMOVE RINGS NECKLACES OTHER JEWELRY AND LOOSE CLOTHING FAILURE TO COMPLY MAY CAUSE PERMANENT INJURY OR DEATH 4 ENSURE THAT THE SECTION OF THE FUEL DISTRIBUTION SYSTEM BEING SERVICED IS PROPERLY ISOLATED LOCKED OUT AND TAGGED OUT DEPRESSURIZED DRAINED FLUSHED AND MADE SAFE AS REQUIRED WITH THE LEVEL AND TYPE OF MAINTENANCE TO BE PERFORMED FAILURE TO COMPLY MAY CAUSE PERMANENT INJURY OR DEATH 5 DO NOT PERFORM ANY HOT WORK ON A PIPING SYSTEM TO INCLUDE GRINDING SAWING OR SOLDERING DO NOT PERFORM CUTTING OR WELDING ON A PIPING SYSTEM THAT CONTAINS FLAMMABLE FLUIDS OR FUEL RESIDUES WITHOUT DRAINING FLUSHING VENTING AND MAKING THE PIPING SYSTEM SAFE TO REMOVE AND MAINTAIN FUEL VAPOR LEVELS BELOW THE LOWER EXPLOSIVE LIMIT OF FLAMMABLE LIQUID FAILURE TO COMPLY MAY CAUSE PERMANENT INJURY OR DEATH WARNING DO NOT ATTEMPT TO SERVICE OR MAKE ADJUSTMENTS CONNECTIONS OR RECONNECTIONS OF WIRES OR CABLES UNTIL THE GENERATOR SET IS SHUT DOWN AND COMPLETELY DE ENERGIZED FAILURE TO COMPLY MAY CAUSE IMMEDIATE INJURY OR EQUIPMENT DAMAGE CAUTI
140. E TO COMPLY MAY CAUSE PERMANENT INJURY OR DEATH Standards Safely service an ATS by inspecting and testing it according to the manufacturer s literature and record the results Repair or replace the ATS based on the test results Performance Steps 1 Review danger warning and caution notices 2 Review the manufacturer s literature and wiring diagrams 3 Review maintenance logbooks and historical data pertaining to the equipment 4 Perform lockout and tagout procedures 5 Perform a visual and manual inspection of the ATS NOTE Microhm or millivolt drop values should not exceed high levels of the normal range as specified in the manufacturer s literature If the manufacturer s literature is not available investigate values that deviate from adjacent poles or similar breakers by more than 25 to 50 percent of the lowest value Verify the appropriate anchorage and area clearance Verify the appropriate equipment grounding Verify the correct blade alignment penetration travel stops and mechanical operation Verify that fuse sizes and types are according to the manufacturer s literature Verify that expulsion limiting devices are in place on holders having expulsion type elements Verify that each fuse holder has adequate mechanical support Inspect bolted electrical connections for high resistance 1 Use the low resistance ohmmeter 2 Verify the tightness of bolted connections using a calibrated torque wrench according t
141. ENT DAMAGE 2 THE SPLICER S TOOLS HANDS AND TERMINATION MATERIAL MUST BE KEPT CLEAN DURING THE CONSTRUCTION OF A TERMINATION FAILURE TO COMPLY MAY CAUSE INJURY OR EQUIPMENT DAMAGE Standards Terminate a medium voltage power cable to ensure that the termination meets the rating of the original cable and that it does not cause an electrical hazard to personnel or damage to equipment The cable must be able to transmit the maximum electrical load without undue heating and must be at the full mechanical load strength of the conductors Performance Steps NOTES 1 There are several different types of termination kits available for use with a medium voltage power cable Each kit contains specific instructions on how to construct the termination Always follow the manufacturer s instructions for the specific kit used 2 This task covers a 5 to 35 kilovolt single conductor shielded power cable that is made of polyethylene cross linked polyethylene butyl or other rubberlike insulation with a polyvinyl chloride PVC or neoprene jacket 3 The insulation resistance value should exceed 80 percent of the cable s insulation rating 1 Perform lockout and tagout procedures 2 Inspect the termination kit a Ensure that you use the correct termination kit for each cable b Inventory the kit to ensure that all components parts are present 3 Prepare the cable and termination as specified in the manufacturer s literature a Measure and
142. ENT INJURY OR DEATH AND EQUIPMENT DAMAGE 4 REMOVE RINGS NECKLACES OTHER JEWELRY AND LOOSE CLOTHING FAILURE TO COMPLY MAY CAUSE PERMANENT INJURY OR DEATH NOTE Keep the work area neat and organized Keep the controller and equipment stable while performing this task Failure to comply may lead to unreliable test readings Standards Service a PLC by safely testing it as specified in the manufacturer s literature Reinstall or replace the controller based on the test results Performance Steps NOTE The low voltage side of the potential transformer that supplies voltage to the controller may be fuse protected To further isolate the circuit electrically and as an additional safety measure this fuse may be removed Check the schematics for verification 1 Review danger warning and caution notices before proceeding Review the manufacturer s literature with schematics and wiring diagrams Review maintenance logbooks and historical data pertaining to the equipment Identify the circuit connected to the PLC by using the schematics Perform lockout and tagout procedures O oa A W N Test the circuit for voltage presence a Proceed to step 7 if there is no voltage present b Stop if there is voltage present and perform the following checks until voltage is no longer present 1 Check the schematics for proper circuit identification 2 Check for back fed circuits 3 Check for the proper use of safe clearance proc
143. ER 1 REMOVE RINGS NECKLACES OTHER JEWELRY AND LOOSE CLOTHING FAILURE TO COMPLY MAY CAUSE PERMANENT INJURY OR DEATH 2 THE SOLDERING IRON IS VERY HOT DURING OPERATION USE CAUTION TO AVOID SETTING FIRE TO YOURSELF OR THE WORKPLACE FAILURE TO COMPLY MAY RESULT IN PERMANENT INJURY OR DEATH NOTE Keep the work area neat and organized Keep the meter and equipment stable Failure to comply may lead to unreliable test readings Standards Produce a functional electronic circuit Performance Steps 1 Identify circuit components correctly 2 Inspect components for damage and serviceability 3 Install components in the circuit board as specified in schematics a Insert each component individually into its proper position b Ensure that polarity sensitive components are properly oriented c Place the heat sink clips on temperature sensitive components d Solder the component in place using the proper technique to ensure that there is a good electrical connection 4 Inspect the final product for flaws or damage 5 Test the circuit for proper operation 6 Ensure that the items listed in the conditions are properly cleaned and stored Evaluation Preparation Setup Provide the Soldier with the items listed in the conditions Give the Soldier a safety briefing before starting the test and ensure that safety precautions are followed Prepare the testing area and equipment in advance to ensure that task standards can be met Brie
144. ERATE THE ENERGY ISOLATING DEVICES AND DISCONNECTORS FAILURE TO COMPLY MAY CAUSE PERMANENT INJURY OR DEATH 16 Test each phase conductor or circuit part with an adequately rated voltage detector to verify that they are de energized a Check an energized circuit to ensure that the voltage detector is working properly b Check for the presence of voltage on the de energized circuit c Check the energized circuit again to verify that the voltage detector is working properly 17 Perform maintenance and service on the phase conductor or circuit part 18 Request permission from the project supervisor to close out lockout and tagout procedures 19 Perform an inspection with the personnel performing the work and the project supervisor to ensure that all affected personnel are notified when the lockout and tagout devices are ready for removal WARNING BEFORE THE LOCKOUT OR TAGOUT DEVICES ARE REMOVED AND EQUIPMENT AND ELECTRIC CIRCUITS ARE REENERGIZED APPROPRIATE TESTS AND VISUAL INSPECTIONS WILL BE CONDUCTED BY THE INSTALLER THE INSTALLER WILL VERIFY THAT ALL TOOLS MECHANICAL RESTRAINTS ELECTRICAL JUMPERS SHORTS AND GROUNDS HAVE BEEN REMOVED THE ENTIRE WORK AREA WILL BE INSPECTED AND NONESSENTIAL ITEMS WILL BE REMOVED FROM THE SYSTEM FAILURE TO COMPLY MAY CAUSE INJURY OR EQUIPMENT DAMAGE 20 Close out lockout and tagout procedures by removing locking and tagging devices NOTE Ensure that each lockout and tagout device is removed by the in
145. ETAL TO STRIKE METAL FAILURE TO COMPLY MAY CAUSE IMMEDIATE PERSONAL INJURY Standards Perform a crossarm change out from a minimum height of 35 feet and in less than 30 minutes by removing the old crossarm lowering it to the ground and raising and installing the new crossarm Performance Steps 1 Inspect the climbing equipment tools and handline for defects 2 Perform lockout and tagout procedures 3 Lay out the handline and attach it to your body belt 4 Ascend the pole until you are eye level with the lag screw and then belt in 5 Remove the crossarm a Remove the lag screw b Hitchhike up and attach the handline to the pole using the collar rope with the hook facing down Tie the clove hitch to the end of the crossarm Remove the through bolt nut Remove the crossarm and place it on the safety strap Lower one end of the crossarm to allow hanging it on your safety strap using the insulator pin Tie a half hitch loop below the insulator pin Communicate your intentions with the groundman guide the crossarm down and allow the groundman to lower the crossarm to the ground TO 90DA0 6 Install the new crossarm a Place the safety strap over the head of the through bolt b Tell the groundman to raise the crossarm by using the insulator pin end of the crossarm being sent up first to just below your feet c Correctly communicate your intentions with the groundman and then guide the crossarm up until you are a
146. ETER FAILURE TO COMPLY MAY CAUSE PERMANENT INJURY OR DEATH AND EQUIPMENT DAMAGE 4 REMOVE RINGS NECKLACES OTHER JEWELRY AND LOOSE CLOTHING FAILURE TO COMPLY MAY CAUSE PERMANENT INJURY OR DEATH NOTE Keep the work area neat and organized Keep the relay stable while performing this task Failure to comply may lead to unreliable test readings Standards Service a solid state relay by testing and calibrating it and then installing or replacing the relay Test the relay as specified in the manufacturer s literature and keep a record of the results Reinstall or replace the relay based on the test results Performance Steps NOTE The low voltage side of the potential transformer that supplies voltage to the relay may be fuse protected To further isolate the circuit electrically and as an additional safety measure this fuse may be removed Check the schematics for verification 1 Review danger warning and caution notices before proceeding Review the manufacturer s literature with schematics and wiring diagrams Review maintenance logbooks and historical data pertaining to the equipment Identify the circuit connected to the relay by using the schematics Perform lockout and tagout procedures O oa A W N Test the circuit for voltage presence a Proceed to step 7 if there is no voltage present b Stop if there is voltage present and perform the following checks until voltage is no longer present 1 Check the sche
147. FIED PERSONNEL WHO ARE KNOWLEDGEABLE IN THE INSTALLATION AND OPERATION OF DIESEL ENGINES AND THE ASSOCIATED HAZARDS FAILURE TO COMPLY MAY CAUSE PERMANENT INJURY OR DEATH CAUTION 1 NOISE LEVELS IN EXCESS OF 85 DECIBELS EXIST WITHIN A 50 FOOT RADIUS OF OPERATING EQUIPMENT PERSONNEL MUST WEAR SINGLE HEARING PROTECTION WITHIN A 50 FOOT RADIUS FAILURE TO COMPLY MAY CAUSE PERSONAL INJURY 2 DO NOT REMOVE THE CYLINDER HEADS WITHOUT REMOVING THE INJECTORS DAMAGE TO THE INJECTOR TIP CAN OCCUR DURING THE REMOVAL OF THE CYLINDER HEAD OR SUBSEQUENT HANDLING FAILURE TO COMPLY MAY CAUSE EQUIPMENT DAMAGE 3 DO NOT USE A CONNECTING ROD THAT IS NICKED OR CUT OR HAS ANY SIGNS OF DAMAGE ALONG THE RIBBED SURFACES CONNECTING RODS DAMAGED IN THIS MANNER ARE SUBJECT TO FAILURE FAILURE TO COMPLY MAY CAUSE EQUIPMENT DAMAGE 4 TO AVOID PISTON DAMAGE DO NOT DRIVE PRESS OR FORCE A PISTON PIN FROM THE PISTON REMOVE THE PISTON PIN USING THUMB PRESSURE ONLY IF THE PISTON PIN IS DIFFICULT TO REMOVE HEAT THE PISTON IN HOT WATER OR FOR 15 MINUTES IN AN OVEN SET TO A MAXIMUM TEMPERATURE OF 210 F FAILURE TO COMPLY MAY CAUSE EQUIPMENT DAMAGE 5 TO AVOID DAMAGE TO THE UPPER MAIN BEARING SHELLS DURING INSTALLATION TWO TECHNICIANS ARE REQUIRED ENSURE THAT BEARING SHELLS ARE NOT INTERCHANGED THE UPPER MAIN BEARING SHELLS HAVE DRILLED HOLES THAT ALLOW LUBRICATING OIL PASSAGE AND MUST BE INSTALLED IN THE CYLINDER BLOCK IF THE LOWER UNDRILLED BEARING SHELL I
148. G THE TEST DO NOT TOUCH THE CABLE BEING TESTED OR THE TEST LEADS ALWAYS REMOVE THE POWER AND DISCHARGE AND GROUND THE CIRCUIT FOR TWICE THE AMOUNT OF TIME THAT IT WAS TESTED BEFORE HANDLING FAILURE TO COMPLY MAY CAUSE PERMANENT INJURY OR DEATH WARNING HEATERS IN THE ENCLOSURE MAY CAUSE SERIOUS BURNS EVEN AFTER THE POWER HAS BEEN REMOVED CONTACT WITH HEATERS MAY CAUSE IMMEDIATE PERSONAL INJURY NOTE Conduct tests as specified in the manufacturer s literature or industry standards Standards Perform maintenance on electrical distribution equipment by inspecting and testing as specified in the applicable manufacturer s literature Reinstall or repair equipment based on the test results 3 306 STP 5 21P2 SM TG 31 March 2009 MOS Skill Level Tasks Performance Steps 1 oO ON DOD Oa A OO N a A l O a M A OO N gt O Review danger warning and caution notices before proceeding Review the manufacturer s literature electrical construction prints and wiring diagrams Ensure that PPE is correctly tested and fully mission capable Inspect tools and testing equipment for serviceability Perform lockout and tagout procedures Ascend the pole to the required height if necessary Test the phases to ensure that there is no voltage present Install personal protective grounds Perform maintenance on electrical distribution equipment by inspecting and testing it according to the applicable manufacturer s litera
149. HEIR ASSOCIATED HAZARDS FAILURE TO COMPLY MAY CAUSE PERMANENT INJURY OR DEATH 2 ENSURE THAT THE TRANSFORMER IS DE ENERGIZED AND ELECTRICALLY SHORTED BEFORE SERVICING FAILURE TO COMPLY MAY CAUSE PERMANENT INJURY OR DEATH 3 DO NOT TOUCH EXPOSED ELECTRICAL CONNECTIONS WHEN THE POWER SOURCE IS CONNECTED TO THE TRANSFORMER FAILURE TO COMPLY MAY CAUSE PERMANENT INJURY OR DEATH 4 REMOVE RINGS NECKLACES OTHER JEWELRY AND LOOSE CLOTHING FAILURE TO COMPLY MAY CAUSE PERMANENT INJURY OR DEATH Standards Safely service a CT by inspecting and testing it according to the manufacturer s literature and record the results Reinstall or replace the CT based on the test results Performance Steps NOTE Tests should be conducted according to the manufacturer s literature When the manufacturer s literature is not available industry standards should be used 1 Review danger warning and caution notices 2 Review the manufacturer s literature and wiring diagrams 3 Review maintenance logbooks and historical data pertaining to the equipment 4 Perform lockout and tagout procedures 5 Test the circuit for voltage a Proceed to step 6 if no voltage is present b Stop if voltage is present and do not proceed to step 6 until voltage is no longer present 1 Check the schematics for proper circuit identification 2 Check for possible back fed circuits 3 Check for the proper installation of safe clearances 6 Inspect the condition
150. IZED APPROPRIATE TESTS AND VISUAL INSPECTIONS MUST BE CONDUCTED BY AUTHORIZED PERSONNEL THE INSTALLER THE INSTALLER WILL VERIFY THAT TOOLS MECHANICAL RESTRAINTS AND ELECTRICAL JUMPERS SHORTS AND GROUNDS HAVE BEEN REMOVED THE ENTIRE WORK AREA IS INSPECTED AND NONESSENTIAL ITEMS ARE REMOVED FROM THE SYSTEM FAILURE TO COMPLY MAY CAUSE IMMEDIATE INJURY OR EQUIPMENT DAMAGE 12 Ensure that the items listed in the conditions are properly cleaned and stored Evaluation Preparation Setup Provide the Soldier with the items listed in the conditions Give the Soldier a safety briefing before starting the test and ensure that safety precautions are followed Prepare the testing area and equipment in advance to ensure that task standards can be met Brief Soldier Direct the Soldier install a grounding set Performance Measures GO NO GO 1 Inspected tools and equipment for serviceability 2 Performed lockout and tagout procedures 3 Tested phases to ensure that they were isolated and that there was no voltage present 4 Connected one end of the grounding conductor to an established ground usually the grounded neutral conductor 5 Installed a grounding cluster block on the pole below the work area if work was performed on a wooden pole 6 Connected the other end of the grounding conductor using a hot line tool to the bottom conductor on vertical constructions or the cl
151. JURY OR DEATH Standards Identify electrical faults using an IR camera by detecting hot spots in the viewer mode Keep a record of the images and descriptions Conduct an IR survey and prepare a report of the images taken Performance Steps 1 Prepare an inventory list of the equipment items or components parts to be tested 2 Arrange the inventory list items in a logical sequence 3 Coordinate with the equipment maintenance supervisor if the system is unknown a Obtain a description of the system b Obtain information on known current faults c Obtain information on symptoms of possible faults d Obtain information on the possible system hazards 4 Conduct an IR survey a View the system with the IR camera for a possible electrical fault b Photograph the possible electrical fault Ensure that the camera is 1 Set properly 2 Placed at a proper distance from the electrical fault 3 Properly focused 4 Stable c Keep a record of the information for each picture such as the 1 Detailed location 2 Item name or type of equipment 3 Item description 4 Operating condition 5 Environmental conditions 6 Weather air temperature wind speed sky conditions 7 Lighting conditions 8 Radiation transmitters or reflectors NOTE Weather and light conditions can cause a false electrical fault or mask the severity of a potential problem d Analyze the picture for possible problems such as 1 Phase imb
152. LD MUST NOT BE BETWEEN THE TESTER AND THE CONDUCTORS OF THE CIRCUIT BEING TESTED FAILURE TO COMPLY MAY CAUSE PERMANENT INJURY OR DEATH WARNING 1 THE SPLICER S TOOLS HANDS AND SPLICING MATERIALS MUST BE KEPT CLEAN DURING CONSTRUCTION FAILURE TO COMPLY MAY CAUSE IMMEDIATE PERSONAL INJURY OR EQUIPMENT DAMAGE 2 EMPLOY EVERY RESOURCE TO PREVENT MOISTURE DRIPPINGS CONDENSATION PERSPIRATION FROM ENTERING THE JOINT INSULATION FAILURE TO COMPLY MAY CAUSE IMMEDIATE PERSONAL INJURY OR EQUIPMENT DAMAGE NOTE There are several types of splicing kits available for use with medium voltage power cables Each kit contains specific instructions on how to make the splice Always follow the manufacturer s guidelines for the particular kit used Standards Splice a medium voltage power cable so that the splice meets the rating of the original cable and does not create an electrical hazard to personnel or equipment Ensure that the cable is capable of transmitting the maximum electrical load without excessive heating and is at the full mechanical strength of the conductors Performance Steps 1 Perform lockout and tagout procedures NOTES 1 If the two cables are not long enough to be spliced an additional length of cable will be needed 2 Some performance steps will be omitted when splicing overhead medium voltage cable 2 Inspect the splice kit a Use the correct splice kit for the cable b Inventory the kit to ensure that all co
153. LY SHORTED BEFORE SERVICING THE METER IF ENERGIZED AN OPEN CURRENT TRANSFORMER CIRCUIT WILL PRODUCE VERY HIGH VOLTAGES FAILURE TO COMPLY MAY CAUSE PERMANENT INJURY OR DEATH 3 ENSURE THAT POTENTIAL TRANSFORMERS FEEDING MODULES OR METERS ARE DE ENERGIZED BEFORE SERVICING THE METER FAILURE TO COMPLY MAY CAUSE PERMANENT INJURY OR DEATH AND EQUIPMENT DAMAGE 4 REMOVE RINGS NECKLACES OTHER JEWELRY AND LOOSE CLOTHING FAILURE TO COMPLY MAY CAUSE PERMANENT INJURY OR DEATH NOTE Keep the work area neat and organized Keep the meter and equipment stable while performing this task Failure to comply may lead to unreliable test readings Standards Service the meter safely Test and calibrate the meter and then reinstall or replace it Test the meter according to the manufacturer s literature Reinstall or replace the meter based on the test results Performance Steps NOTES 1 Some meters are usually tested with the associated transducer The meter and transducer may come as a matched set and should be tested and replaced accordingly Refer to the manufacturer s literature and equipment technical manuals for further information For the purpose of this task references to the meter include the transducer unless otherwise specified 2 The low voltage side of the potential transformer that supplies voltage to the module may be fuse protected To further isolate the circuit electrically and as an additional safety measure this fuse may be
154. MANUFACTURER S LITERATURE MAY RESULT IN EQUIPMENT DAMAGE 31 March 2009 STP 5 21P2 SM TG 3 173 Chapter 3 Performance Steps NOTE The following Inspections and checks are guidelines and may be done in any order Replace repair or clean any defective components parts as necessary 6 10 11 12 13 14 15 16 17 Remove fuel filters and strainers for replacement or cleaning as required by the maintenance schedule Inspect pickup pumps and engine mounted fuel pumps a Check for loosened mounting bolts b Check for deteriorated couplings c Check for loose fittings d Check for leakage Clean debris from in line strainers located on the inlet side of the pumps Perform a detailed inspection of all portions of the system a Check for leakage b Check for damage c Check for deterioration d Check for rust e Check for corrosion f Check for dry rot Inspect connection points closely for signs of leakage Inspect valves closely a Check for leakage b Check for damage c Check for deterioration d Check for inoperability Cycle each valve fully opened and closed to ensure proper operation Prime the fuel system to eliminate air Close out lockout and tagout procedures by removing locking and tagging devices Start the diesel engine and observe the fuel system for leaks Record actions taken on DA Form 2404 or DA Form 5988 E and maintenance logbooks Ensure that the items
155. MEDIATE INJURY 7 Install load cables 8 Close the main breaker 9 Check the voltage to ensure that the output is correct for the load requirements 3 66 STP 5 21P2 SM TG 31 March 2009 MOS Skill Level Tasks Performance Steps 10 Energize the equipment 11 Monitor the equipment to ensure proper operation 12 Ensure that the items listed in the conditions are properly cleaned and stored Evaluation Preparation Setup Provide the Soldier with the items listed in the conditions Give the Soldier a safety briefing before starting the test and ensure that safety precautions are followed Prepare the testing area and equipment in advance to ensure that task standards can be met Brief Soldier Direct the Soldier to install low voltage organic equipment Performance Measures GO NO GO 1 Reviewed danger warning and caution notices 2 Reviewed the manufacturer s literature electrical construction prints and wiring diagrams Inventoried equipment Positioned equipment Performed PMCS on equipment Installed ground rods Installed load cables Closed the main breaker n oO ON DOD a KF Q Checked the voltage to ensure that the output was correct for the load requirements 10 Energized the equipment 11 Monitored the equipment to ensure proper operation 12 Ensured that the items listed in the condition
156. MI NMI MIND NIN AAT RP PRP RP RTA AYA NN NM AYA 2 4 052 204 2217 NTMI NMI NM M AYR RL RTA 052 204 1129 Splice a Medium Voltage Power Cable ASI SD 2 2 4 4 2 4 31 March 2009 STP 5 21P2 SM TG 2 5 Chapter 2 Table 2 1 MOS 21P2 Critical Tasks continued Task Number Title Training Location Subject Area 6 S3 and E5 Combined Tasks 052 266 2106 Service Potential Transtomer am m 052 2642107 Service a Current Transtomer c m m 052 2642108 Solder an Electrical or Electronic Component ar mw 2 052 264 2109 Perform Advanced Electical Troubleshooting Procedures AMT an 2 052 264 2110 Determine the Transtormer Poariy m mn 0522642112 Service an Automatic Transfer Swich ATS at an 0522642113 Serice a Votage Regulator m m Subject Area 7 S3 and S2 Combined Tasks 052 264 2105 Service an Electronic Governor am a 052 264 2115 Troubleshoot the Improper Operation of an Electrical cca ee ee Motor Subject Area 8 S2 and E5 Combined Tasks 052 264 2104 Service an Auxiliary and or an Instrumentation Sensing Device NT NM MT NM NM 2 6 STP 5 21P2 SM TG 31 March 2009 Chapter 3 MOS Skill Level Tasks Skill Level 2 Subject Area 1 Overall 21P20 Tasks Perform Generator Set Hourly Checks 052 244 2101 Conditions As a power plant operator in a tactical or nontactical environment during power plant operations you are given an oper
157. NANCE OF MEDIUM VOLTAGE ELECTRICAL POWER GENERATION EQUIPMENT AND ITS ASSOCIATED HAZARDS FAILURE TO COMPLY MAY CAUSE PERMANENT INJURY OR DEATH 2 DO NOT TOUCH EXPOSED ELECTRICAL CONNECTIONS WHEN A POWER SOURCE SUCH AS UTILITY POWER OR ANOTHER GENERATOR SET IS CONNECTED TO LOAD TERMINALS FAILURE TO COMPLY MAY CAUSE PERMANENT INJURY OR DEATH 3 DO NOT OPERATE THE GENERATOR SET UNLESS IT HAS BEEN PROPERLY GROUNDED FAILURE TO COMPLY MAY CAUSE PERMANENT INJURY OR DEATH 4 REMOVE RINGS NECKLACES OTHER JEWELRY AND LOOSE CLOTHING FAILURE TO COMPLY MAY CAUSE PERMANENT INJURY OR DEATH WARNING AVOID CONTACT WITH BATTERY ELECTROLYTES THEY CONTAIN SULFURIC ACID THAT MAY CAUSE SEVERE CHEMICAL BURNS SKIN AND EYE PROTECTION IS REQUIRED FAILURE TO COMPLY MAY CAUSE INJURY CAUTION NOISE LEVELS IN EXCESS OF 85 DECIBELS EXIST WITHIN A 50 FOOT RADIUS OF OPERATING EQUIPMENT ALWAYS WEAR SINGLE HEARING PROTECTION WITHIN A 50 FOOT RADIUS OF OPERATING EQUIPMENT FAILURE TO COMPLY MAY CAUSE INJURY Standards Perform PMCS on an MEP 012 or 208 generator according to the TM Ensure that system parameters are met without causing injury or equipment damage Performance Steps 1 Review danger warning and caution notices Perform before operation PMCS Perform preoperational checks and start the generator Perform during operation PMCS Perform after operation PMCS Record actions taken on DA Form 2404 or DA Form 5988 E Perform opera
158. O COMPLY MAY CAUSE PERMANENT INJURY OR DEATH 6 USE EXTREME CAUTION WHEN HANDLING COMPRESSED GASES ACCIDENTAL REMOVAL OF THE REGULATOR COULD TURN THE TANK INTO A POTENTIALLY LETHAL PROJECTILE FAILURE TO COMPLY MAY CAUSE PERMANENT INJURY OR DEATH WARNING 1 DO NOT CUT DIRECTLY ON CONCRETE OR ASPHALT CONCRETE WILL POP AND SPALL AND ASPHALT WILL IGNITE FAILURE TO COMPLY MAY CAUSE IMMEDIATE PERSONAL INJURY OR EQUIPMENT DAMAGE 2 CUTTING PRESSURES ARE SPECIFIC TO TIP SIZE AND VARY GREATLY IMPROPER GAS PRESSURES WILL GREATLY AND ADVERSELY AFFECT THE ABILITY OF THE EQUIPMENT TO CUT AND THE QUALITY OF THE CUT MADE FAILURE TO COMPLY MAY CAUSE IMMEDIATE PERSONAL INJURY OR EQUIPMENT DAMAGE 3 THE ACETYLENE TANK VALVE SHOULD ONLY BE OPENED APPROXIMATELY ONE QUARTER TO ONE HALF TURN TO ALLOW THE TANK TO BE SHUT OFF RAPIDLY IF A MALFUNCTION OCCURS FAILURE TO COMPLY MAY CAUSE IMMEDIATE PERSONAL INJURY OR EQUIPMENT DAMAGE 31 March 2009 STP 5 21P2 SM TG 3 141 Chapter 3 Standards Use the materials provided and safely cut the metal into the shape required Ensure that the cut penetrates through the metal and is smooth enough to prevent the need for excessive grinding Performance Steps 1 Prepare the cutting area and the material to be cut a Inspect and clear the cutting area of any readily combustible material b Position the material to be cut in a safe location c Draw the pattern to be cut on the material 2 Inspect oxyace
159. OF OPERATING EQUIPMENT PERSONNEL MUST WEAR SINGLE HEARING PROTECTION WITHIN A 50 FOOT RADIUS FAILURE TO COMPLY MAY CAUSE PERSONAL INJURY Standards Service the cylinder head of a diesel engine by inspecting and replacing or repairing defective components parts Performance Steps 1 Review maintenance logbooks and historical data for the equipment to verify that the diesel engine cylinder head needs to be serviced 2 Perform lockout and tagout procedures NOTE The following inspections and checks are guidelines and may be done in any order If defective components parts are found replace repair or clean them as necessary 3 Visually inspect the exterior of the cylinder head for obvious faults a Check for a cracked head b Check for loose or missing head bolts c Check for a bad gasket or seal d Check for a broken valve train e Check for a bent valve f Check for a broken rocker assembly 4 Remove the cylinder head according to the manufacturer s literature WARNING SPECIAL CARE SHOULD BE GIVEN WHEN REMOVING THE CYLINDER HEAD BECAUSE IT IS VERY HEAVY SPECIAL LIFTING DEVICES OR AT A MINIMUM TWO PEOPLE 31 March 2009 STP 5 21P2 SM TG 3 135 Chapter 3 Performance Steps SHOULD BE RESPONSIBLE FOR REMOVING THE CYLINDER HEAD WHEN THE CYLINDER HEAD IS REMOVED DO NOT PLACE IT FACE DOWN FAILURE TO COMPLY MAY CAUSE IMMEDIATE PERSONAL INJURY OR EQUIPMENT DAMAGE 5 10 11 12 13 Clean the cylinder head
160. ON NOISE LEVELS IN EXCESS OF 85 DECIBELS EXIST WITHIN A 50 FOOT RADIUS OF OPERATING EQUIPMENT PERSONNEL MUST WEAR SINGLE HEARING PROTECTION WITHIN A 50 FOOT RADIUS FAILURE TO COMPLY MAY CAUSE PERSONAL INJURY Standards Service an external fuel system of a diesel engine by ensuring that system parameters are met without causing injury to personnel or equipment damage Performance Steps 1 Review maintenance logbooks and historical data pertaining to the equipment to verify that the external fuel system needs to be serviced 2 Perform lockout and tagout procedures 3 Shut off fuel supply lines 3 176 STP 5 21P2 SM TG 31 March 2009 MOS Skill Level Tasks Performance Steps 4 Depressurize and drain the affected portion of the system if required for specific system service 5 Locate and determine the type of external tank blivet fuel pod or tanker NOTE The following inspections and checks are guidelines and may be done in any order Replace repair or clean defective components parts as necessary 6 Remove the fuel water separator and strainers for replacement or cleaning 7 Drain the water through the bottom petcocks on aboveground tanks 8 Clean debris from in line strainers located on the inlet side of the pumps 9 Check the fuel system for leaks or faulty components a Check the external tank for leaks b Check the external fuel lines for 1 Secure mounting 2 Deteriorated couplings 3 Loose fittings
161. OOSE CLOTHING FAILURE TO COMPLY MAY CAUSE PERMANENT INJURY OR DEATH 2 ENSURE THAT THE EQUIPMENT IS PROPERLY LOCKED OUT AND TAGGED OUT FAILURE TO COMPLY MAY CAUSE PERMANENT INJURY OR DEATH CAUTION NOISE LEVELS IN EXCESS OF 85 DECIBELS EXIST WITHIN A 50 FOOT RADIUS OF OPERATING EQUIPMENT PERSONNEL MUST WEAR SINGLE HEARING PROTECTION WITHIN A 50 FOOT RADIUS FAILURE TO COMPLY MAY CAUSE PERSONAL INJURY Standards Troubleshoot an engine failure to start by identifying the cause by testing it as specified in the manufacturer s literature for the particular diesel engine Performance Steps NOTE This task follows the assumption that that all relays and fuses are in good working condition 1 Review maintenance logbooks manufacturer s literature and historical data pertaining to the equipment 2 Identify warning lights on the generator set through visual inspection 3 Connect the Caterpillar ET tool and hardware to the engine and run a diagnostic test if the engine is equipped with an electronic troubleshooting system 4 Check the engine starter NOTE Checking the voltage and current draw at the starter eliminates troubleshooting from the battery to the starter a Check the voltage b Perform a current draw test 5 Determine what caused the malfunction a Check for a closed fuel valve b Check fuel filters c Check for slow engine cranking speed d Check for air in the fuel e Check for incorrect fuel grade or poor f
162. ORINATED BIPHENYL PCB FAILURE TO COMPLY MAY CAUSE SKIN AILMENTS REPRODUCTIVE DISORDERS LIVER DISEASE AND OTHER ADVERSE HEALTH CONDITIONS Standards Safely service the oil switch by inspecting and testing it Test the oil switch according to the manufacturer s literature Reinstall or repair the oil switch based on the test results Performance Steps NOTES 1 Conduct tests according to the manufacturer s literature when available Use industry standards when the manufacturer s literature cannot be obtained 2 Microhm or millivolt drop values should not exceed the high levels of the normal range as indicated in the manufacturer s literature If the manufacturer s literature is not available investigate the values that deviate from adjacent poles or similar breakers by more than 50 percent of the lowest value 1 Review danger warning and caution notices 2 Review the manufacturer s literature electrical construction prints and wiring diagrams 3 Perform lockout and tagout procedures 4 Inspect the oil switch condition visually and manually and ensure that the mechanical functions operate smoothly and that there is no physical damage a Clean the unit thoroughly before testing unless as found or as left tests are required b Keep a record of as left and as found operation counter readings if applicable c Inspect the anchorage alignment and grounding d Perform mechanical operator tests according to the manufacturer s l
163. OSPHERIC CONDITIONS ARE TESTED AND FOUND TO BE IN COMPLIANCE WITH OCCUPATIONAL SAFETY AND HEALTH ADMINISTRATION OSHA STANDARDS FAILURE TO COMPLY MAY CAUSE PERMANENT INJURY OR DEATH 3 NEVER ENTER A MANHOLE WITHOUT AN ASSISTANT LOCATED OUTSIDE THE MANHOLE FAILURE TO COMPLY MAY CAUSE PERMANENT INJURY OR DEATH 4 DO NOT ENTER A MANHOLE TO PUMP OUT WATER LOWER THE PUMP OR HOSE INTO THE HOLE AND REMOVE STANDING WATER FAILURE TO COMPLY MAY CAUSE PERMANENT INJURY OR DEATH CAUTION USE PROPER LIFTING PROCEDURES FAILURE TO COMPLY MAY CAUSE PERSONAL INJURY NOTE Failure to verify whether the manhole is a permit or nonpermit confined space may cause personnel to be subject to fines or legal action Standards Prepare a manhole for safe entry by ensuring that traffic barriers are strategically placed the cover is properly removed water is removed gas detection is performed ventilation procedures are performed and the extraction system for confined space entry and rescue is in the correct position to allow for extraction in the event of an injury Performance Steps 1 Ensure that tools and equipment are in proper working condition 2 Conduct a safety briefing 3 Set up traffic control equipment 4 Remove the manhole cover 5 Test the air quality tester for proper operation NOTES 1 Due to many different manufacturers it is essential that the manufacturer s instructions for the air quality tester being used are referenced for
164. OUS AREAS FAILURE TO COMPLY MAY CAUSE PERMANENT INJURY OR DEATH 3 REMOVE RINGS NECKLACES OTHER JEWELRY AND LOOSE CLOTHING FAILURE TO COMPLY MAY CAUSE PERMANENT INJURY OR DEATH NOTE All power plant equipment is not the same and may function differently depending on the make model or manufacturer The troubleshooting steps are similar but may vary Always consult the applicable manufacturer s literature for each piece of equipment Standards Perform power plant BDAR by identifying the cause s of the damage and completing the BDAR without causing personal injury or equipment damage Initiate the additional actions required as a result of the inspection Performance Steps 1 Review danger warning and caution notices 2 Review the manufacturer s literature electrical construction prints and wiring diagrams 3 Review maintenance logbooks and historical data pertaining to the equipment 4 Perform lockout and tagout procedures 5 Perform an equipment inspection a Locate the damaged components parts b Test the salvageable components parts to ensure serviceability 6 Determine the extent of the equipment damage a Determine if the damage is minor enough to repair on the spot b Determine if the damage warrants equipment recovery at a maintenance facility if possible c Determine if the damage warrants abandonment or destruction of the equipment in place 7 Perform expedient repairs a Use substitute components part
165. Oa A O 12 Reviewed danger warning and caution notices Reviewed the manufacturer s literature electrical construction prints and wiring diagrams Reviewed the maintenance logbook and historical data pertaining to equipment Identified the location of the fault Checked the fuel system Checked the governor for proper operation Checked air filters for restrictions Checked the engine electrical components parts Tested the engine to ensure that the suspected fault was the cause of the malfunction Repaired the fault if possible 11 Recorded actions taken on DA Form 2404 or DA Form 5988 E and the maintenance logbook Ensured that the items listed in the conditions were properly cleaned and stored Evaluation Guidance Score the Soldier GO if all measures are passed P Score the Soldier NO GO if any measure is failed F If the Soldier fails any measure show him how to do it correctly References Required Related DA FORM 2404 DA FORM 5988 E 3 62 STP 5 21P2 SM TG 31 March 2009 MOS Skill Level Tasks Troubleshoot a Generator s Improper Voltage Output 052 244 2135 Conditions As a power plant operator in a tactical or nontactical environment when the generator s output voltage is not within the correct parameters you are given the corresponding technical manual or the manufacturer s literature a maintenance logbook electrical construction prints wiring diagrams and a general
166. P Score the Soldier NO GO if any measure is failed F If the Soldier fails any measure show him how to do it correctly References Required Related FM 3 34 480 3 120 STP 5 21P2 SM TG 31 March 2009 MOS Skill Level Tasks Service a Digital Synchronizer and Load Controller DSLC 052 207 2123 Conditions As a power station instrument technician in a tactical or nontactical environment during scheduled maintenance or if the DSLC is suspected of being defective you are given a lockout and tagout kit a multimeter wiring diagrams a relay test set with manual an oscilloscope a handheld DSLC programmer an electronic tool kit a DSLC operations and calibration manual wiring diagrams maintenance logbooks and the applicable manufacturer s literature with schematics DANGER 1 ENSURE THAT POWER TO THE CONTROLLER IS DISCONNECTED BEFORE SERVICING APPLY SAFE CLEARANCE PROCEDURES TO ASSOCIATED CIRCUITS FAILURE TO COMPLY MAY CAUSE PERMANENT INJURY OR DEATH 2 ENSURE THAT CURRENT TRANSFORMERS SUPPLYING CURRENT TO THE CONTROLLER ARE DE ENERGIZED AND ELECTRICALLY SHORTED BEFORE SERVICING THE CONTROLLER IF ENERGIZED AN OPEN CURRENT TRANSFORMER CIRCUIT WILL PRODUCE VERY HIGH VOLTAGES FAILURE TO COMPLY MAY CAUSE PERMANENT INJURY OR DEATH 3 ENSURE THAT POTENTIAL TRANSFORMERS FEEDING THE CONTROLLER ARE DE ENERGIZED BEFORE SERVICING THE CONTROLLER FAILURE TO COMPLY MAY CAUSE PERMANENT INJURY OR DEATH AND EQUIPMENT DAMAGE 4 REMO
167. PMENT REQUIRED FOR INSPECTIONS IN HAZARDOUS AREAS FAILURE TO COMPLY MAY CAUSE PERMANENT INJURY OR DEATH Standards Perform a facility load assessment to obtain the estimated load Determine DA Form 2702 information the means of connection and other mission specific requirements Performance Steps NOTE Some performance steps will be omitted when conducting an emergency generation load assessment 1 Establish a point of contact 2 Determine the original use of the facility 3 Determine the intended use of the facility NOTE If conducting an emergency generation load assessment and not calculating a load for permanent or semipermanent usage skip steps 4 through 14 4 Extract data from specific sources a Extract data from electrical plans b Extract data from construction specifications c Extract data from equipment specifications d Extract data from on site visual inspections 5 Define the four critical load areas a Define the critical load areas in general lighting b Define the critical load areas in receptacle outlets c Receptacle outlets d Define the critical load areas in other major appliances or loads e Other major appliances or loads f Define the critical load areas in motor loads g Motor loads 6 Determine the lighting load by obtaining values from blueprints specifications or direct visual inspection NOTE Lighting outlets shown on the drawings are listed in the specifications along with the
168. Perform Generator SetHourly Ches m m 0522442102 Splice a Medium Voltage Power Cabe m m 052 244 2106 Perform Preventive Maintenance on Safety Equipment 052 244 2109 Perform Operator Preventive Maintenance Checks and Services PMCS on Test Measurement and Diagnostic Equipment TMDE 052 244 2111 Troubleshoot an Engine Failure to Stop 052 244 2112 Perform Lockout and Tagout Procedures 052 244 2114 Operate a Mobile Electric Power MEP 810A or B AIT AN 2 Generator 052 244 2115 Operate a Mobile Electric Power MEP 012 or 208 AIT AN 2 Generator 052 244 2116 Operate a Mobile Electric Power MEP 029 Generator UNIT 052 244 2117 Perform Preventive Maintenance Checks and Services AIT AN 2 PMCS on a Mobile Electric Power MEP 810A or B Generator 052 244 2118 Perform Preventive Maintenance Checks and Services PMCS on a Mobile Electric Power MEP 012 or 208 Generator 052 244 2121 Read an Electrical One Line Diagram AIT 052 244 2123 Operate a Multiunit Power Plant AIT 052 244 2124 Install a Nonorganic Generator 2 2 STP 5 21P2 SM TG 31 March 2009 Trainer s Guide Table 2 1 MOS 21P2 Critical Tasks continued Task Number Title Training Sust Sust Location Tng Tng SL Freq 052 244 2125 Operate a Nonorganic Generator UNIT 2 052 244 2127 Identify the Hazards of a Power Generation and AIT AN Distribution System 052 244 2128 Troubleshoot a Direct Current DC Voltage System S 052 244 2129 Troublesh
169. Performance Measures GO NO GO 1 2 Reviewed danger warning and caution notices Reviewed the manufacturer s literature electrical construction prints and wiring diagrams Performed lockout and tagout procedures Inspected the oil switch condition visually and manually and ensured that the 3 202 STP 5 21P2 SM TG 31 March 2009 MOS Skill Level Tasks Performance Measures 10 11 12 13 14 mechanical functions operated smoothly and that there was no physical damage Performed resistance measurements on the bolted connections using a low resistance ohmmeter and ensured that the bolt torque levels matched the manufacturer s specifications Removed a sample of the insulating oil according to ASTM D923 Performed a contact resistance test and compared the contact resistances of the electrical connections to the values of similar connections according to the manufacturer s literature Performed insulation resistance tests pole to pole pole to ground and across the open poles Ensured that the test values were not less than 1 000 megohms at a DC test voltage of 2 500 volts minimum unless otherwise stated in the manufacturer s literature Performed an insulation resistance test on the control wiring at 1 000 volts DC minimum of 2 megohms according to the manufacturer s literature and followed the manufacturer s recommendations for units with solid state
170. Performed an overpotential test according to the manufacturer s literature and ensured that the insulation withstood the applied overpotential test voltage Verified that the trip close trip free and antipump functions operated properly and ensured that the minimum pickup for the trip and close coils conformed to the specifications in the manufacturer s literature Tripped the circuit breaker by operating each protective device Closed out lockout and tagout procedures by removing locking and tagging devices Ensured that the items listed in the conditions were properly cleaned and stored Evaluation Guidance Score the Soldier GO if all measures are passed P Score the Soldier NO GO if any measure is failed F If the Soldier fails any measure show him how to do it correctly References Required Related DA FORM 2404 NESC NETA TM 9 6115 604 12 3 238 STP 5 21P2 SM TG 31 March 2009 MOS Skill Level Tasks Identify Electrical Faults Using an Infrared IR Camera 052 206 2133 Conditions As a power station electrician in a tactical or nontactical environment during a maintenance interval you are given the electrical equipment to be tested a general mechanic s tool box an IR or digital camera the appropriate manufacturer s literature applicable software and a computer DANGER KNOW THE SYSTEM VOLTAGES AND MAINTAIN PROPER SAFE DISTANCES FROM THE ENERGIZED EQUIPMENT FAILURE TO COMPLY MAY CAUSE PERMANENT IN
171. RATING EQUIPMENT ALWAYS WEAR SINGLE HEARING PROTECTION WITHIN A 50 FOOT RADIUS OF OPERATING EQUIPMENT FAILURE TO COMPLY MAY CAUSE PERSONAL INJURY Standards Operate the multiunit power plant according to the TMs to ensure that the system parameters are met without causing injury or equipment damage Operate the power plant in an isolated mode or parallel to a power grid while balancing the load and maintaining system voltage amperage kilowatts and power factor limitations Performance Steps 1 Perform preoperational PMCS 2 Start the units and conduct preoperation checks 3 Adjust the frequency adjustment rheostat for a frequency meter reading of 50 or 60 hertz 4 Adjust the voltage adjustment rheostat for an alternating current AC reading of the desired value 5 Perform isolated or parallel operations Adjust the incoming frequency of the generator to the approximate frequency of the bus Adjust the incoming voltage of the generator to the approximate voltage of the bus Energize a synchronizing circuitry Ensure that phase rotation is going slow in the fast direction Adjust the incoming frequency of the generator to a frequency that is slightly higher than that of the bus f Adjust the incoming voltage of the generator to a voltage that is slightly higher than that of the bus g Close the circuit breaker at a synchronous moment to assume the load h De energize the synchronizing circuit Stabilize the inc
172. RED FOR INSPECTIONS IN HAZARDOUS AREAS FAILURE TO COMPLY MAY CAUSE PERMANENT INJURY OR DEATH 3 REMOVE RINGS NECKLACES OTHER JEWELRY AND LOOSE CLOTHING FAILURE TO COMPLY MAY CAUSE PERMANENT INJURY OR DEATH Standards Troubleshoot an AC control voltage circuit by safely and accurately identifying locating and correcting the malfunction in the circuit without causing injury or equipment damage Performance Steps 1 Review danger warning and caution notices Review the manufacturer s literature electrical construction prints and wiring diagrams Review the maintenance logbook and historical data pertaining to the equipment Isolate the system circuits that need troubleshooting Perform lockout and tagout procedures O a A W N Identify the symptoms of the problem a Check for unusual sounds b Identify physical abnormalities c Check for unusual smells 7 Locate the fault or problem a Determine which portions of the circuit are working correctly Eliminate circuits or portions of circuits to allow smaller more isolated looks at the fault or problem b Verify that circuit components parts function properly c Identify faulty components parts 8 Repair or replace defective components parts when possible 9 Verify that the fault was corrected 10 Close out lockout and tagout procedures by removing locking and tagging devices 11 Perform a functions check on the AC control voltage circuit 12 Ensure that
173. RESULT IN EQUIPMENT DAMAGE NOTES 1 All equipment is not the same and may function differently depending on the make model or manufacturer The troubleshooting steps are similar but may vary Always consult the applicable manufacturer s literature for each piece of equipment 2 Defective equipment should be repaired or replaced immediately and before use 3 Conduct tests according to the manufacturer s literature when available Use industry standards when the manufacturer s literature cannot be obtained Standards Troubleshoot a nonorganic prime mover that fails to maintain the normal operating speed Identify the fault and test the fault to verify that it is the cause of the malfunction 3 90 STP 5 21P2 SM TG 31 March 2009 MOS Skill Level Tasks Performance Steps 1 2 3 4 5 Review danger warning and caution notices Review the appropriate technical manuals construction prints wiring diagrams manufacturer s literature or industry standards maintenance logbook and historical data pertaining to the equipment Ensure that the PPE has been correctly tested and is fully operable Inspect the tools and testing equipment for serviceability Determine which systems are critical to the operation NOTE This list is meant to be a guideline and is not all inclusive 6 Check the intake system Check the exhaust system Check the lubrication system Check the cooling system Check the gove
174. RGIZED LOCKED OUT AND TAGGED OUT BEFORE SERVICING THE CONTROLLER FAILURE TO COMPLY MAY CAUSE PERMANENT INJURY OR DEATH WARNING ENSURE THAT THE VALVE IS IN THE OPEN POSITION WITH THE VALVE SEALING FACE BACKED OFF ITS SEAT BEFORE TIGHTENING THE VALVE DAMAGE TO THE VALVE WILL RESULT IF THE BONNET IS TIGHTENED WITH THE VALVE SEATED IN THE CLOSED POSITION Standards Service a piping system to ensure that fluid distribution systems operate within established standards Performance Steps 1 Review maintenance logbooks and historical data pertaining to the equipment to verify that the piping system needs to be serviced 2 Ensure that service tools and parts are on hand before servicing the system a Ensure that the appropriate TMs are on hand b Ensure that a general mechanic s tool box is on hand c Ensure that specialized piping system maintenance and repair tools are on hand d Ensure that the replacement fluids needed to put the system back into service when maintenance is complete are on hand 3 Perform safety requirements before servicing or repairing the piping system a Shut down the section to be serviced or repaired from the rest of the system b Isolate the section to be serviced or repaired from the rest of the system c Perform lockout and tagout procedures d Depressurize and drain the affected portion of the system 4 Inspect pump or compressor drive mechanisms for signs of loose mounting bolts deteriorated coupli
175. RNING 1 NOISE LEVELS IN EXCESS OF 85 DECIBELS EXIST WITHIN A 50 FOOT RADIUS OF OPERATING EQUIPMENT PERSONNEL MUST WEAR SINGLE HEARING PROTECTION WITHIN A 50 FOOT RADIUS FAILURE TO COMPLY MAY CAUSE PERSONAL INJURY 2 WHEN DISCONNECTING BATTERY CABLES ALWAYS DISCONNECT THE NEGATIVE TERMINAL FIRST WHEN RECONNECTING CONNECT THE POSITIVE TERMINAL FIRST FAILURE TO COMPLY MAY RESULT IN SPARKING AND CONSEQUENT BATTERY EXPLOSION AND MAY CAUSE IMMEDIATE INJURY OR EQUIPMENT DAMAGE 3 DO NOT PERFORM MAINTENANCE ON THE ENGINE EXHAUST SYSTEM WHILE THE SYSTEM IS HOT SERIOUS BURNS CAN RESULT FAILURE TO COMPLY MAY CAUSE IMMEDIATE INJURY OR EQUIPMENT DAMAGE CAUTION REPLACE FILTER ELEMENTS IN PAIRS TO PREVENT THE DETERIORATION OF REPLACEMENT PARTS REPEATED FAILURE TO FOLLOW THE CORRECT PROCEDURES MAY CAUSE EQUIPMENT DAMAGE Standards Troubleshoot a diesel engine for loss of power by identifying what caused the loss of power Test the engine to verify what caused the malfunction annotate the problem in the maintenance logbook Performance Steps 1 Review maintenance logbooks and historical data pertaining to the equipment 2 Determine what caused the malfunction Check for fuel flow restriction Check for high fuel temperature Check for air in the fuel system Check for a plugged fuel filter Check for the incorrect fuel grade or poor quality fuel Check for incorrect timing Check for positive crankcase pressure
176. ROUND THE CIRCUIT FOR TWICE THE AMOUNT OF TIME IT WAS TESTED BEFORE HANDLING FAILURE TO COMPLY MAY CAUSE PERMANENT INJURY OR DEATH 4 A VOLTAGE DETECTOR SHOULD BE USED TO ENSURE THAT THE CABLES ARE NOT ENERGIZED THERE MUST BE NO MATERIALS SUCH AS A LEAD SHEATH THAT ACTS AS A SHIELD BETWEEN THE TESTER AND THE CONDUCTORS OF THE CIRCUIT BEING TESTED FAILURE TO TEST THE CABLES MAY CAUSE PERMANENT INJURY OR DEATH WARNING THIS TASK SHOULD NOT BE PERFORMED ON EQUIPMENT CONTAINING POLYCHLORINATED BIPHENYL PCB FAILURE TO COMPLY MAY CAUSE SKIN AILMENTS REPRODUCTIVE DISORDERS LIVER DISEASE AND OTHER ADVERSE HEALTH CONDITIONS RESULTING IN PERMANENT INJURY OR DEATH Standards Perform an insulation resistance test by determining the condition of the insulation based on the test results and according to the applicable manufacturer s literature or industry standards Repair or replace the equipment if necessary Retest repaired or replaced equipment Performance Steps 1 Review danger warning and caution notices 2 Perform lockout and tagout procedures on the system where the equipment is installed 3 Use a voltage detector to verify that there is no voltage at connection points 4 Install safety grounds 5 Prepare an as found wiring diagram that shows the connection configuration used to attach the equipment to the system 6 Mark cable ends to identify their connection points and designated phases NOTE If as found results are neede
177. RS FEEDING THE RELAY ARE DE ENERGIZED BEFORE SERVICING THE METER FAILURE TO COMPLY MAY CAUSE PERMANENT INJURY OR DEATH AND EQUIPMENT DAMAGE 4 REMOVE RINGS NECKLACES OTHER JEWELRY AND LOOSE CLOTHING FAILURE TO COMPLY MAY CAUSE PERMANENT INJURY OR DEATH NOTE Keep the work area neat and organized Keep the meter and equipment stable Failure to comply may lead to unreliable test readings Standards Service the timing relay circuit safely by testing and calibrating it and then reinstalling or replacing the relay Calibrate and reinstall or replace the relay based on test results Performance Steps 1 Review danger warning and caution notices before proceeding Review the manufacturer s literature with schematics and wiring diagrams Review maintenance logbooks and historical data pertaining to the equipment Identify which circuit needs to be tested using schematics Perform lockout and tagout procedures O oa A W N Test the circuit for voltage presence a Proceed to step 7 if there is no voltage present b Stop if there is voltage present and perform the following checks until voltage is no longer present 1 Check the schematics for proper identification of the circuit 2 Check for back fed circuits 3 Check for the proper use of safe clearance procedures 7 Remove the timing relay from the base according to the manufacturer s literature 8 Identify relay contacts a Identify the main coil b Identif
178. RY AND LOOSE CLOTHING FAILURE TO COMPLY MAY CAUSE PERMANENT PERSONAL INJURY OR DEATH WARNING 1 DO NOT ATTEMPT TO SERVICE OR MAKE ADJUSTMENTS CONNECTIONS OR RECONNECTIONS OF WIRES OR CABLES UNTIL THE GENERATOR SET IS SHUT DOWN AND COMPLETELY DE ENERGIZED FAILURE TO COMPLY MAY CAUSE IMMEDIATE PERSONAL INJURY OR EQUIPMENT DAMAGE 2 ENSURE THAT THE STRAINER IS ISOLATED FROM THE FUEL SUPPLY PRESSURE TO PREVENT AN OVERFLOW WHEN THE STRAINER IS OPENED ENSURE THAT CONTAINMENT EQUIPMENT IS AT THE STRAINER TO CATCH THE MINOR AMOUNT OF FUEL AND DEBRIS THAT IS RELEASED FAILURE TO COMPLY MAY CAUSE IMMEDIATE PERSONAL INJURY OR EQUIPMENT DAMAGE CAUTION NOISE LEVELS IN EXCESS OF 85 DECIBELS EXIST WITHIN A 50 FOOT RADIUS OF OPERATING EQUIPMENT PERSONNEL MUST WEAR SINGLE HEARING PROTECTION WITHIN A 50 FOOT RADIUS FAILURE TO COMPLY MAY CAUSE PERSONAL INJURY Standards Service an internal fuel system for a diesel engine by ensuring that system parameters are met without causing personnel injury or equipment damage Performance Steps 1 Review maintenance logbooks and historical data pertaining to the equipment to verify that the internal fuel system needs to be serviced 2 Perform lockout and tagout procedures 3 Shut off fuel supply lines 4 Depressurize and drain the affected portion of the system if required for a specific system service 5 Drain the water from the fuel water separator as applicable CAUTION FAILURE TO FOLLOW THE
179. Repair or replace defective components parts when possible 10 Verify that the fault was corrected 11 Close out the lockout and tagout procedures by removing locking and tagging devices 12 Put the system back into service 3 50 STP 5 21P2 SM TG 31 March 2009 MOS Skill Level Tasks Performance Steps 13 Ensure that the items listed in the conditions are properly cleaned and stored 14 Ensure that deficiencies and troubleshooting procedures are recorded in the maintenance logbook Evaluation Preparation Setup Provide the Soldier with the items listed in the conditions Give the Soldier a safety briefing before starting the test and ensure that safety precautions are followed Prepare the testing area and equipment in advance to ensure that task standards can be met Brief Soldier Direct the Soldier to troubleshoot a DC voltage system Performance Measures GO NO GO 1 Reviewed danger warning and caution notices 2 Reviewed the manufacturer s literature electrical construction prints and wiring diagrams Reviewed the maintenance logbook and historical data pertaining to equipment Isolated the system circuits that needed troubleshooting Performed lockout and tagout procedures Identified the symptoms of the problem Reviewed the references Located the fault or problem Repaired or replaced defective components parts when possibl
180. S FAILURE TO COMPLY MAY CAUSE PERMANENT INJURY OR DEATH 2 DO NOT TOUCH EXPOSED ELECTRICAL CONNECTIONS WHILE A POWER SOURCE IS CONNECTED TO THE CIRCUIT BREAKER FAILURE TO COMPLY MAY CAUSE PERMANENT INJURY OR DEATH 3 REMOVE RINGS NECKLACES OTHER JEWELRY AND LOOSE CLOTHING FAILURE TO COMPLY MAY CAUSE PERMANENT INJURY OR DEATH 4 THE INSULATION TESTER PRODUCES HIGH VOLTAGE DO NOT TOUCH THE CABLE BEING TESTED OR THE TEST LEADS REMOVE THE POWER AND DISCHARGE AND GROUND THE CIRCUIT FOR TWICE THE AMOUNT OF TIME IT WAS TESTED BEFORE HANDLING FAILURE TO COMPLY MAY CAUSE PERMANENT INJURY OR DEATH Standards Safely service an air magnetic circuit breaker by inspecting and testing the circuit breaker according to the manufacturer s literature If the manufacturer s literature is not available use the industry standards Reinstall or repair the circuit breaker based on the test results Performance Steps NOTE Conduct tests according to the manufacturer s literature Use industry standards when the manufacturer s literature cannot be obtained 1 Review danger warning and caution notices 2 Review the manufacturer s literature and wiring diagrams 3 Review maintenance logbooks and historical data pertaining to the equipment 4 Perform lockout and tagout procedures 5 Keep a record of as left and as found operation counter readings 6 Inspect the condition of the circuit breaker visually and manually NOTE Microhm or millivolt
181. S III LEAK SHOULD NOT BE OPERATED AND MUST BE REPAIRED OR SENT FOR REPAIR IMMEDIATELY FAILURE TO COMPLY MAY RESULT IN EQUIPMENT DAMAGE NOTES 1 All equipment is not the same and may function differently depending on the make model or manufacturer The troubleshooting steps are similar but may vary Always consult the applicable manufacturer s literature for each piece of equipment 2 Conduct tests should be conducted according to the manufacturer s literature when available Use industry standards when the manufacturer s literature cannot be obtained 3 Repair or replace defective components parts before use Standards Service a nonorganic prime mover by inspecting testing cleaning repairing or replacing system components parts 31 March 2009 STP 5 21P2 SM TG 3 87 Chapter 3 Performance Steps 1 2 3 4 5 Review danger warning and caution notices Review the appropriate technical manuals construction prints wiring diagrams manufacturer s literature or industry standards maintenance logbook and historical data pertaining to the equipment Ensure that the PPE has been correctly tested and is fully operable Inspect the tools and testing equipment for serviceability Determine which systems are due for service NOTE This list is meant to be a guideline and is not all inclusive Check the intake system Check the exhaust system Check the lubrication system Check the cooling system
182. S INSTALLED IN THE BLOCK SEVERE CRANKSHAFT DAMAGE WILL OCCUR FAILURE TO COMPLY MAY CAUSE EQUIPMENT DAMAGE Standards Replace a diesel engine piston assembly safely and as specified in the applicable manufacturer s literature Performance Steps 1 Perform lockout and tagout procedures 2 Remove the cylinder head 3 Remove inspection covers 31 March 2009 STP 5 21P2 SM TG 3 161 Chapter 3 Performance Steps O Oo N O ON A 1 20 Remove the piston assembly Disassemble the piston and connecting rod Remove connecting rod bearings Remove main bearings Remove the cylinder liner and seals Inspect the piston and connecting rod assembly Inspect connecting rod bearings 11 12 13 14 15 16 17 18 19 Inspect the crankshaft journal Inspect main bearings Inspect the cylinder liner and seals Repair defective parts Replace parts that cannot be repaired Reassemble the piston and connecting rod Close out lockout and tagout procedures by removing locking and tagging devices Operate the prime mover and check for proper operation Record actions taken on DA Form 2404 or DA Form 5988 E and maintenance logbooks Ensure that the items listed in the conditions are properly cleaned and stored Evaluation Preparation Setup Provide the Soldier with the items listed in the conditions Give the Soldier a safety briefing before starting the test and ensure that safety precautions are
183. SE PERMANENT INJURY OR DEATH 3 REMOVE RINGS NECKLACES OTHER JEWELRY AND LOOSE CLOTHING FAILURE TO COMPLY MAY CAUSE PERMANENT INJURY OR DEATH Standards Safely service a potential transformer by inspecting and testing it according to the manufacturer s literature and record the results Reinstall or repair the potential transformer based on the test results Performance Steps NOTE Tests should be conducted according to the manufacturer s literature When the manufacturer s literature is not available industry standards should be used 1 Review danger warning and caution notices 2 Review the manufacturer s literature and wiring diagrams 3 Review maintenance logbooks and historical data pertaining to the equipment 4 Perform lockout and tagout procedures 5 Inspect the condition of the potential transformer visually and manually to ensure that mechanical functions operate smoothly and that there is no physical damage to the oil switch O Test the fuses 7 Perform individual continuity checks on primary and secondary windings of the transformer to ensure that the winding resistance is consistent with the manufacturer s specifications 8 Perform an insulation resistance test on the transformer at a test voltage recommended in the manufacturer s literature a Ensure that insulation resistance readings are a minimum of 20 megohms from the primary lead to the ground terminal b Ensure that insulation resistance
184. STP 5 21P2 SM TG Soldier s Manual and Trainer s Guide MOS 21P Prime Power Production Specialist Skill Level 2 March 2009 DISTRIBUTION RESTRICTION Approved for public release distribution is unlimited HEADQUARTERS DEPARTMENT OF THE ARMY This publication is available at Army Knowledge Online lt www us army mil gt and the General Dennis J Reimer Training and Doctrine Digital Library at lt www train army mil gt STP 5 21P2 SM TG SOLDIER TRAINING HEADQUARTERS PUBLICATION DEPARTMENT OF THE ARMY No 5 21P2 SM TG Washington DC 31 March 2009 Soldier s Manual and Trainer s Guide MOS 21P Prime Power Production Specialist Skill Level 2 Skill Level 2 TABLE OF CONTENTS PAGE Table of Contents iiacicciescsccsssecticcciteeteeceeline cdevenieceeesttecseveeieeeeeniueceunetieceee nie csivnnieecdd na ieceieiectewnuecsivaieedeenies i ProfaCE sarson kunnan AR AAEN AA AAAA RAA AA OERA AAAA PARER AAAA RAA AAEE ARAT AAAA v Chapter 1 Introduction sissioni araa aR Kar aa a aaa a Ea aa EEEN EEEN RES 1 1 Chapter 2 Trainers Guide ijesa a aa aE iene aO aE a ENEE REEN 2 1 Chapter 3 MOS Skill Level Tasks cccceeeeeceeeeeeeeeeeeenee ener ee senseeaneeseeeeee seas eaeeeseseeeseasseaneeseseneeeeseeanes 3 1 Skill Level 2 Subject Area 1 Overall 21P20 Tasks 052 244 2101 Perform Generator Set Hourly CheCKS 0 eccceceeeeeeeeeneee ee eeneeeeeteeeeeeetieeeeetieeeeetea 3 1 052 244 2102 Splice a Medium Voltage Power Cable
185. STRUCTIONS FAILURE TO COMPLY MAY CAUSE PERMANENT INJURY OR DEATH Standards Perform preventive maintenance on the safety equipment using the materials provided Remove all unsafe equipment from the inventory Performance Steps NOTE All safety equipment will be inspected and maintained as specified in the equipment technical manual and the manufacturer s literature 1 Inspect the hot sticks a Check for valid calibration stamps b Inspect for excessive wear to the wood or fiberglass 2 Inspect the grounding sticks a Check for valid calibration stamps b Inspect for excessive wear to the wood or fiberglass c Check for good electrical connections to the grounding cables 3 Inspect the ground clusters a Check for valid calibration stamps b Inspect for excessive wear c Inspect for obvious damage d Check for good electrical connections on interconnecting cables 4 Maintain the rubber gloves a Check for valid calibration stamps b Perform user tests by rolling the gloves and feeling for air leaks c Ensure that the leather liners are serviceable and free of holes 5 Maintain the rubber sleeves a Check for valid calibration stamps b Submit for scheduled electrical testing c Inspect for holes or cracking 6 Maintain the rubber blankets and mats a Check for valid calibration stamps b Submit for scheduled testing c Inspect for holes or cracking 7 Inspect the flash suits a Check for valid calibr
186. T OF CONTROL FAILURE TO COMPLY MAY CAUSE DEATH PERMANENT INJURY OR EQUIPMENT DAMAGE 2 NEVER POSITION YOURSELF UNDER A SUSPENDED LOAD FAILURE TO COMPLY MAY CAUSE PERMANENT INJURY OR DEATH Standards Supervise the loading and unloading of utility poles by ensuring that the poles are loaded and unloaded safely Performance Steps 1 Review danger warning and caution notices before proceeding 2 Ensure that PPE is correctly tested and fully mission capable 3 Complete DA Form 2702 for the tools and equipment necessary to perform this task Inspect tools and rigging equipment for serviceability Develop a plan for obtaining nonorganic tools and the equipment necessary to perform the mission Issue a safety briefing that highlights safety precautions and the concept of the operation Assign personnel positions and ensure that they understand their role in accomplishing this task Ensure that equipment brakes are set and wheels are chocked Ensure that utility poles are loaded and unloaded safely 1 O Oo N OD ON A Ensure that the items listed in the conditions are properly cleaned and stored Evaluation Preparation Setup Provide the Soldier with the items listed in the conditions Give the Soldier a safety briefing before starting the test and ensure that safety precautions are followed Prepare the testing area and equipment in advance to ensure that task standards can be met Brief Soldier Direct the Soldier to s
187. T RADIUS OF OPERATING EQUIPMENT PERSONNEL MUST WEAR SINGLE HEARING PROTECTION WITHIN A 50 FOOT RADIUS FAILURE TO COMPLY MAY CAUSE IMMEDIATE PERSONAL INJURY Standards Service an electronic governor Determine if the electronic governor meets specifications in the appropriate TM or manufacturer s literature If the electronic governor fails to meet specifications perform adjustments or replacements necessary to bring the electronic governor to a serviceable condition Performance Steps 1 Review danger warning and caution notices Review the manufacturer s literature and wiring diagrams Review maintenance logbooks and historical data pertaining to the equipment Identify the circuit or device being tested Perform lockout and tagout procedures Inspect electrical connections for cleanness correctness and tightness Inspect the magnetic pickup for tightness proper clearance and proper voltage oN DOO A OO N Check for proper voltages on related electronic governor circuitry according to the TM or manufacturer s literature 9 Test the governor system components parts according to the TM or manufacturer s literature 10 Repair faulty electronic governor system components parts if possible 11 Replace faulty electronic governor system components parts that cannot be repaired 12 Adjust the electronic governor for gain stability frequency and droop 13 Close out lockout and tagout procedures by removing locking and t
188. UCTIONS FAILURE TO PERFORM REQUIRED MAINTENANCE MAY CAUSE EQUIPMENT DAMAGE AND PERMANENT INJURY OR DEATH Standards Inspect hot line equipment ensuring that maintenance is performed according to the applicable manufacturer s literature with maintenance instructions DA Form 2404 and applicable SOPs Remove unsafe equipment from the inventory Performance Steps 1 Inspect hot sticks a Check for valid calibration stamps b Inspect for excessive wear to the fiberglass 2 Inspect grounding sticks a Check for valid calibration stamps b Inspect for excessive wear to the fiberglass c Check for good electrical connections to grounding cables 3 Inspect ground clusters a Check for valid calibration stamps b Inspect for excessive wear c Inspect for obvious damage d Check for good electrical connections on interconnecting cables 4 Inspect rubber gloves a Check for valid calibration stamps b Perform user tests by filling the gloves with air and rolling them while feeling for air leaks and cracks c Ensure that leather liners are serviceable and free of holes 5 Inspect rubber sleeves a Check for valid calibration stamps b Perform user tests by rolling the rubber sleeves while feeling for holes and cracks 6 Inspect rubber blankets and mats a Check for valid calibration stamps b Perform user tests by rolling the rubber blankets and mats while looking for holes and cracks 7 Inspect flash suits a Che
189. ULD ONLY BE PERFORMED BY QUALIFIED PERSONNEL WHO ARE KNOWLEDGEABLE IN THE INSTALLATION AND MAINTENANCE OF A SWITCHGEAR AND POWER EQUIPMENT AND THEIR ASSOCIATED HAZARDS FAILURE TO COMPLY MAY CAUSE PERMANENT INJURY OR DEATH 2 DO NOT TOUCH EXPOSED ELECTRICAL CONNECTIONS WHILE A POWER SOURCE IS CONNECTED TO THE SWITCH FAILURE TO COMPLY MAY CAUSE PERMANENT INJURY OR DEATH 3 REMOVE RINGS NECKLACES OTHER JEWELRY AND LOOSE CLOTHING FAILURE TO COMPLY MAY CAUSE PERMANENT INJURY OR DEATH Standards Safely service the nonaerial air switch by inspecting and testing it according to the manufacturer s literature Repair the nonaerial air switch based on the test results Performance Steps NOTES 1 Conduct tests according to the manufacturer s literature when available Use industry standards when the manufacturer s literature cannot be obtained 2 Microhm or millivolt drop values should not exceed the high levels of the normal range as indicated in the manufacturer s literature If the manufacturer s literature is not available investigate the values that deviate from adjacent poles or similar breakers by more than 50 percent of the lowest value 1 Review danger warning and caution notices 2 Review the manufacturer s literature electrical construction prints and wiring diagrams 3 Perform lockout and tagout procedures 4 Perform visual and manual inspections of the nonaerial air switch to identify and correct deficiencies Clea
190. ULIC PUMP KEEP FLUID LEVELS BETWEEN THE RED AND BLACK LINES ON THE SIGHT GAUGE FAILURE TO COMPLY MAY CAUSE EQUIPMENT DAMAGE 3 HYDRAULIC FLUIDS MAY BE HOT FAILURE TO WEAR PPE MAY CAUSE SERIOUS INJURIES TO UNPROTECTED SKIN OR EYES Standards Service the hydraulic system safely by ensuring that proper lockout and tagout procedures are followed inspecting the entire system and performing scheduled maintenance Performance Steps 1 Review maintenance logbooks and historical data pertaining to the equipment to verify that the hydraulic system needs to be serviced 2 Ensure that service items are on hand before servicing the system a Ensure that the applicable manufacturer s literature is on hand b Ensure that a general mechanic s tool kit is on hand c Ensure that filters are on hand d Ensure that the correct fluid for the plant application is on hand 3 Perform safety requirements before servicing the system a Shut down the unit and isolate it from the rest of the system b Perform lockout and tagout procedures 4 Remove unit side panels a Remove the large panel and store it away from the work area b Remove the left and right small panels of the radiator and aftercooler 5 Inspect the hydraulic system by tracing the entire system and checking for leaks loose connections 3 164 STP 5 21P2 SM TG 31 March 2009 MOS Skill Level Tasks Performance Steps hoses rubbing against each other and dry rotted hoses
191. UNNING BE AWARE OF MOVING MECHANICAL PARTS FAILURE TO COMPLY MAY CAUSE PERMANENT INJURY OR DEATH 2 REMOVE RINGS NECKLACES OTHER JEWELRY AND LOOSE CLOTHING FAILURE TO COMPLY MAY CAUSE PERMANENT INJURY OR DEATH 3 ENSURE THAT THE COMMUNICATION ADAPTOR OPERATES ON 24 VOLTS DIRECT CURRENT DC SUPPLIED BY THE BATTERY THROUGH THE SERVICE TOOL CABLE FAILURE TO COMPLY MAY CAUSE IMMEDIATE INJURY OR EQUIPMENT DAMAGE WARNING DURING MAINTENANCE ACTIVITIES WITH THE SIDE DOORS OPEN NOISE LEVELS IN ACCESS OF 113 DECIBELS EXIST WITHIN A 12 FOOT RADIUS OF A DPGDS PERSONNEL MUST WEAR DOUBLE HEARING PROTECTION WITHIN 12 FEET OF A RUNNING DPGDS EXPOSURE MUST BE LIMITED TO LESS THAN 2 5 HOURS HEARING LOSS WILL OCCUR IF THIS NOTICE IS NOT OBSERVED AND ENFORCED NOTE The Caterpillar ET tool can also be used when the engine is not running To use the Caterpillar ET tool when the engine is not running ensure that the A B connection cables have been removed to isolate the DPGDS The DC breaker must be closed to power the Caterpillar ET tool and the engine control switch must be in the RUN position Standards Operate the Caterpillar ET tool by installing it while the engine is running Perform a diagnostic code check to identify any malfunctions in the DPGDS Performance Steps NOTES 1 Caterpillar part NEXG4523 service program module for the Caterpillar communication adapter PN 171 4400 is updated at regular intervals Contact Caterpillar In
192. URCE IS CONNECTED TO THE SWITCH FAILURE TO COMPLY MAY CAUSE PERMANENT INJURY OR DEATH 3 REMOVE RINGS NECKLACES OTHER JEWELRY AND LOOSE CLOTHING FAILURE TO COMPLY MAY CAUSE PERMANENT INJURY OR DEATH 4 DO NOT EXCEED THE MAXIMUM VOLTAGE STIPULATED FOR THIS TEST FAILURE TO COMPLY MAY CAUSE THE VACUUM BOTTLES TO EXPLODE AND MAY RESULT IN PERMANENT INJURY OR DEATH WARNING 1 SOME DIRECT CURRENT DC HIGH POTENTIAL TEST SETS ARE HALF WAVE RECTIFIED AND MAY PRODUCE PEAK VOLTAGES IN EXCESS OF THE MANUFACTURER S RECOMMENDED MAXIMUM FOR VACUUM SWITCHES FAILURE TO FOLLOW TEST SET INSTRUCTIONS MAY CAUSE IMMEDIATE PERSONAL INJURY OR EQUIPMENT DAMAGE 2 AN APPLICATION OF HIGH VOLTAGE ACROSS AN OPEN GAP IN A VACUUM CAN PRODUCE AN X RAY EMISSION THAT MAY CAUSE IMMEDIATE PERSONAL INJURY Standards Safely service the vacuum switch by inspecting and testing it Conduct tests according to the manufacturer s literature when available and use industry standards when the manufacturer s literature cannot be obtained Reinstall or repair the vacuum switch based on the test results Performance Steps NOTE Microhm or millivolt drop values should not exceed the high levels of the normal range as indicated in the manufacturer s literature If the manufacturer s literature is not available investigate the values that deviate from adjacent poles or similar breakers by more than 25 percent of the lowest value 1 Review danger warning and caution n
193. USE PERMANENT INJURY OR DEATH AND EQUIPMENT DAMAGE 4 REMOVE RINGS NECKLACES OTHER JEWELRY AND LOOSE CLOTHING FAILURE TO COMPLY MAY CAUSE PERMANENT INJURY OR DEATH NOTE Keep the work area neat and organized Keep equipment stable while performing this task Failure to comply may lead to unreliable test readings Standards Service the optoelectronic equipment by safely testing it as specified in the manufacturer s literature Reinstall or replace the controller based on test results Performance Steps NOTE The low voltage side of the potential transformer that supplies voltage to the equipment may be fuse protected To further isolate the circuit electrically and as an additional safety measure this fuse may be removed Check the schematics for verification 1 Review danger warning and caution notices before proceeding Review the manufacturer s literature with schematics and wiring diagrams Review maintenance logbooks and historical data pertaining to the equipment Identify the circuit connected to the optoelectronic equipment by using the schematics Perform lockout and tagout procedures O oa A W N Test the circuit for voltage presence a Proceed to step 7 if there is no voltage present b Stop if there is voltage present and perform the following checks until voltage is no longer present 1 Check the schematics for proper circuit identification 2 Check for back fed circuits 3 Check for the prop
194. VE RINGS NECKLACES OTHER JEWELRY AND LOOSE CLOTHING FAILURE TO COMPLY MAY CAUSE PERMANENT INJURY OR DEATH WARNING KEEP THE WORK AREA NEAT AND ORGANIZED KEEP THE CONTROLLER STABLE WHILE PERFORMING THIS TASK FAILURE TO COMPLY MAY LEAD TO UNRELIABLE TEST READINGS Standards Service a DSLC by safely testing it as specified in the manufacturer s literature Reinstall or replace the controller based on the test results Performance Steps NOTE The low voltage side of the potential transformer that supplies voltage to the controller may be fuse protected To further isolate the circuit electrically and as an additional safety measure this fuse may be removed Check the schematics for verification 1 Review danger warning and caution notices before proceeding Review the manufacturer s literature with schematics and wiring diagrams Review maintenance logbooks and historical data pertaining to the equipment Identify the circuit connected to the DSLC by using the schematics Perform lockout and tagout procedures O oa A W N Test the circuit for voltage presence a Proceed to step 7 if there is no voltage present b Stop if there is voltage present and perform the following checks until voltage is no longer present 1 Check the schematics for proper circuit identification 2 Check for back fed circuits 3 Check for the proper use of safe clearance procedures 31 March 2009 STP 5 21P2 SM TG 3 121 Chapter 3
195. W CATS CMF CPL CSM 31 March 2009 Glossary registered trademark first sergeant active component alternating current Army Correspondence Course Program American Electricians Handbook advanced individual training annually Army Navy Advanced Noncommissioned Officer Course angle of repose armor Army regulation Army National Guard Army National Guard of the United States additional skill identifier American Society for Testing and Materials air traffic service assign terminal service automatic transfer switch attention American wire gauge biannually battle damage assessment and repair Basic Noncommissioned Officer Course bill of materials biweekly biological warfare combined arms training strategy combined arms training strategies career management field corporal command sergeant major STP 5 21P2 SM TG Glossary 1 Glossary CT CTT DA DC DPGDS DSLC EM eng EPA EPMS EPS ER ET FLA FM freq GE GED GEN gen IEEE JOAP KVA LCH LED Glossary 2 counterterrorism current transformer cycle time common task test common task training Department of the Army data adapter data administrator direct action directorate for administration double agent aerospace drift Dental Corps direct current dislocated civilian District of Columbia Deployable Power Generation and Distribution System digital synchronizer and load controller earthmoving electromagnetic
196. XPLOSION MAY CAUSE IMMEDIATE PERSONAL INJURY OR EQUIPMENT DAMAGE Standards Service a governor by inspecting the components parts and repairing or replacing faulty components parts as specified in the manufacturer s literature Performance Steps 1 Review maintenance logbooks and historical data pertaining to the equipment to verify that the governor system needs to be serviced 2 Perform lockout and tagout procedures 3 Perform a visual inspection of the governor exterior for obvious faults a Check oil levels b Check for leaking lines c Check for misalignment d Check for bent or damaged linkage e Check for broken or missing hardware Remove the governor Clean the governor Inspect the governor by taking measurements Repair components parts that are not within tolerance oN O ON A Replace components parts when repairs do not return the governor to operation 9 Reinstall the governor on the generator or the designated test stand NOTE During governor reassembly ensure that the linkage is not put on in a way that would prevent equipment shutdown 10 Close out lockout and tagout procedures by removing locking and tagging devices 11 Start the unit and observe it for proper operation or observe the results while the governor is on a designated test stand 12 Record actions taken on DA Form 2404 or DA Form 5988 E and maintenance logbooks 31 March 2009 STP 5 21P2 SM TG 3 171 Chapter 3 Per
197. Y MAY CAUSE PERMANENT INJURY OR DEATH 2 REMOVE RINGS NECKLACES OTHER JEWELRY AND LOOSE CLOTHING FAILURE TO COMPLY MAY CAUSE PERMANENT INJURY OR DEATH 3 DO NOT OPERATE THE GENERATOR SET UNLESS IT HAS BEEN PROPERLY GROUNDED FAILURE TO COMPLY MAY CAUSE PERMANENT INJURY OR DEATH CAUTION NOISE LEVELS IN EXCESS OF 85 DECIBELS EXIST WITHIN A 50 FOOT RADIUS OF OPERATING EQUIPMENT ALWAYS WEAR SINGLE HEARING PROTECTION WITHIN A 50 FOOT RADIUS OF OPERATING EQUIPMENT FAILURE TO COMPLY MAY CAUSE INJURY Standards Operate an MEP 810A or B generator in manual and automatic mode according to TM guidelines to ensure that the system parameters are met without causing injury or equipment damage Performance Steps 1 Perform preoperational checks according to the TM Perform a preoperational run according to the TM Perform an operator remote terminal setup according to the TM Complete the switch arrangements Verify the lamp indicators Place the engine control switch in MANUAL mode Ensure that the generator starts and accelerates to the correct operating voltage and frequency Place the synchronous source switch at the master control panel in the G1 position Close the G1 breaker by cycling the breaker control switch to the CLOSE position O o N O Oa A OO N _ Ensure that the breaker control switch closes Return the synchronous source switch to the OFF position N Place the engineer cont
198. a pertaining to the equipment 4 Perform lockout and tagout procedures 5 Ground out residual voltage a Ground out the primary side b Ground out the secondary side Keep a record of how the transformer is wired Disconnect the transformer Apply grounds on the incoming and load cables o Oo N O Test for polarity on a single phase power and potential transformer and proceed to step 11 if the test is performed on a CT a Connect the variable AC source to the H1 and H2 terminals b Connect a jumper wire from the H1 terminal to the X2 terminal c Connect a multimeter to the H2 and X1 terminals to measure the voltage d Apply AC voltage consistent with the ratio of the transformer such as 120 volts for a 120 1 transformer ratio e Record the voltage readings 3 328 STP 5 21P2 SM TG 31 March 2009 MOS Skill Level Tasks Performance Steps f g h m n O Turn off the variable AC source Ground the transformer terminals Remove the jumper wire from the H1 and X2 terminals and place it on the H2 and X1 terminals i Connect the multimeter to the H1 and X2 terminals j Apply the same AC voltage that was applied in step 9d k Determine if the voltage reading in step Ye is higher than the one in step 9k The transformer Record the voltage readings is additive if the reading is higher the transformer is subtractive if it is lower Turn off the variable AC source Ground the transfo
199. a power station electrician in a tactical or nontactical environment during maintenance or when an electrical equipment grounding system is initially installed you are given a general mechanic s took kit a voltage detector the National Electric Code Handbook electrical construction prints wiring diagrams personal protective gear and a multimeter DANGER REMOVE RINGS NECKLACES OTHER JEWELRY AND LOOSE CLOTHING FAILURE TO COMPLY MAY CAUSE PERMANENT INJURY OR DEATH Standards Service an electrical equipment grounding system by inspecting the grid system and testing for continuity and resistance Repair or replace deficiencies Performance Steps NOTE This task does not include ground resistance testing see task 052 206 2104 1 Review danger warning and caution notices 2 Review the manufacturer s literature electrical construction prints and wiring diagrams 3 Perform lockout and tagout procedures 4 Conduct a visual inspection a Locate the major components parts of the system such as the equipment enclosures and system neutrals b Inspect the system for common faults at the connection points such as corrosion loose or broken connections and overheating 5 Service the connection points by repairing replacing or cleaning them 6 Conduct electrical tests point to point between the main grounding system connection point and the major electrical equipment frames and system neutrals to ensure a solid bond throughou
200. ach performance step from the evaluation guide in column A Enter in column B each performance step from the evaluation guide that corresponds to the number in column A abbreviate the information if necessary Locally reproduce the partially completed form if more than one Soldier will be evaluated on the specific task or the same Soldier will be evaluated more than once Enter the date evaluator s name and Soldiers name and unit before starting the evaluation e Enter a check in column c or column d for each performance step evaluated as appropriate Check the status block GO or NO GO NOTE TO THE TRAINING MANAGER The training status of groups teams squads platoons can be maintained in key critical MOSs at any level by entering the level 1st platoon 2d platoon 3d platoon in column headings Simply have the trainers report the percentage of their Soldiers who have GO and have not NO GO demonstrated proficiency on each task and record this information for each level 1 9 Enlisted Personnel Management System The Enlisted Personnel Management System EPMS Army Regulation AR 614 200 is the Army overall system to improve the professionalism of the enlisted force It integrates policies relating to training evaluation classification and promotion into an overall system It provides the Soldier with a means to look to the future and see a realistic clear and viable career progression path from private PVT
201. aeeeeeeaes 3 167 052 205 2124 Operate a Caterpillar Electronic Technician ET Tool 3 168 STP 5 21P2 SM TG 31 March 2009 052 205 2125 052 205 2126 052 205 2127 052 205 2128 052 205 2129 052 205 2130 052 205 2131 052 205 2132 052 205 2133 052 205 2134 Contents Service a Governor for Generating Equipment 0 cceceeecceeeeeeeeeeseeseeeeees Service an Internal Fuel System for a Diesel Engine 0 ccceeeeeeeeeeeesteeeeenes Service an External Fuel System for a Diesel Engine Service a Diesel Engine Starting System cc cece eeteeeeeeeneeeetteeeeetneeeereae Troubleshoot a Diesel Engine Lube Oil System eceeeeeeeeeeeeeeenteeeeeeeneeees Troubleshoot a Diesel Engine Cooling System uo cceeeeeeeeeeeeeeeenteeeeeeenaeees Troubleshoot a Diesel Engine Air Intake and or Exhaust System ceee Repair a Diesel Engine Lube Oil System 0 0 eeeeeeeeeeeeeeneeeeeeneeeeeeeneeeeneaes Repair a Diesel Engine Cooling System cccceecseeseeeeeeeeeeeeeeenieeeeeeeneeeeseaes Repair an Engine Air Intake and or Exhaust System ceeceeeeeeeeeetteeeeeenaees Subject Area 4 S3 Electrical Equipment Maintenance Power Station Tasks 052 206 2100 052 206 2101 052 206 2102 052 206 2103 052 206 2104 052 206 2105 052 206 2108 052 206 2114 052 206 2115 052 206 2116 052 206 2122 052 206 2123 052 206 2124 052 206 2125 052 206 2127 052 206 2133 052 206 2134 052 206 2135 052 206 2136 052 204 11
202. after a power plant has been fully installed and is operational you are given an MEP 012 or 208 generator TM 9 6115 604 12 other appropriate TMs and personal protective equipment for a routine start up and operation DANGER 1 THIS TASK SHOULD ONLY BE PERFORMED BY QUALIFIED PERSONNEL WHO ARE KNOWLEDGEABLE IN THE INSTALLATION OPERATION AND MAINTENANCE OF MEDIUM VOLTAGE ELECTRICAL POWER GENERATION EQUIPMENT AND ITS ASSOCIATED HAZARDS FAILURE TO COMPLY MAY CAUSE PERMANENT INJURY OR DEATH 2 DO NOT OPERATE THE GENERATOR SET UNLESS IT HAS BEEN PROPERLY GROUNDED FAILURE TO COMPLY MAY CAUSE PERMANENT INJURY OR DEATH 3 REMOVE RINGS NECKLACES OTHER JEWELRY AND LOOSE CLOTHING FAILURE TO COMPLY MAY CAUSE PERMANENT INJURY OR DEATH CAUTION NOISE LEVELS IN EXCESS OF 85 DECIBELS EXIST WITHIN A 50 FOOT RADIUS OF OPERATING EQUIPMENT ALWAYS WEAR SINGLE HEARING PROTECTION WITHIN A 50 FOOT RADIUS FAILURE TO COMPLY MAY CAUSE PERSONAL INJURY Standards Operate the generating units according to the TMs to ensure that the system parameters are met without causing injury or equipment damage Performance Steps 1 Perform before operation preventive maintenance checks and services PMCS 2 Place the 24 volt direct current DC control power circuit breaker in the ON position 3 Place the maintenance lockout switch in the MANUAL position 4 Place the operation selector switch in the MANUAL position 5 Place the parallel switch in the
203. age and serviceability Prepared components parts to be soldered Soldered the components parts together using the appropriate technique Inspected the final product for flaws and damage O oa A W N Tested the connection using a multimeter to ensure that the resistance measured 0 ohms Evaluation Guidance Score the Soldier GO if all measures are passed P Score the Soldier NO GO if any measure is failed F If the Soldier fails any measure show him how to do it correctly References Required Related TB SIG 222 31 March 2009 STP 5 21P2 SM TG 3 325 Chapter 3 Perform Advanced Electrical Troubleshooting Procedures 052 264 2109 Conditions As a power station electrician or power station instrument technician in a tactical or nontactical environment when an electrical circuit or distribution system requires troubleshooting you are given safety standing operating procedures a lockout and tagout kit a multimeter an electrician s tool kit a megohmmeter electrical construction prints wiring diagrams maintenance logbooks and the manufacturer s literature with schematics DANGER 1 TROUBLESHOOTING ELECTRICAL CIRCUITS AND DISTRIBUTION SYSTEMS REQUIRES CONDUCTORS TO BE ENERGIZED AND IN OPERATION DE ENERGIZE AND GROUND ELECTRICAL CIRCUITS BEFORE PHYSICAL CONTACT OR WHEN WORKING IN CLOSE PROXIMITY WITH ELECTRICAL COMPONENTS PARTS FAILURE TO COMPLY MAY CAUSE PERMANENT INJURY
204. agged out Checked the electrical system Checked the engine for seizure Lifted the clearance for testing Tested the suspected fault to determine if it was the cause of the malfunction Repaired the fault if possible O OO N O ON A Closed out the lockout and tagout procedures by removing locking and tagging devices 11 Attempted to start the generator 12 Recorded malfunctions and corrections made in the maintenance logbook 13 Recorded actions taken on the maintenance logbook 14 Ensured that the items listed in the conditions were properly cleaned and stored Evaluation Guidance Score the Soldier GO if all measures are passed P Score the Soldier NO GO if any measure is failed F If the Soldier fails any measure show him how to do it correctly References Required Related DA FORM 2404 3 60 STP 5 21P2 SM TG 31 March 2009 MOS Skill Level Tasks Troubleshoot an Engine Failure to Accelerate and or Maintain a Rated Speed 052 244 2133 Conditions As a power plant operator in a tactical or nontactical environment when an engine fails to accelerate or maintain a rated speed you are given a generator engine appropriate technical manuals the manufacturer s literature a maintenance logbook a general mechanic s tool box a multimeter and DA Form 2404 Equipment Inspection and Maintenance Worksheet o
205. agging 3 242 STP 5 21P2 SM TG 31 March 2009 MOS Skill Level Tasks Performance Measures GO NO GO devices 12 Ensured that the items listed in the conditions were properly cleaned and stored Evaluation Guidance Score the Soldier GO if all measures are passed P Score the Soldier NO GO if any measure is failed F If the Soldier fails any measure show him how to do it correctly References Required Related FM 3 34 480 NESC NETA 31 March 2009 STP 5 21P2 SM TG 3 243 Chapter 3 Service a Vacuum Circuit Breaker 052 206 2135 Conditions As a power station electrician in a tactical or nontactical environment during maintenance you are given safety standing operating procedures a general mechanic s tool box a digital low resistance ohmmeter a megohmmeter wiring diagrams a high potential test set or vacuum bottle test set grounding equipment and the applicable manufacturer s literature with schematics DANGER 1 THIS TASK SHOULD ONLY BE PERFORMED BY QUALIFIED PERSONNEL WHO ARE KNOWLEDGEABLE IN THE INSTALLATION AND MAINTENANCE OF VACUUM CIRCUIT BREAKERS AND POWER EQUIPMENT AND THEIR ASSOCIATED HAZARDS FAILURE TO COMPLY MAY CAUSE PERMANENT INJURY OR DEATH 2 DO NOT TOUCH EXPOSED ELECTRICAL CONNECTIONS WHILE A POWER SOURCE IS CONNECTED TO THE SWITCH FAILURE TO COMPLY MAY CAUSE PERMANENT INJURY OR DEATH 3 REMOVE RINGS NECKLACES OTHER JEWELRY AND LOOSE CLOTHING FAILURE TO COMPLY M
206. agging devices 14 Energize the circuit and check for proper operation 31 March 2009 STP 5 21P2 SM TG 3 339 Chapter 3 Performance Steps 15 16 17 18 Verify adjustments made to the governor during operation a Adjust the governor for initial engine start up b Adjust the governor when the engine is at operating temperature to obtain engine speed 1 Maintain optimum speed 2 Maintain desired speed 3 Maintain stability Perform a load test on the generator to ensure proper operation Keep a record of the test results and actions taken Ensure that the items listed in the conditions are properly cleaned and stored Evaluation Preparation Setup Provide the Soldier with the items listed in the conditions Give the Soldier a safety briefing before starting the test and ensure that safety precautions are followed Prepare the testing area and equipment in advance to ensure that task standards can be met Brief Soldier Direct the Soldier to service an electronic governor Performance Measures 1 N O Oo FB W N 10 11 12 13 14 15 16 Reviewed danger warning and caution notices Reviewed the manufacturer s literature and wiring diagrams Reviewed maintenance logbooks and historical data pertaining to the equipment Identified the circuit or device being tested Performed lockout and tagout procedures Inspected electrical connections for cleanness correctness and tig
207. aining to the equipment Performed lockout and tagout procedures Inspected the condition of the vacuum circuit breaker visually and manually Performed resistance measurements through the bolted connections with a low resistance ohmmeter and ensured that the bolt torque levels matched the manufacturer s literature 31 March 2009 STP 5 21P2 SM TG 3 245 Chapter 3 Performance Measures GO NO GO 7 Performed a contact resistance test and compared contact resistances of electrical connections to the values of similar connections and to the values specified in the manufacturer s literature 8 Verified that trip close trip free and antipump functions operated properly 9 Tripped the circuit breaker by operating each protective device to verify thatopen and close protective devices were operational and functioned according to the recommended values specified in the manufacturer s literature 10 Performed insulation resistance tests pole to pole pole to ground and across open poles and ensured that insulation resistance test values were no less than 1 000 megohms at a DC voltage of 2 500 volts unless otherwise specified in the manufacturer s literature 11 Performed a vacuum bottle integrity test across each vacuum bottle with the switch in the OPEN position and according to the manufacturer s literature 12 Kept a record of the test r
208. air lines and look for damaged or leaking lines 4 Inspect connections at the starter for damage 5 Check for sufficient air pressure in the reservoir to crank the engine 3 Correct the appropriate malfunction NOTE Only one of the following starting systems is inspected a Service the electric start 1 Clean battery terminals and or connections 2 Refill the battery electrolyte to the proper level 3 Repair the starter and battery terminals or connections 4 Replace the starter batteries and or connections b Service the air start 1 Drain and clean air lines 2 Repair or replace the air compressor 3 Repair or replace connections at the starter or air compressor 4 Fix or replace damaged air lines 5 Connect the largest air reservoir YS YS wm wa 4 Record actions taken on DA Form 2404 or DA Form 5988 E and maintenance logbooks 5 Ensure that the items listed in the conditions are properly cleaned and stored 31 March 2009 STP 5 21P2 SM TG 3 179 Chapter 3 Evaluation Preparation Setup Provide the Soldier with the items listed in the conditions Give the Soldier a safety briefing before starting the test and ensure that safety precautions are followed Prepare the testing area and equipment in advance to ensure that task standards can be met Brief Soldier Direct the Soldier to service a diesel engine starting system Performance Measures GO NO GO 1 Reviewed maintenance logbooks and historica
209. aker control switch to the CLOSE position when the two green triangular LEDs showing 12 o clock on the synchroscope were energized Ensured that the breaker control switch closed Returned the synchronous source switch to the OFF position Closed the required feeder tie breaker s from the local control panel and allowed it run for 20 minutes through various load changes Shut down the generator according to the TM Performed a preoperational run according to the TM Performed an operator remote terminal setup according to the TM Ensured that Generator 1 automatically started and accelerated to the correct operating voltage and frequency Ensured that Generator 1 automatically closed to the system bus Ensured that the tie breaker automatically closed Ensured that Generator 2 automatically started and accelerated to the correct operating voltage and frequency Ensured that Generator 2 automatically paralleled the system bus Shut down the generator according to the TM Evaluation Guidance Score the Soldier GO if all measures are passed P Score the Soldier NO GO if any measure is failed F If the Soldier fails any measure show him how to do it correctly References Required Related FM 3 34 480 3 26 STP 5 21P2 SM TG 31 March 2009 MOS Skill Level Tasks Operate a Mobile Electric Power MEP 012 or 208 Generator 052 244 2115 Conditions As a power plant operator in a tactical or nontactical environment
210. al laws and regulations without causing personal injury or equipment damage Performance Steps NOTES 1 This task requires subtasks specific to each generating unit Each generating unit has its own danger warning and caution notices 2 Because of the different generating units available the various methods of transportation offered and the numerous laws and regulations that govern each type of movement including international and host country laws these steps are only a guideline Refer to the generating unit manuals laws and regulations that apply to each situation 1 Review danger warning and caution notices Review the manufacturer s literature electrical construction prints and wiring diagrams Contact unit movement personnel to arrange for shipment of the power plant Shut down the power plant Apply safe clearance procedures to the power plant Isolate the power plant from exterior electrical connections Disconnect or remove batteries according to the shipping requirements Remove ground connections Drain fluids to the allowable levels according to the shipping requirements O OoOo N O oO A OO N _ Prepare the generator accessories for movement a Identify the following accessories 1 Identify the lifting rigging and positioning equipment 2 Identify the operator remote terminal 31 March 2009 STP 5 21P2 SM TG 3 77 Chapter 3 Performance Steps 11 12 13 14 1
211. alance 2 Loose connections 3 Faulty components parts e Produce a report of the IR survey if necessary including 1 A normal picture of the equipment containing the fault during daytime hours 2 An IR picture of the fault 3 A description of the fault 4 The suggested priority of repairs 5 A strip map containing the location of each fault 5 Brief the report to the individual who requested the IR survey 31 March 2009 STP 5 21P2 SM TG 3 239 Chapter 3 Evaluation Preparation Setup Provide the Soldier with the items listed in the conditions Give the Soldier a safety briefing before starting the test and ensure that safety precautions are followed Prepare the testing area and equipment in advance to ensure that task standards can be met Brief Soldier Direct the Soldier to identify electrical faults using an IR camera Performance Measures GO NO GO 1 Prepared an inventory list of the equipment items or components parts to be tested 2 Arranged the inventory list items in a logical sequence 3 Coordinated with the equipment maintenance supervisor if the system was unknown 4 Conducted an IR survey 5 Briefed the report to the individual who requested the IR survey Evaluation Guidance Score the Soldier GO if all measures are passed P Score the Soldier NO GO if any measure is failed F If the Soldier fails any measure show him how to do it c
212. allasts and wiring as specified in electrical construction prints an electrician s tool kit a voltage detector applicable climbing and rigging equipment a multimeter the applicable manufacturer s literature wiring diagrams the Lineman s and Cableman s Handbook LCH and the applicable personal protective equipment PPE DANGER 1 FOLLOW ELECTRICAL SAFETY PRACTICES AND WEAR APPLICABLE PPE AS REQUIRED FAILURE TO COMPLY MAY CAUSE PERMANENT INJURY OR DEATH 2 A VOLTAGE DETECTOR SHOULD BE USED TO ENSURE THAT THE CABLE IS NOT ENERGIZED MATERIAL SUCH AS A LEAD SHEATH THAT ACTS AS A SHIELD MUST NOT BE BETWEEN THE TESTER AND THE CONDUCTORS OF THE CIRCUIT BEING TESTED FAILURE TO TEST CABLES MAY CAUSE PERMANENT INJURY OR DEATH 3 REMOVE RINGS NECKLACES OTHER JEWELRY AND LOOSE CLOTHING FAILURE TO COMPLY MAY CAUSE PERSONAL INJURY OR DEATH WARNING ENSURE THAT YOU LIFT WITH YOUR LEGS BE AWARE OF THE POSITION OF YOUR HANDS AND FINGERS AND WEAR EYE PROTECTION IF NEEDED FAILURE TO COMPLY MAY CAUSE IMMEDIATE PERSONAL INJURY OR EQUIPMENT DAMAGE Standards Install high intensity lights and ballasts on a pre positioned pole to fully illuminate the designated area Performance Steps 1 Review the applicable manufacturer s literature electrical construction prints and wiring diagrams 2 Perform lockout and tagout procedures 3 Ensure that personnel follow safety clearances 4 Ascend the pole if necessary 5 Wear the correct PP
213. an be met Brief Soldier Direct the Soldier to produce a mechanical drawing Performance Measures GO NO GO 1 Identified the mechanical system to be depicted as a drawing 2 Identified key items in the system to be produced 3 Represented equipment with correct symbols and color schemes 4 Created an illustration of the mechanical system 5 Used the mechanical drawing for a briefing or post drawing Evaluation Guidance Score the Soldier GO if all measures are passed P Score the Soldier NO GO if any measure is failed F If the Soldier fails any measure show him how to do it correctly References Required Related FM 3 34 471 31 March 2009 STP 5 21P2 SM TG 3 167 Chapter 3 Operate a Caterpillar Electronic Technician ET Tool 052 205 2124 Conditions As a power station mechanic in a nontactical environment you are given a Deployable Power Generation and Distribution System DPGDS prime power unit an operator remote terminal a Caterpillar ET tool a serial cable RS 232 connector part number PN 160 0141 a Caterpillar communication adapter II PN 171 4400 a Caterpillar data link cable PN 160 0133 the applicable technical manuals TMs the applicable manufacturers literature and DA Form 2404 Equipment Inspection and Maintenance Worksheet or DA Form 5988 E Equipment Inspection Maintenance Worksheet DANGER 1 PERFORM THIS TASK WHILE THE ENGINE IS R
214. and opens NOTE Continuity between phases may indicate a short Opens across closed breakers and switches indicate failure of the device 9 Perform underground cable and or fault procedures if necessary 10 Check the physical condition of the conductors a Inspect conductors from end to end when a short or open is indicated in previous steps b Check for burnt insulation 3 326 STP 5 21P2 SM TG 31 March 2009 MOS Skill Level Tasks Performance Steps 11 12 13 14 Conduct a load assessment to find the initial cause of the fault Replace defective components parts a Replace or splice faulty cables b Replace faulty circuit breakers c Ensure that protective relays are operating properly at correct settings d Replace blown fuses Monitor the circuits Ensure that the items listed in the conditions are properly cleaned and stored Evaluation Preparation Setup Provide the Soldier with the items listed in the conditions Give the Soldier a safety briefing before starting the test and ensure that safety precautions are followed Prepare the testing area and equipment in advance to ensure that task standards can be met Brief Soldier Direct the Soldier to perform advanced electrical troubleshooting procedures Performance Measures 1 2 Reviewed danger warning and caution notices Reviewed the manufacturer s literature electrical construction prints and wiring diagrams Reviewed maintenance lo
215. and remove any that are found c Inspect the cable jacket for nicks and remove any that are found NOTE Do not ring cut into the metallic shielding or the insulation when removing the jacket 3 4 STP 5 21P2 SM TG 31 March 2009 MOS Skill Level Tasks Performance Steps 4 5 Align cables so that the ends of the conductors conjoin squarely a Ensure that all cuts are made squarely and leave a smooth edge b Perform ring cuts as needed without damaging the other components parts of the cable Remove the jacket using the distance indicated in the splice kit instructions NOTE Make cuts square to the conductor 6 Remove the metallic shield of the cable from the edge of the jacket using the distance indicated in the splice kit instructions NOTE Do not ring cut into the metallic shielding or the insulation when removing the jacket 7 8 10 11 12 13 14 15 16 17 18 Remove the high voltage insulation layer using the distance indicated in the splice kit instructions Remove the semiconductor from the edge of the metallic shield using the distance indicated in the splice kit instructions Apply the connector using the correct compression tool a Measure back the depth needed for the conductor to penetrate the connector plus the distance indicated in the splice kit b Clean the entire area of the splice with cable cleaning solvent c Remove sharp edges d Place two crimps on the connector
216. and time delay of the circuit breaker by using the primary current injection test method and ensuring that the times fell within the guidelines specified in the manufacturer s literature 10 Determined the ground fault pickup and time delay of the circuit breaker by using the primary current injection test method and ensuring that the times fell within the guidelines specified in the manufacturer s literature 11 Tested the instantaneous pickup using the primary current injection method Applied current using the run up or pulse method to ensure that the instantaneous trip times of the circuit breaker fell within the guidelines specified in the manufacturer s literature 12 Ensured that the trip characteristics of the breakers fell within the manufacturer s published time current characteristic tolerance band including adjustment factors Verified the correct operation of the auxiliary features 13 Closed out lockout and tagout procedures by removing locking and tagging devices 14 Reenergized the circuit 15 Ensured that the circuits worked as designed 16 Ensured that the items listed in the conditions were properly cleaned and stored Evaluation Guidance Score the Soldier GO if all measures are passed P Score the Soldier NO GO if any measure is failed F If the Soldier fails any measure show him how to do it correctly References Required Related EM 38
217. andards can be met Brief Soldier Direct the Soldier to service a solid state relay Performance Measures GO NO GO 1 oO oo N DO a FF W ND oy Sek a N gt O Reviewed danger warning and caution notices before proceeding Reviewed the manufacturer s literature with schematics and wiring diagrams Reviewed maintenance logbooks and historical data pertaining to the equipment Identified the circuit connected to the relay by using the schematics Performed lockout and tagout procedures Tested the circuit for voltage presence Removed the relay and tagged the leads Tested the relay according to the manufacturer s literature Compared the results with the manufacturer s specifications and took appropriate action Calibrated reinstalled or replaced the relay Tested the circuit for voltage presence Reinstalled the relay 13 Closed out lockout and tagout procedures by removing locking and tagging 31 March 2009 STP 5 21P2 SM TG 3 119 Chapter 3 Performance Measures GO NO GO devices 14 Energized the circuit and ensured that it was operating properly 15 Kept a record of results and actions taken 16 Ensured that the items listed in the conditions were properly cleaned and stored Evaluation Guidance Score the Soldier GO if all measures are passed
218. anufacturer s literature and ensured that the insulation withstood the voltage applied during the test 7 Performed resistance measurements on the bolted connections using a low resistance ohmmeter and ensured that the bolt torque levels matched the manufacturer s literature 8 Measured the contact resistance across each switchblade and fuse holder and compared the contact resistances of the electrical connections to the values of similar connections and the manufacturer s literature 9 Measured the resistance across each fuse and verified that the fuse resistance values did not deviate from each other by more than 15 percent 10 Performed corrective action as necessary 11 Closed out lockout and tagout procedures by removing locking and tagging devices 12 Reconnected the air switch to the system 13 Performed a functions check on the nonaerial air switch 14 Reenergized the power to the equipment 15 Ensured that the items listed in the conditions were properly cleaned and stored Evaluation Guidance Score the Soldier GO if all measures are passed P Score the Soldier NO GO if any measure is failed F If the Soldier fails any measure show him how to do it correctly References Required Related NESC TM 5 684 31 March 2009 STP 5 21P2 SM TG 3 211 Chapter 3 Service an Electrical Equipment Grounding System 052 206 2108 Conditions As
219. anufacturer s literature cannot be obtained 1 Review danger warning and caution notices 2 Review the manufacturer s literature and wiring diagrams 3 Review maintenance logbooks and historical data pertaining to the equipment 4 Perform lockout and tagout procedures 5 Inspect the condition of the SF6 switch visually and manually NOTE Microhm or millivolt drop values should not exceed the high levels of the normal range as indicated in the manufacturer s literature If the manufacturer s literature is not available investigate the values that deviate from adjacent poles or similar breakers by more than 50 percent of the lowest value a Clean the switch before testing unless as found and as left tests are required b Keep a record of as left and as found operation counter readings if applicable c Inspect the anchorage and grounding d Perform mechanical operator tests according to the manufacturer s literature if applicable e Verify the correct operation and adjustments of motor operator limit switches and mechanical interlocks if applicable Inspect insulating assemblies for evidence of physical damage or contaminated surfaces Check each fuse holder for adequate support and contact Verify that fuse sizes and types correspond to the drawings if provided Test for gas leaks according to the manufacturer s literature Verify the correct operation of air and SF6 gas pressure alarms and cutouts Test electrical and mechan
220. applicable technical manuals TMs the applicable manufacturer s literature maintenance logbooks and DA Form 2404 Equipment Inspection and Maintenance Worksheet or DA Form 5988 E Equipment Inspection Maintenance Worksheet DANGER 1 ENSURE THAT EQUIPMENT IS PROPERLY LOCKED OUT AND TAGGED OUT FAILURE TO COMPLY MAY CAUSE PERMANENT INJURY OR DEATH 2 REMOVE RINGS NECKLACES OTHER JEWELRY AND LOOSE CLOTHING FAILURE TO COMPLY MAY CAUSE PERMANENT INJURY OR DEATH WARNING 1 WHEN DISCONNECTING BATTERY CABLES ALWAYS DISCONNECT THE NEGATIVE TERMINAL FIRST WHEN RECONNECTING CONNECT THE POSITIVE TERMINAL FIRST FAILURE TO COMPLY MAY RESULT IN SPARKING OR BATTERY EXPLOSION AND MAY CAUSE IMMEDIATE PERSONAL INJURY OR EQUIPMENT DAMAGE 2 THE ENGINE EXHAUST SYSTEM CAN REACH TEMPERATURES ABOVE 2 000 F DO NOT REMOVE EXHAUST SYSTEM COMPONENTS PARTS UNTIL THE ENGINE HAS COOLED FAILURE TO COMPLY MAY CAUSE IMMEDIATE PERSONAL INJURY Standards Service an engine air intake system and or exhaust system by inspecting and replacing or repairing faulty components parts Performance Steps NOTE The following inspections and checks are guidelines and may be done in any order Replace repair or clean defective components parts as necessary 1 Review maintenance logbooks and historical data pertaining to the equipment to verify that the air intake and or exhaust system needs to be serviced 2 Perform lockout and tagout procedures 3 I
221. appropriate position for the operating conditions and ensure that the indicator light is illuminated O Place the local remote switch in the LOCAL position 7 Hold the prelube system switch in the ON position and observe the lube oil pressure gauge for rising oil pressure Release the switch when the pressure stabilizes the pressure should stabilize within 2 minutes 8 Place the master switch in the START position and release it to the RUN position NOTE The engine will automatically crank for 15 seconds and then rest for 15 seconds for a total of four crank cycles until the engine starts 9 Release the prelube system switch 10 Adjust the frequency adjustment rheostat for a frequency meter reading of 50 or 60 hertz as applicable 11 Place the GEN BUS voltmeter switch in the GEN 3 1 position 12 Adjust the voltage adjustment rheostat for an alternating current AC kilovolt ampere KVA reading of 4 16 KVA for a 60 hertz operation or 3 8 KVA for a 50 hertz operation 31 March 2009 STP 5 21P2 SM TG 3 27 Chapter 3 Performance Steps 13 14 15 16 17 18 Verify that the AC KVA reading is the same at all three GEN BUS settings Place the breaker control switch in the CLOSE position and ensure that the indicator light is illuminated Monitor the engine and generator indicators to ensure that the operation continues through the various load changes Perform during operation PMCS Conduct u
222. ards the InterNational Electrical Test Association NETA Maintenance Testing Specifications for Electrical Power Distribution Equipment and Systems electrical construction prints wiring diagrams and the applicable manufacturer s literature DANGER 1 THIS TASK SHOULD ONLY BE PERFORMED BY QUALIFIED PERSONNEL WHO ARE KNOWLEDGEABLE IN THE INSTALLATION AND MAINTENANCE OF TRANSFORMERS AND POWER EQUIPMENT AND THEIR ASSOCIATED HAZARDS FAILURE TO COMPLY MAY CAUSE PERMANENT INJURY OR DEATH 2 DO NOT TOUCH EXPOSED ELECTRICAL CONNECTIONS WHILE A POWER SOURCE IS CONNECTED TO THE TRANSFORMER FAILURE TO COMPLY MAY CAUSE PERMANENT INJURY OR DEATH 3 REMOVE RINGS NECKLACES OTHER JEWELRY AND LOOSE CLOTHING FAILURE TO COMPLY MAY CAUSE PERMANENT INJURY OR DEATH WARNING THIS TASK SHOULD ONLY BE PERFORMED ON EQUIPMENT THAT DOES NOT CONTAIN POLYCHLORINATED BIPHENYL PCB FAILURE TO COMPLY MAY CAUSE SKIN AILMENTS REPRODUCTIVE DISORDERS LIVER DISEASE AND OTHER ADVERSE HEALTH CONDITIONS Standards Safely service a distribution transformer by inspecting and testing it Test the transformer according to the manufacturer s literature Reinstall or repair the transformer based on the test results Performance Steps NOTE Conduct tests according to the manufacturer s literature when available Use industry standards when the manufacturer s literature cannot be obtained 1 Review danger warning and caution notices 2 Review the manufacturer s
223. are given electrical construction prints applicable distribution equipment as specified in the electrical construction prints wiring diagrams applicable climbing and rigging equipment an electrician s tool kit a voltage detector a lockout and tagout kit grounding equipment safety standing operating procedures SOPs manufacturer s literature the Lineman s and Cableman s Handbook LCH and the applicable personal protective equipment PPE DANGER 1 THIS TASK SHOULD ONLY BE PERFORMED BY QUALIFIED PERSONNEL KNOWLEDGEABLE IN THE INSTALLATION AND MAINTENANCE OF ELECTRICAL DISTRIBUTION SYSTEMS AND POWER EQUIPMENT AND THE ASSOCIATED HAZARDS FAILURE TO COMPLY MAY CAUSE PERMANENT INJURY OR DEATH 2 IT IS VITAL TO ENSURE THAT THE CIRCUIT IS COMPLETELY DE ENERGIZED AND CORRECTLY GROUNDED BEFORE PERFORMING ANY WORK FAILURE TO COMPLY MAY CAUSE PERMANENT INJURY OR DEATH 3 A VOLTAGE DETECTOR SHOULD BE USED TO ENSURE THAT THE CABLES ARE NOT ENERGIZED MATERIAL SUCH AS A LEAD SHEATH THAT ACTS AS A SHIELD MUST NOT BE BETWEEN THE TESTER AND THE CONDUCTORS OF THE CIRCUIT BEING TESTED FAILURE TO TEST CABLES MAY CAUSE PERMANENT INJURY OR DEATH 4 NEVER POSITION YOURSELF UNDER A SUSPENDED LOAD FAILURE TO COMPLY MAY CAUSE PERMANENT INJURY OR DEATH 5 REMOVE RINGS NECKLACES OTHER JEWELRY AND LOOSE CLOTHING FAILURE TO COMPLY MAY CAUSE PERMANENT INJURY OR DEATH NOTE All distribution equipment is not the same and may function differently
224. are the contact resistances of the electrical connections to the values of similar connections according to the manufacturer s literature Verify that open and close control devices are operational and functional according to the manufacturer s specifications Perform insulation resistance tests pole to pole pole to ground and across the open poles and ensure that the test values are not less than 1 000 megohms at a DC test voltage of 2 500 volts minimum unless otherwise stated in the manufacturer s literature Perform a vacuum bottle integrity test across each vacuum bottle with the switch in the OPEN position according to the manufacturer s literature and ensure that the test set does not trip when an overpotential voltage is applied a Provide adequate barriers and protection against x radiation during this test b Do not perform this test unless the contact displacement of each interrupter is within the manufacturer s tolerance Reconnect the isolated equipment Close out lockout and tagout procedures by removing locking and tagging devices Reenergize the de energized equipment and perform a functions check Ensure that the items listed in the conditions are properly cleaned and stored Evaluation Preparation Setup Provide the Soldier with the items listed in the conditions Give the Soldier a safety briefing before starting the test and ensure that safety precautions are followed Prepare the testing area and equ
225. ary and secondary windings of the transformer to ensure that the winding resistance was consistent with the manufacturer s specifications Performed an insulation resistance test on the transformer at a test voltage recommended in the manufacturer s literature Performed a transformer turn to turn ratio test 10 11 Reconnected the isolated equipment Closed out lockout and tagout procedures by removing locking and tagging devices Ensured that the items listed in the conditions were properly cleaned and stored Evaluation Guidance Score the Soldier GO if all measures are passed P Score the Soldier NO GO if any measure is failed F If the Soldier fails any measure show him how to do it correctly References Required Related NESC NETA 3 320 STP 5 21P2 SM TG 31 March 2009 MOS Skill Level Tasks Service a Current Transformer CT 052 264 2107 Conditions As a power station electrician or instrument technician in a tactical or nontactical environment during maintenance you are given safety standing operating procedures a general mechanic s tool box a digital low resistance ohmmeter a megohmmeter a lockout and tagout kit grounding equipment maintenance logbooks and the applicable manufacturer s literature with schematics DANGER 1 THIS TASK SHOULD ONLY BE PERFORMED BY QUALIFIED PERSONNEL WHO ARE KNOWLEDGEABLE IN THE INSTALLATION AND MAINTENANCE OF TRANSFORMERS AND POWER EQUIPMENT AND T
226. ate through various load changes b Perform operational PMCS according to TM 5 6115 593 12 and record the operation and maintenance data 4 Stop the MEP 029 generator a Place the AC power circuit breaker to the OPEN position for about 2 or 3 seconds The AC power circuit breaker closed light should turn off b Place the master switch to the STOP position after allowing the engine to cool by operating it at no load for about 5 minutes c Remove the DC control power after the engine stops by setting the 24 volt DC control circuit breaker to the OFF position ao Evaluation Preparation Setup Provide the Soldier with the items listed in the conditions Give the Soldier a safety briefing before starting the test and ensure that safety precautions are followed Prepare the testing area and equipment in advance to ensure that task standards can be met Brief Soldier Direct the Soldier to operate an MEP 029 generator Performance Measures GO NO GO 1 Prepared the MEP 029 generator for start up 2 Started the MEP 029 generator 3 Operated the MEP 029 generator 31 March 2009 STP 5 21P2 SM TG 3 31 Chapter 3 Performance Measures G NO GO 4 Stopped the MEP 029 generator Evaluation Guidance Score the Soldier GO if all measures are passed P Score the Soldier NO GO if any measure is failed F If the Soldier fails any measure show him how to do it correctly References Required Relat
227. ating generator technical manuals TMs manufacturer s literature an hourly log sheet a pen a clipboard a wiping cloth personal protective equipment and DA Form 2404 Equipment Inspection and Maintenance Worksheet or DA Form 5988 E Equipment Inspection Maintenance Worksheet DANGER 1 THIS TASK SHOULD ONLY BE PERFORMED BY QUALIFIED PERSONNEL WHO ARE KNOWLEDGEABLE IN THE OPERATION OF MEDIUM VOLTAGE ELECTRICAL POWER GENERATION EQUIPMENT AND ITS ASSOCIATED HAZARDS FAILURE TO COMPLY MAY CAUSE PERMANENT INJURY OR DEATH 2 DO NOT OPEN THE HIGH VOLTAGE CABINET DURING OPERATIONS FAILURE TO COMPLY MAY CAUSE PERMANENT INJURY OR DEATH 3 DO NOT REACH HANDS AROUND THE INSTALLED EQUIPMENT GUARDS IN THE ENGINE COMPARTMENT FAILURE TO COMPLY MAY CAUSE PERMANENT INJURY OR DEATH 4 REMOVE RINGS NECKLACES OTHER JEWELRY AND LOOSE CLOTHING FAILURE TO COMPLY MAY CAUSE PERMANENT INJURY OR DEATH WARNING 1 ALWAYS WEAR EYE PROTECTION WHEN ENTERING THE GENERATOR ENGINE COMPARTMENT FAILURE TO COMPLY MAY CAUSE IMMEDIATE PERSONAL INJURY 2 BATTERY ELECTROLYTE CONTAINS SULFURIC ACID WHICH CAN CAUSE SEVERE CHEMICAL BURNS AVOID CONTACT WITH SKIN OR EYES FAILURE TO COMPLY MAY CAUSE IMMEDIATE PERSONAL INJURY CAUTION NOISE LEVELS IN EXCESS OF 85 DECIBELS EXIST WITHIN A 50 FOOT RADIUS OF OPERATING EQUIPMENT PERSONNEL MUST WEAR SINGLE HEARING PROTECTION WITHIN A 50 FOOT RADIUS FAILURE TO COMPLY MAY CAUSE INJURY Standards Perform hourl
228. ation stamps b Inspect for holes c Check for damage to the face shields 8 Maintain the hard hats a Check for valid calibration stamps b Inspect for obvious damage 3 12 STP 5 21P2 SM TG 31 March 2009 MOS Skill Level Tasks Performance Steps 9 10 11 12 13 14 15 16 17 18 19 Inspect the safety glasses and face shields a Inspect for scratches b Inspect for structural damage Inspect the antislip floor mats a Check for tears b Inspect for excessive wear Maintain the petroleum spill kits a Check the inventory for correct stockage b Ensure that the kits are placed in the correct areas Maintain the lighted exit signs a Inspect for damage b Perform function tests Maintain the safety board a Ensure that the equipment is functional b Restock the first aid kit Inspect the fire extinguishers a Inspect for proper pressure b Check for obvious damage Inspect the eyewash stations a Perform function tests b Inspect for proper pressure Maintain the emergency lights a Perform function tests b Change the batteries and bulbs as necessary Maintain the smoke detectors a Perform a function test b Change the batteries as necessary Record actions taken on DA Form 2404 Ensure that all cleaning material electrician tools and safety equipment are properly cleaned and stored Evaluation Preparation Setup Provide the Soldier with the items
229. b Stop If there is voltage present and perform the following steps until voltage is no longer present 1 Check the schematics for proper circuit identification 2 Check for back fed circuits 3 Check for the proper use of safe clearance procedures Tag the current boost module with the appropriate calibration sticker including the name and testing date Reinstall the current boost module a Attach tagged leads b Verify connections Close out lockout and tagout procedures by removing locking and tagging devices Energize the circuit and ensure that it is operating properly Keep a record of results and actions taken Ensure that the items listed in the conditions are properly cleaned and stored Evaluation Preparation Setup Provide the Soldier with the items listed in the conditions Give the Soldier a safety briefing before starting the test and ensure that safety precautions are followed Prepare the testing area and equipment in advance to ensure that task standards can be met Brief Soldier Direct the Soldier to service a current boost module Performance Measures GO NO GO 1 A W N oOo Oo N O O Reviewed danger warning and caution notices before proceeding Reviewed the manufacturer s literature with schematics and wiring diagrams Reviewed maintenance logbooks and historical data pertaining to the equipment Identified the circuit connected to the current boost module by us
230. ble to rest the insulator pin on your belt d Remove the half hitch e Tell the groundman to raise the crossarm to allow you to set the crossarm across your safety strap Install the crossarm onto the through bolt g Tighten the through bolt nut al 31 March 2009 STP 5 21P2 SM TG 3 283 Chapter 3 Performance Steps h Remove the clove hitch i Level the crossarm j Drive in the lag screw k Lower the handline 7 Unbelt and descend the pole 8 Ensure that the items listed in the conditions are properly cleaned and stored Evaluation Preparation Setup Provide the Soldier with the items listed in the conditions Give the Soldier a safety briefing before starting the test and ensure that safety precautions are followed Prepare the testing area and equipment in advance to ensure that task standards can be met Brief Soldier Direct the Soldier to perform a crossarm change out Performance Measures GO NO GO 1 Inspected the climbing equipment tools and handline for defects Performed lockout and tagout procedures Laid out the handline and attached it to his body belt Ascended the pole until he was eye level with the lag screw and then belted in Removed the crossarm Installed the new crossarm Unbelted and descended the pole oN O oO A W N Ensured that the items listed in the conditions were properly cleaned and stored E
231. breaths e Cut the victim s safety strap on the opposite side of the desired swing DANGER DO NOT CUT YOUR OWN SAFETY STRAP OR RESCUE LINE FAILURE TO COMPLY MAY CAUSE PERMANENT INJURY OR DEATH f Lower the victim to the ground 6 Continue administering first aid until qualified medical personnel arrive Evaluation Preparation Setup Provide the Soldier with the items listed in the conditions Give the Soldier a safety briefing before starting the test and ensure that safety precautions are followed Prepare the testing area and equipment in advance to ensure that task standards can be met Brief Soldier Direct the Soldier to rescue an injured victim from a utility pole Performance Measures GO NO GO 1 Evaluated the situation by calling to the victim Ensured your own protection Climbed to the rescue position Determined the victim s condition Lowered the victim to the ground O oa A W N Continued administering first aid until qualified medical personnel arrived Evaluation Guidance Score the Soldier GO if all measures are passed P Score the Soldier NO GO if any measure is failed F If the Soldier fails any measure show him how to do it correctly References Required Related EM 385 1 1 FM 4 25 11 LCH TM 5 682 TM 5 684 3 256 STP 5 21P2 SM TG 31 March 2009 MOS Skill Level Tasks Rescue an Injured Victim From a Manhole 052 204 1115 Conditions
232. by removing locking and tagging devices Evaluation Guidance Score the Soldier GO if all measures are passed P Score the Soldier NO GO if any measure is failed F If the Soldier fails any measure show him how to do it correctly References Required Related EM 385 1 1 FM 3 34 480 FM 5 412 LCH NESC TM 5 682 TM 5 684 TM 5 686 TM 5 811 1 TM 5 811 3 STP 5 21P2 SM TG 31 March 2009 MOS Skill Level Tasks Terminate a Medium Voltage Power Cable 052 244 2103 Conditions As a power plant operator in a tactical or nontactical environment during an initial installation of cables where the power cables must be terminated or when an existing power cable termination is damaged beyond repair you are given an electrician s tool kit a lockout and tagout kit grounding equipment a megohmmeter test set a voltage detector a termination kit with instructions the tools specified in the termination kit instructions manufacturer s literature and personal protective equipment PPE DANGER 1 A VOLTAGE DETECTOR SHOULD BE USED TO ENSURE THAT THE CABLES ARE NOT ENERGIZED MATERIAL SUCH AS A LEAD SHEATH THAT ACTS AS A SHIELD MUST NOT BE BETWEEN THE DETECTOR AND THE CONDUCTORS OF THE CIRCUIT BEING TESTED FAILURE TO COMPLY MAY CAUSE PERMANENT INJURY OR DEATH WARNING 1 USE EVERY RESOURCE TO PREVENT MOISTURE DRIPPINGS CONDENSATION PERSPIRATION FROM ENTERING THE JOINT INSULATION FAILURE TO COMPLY MAY CAUSE INJURY OR EQUIPM
233. cal Code NEC Handbook requires that supplemental rods be placed at least 6 feet apart but notes that increasing the distance will improve the paralleling efficiency of 3 72 STP 5 21P2 SM TG 31 March 2009 MOS Skill Level Tasks Performance Steps the rods 6 10 11 12 Perform a ground resistance test If the resistance exceeds the required resistance levels proceed to step 7 Treat the soil with a chemical treatment a Administer magnesium sulfate least corrosive b Administer rock salt cheaper does the job if applied in a trench c Administer bentonite clay inexpensive but requires large amounts of moisture Use chemical methods to reduce the soil resistivity a Apply the pipe technique Fill a pipe that is 8 inches or larger in diameter and has a minimum length of 1 4 the ground rod length with a chemical and drive it into the soil about 4 inches from the ground rod b Prepare a circular trench by digging around the ground rod and fill it with about 40 to 90 pounds of chemical which should last 2 to 3 years Perform a ground resistance test If the resistance exceeds the required resistance levels proceed to step 10 Apply any combination of the above methods to achieve the required resistance levels Perform a ground resistance test If the resistance exceeds the required resistance levels repeat step 10 Ensure that the testing equipment and tools are properly cleaned and stored
234. ce that was tested with the schematics Performed lockout and tagout procedures Tested the circuit for voltage Removed the sensing device and tagged leads Tested the sensing device according to the manufacturer s literature and recorded the results Compared the test results with the manufacturer s specifications and took proper action Tested the circuit for voltage Reinstalled the sensing device Closed out lockout and tagout procedures by removing locking and tagging devices Energized the circuit 31 March 2009 STP 5 21P2 SM TG 3 345 Chapter 3 Performance Measures GO NO GO 14 Performed a function check 15 Kept a record of the test results and actions taken 16 Ensured that the items listed in the conditions were properly cleaned and stored Evaluation Guidance Score the Soldier GO if all measures are passed P Score the Soldier NO GO if any measure is failed F If the Soldier fails any measure show him how to do it correctly References Required Related TM 5 6115 593 12 TM 5 6115 593 34 3 346 STP 5 21P2 SM TG 31 March 2009 Appendix A Metric Conversion Chart This appendix complies with current Army directives which state that the metric system will be incorporated into all new publications Table A 1 is a metric conversion chart Table A 1 Metric Conversion Chart U S Units Multiplied By Equals Metric Units Length Feet 0 30480 Meters I
235. ces Ensure that the items listed in the conditions are properly cleaned and stored Evaluation Preparation Setup Provide the Soldier with the items listed in the conditions Give the Soldier a safety briefing before starting the test and ensure that safety precautions are followed Prepare the testing area and equipment in advance to ensure that task standards can be met Brief Soldier Direct the Soldier to perform a power factor and dissipation factor test Performance Measures 1 2 10 11 12 13 14 15 16 17 Reviewed danger warning and caution notices Reviewed the manufacturer s literature electrical construction prints and wiring diagrams Performed lockout and tagout procedures Used a voltage detector to verify that no voltage existed at equipment connection points Installed safety grounds Prepared an as found wiring diagram that showed the connection configuration used to attach the equipment to the system Disconnected the cables from the equipment terminals as necessary to perform the test Marked the cable ends to identify connection points and designated phases Cleaned the equipment to be tested after the as found test was completed if the as found readings were needed Employed the test equipment and performed a power factor and dissipation factor test according to the manufacturer s literature Kept a record of the test results Kept a recorded of the en
236. ces Required Related EM 385 1 1 FM 3 34 480 3 42 STP 5 21P2 SM TG 31 March 2009 MOS Skill Level Tasks Install a Nonorganic Generator 052 244 2124 Conditions As a power plant operator in a tactical or nontactical environment with a mission to install a nonorganic generator that is properly sited and has fuel lines and electrical connections you are given technical manuals a general mechanic s tool box a multimeter ground rods a slide hammer cable rated for generator output with terminations a high voltage insulation tester and personal protective equipment DANGER 1 THIS TASK SHOULD ONLY BE PERFORMED BY QUALIFIED PERSONNEL WHO ARE KNOWLEDGEABLE IN THE INSTALLATION OPERATION AND MAINTENANCE OF ELECTRICAL POWER GENERATION EQUIPMENT AND ITS ASSOCIATED HAZARDS FAILURE TO COMPLY MAY CAUSE PERMANENT INJURY OR DEATH 2 DO NOT OPERATE THE GENERATOR SET UNLESS IT HAS BEEN PROPERLY GROUNDED IT MAY BE POSSIBLE TO CONNECT INTO AN EXISTING GROUND GRID AT THE TIME OF INSTALLING THE GROUND THE GROUND RESISTANCE MUST BE MEASURED AND MUST NOT EXCEED 25 OHMS FAILURE TO COMPLY MAY CAUSE PERMANENT INJURY OR DEATH 3 THE INSULATION TESTER PRODUCES HIGH VOLTAGE DO NOT TOUCH THE CABLE BEING TESTED OR THE TEST LEADS ALWAYS REMOVE POWER AND THEN DISCHARGE AND GROUND THE CIRCUIT FOR TWICE THE AMOUNT OF TIME IT WAS TESTED BEFORE HANDLING IT FAILURE TO COMPLY MAY CAUSE PERMANENT INJURY OR DEATH 4 REMOVE RINGS NECKLACES OTHER JEWELRY
237. citer rotor assembly to ensure that ohm values are more than 1 megohm a Apply the manufacturer s recommended voltage for 60 seconds using the megohmmeter b Keep a record of the readings c Perform preventive measures cleaning drying repairing replacing Test the exciter stator to ensure that ohm values are more than 1 megohm a Apply the manufacturer s recommended voltage for 60 seconds using the megohmmeter b Keep a record of the readings c Perform preventive measures cleaning drying repairing replacing Test the rotating rectifier a Remove bolted lead wires from rectifiers at the terminal studs b Test the resistance between the disconnected lead wire and the base of each rectifier c Note the reading and reverse the multimeter probes one reading will be high and the other low if the rectifier is good d Repair the rotating rectifier assembly by replacing damaged or defective components parts Replace bolted lead wires on rectifiers at the terminal studs Close out lockout and tagout procedures by removing locking and tagging devices Ensure that the items listed in the conditions are properly cleaned and stored Evaluation Preparation Setup Provide the Soldier with the items listed in the conditions Give the Soldier a safety briefing before starting the test and ensure that safety precautions are followed Prepare the testing area and equipment in advance to ensure that task standards can be met Brief Soldier
238. ck for valid calibration stamps b Inspect for holes c Check for face shield damage Evaluation Preparation Setup Provide the Soldier with the items listed in the conditions Give the Soldier a safety briefing before starting the test and ensure that safety precautions are followed Prepare the testing area and equipment in advance to ensure that task standards can be met 31 March 2009 STP 5 21P2 SM TG 3 261 Chapter 3 Brief Soldier Direct the Soldier to inspect hot line equipment Performance Measures 1 2 3 Inspected hot sticks Inspected grounding sticks Inspected ground clusters Inspected rubber gloves 4 5 6 7 Inspected rubber sleeves Inspected rubber blankets and mats Inspected flash suits Evaluation Guidance Score the Soldier GO if all measures are passed P Score the Soldier NO GO if any measure is failed F If the Soldier fails any measure show him how to do it correctly References Required Related DA FORM 2404 LCH TM 5 682 TM 5 684 3 262 STP 5 21P2 SM TG 31 March 2009 MOS Skill Level Tasks Maintain Climbing and Rigging Equipment 052 204 1118 Conditions As a power line distribution specialist in a tactical or nontactical environment during scheduled or unscheduled maintenance when climbing and rigging equipment needs maintenance you are given the applicable cleaning and maintenance supplies the applicable manufacturer s literature and the applicab
239. connected the transformer Closed out lockout and tagout procedures by removing locking and tagging devices Ensured that the items listed in the conditions were properly cleaned and stored Evaluation Guidance Score the Soldier GO if all measures are passed P Score the Soldier NO GO if any measure is failed F If the Soldier fails any measure show him how to do it correctly References Required Related EM 385 1 1 TM 5 686 3 330 STP 5 21P2 SM TG 31 March 2009 MOS Skill Level Tasks Service an Automatic Transfer Switch ATS 052 264 2112 Conditions As a power plant operator in a tactical or nontactical environment during maintenance intervals you are given a lockout and tagout kit a general mechanic s tool box an electrician s tool kit a low resistance ohmmeter a megohmmeter a torque wrench maintenance logbooks wiring diagrams a grounding cluster conductive and nonconductive grease and applicable manufacturer s literature with schematics DANGER 1 THIS TASK SHOULD ONLY BE PERFORMED BY QUALIFIED PERSONNEL WHO ARE KNOWLEDGEABLE IN THE INSTALLATION AND MAINTENANCE OF SWITCHGEAR AND POWER EQUIPMENT AND THEIR ASSOCIATED HAZARDS FAILURE TO COMPLY MAY CAUSE PERMANENT INJURY OR DEATH 2 DO NOT TOUCH EXPOSED ELECTRICAL CONNECTIONS WHEN THE POWER SOURCE IS CONNECTED TO THE SWITCH FAILURE TO COMPLY MAY CAUSE PERMANENT INJURY OR DEATH 3 REMOVE RINGS NECKLACES OTHER JEWELRY AND LOOSE CLOTHING FAILUR
240. corporated for program updates 2 Do not troubleshoot logged events while they are listed as inactive 1 Inventory Caterpillar ET tool parts NOTES 1 The Caterpillar ET tool is designed to help the power station mechanic obtain and analyze data and diagnose potential and existing problems within the electronic system This tool is required to perform calibrations and read or change programmable parameters 2 The Caterpillar ET tool can be used to service electronic engines The Caterpillar communication adaptor is required to communicate with the electronic control module 3 168 STP 5 21P2 SM TG 31 March 2009 MOS Skill Level Tasks Performance Steps 3 The engine control switch should be turned to the OFF and RESET positions so that the engine does not start 2 Connect the Caterpillar ET tool with the communication adaptor to the engine a Connect the serial cable RS 232 PN 160 0141 to the operator remote terminal b Connect the serial cable RS 232 PN 160 0141 to the communication adaptor PN 171 4400 c Connect data link cable PN 160 0133 to the service connector on the engine d Use the data link cable PN 160 0133 to connect the service connector to the communication adaptor PN 171 4400 3 Turn the operator s remote terminal to the ON position a Click on the Caterpillar ET tool icon the window displays Caterpillar Electronic Technician b Click to open the active diagnostic codes the screen should sho
241. ction Maintenance Worksheet DANGER 1 ENSURE THAT EQUIPMENT IS PROPERLY LOCKED OUT AND TAGGED OUT FAILURE TO COMPLY MAY CAUSE PERMANENT INJURY OR DEATH 2 REMOVE RINGS NECKLACES OTHER JEWELRY AND LOOSE CLOTHING FAILURE TO COMPLY MAY CAUSE PERMANENT INJURY OR DEATH WARNING 1 WHEN DISCONNECTING BATTERY CABLES ALWAYS DISCONNECT THE NEGATIVE TERMINAL FIRST WHEN RECONNECTING CONNECT THE POSITIVE TERMINAL FIRST FAILURE TO COMPLY MAY RESULT IN SPARKING OR BATTERY EXPLOSION AND MAY CAUSE IMMEDIATE PERSONAL INJURY OR DAMAGE TO THE EQUIPMENT 2 ENGINE OIL GETS VERY HOT DURING OPERATION DO NOT REMOVE ANY OIL OR LUBE OIL COMPONENTS UNTIL THE ENGINE HAS COOLED FAILURE TO COMPLY MAY CAUSE IMMEDIATE PERSONAL INJURY CAUTION NOISE LEVELS IN EXCESS OF 85 DECIBELS EXIST WITHIN A 50 FOOT RADIUS OF OPERATING EQUIPMENT PERSONNEL MUST WEAR SINGLE HEARING PROTECTION WITHIN A 50 FOOT RADIUS FAILURE TO COMPLY MAY CAUSE INJURY Standards Service a diesel engine lube oil system by inspecting and replacing or repairing the defective components parts 3 148 STP 5 21P2 SM TG 31 March 2009 MOS Skill Level Tasks Performance Steps 1 Review maintenance logbooks and historical data pertaining to the equipment to verify that the diesel engine lube oil system needs to be serviced 2 Perform lockout and tagout procedures NOTE The following inspections and checks are guidelines and may be done in any order If defective components pa
242. ction using the safety checklist detailed job description and applicable safety SOPs Record deficiencies on the safety checklist Stop actions that appear to be unsafe Performance Steps 1 Obtain standards for the inspection Inform personnel of the inspection Conduct the inspection Note deficiencies found during the inspection on the safety checklist Inform personnel of deficiencies found during the inspection O oa A W N Verify that the deficiencies are corrected Evaluation Preparation Setup Provide the Soldier with the items listed in the conditions Brief Soldier Direct the Soldier to conduct a safety inspection Performance Measures GO NO GO 1 Obtained standards for the inspection Informed personnel of the inspection Conducted the inspection Noted deficiencies found during the inspection on the safety checklist Informed personnel of deficiencies found during the inspection O oa A OO N Verified that the deficiencies were corrected Evaluation Guidance Score the Soldier GO if all measures are passed P Score the Soldier NO GO if any measure is failed F If the Soldier fails any measure show him how to do it correctly References Required Related FM 5 19 AR 385 10 EM 385 1 1 ER 385 1 31 LCH TM 5 682 TM 5 684 3 296 STP 5 21P2 SM TG 31 March 2009 MOS Skill Level Tasks Develop a Bill of Materials BOM List 052 204 2
243. cturer s literature and ensured that the test set did not trip when an overpotential voltage was applied Reconnected the isolated equipment Closed out lockout and tagout procedures by removing locking and tagging devices Reenergized the de energized equipment and performed a functions check Ensured that the items listed in the conditions were properly cleaned and stored Evaluation Guidance Score the Soldier GO if all measures are passed P Score the Soldier NO GO if any measure is failed F If the Soldier fails any measure show him how to do it correctly References Required Related FM 3 34 480 NESC NETA 3 206 STP 5 21P2 SM TG 31 March 2009 MOS Skill Level Tasks Service a System Ground 052 206 2104 Conditions As a power station electrician in a tactical or nontactical environment during maintenance or when a system ground is initially installed you are given a general mechanic s tool box a ground resistive test set a 3 pound hammer personal protective gear electrical construction prints wiring diagrams the National Electrical Code NEC Handbook the Institute of Electrical and Electronics Engineers IEEE Green Book and a multimeter DANGER 1 A FAULT IN THE POWER SYSTEM WILL CAUSE A HIGH CURRENT TO FLOW INTO THE GROUND SYSTEM WHILE THE TEST IS IN PROGRESS ALWAYS WEAR RUBBER GLOVES WHEN TESTING ENERGIZED CIRCUITS FAILURE TO COMPLY MAY CAUSE PERMANENT INJURY OR DEATH 2 REMOVE RINGS
244. d the equipment should be cleaned after the test 7 Clean the equipment to be tested NOTE Complete a megohmmeter test before performing a high potential test The megohmmeter test is less destructive and can locate faults before the high potential test can find them 8 Determine which type of insulation test such as the megohmmeter or high potential test to use 31 March 2009 STP 5 21P2 SM TG 3 247 Chapter 3 Performance Steps 9 Disconnect cables from the equipment terminals as necessary to perform the test 10 Employ the test equipment and perform the insulation resistance test according to operation instructions provided with the test set NOTE When electrical equipment has multiple primary and secondary windings all primary and secondary windings that are not being tested must be shorted together and shorted to the ground NOTE If no standards or test records for the equipment can be found the minimum accepted standard for the megohmmeter test is 1 megohm per kilovolt of rated voltage plus 1 megohm 11 Keep a record of the test results 12 Determine the status of the insulation by interpreting the test a Proceed to step 13 if results are acceptable b Clean repair or replace the equipment if results are unacceptable c Retest the equipment 13 Reconnect and torque cables as necessary 14 Remove safety grounds 15 Close out lockout and tagout procedures by removing locking and tagging devices 16 Reene
245. d because they can change earth electrode requirements over a period of time include e Expanding the facility size or incorporating different pieces of electrical equipment which can render formerly suitable low earth resistance standards obsolete e Increasing the use of nonmetallic pipes and conduits which can change the overall effectiveness of low resistance ground connections e Decreasing the area water table which can result in a drier high earth resistance Standards Improve resistance of the ground system to meet required parameters Review existing grounding methods and techniques and determine which ones are best for improving ground resistance Performance Steps 1 Determine the soil condition a Assess the type of soil and determine if it is 1 Sandy 2 Rocky 3 Loam 4 Gravel b Record the moisture level of the soil 2 Assemble multiple rods to lengthen the earth electrode a Ensure that the connection is rigid b Ensure that the minimum diameter of the rod is at least 5 8 inch 3 Align the electrode at an oblique angle that does not exceed 45 and drive the rod a minimum of 8 feet deep in contact with the soil 4 Perform a ground resistance test If the resistance exceeds the required resistance levels proceed to step 5 7 and or 8 5 Place multiple rods a Space the rods further than the length of their immersion b Maintain at least 6 feet between each rod NOTE The National Electri
246. d cutouts i Slow the close open breaker and check for binding j Perform a time travel analysis k Verify that contact lubricant is present on moving current carrying parts 3 236 STP 5 21P2 SM TG 31 March 2009 MOS Skill Level Tasks Performance Steps 6 Verify that lubrication is present on moving sliding surfaces Perform resistance measurements through the bolted connections using a low resistance ohmmeter and compare contact resistances of electrical connections to the values of similar connections and to the values specified in the manufacturer s literature Perform insulation resistance tests pole to pole pole to ground and across open poles and ensure that insulation resistance test values at 1 minute are no less than 1 000 megohms at a direct current DC voltage of 2 500 volts unless otherwise specified in the manufacturer s literature Perform an insulation resistance test on the control wiring according to the manufacturer s literature ensure that the insulation resistance of the control wiring is a minimum of 2 megohms and for units with solid state components parts follow the manufacturer s recommendations Perform a power factor and dissipation factor test on the breaker and bushings compare the results to the manufacturer s specifications and if the manufacturer s literature is not available compare the test results to similar circuit breakers NOTE Test results should be within 10 pe
247. d tagging devices Ensure that the items listed in the conditions are properly cleaned and stored Evaluation Preparation Setup Provide the Soldier with the items listed in the conditions Give the Soldier a safety briefing before starting the test and ensure that safety precautions are followed Prepare the testing area and equipment in advance to ensure that task standards can be met Brief Soldier Direct the Soldier to service an air magnetic circuit breaker Performance Measures GO NO GO 1 2 3 Reviewed danger warning and caution notices _ Reviewed the manufacturer s literature and wiring diagrams Reviewed maintenance logbooks and historical data pertaining to the equipment 4 Performed lockout and tagout procedures 31 March 2009 STP 5 21P2 SM TG 3 231 Chapter 3 Performance Measures 5 6 7 10 11 12 13 14 15 Kept a record of as left and as found operation counter readings Inspected the condition of the circuit breaker visually and manually Performed resistance measurements through the bolted connections using a low resistance ohmmeter and compared contact resistances of electrical connections to the values of similar connections if the manufacturer s literature was not available Performed insulation resistance tests pole to pole pole to ground and across open poles and ensured that insulation resistance test values at 1 minute were no l
248. d the lines and symbols on the diagram 3 Determined the functions of symbols on the one line diagram and the relationships between electrical devices 4 Identified possible electrical paths depending on switchgear positioning Evaluation Guidance Score the Soldier GO if all measures are passed P Score the Soldier NO GO if any measure is failed F If the Soldier fails any measure show him how to do it correctly References Required Related EM 385 1 1 FM 3 34 480 FM 5 412 LCH TM 5 684 TM 5 686 TM 5 811 1 TM 5 811 3 31 March 2009 STP 5 21P2 SM TG 3 287 Chapter 3 Splice a Medium Voltage Power Cable 052 204 1129 Conditions As a power line distribution specialist in a tactical or nontactical environment during an initial installation of cables where power cables must be joined or a power cable is damaged beyond repair you are given an applicable splice kit with instructions applicable tools specified in the splice kit instructions an electrician s tool kit a lockout and tagout kit grounding equipment a megohmmeter test set a voltage detector applicable manufacturer s literature applicable personal protective equipment applicable climbing and rigging equipment two conductor grips universal sticks with attachments and resistor sticks for overhead splices DANGER A VOLTAGE DETECTOR SHOULD BE USED TO ENSURE THAT CABLES ARE NOT ENERGIZED MATERIALS SUCH AS A LEAD SHEATH THAT ACTS AS A SHIE
249. ditions in the Remarks section of the log sheet 8 Record hydraulic system readings such as the sight glass and the dipstick 9 Record actions taken on DA Form 2404 or DA Form 5988 E Evaluation Preparation Setup Provide the Soldier with the items listed in the conditions Give the Soldier a safety briefing before starting the test and ensure that safety precautions are followed Prepare the testing area and equipment in advance to ensure that task standards can be met Brief Soldier Direct the Soldier to perform generator set hourly checks Performance Measures GO NO GO 1 Reviewed danger warning and caution notices 2 Recorded administrative data 3 Recorded instrument panel readings 4 Recorded the engine oil level reading from the engine compartment oil pan dipstick or sight glass S Recorded the coolant level from the radiator sight glass 6 Recorded the battery charger voltage and amperes 7 Checked the generator set for damage excessive or discolored smoke and unusual noise Recorded unusual conditions in the Remarks section of the log 3 2 STP 5 21P2 SM TG 31 March 2009 MOS Skill Level Tasks Performance Measures GO NO GO sheet 8 Recorded hydraulic system readings such as the sight glass and the dipstick 9 Recorded actions taken on DA Form 2404 or DA Form 5988 E Evaluation Guidance Score the Sold
250. e O OO N O oO KR Q Verified that the fault was corrected gt Closed out the lockout and tagout procedures by removing locking and tagging devices 12 Put the system back into service 13 Ensured that items listed in the conditions were properly cleaned and stored 14 Ensured that deficiencies and troubleshooting procedures were recorded in the maintenance logbook Evaluation Guidance Score the Soldier GO if all measures are passed P Score the Soldier NO GO if any measure is failed F If the Soldier fails any measure show him how to do it correctly References Required Related UGLYS DA FORM 2404 EM 385 1 1 31 March 2009 STP 5 21P2 SM TG 3 51 Chapter 3 Troubleshoot an Alternating Current AC Control Voltage Circuit 052 244 2129 Conditions As a power plant operator in a tactical or nontactical environment when an AC control voltage circuit malfunctions you are given Ugly s Electrical Reference a general mechanic s tool box a maintenance logbook and the manufacturer s literature with schematics DANGER 1 THIS TASK SHOULD ONLY BE PERFORMED BY QUALIFIED PERSONNEL WHO ARE KNOWLEDGEABLE IN THE INSTALLATION OPERATION AND MAINTENANCE OF ELECTRICAL POWER GENERATION EQUIPMENT AC SYSTEMS AND THEIR ASSOCIATED HAZARDS FAILURE TO COMPLY MAY CAUSE PERMANENT INJURY OR DEATH 2 ALWAYS WEAR THE PERSONAL PROTECTIVE EQUIPMENT REQUI
251. e electrical construction prints and wiring diagrams 3 Perform lockout and tagout procedures 4 Remove barriers and covers to gain access to the bus bars NOTE If an IR camera is available and the equipment can be energized safely with the barriers and covers removed perform an IR survey of the electrical connections 5 Ensure that the grounding cluster is installed and that the equipment being tested is properly grounded 6 Inspect the bus bars a Check for discoloration b Check for excess debris c Check for tracking d Check for poor alignment e Check for improper connections f Check for moisture 7 Test electrical connections using a digital low resistance ohmmeter 8 Keep a record of the findings from the inspection 9 Clean the bus bars 10 Clean the nonconductive material such as the insulators and standoffs 11 Correct deficiencies if possible 31 March 2009 STP 5 21P2 SM TG 3 221 Chapter 3 Performance Steps 12 Keep a record of deficiencies that cannot be corrected 13 Remove the grounding cluster 14 Replace barriers and covers 15 Close out lockout and tagout procedures by removing locking and tagging devices 16 Reenergize the equipment 17 Ensure that the items listed in the conditions are properly cleaned and stored Evaluation Preparation Setup Provide the Soldier with the items listed in the conditions Give the Soldier a safety briefing before starting the test and ensure that saf
252. e manufacturer s literature e Perform an excitation test using the test equipment according to the manufacturer s literature Measure the resistance of each winding at the designated tap position and compare the measurements within 1 percent of previously obtained results after factoring in temperature al 31 March 2009 STP 5 21P2 SM TG 3 215 Chapter 3 Performance Steps corrections 7 Reconnect the isolated equipment 8 Close out lockout and tagout procedures by removing locking and tagging devices 9 Reenergize the de energized equipment 10 Check the primary and secondary sides of the transformer for the proper voltages listed on the equipment data plate 11 Ensure that the items listed in the conditions are properly cleaned and stored Evaluation Preparation Setup Provide the Soldier with the items listed in the conditions Give the Soldier a safety briefing before starting the test and ensure that safety precautions are followed Prepare the testing area and equipment in advance to ensure that task standards can be met Brief Soldier Direct the Soldier to service a power transformer Performance Measures GO NO GO 1 Reviewed danger warning and caution notices 2 Reviewed the manufacturer s literature electrical construction prints and wiring diagrams Performed lockout and tagout procedures Serviced a dry type power transformer Serviced a liquid filled power t
253. e 2007 DA forms are available on the APD website lt www apd army mil gt DA FORM 2028 DA FORM 2404 DA FORM 2702 DA FORM 3758 R DA FORM 5164 R DA FORM 5988 E Field Manuals FM 25 4 FM 25 5 FM 5 19 FM 5 424 FM 7 0 FM 7 1 Other Product Types ASTM D1500 ASTM D1524 ASTM D1816 ASTM D3612 ASTM D877 ASTM D923 ASTM D971 ASTM D974 31 March 2009 Recommended Changes to Publications and Blank FORMS Equipment Inspection and Maintenance Worksheet Bill of Materials Calibration and Repair Requirements Worksheet LRA Hands On Evaluation Equipment Inspection Maintenance Worksheet EGA How to Conduct Training Exercises 10 September 1984 Training for Mobilization and War 25 January 1985 Composite Risk Management 21 August 2006 Theater of Operations Electrical Systems 25 June 1997 Training for Full Spectrum Operations 12 December 2008 Battle Focused Training 15 September 2003 Standard Test Method for ASTM Color of Petroleum Products ASTM Color Scale 1 November 2004 lt http Awww astm org Standards D1500 htm gt Standard Test Method for Visual Examination of Used Electrical Insulating Oils of Petroleum Origin in the Field 1 October 2004 lt http Awww astm org Standards D1524 htm gt Standard Test Method for Dielectric Breakdown Voltage of Insulating Oils of Petroleum Origin Using VDE Electrodes 1 February 2004 lt http www astm org Standards D1816 htm gt Standard Test Method for Analysis of Gases
254. e affected portion of the system if required for a specific system service 5 Located and determined the type of external tank blivet fuel pod or tanker 31 March 2009 STP 5 21P2 SM TG 3 177 Chapter 3 Performance Measures GO NO GO 6 Removed the fuel water separator and strainers for replacement or cleaning 7 Drained the water through the bottom petcocks on aboveground tanks 8 Cleaned debris from in line strainers located on the inlet side of the pumps 9 Checked the fuel system for leaks or faulty components 10 Ensured that connection points were properly tightened 11 Closed out lockout and tagout procedures by removing locking and tagging devices 12 Started the diesel engine and observed the fuel system for leaks 13 Recorded actions taken on DA Form 2404 or DA Form 5988 E and maintenance logbooks 14 Ensured that the items listed in the conditions were properly cleaned and stored Evaluation Guidance Score the Soldier GO if all measures are passed P Score the Soldier NO GO if any measure is failed F If the Soldier fails any measure show him how to do it correctly References Required Related DA FORM 2404 EM 385 1 1 DA FORM 5988 E FM 10 67 1 TM 5 6115 456 34P TM 5 6115 593 12 TM 5 6115 593 34 3 178 STP 5 21P2 SM TG 31 March 2009 MOS Skill Level Tasks Service a Diesel Engine Starting System 05
255. e fully extended upper boom third stage with water Wash and clean the hydraulic tank top Sweep the back of the truck bed na0q 0 8 5 Record actions taken on DA Form 2404 or DA Form 5988 E and maintenance logbooks Evaluation Preparation Setup Provide the Soldier with the items listed in the conditions Give the Soldier a safety briefing before starting the test and ensure that safety precautions are followed Prepare the testing area and equipment in advance to ensure that task standards can be met Brief Soldier Direct the Soldier to perform operator PMCS on a line truck with auxiliary equipment Performance Measures GO NO GO 1 Performed before operation PMCS 2 Performed during operation PMCS and annotated the deficiencies 3 Performed after operation PMCS 4 Performed weekly operation PMCS 5 Recorded actions taken on DA Form 2404 or DA Form 5988 E and maintenance logbooks Evaluation Guidance Score the Soldier GO if all measures are passed P Score the Soldier NO GO if any measure is failed F If the Soldier fails any measure show him how to do it correctly References Required Related DA FORM 2404 EM 385 1 1 DA FORM 5988 E LCH TM 5 684 3 268 STP 5 21P2 SM TG 31 March 2009 MOS Skill Level Tasks Install a Grounding Set 052 204 1120 Conditions As a power line distribution specialist in a tactical or nontactical environment when a grounding set ne
256. e heading with the current information of the unit b Record the stock or part number c Record the name and description of the item d Record the unit of issue e Record the total quantity of each item Evaluation Preparation Setup Provide the Soldier with the items listed in the conditions Give the Soldier a safety briefing before starting the test and ensure that safety precautions are followed Prepare the testing area and equipment in advance to ensure that task standards can be met Brief Soldier Direct the Soldier to develop a BOM list Performance Measures GO NO GO 1 Reviewed the electrical construction prints 2 Completed a BOM list 3 Completed DA Form 2702 Evaluation Guidance Score the Soldier GO if all measures are passed P Score the Soldier NO GO if any measure is failed F If the Soldier fails any measure show him how to do it correctly References Required Related DA FORM 2702 FM 3 34 480 31 March 2009 STP 5 21P2 SM TG 3 297 Chapter 3 References Required Related LCH FM 5 412 TM 5 811 1 TM 5 684 3 298 STP 5 21P2 SM TG 31 March 2009 MOS Skill Level Tasks Energize an Electrical Distribution System 052 204 2212 Conditions As a power line distribution supervisor in a tactical or nontactical environment when an electrical distribution system must be energized or reenergized you are given applicable electrical one line diagrams electrical construction pri
257. e inside of the PU by opening the side access door Ensured that battery chargers were plugged into the battery charger receptacle circuit breakers were turned on and chargers were working Inspected the air intake duct for obstructions or foreign objects Drained the crankcase vent reservoir into a proper container Opened the petcock of the primary fuel filter and drained the water and sediment into a proper container Checked oil levels Ensured that the fuel shutoff valve was in the OPEN position Removed splash guards Checked fuel hydraulic and radiator fill tanks for leaks and damage Checked fuel levels with the built in dipstick coolant levels through the coolant sight glass and hydraulic fluid levels through the hydraulic fluid sight glass Checked the fuel transfer pump assembly for secure mounting and leaks Checked the condition of the batteries Ensured that the battery isolation switch was in the OFF position Used a flashlight to check between the generators for leaks loose hardware and other potential problems Ensured that tie output cables were properly connected and that concentric neutrals were connected to the ground Ensured that the tie output cover was locked Checked the PU equipment grounds for proper connection Ensured that the PU interconnect control cable was properly connected Inspected the exterior fuel system for proper connection leaks and fuel availability 31 March 2009 STP 5 21P
258. e items listed in the conditions are properly cleaned and stored Evaluation Preparation Setup Provide the Soldier with the items listed in the conditions Give the Soldier a safety briefing before starting the test and ensure that safety precautions are followed Prepare the testing area and equipment in advance to ensure that task standards can be met Brief Soldier Direct the Soldier to perform PMCS on an MEP 810A or B generator Performance Measures GO NO GO 1 2 Ensured that the parking brake was set by rotating the crank clockwise Ensured that wheels were properly chocked 3 34 STP 5 21P2 SM TG 31 March 2009 MOS Skill Level Tasks Performance Measures 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 Opened the petcock on the air tank to evacuate the air from the spring set brakes Checked the ground connection for tightness Ensured that the operator remote terminal and communication ports were properly connected Ensured that the feeder output cables were properly connected and that the concentric neutrals were grounded Ensured that the feeder output covers were secured Checked parking stands for proper mounting and connection Ensured that the two 120 volt auxiliary duplex receptacles and the 60 amp three phase receptacle cables were securely connected and that the covers were properly installed Inspected th
259. e logbook 8 Record actions taken on DA Form 2404 or DA Form 5988 E 9 Ensure that the items listed in the conditions are properly cleaned and stored Evaluation Preparation Setup Provide the Soldier with the items listed in the conditions Give the Soldier a safety briefing before starting the test and ensure that safety precautions are followed Prepare the testing area and equipment in advance to ensure that task standards can be met Brief Soldier Direct the Soldier to troubleshoot an engine failure to stop 31 March 2009 STP 5 21P2 SM TG 3 17 Chapter 3 Performance Measures GO NO GO 1 Reviewed danger warning and caution notices 2 Reviewed the manufacturer s literature electrical construction prints and wiring _ diagrams 3 Reviewed the maintenance logbook and historical data pertaining to the equipment Checked the system emergency STOP button Checked the stop circuit Corrected deficiencies if possible Recorded faults in the maintenance logbook Recorded actions taken on DA Form 2404 or DA Form 5988 E oO oo N DO ON A Ensured that the items listed in the conditions were properly cleaned and stored Evaluation Guidance Score the Soldier GO if all measures are passed P Score the Soldier NO GO if any measure is failed F If the Soldier fails any measure show him how to do it correctly References Requ
260. eaker operations g Document generator startups and shutdowns h Document unusual plant occurrences i Document names of personnel on shift turnovers j Document times of shift turnovers Evaluation Preparation Setup Provide the Soldier with the items listed in the conditions Give the Soldier a safety briefing before starting the test and ensure that safety precautions are followed Prepare the testing area and equipment in advance to ensure that task standards can be met Brief Soldier Direct the Soldier to record maintenance and or operational data Performance Measures GO NO GO 1 Identified the type of work logged as maintenance or operational 2 Recorded information in the maintenance logbook 3 Recorded information in the operational logbook Evaluation Guidance Score the Soldier GO if all measures are passed P Score the Soldier NO GO if any measure is failed F If the Soldier fails any measure show him how to do it correctly 3 68 STP 5 21P2 SM TG 31 March 2009 MOS Skill Level Tasks References Required Related ASTM D1500 FM 3 34 480 NETA 31 March 2009 STP 5 21P2 SM TG 3 69 Chapter 3 Install Low Voltage Wiring 052 244 2138 Conditions As a power plant operator in a tactical or nontactical environment in which low voltage wiring is being installed you are given the National Electrical Code NEC Handbook manufacturers literature a voltage detector a multim
261. echanic s tool box special manufacturer s tools and DA Form 2404 Equipment Inspection and Maintenance Worksheet or DA Form 5988 E Equipment Inspection Maintenance Worksheet DANGER REMOVE RINGS NECKLACES OTHER JEWELRY AND LOOSE CLOTHING FAILURE TO COMPLY MAY CAUSE PERMANENT INJURY OR DEATH CAUTION NOISE LEVELS IN EXCESS OF 85 DECIBELS EXIST WITHIN A 50 FOOT RADIUS OF OPERATING EQUIPMENT PERSONNEL MUST WEAR SINGLE HEARING PROTECTION WITHIN A 50 FOOT RADIUS FAILURE TO COMPLY MAY CAUSE PERSONAL INJURY Standards Troubleshoot a diesel engine with unusual smoke coming from the exhaust stack Test the engine to verify the cause of the smoke and annotate the problem according to applicable manufacturer s literature Performance Steps 1 Review maintenance logbooks and historical data pertaining to the equipment 2 Identify the smoke color to determine the cause of the malfunction a Identify white or blue smoke and determine that it indicates NOTE White or blue smoke can indicate one or more of the following 1 Incorrect fuel grade 2 Incorrect oil grade 3 Too much oil in the sump NOTE Ensure that the fuel and oil grades are correct for extreme environmental conditions if applicable b Identify black smoke and determine that it indicates NOTE Black smoke can indicate one or more of the following Air restriction in the air filter or combustion chamber 2 Faulty cylinder head or gasket 3 Turbocharger mal
262. ection for tightness Ensure that the operator remote terminal and communication ports are properly connected O oa A OO N Ensure that the feeder output cables are properly connected and that the concentric neutrals are grounded N Ensure that the feeder output covers are secured 8 Check parking stands for proper mounting and connection 9 Ensure that the two 120 volt auxiliary duplex receptacles and the 60 amp three phase receptacle cables are securely connected and that the covers are properly installed 10 Inspect the inside of the power unit PU by opening the side access door a Inspect the area for cleanliness loose electrical connections loose hardware and leaks around the oil filter and oil lines b Check for heat damage and other abnormalities c Check high voltage panels for security 11 Ensure that battery chargers are plugged into the battery charger receptacle circuit breakers are turned on and chargers are working 12 Inspect the air intake duct for obstructions or foreign objects 13 Drain the crankcase vent reservoir into a proper container 31 March 2009 STP 5 21P2 SM TG 3 33 Chapter 3 Performance Steps 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 Open the petcock of the primary fuel filter and drain the water and sediment into a proper container Check oil levels Ensure that the fuel shutoff valve is in the OPEN
263. ed TM 5 6115 593 12 EM 385 1 1 3 32 STP 5 21P2 SM TG 31 March 2009 MOS Skill Level Tasks Perform Preventive Maintenance Checks and Services PMCS on a Mobile Electric Power MEP 810A or B Generator 052 244 2117 Conditions As a power plant operator in a tactical or nontactical environment you are given an MEP 810A or B generator the operator s manual technical manuals TMs DA Form 2404 Equipment Inspection and Maintenance Worksheet or DA Form 5988 E Equipment Inspection Maintenance Worksheet a pen a clipboard a general mechanic s tool box a wiping cloth and personal protective equipment DANGER 1 DO NOT TOUCH EXPOSED ELECTRICAL CONNECTIONS WHEN A POWER SOURCE SUCH AS UTILITY POWER OR ANOTHER GENERATOR SET IS CONNECTED TO THE LOAD TERMINALS FAILURE TO COMPLY MAY CAUSE PERMANENT INJURY OR DEATH 2 REMOVE RINGS NECKLACES OTHER JEWELRY AND LOOSE CLOTHING FAILURE TO COMPLY MAY CAUSE PERMANENT INJURY OR DEATH WARNING AVOID CONTACT WITH BATTERY ELECTROLYTES THEY CONTAIN SULFURIC ACID THAT CAN CAUSE SEVERE CHEMICAL BURNS SKIN AND EYE PROTECTION IS REQUIRED FAILURE TO COMPLY MAY CAUSE INJURY Standards Perform PMCS on an MEP 810A or B generator according to the TMs Performance Steps 1 Ensure that the parking brake is set by rotating the crank clockwise Ensure that wheels are properly chocked Open the petcock on the air tank to evacuate the air from the spring set brakes Check the ground conn
264. eds to be installed you are given electrical construction prints applicable climbing and rigging equipment hot line tools a voltage detector a lockout and tagout kit the Lineman s and Cableman s Handbook LCH and the applicable personal protective equipment PPE DANGER 1 THIS TASK SHOULD ONLY BE PERFORMED BY QUALIFIED PERSONNEL KNOWLEDGEABLE IN THE INSTALLATION OPERATION AND MAINTENANCE OF MEDIUM VOLTAGE ELECTRICAL POWER GENERATION EQUIPMENT AND THE ASSOCIATED HAZARDS FAILURE TO COMPLY MAY CAUSE PERMANENT INJURY OR DEATH 2 A VOLTAGE DETECTOR SHOULD BE USED TO ENSURE THAT CABLES ARE NOT ENERGIZED MATERIAL SUCH AS A LEAD SHEATH THAT ACTS AS A SHIELD MUST NOT BE BETWEEN THE VOLTAGE DETECTOR AND THE CONDUCTORS OF THE CIRCUIT BEING TESTED FAILURE TO TEST CABLES MAY CAUSE PERMANENT INJURY OR DEATH 3 ALL SYSTEMS ARE CONSIDERED ENERGIZED UNTIL THE ENERGY SOURCE IS REMOVED LOCKED OUT WHEN POSSIBLE TAGGED OUT AND GROUNDED WHEN ENERGY ISOLATING DEVICES CANNOT BE PHYSICALLY LOCKED OUT USE TAGOUT PROCEDURES FAILURE TO COMPLY MAY CAUSE PERMANENT INJURY OR DEATH Standards Install a grounding set by electrically connecting conductors to the ground Ensure that conductors are at the same electrical potential using the provided grounding and test equipment Performance Steps 1 Inspect tools and equipment for serviceability 2 Perform lockout and tagout procedures 3 Test phases to ensure that they are isolated and that there
265. edures 7 Remove the controller and tag the leads 8 Inspect the controller for damage 3 112 STP 5 21P2 SM TG 31 March 2009 MOS Skill Level Tasks Performance Steps 9 10 11 12 13 14 15 16 17 18 Test the controller according to the manufacturer s literature Compare the results with the manufacturer s specifications and take appropriate action Reinstall or replace the controller Test the circuit for voltage presence a If there is no voltage present proceed to step 13 b If there is voltage present stop and perform the following checks until voltage is no longer present 1 Check schematics for proper circuit identification 2 Check for back fed circuits 3 Check for the proper installation of safe clearance procedures 4 Check for violations of safe clearance procedures Tag the controller with the appropriate calibration sticker including the name and testing date Reinstall the controller a Attach tagged leads b Verify connections Close out lockout and tagout procedures by removing locking and tagging devices Energize the circuit and ensure that it is operating properly Keep a record of results and actions taken Ensure that the items listed in the conditions are properly cleaned and stored Evaluation Preparation Setup Provide the Soldier with the items listed in the conditions Give the Soldier a safety briefing before starting the test and ensure that safety precaut
266. ef Soldier Direct the Soldier to supervise the mechanical erection of a utility pole Performance Measures 1 2 13 14 15 16 17 Reviewed danger warning and caution notices before proceeding Reviewed the manufacturer s literature electrical construction prints and wiring diagrams Ensured that PPE was correctly tested and fully mission capable Completed DA Form 2702 for the tools and equipment necessary to perform the task Inspected tools and rigging equipment for serviceability Developed a plan for obtaining nonorganic tools and the equipment necessary to perform the mission Issued a safety briefing that highlighted safety precautions and the concept of the operation Assigned personnel positions and ensured that they understood their role in accomplishing the task Inspected the hole to ensure that it was the appropriate depth 10 11 12 Ensured that rigging was done so that the pole did not slip Ensured that the pole was lowered into the center of the hole Inspected the pole while it was in the hole to ensure that the hole was the proper depth and that the pole was centered facing the correct direction and correctly aligned Ensured that the pole was tamped Ensured that a watershed was created at the pole base Rechecked the pole depth centering facing and alignment of the pole before mounting the hardware Ensured that guys and anchors were installed as s
267. egulator c Replace the regulator Test the circuit for voltage a Proceed to step 12 if no voltage is present b Stop if voltage is present and perform checks until the voltage is no longer present 1 Check the schematics for proper circuit identification 2 Check for back fed circuits 3 Check for the proper installation of safe clearance procedures 4 Check for violations of safe clearance procedures Reinstall the voltage regulator a Attach tagged leads b Verify connections by using the schematics Close out lockout and tagout procedures by removing locking and tagging devices Perform a functions check on the voltage regulator Keep a record of the test results and actions taken Ensure that the items listed in the conditions are properly cleaned and stored Evaluation Preparation Setup Provide the Soldier with the items listed in the conditions Give the Soldier a safety briefing before starting the test and ensure that safety precautions are followed Prepare the testing area and equipment in advance to ensure that task standards can be met Brief Soldier Direct the Soldier to service a voltage regulator Performance Measures GO NO GO 1 o ON O a A W N 10 11 12 Reviewed danger warning and caution notices Reviewed the manufacturer s literature and wiring diagrams Reviewed maintenance logbooks and historical data pertaining to the equipment Identified the circ
268. em shows symptoms of faults you are given a hydrometer a filter wrench a lockout and tagout kit a general mechanic s tool box the applicable technical manuals TMs the applicable manufacturer s literature maintenance logbooks and DA Form 2404 Equipment Inspection and Maintenance Worksheet or DA Form 5988 E Equipment Inspection Maintenance Worksheet DANGER 1 ENSURE THAT THE EQUIPMENT IS PROPERLY LOCKED OUT AND TAGGED OUT FAILURE TO COMPLY MAY CAUSE PERMANENT INJURY OR DEATH 2 REMOVE RINGS NECKLACES OTHER JEWELRY AND LOOSE CLOTHING FAILURE TO COMPLY MAY CAUSE PERMANENT INJURY OR DEATH WARNING 1 WHEN DISCONNECTING BATTERY CABLES ALWAYS DISCONNECT THE NEGATIVE TERMINAL FIRST WHEN RECONNECTING CONNECT THE POSITIVE TERMINAL FIRST FAILURE TO COMPLY MAY RESULT IN SPARKING AND CONSEQUENT BATTERY EXPLOSION AND MAY CAUSE IMMEDIATE PERSONAL INJURY OR DAMAGE TO EQUIPMENT 2 THE RADIATOR GETS VERY HOT DURING OPERATION DO NOT REMOVE THE RADIATOR CAP UNTIL THE RADIATOR HAS REACHED A POINT WHERE THERE IS NO STEAM PRESSURE BUILDUP FAILURE TO COMPLY MAY CAUSE IMMEDIATE PERSONAL INJURY CAUTION REPLACE FILTER ELEMENTS IN PAIRS TO PREVENT DETERIORATION OF REPLACEMENT PARTS REPEATED FAILURE TO FOLLOW THE CORRECT PROCEDURES MAY CAUSE EQUIPMENT DAMAGE Standards Service a diesel engine cooling system by inspecting and replacing or repairing the defective components parts Performance Steps 1 Review maintenance logbooks a
269. en an underground cable or fault needs to be located you are given a cable fault locator with the manufacturer s literature an electrician s tool kit and applicable personal protective equipment DANGER 1 THIS TASK SHOULD ONLY BE PERFORMED BY QUALIFIED PERSONNEL WHO ARE KNOWLEDGEABLE IN THE INSTALLATION AND MAINTENANCE OF ELECTRICAL DISTRIBUTION SYSTEMS AND POWER EQUIPMENT AND THEIR ASSOCIATED HAZARDS FAILURE TO COMPLY MAY CAUSE PERMANENT INJURY OR DEATH 2 DO NOT TOUCH EXPOSED ELECTRICAL CONNECTIONS WHEN A POWER SOURCE IS CONNECTED TO THE CABLES FAILURE TO COMPLY MAY CAUSE PERMANENT INJURY OR DEATH 3 REMOVE RINGS NECKLACES OTHER JEWELRY AND LOOSE CLOTHING FAILURE TO COMPLY MAY CAUSE PERMANENT INJURY OR DEATH 4 DO NOT USE CLAMP ON OR DIRECT CONNECT METHODS OF FAULT FINDING UNTIL YOU HAVE VERIFIED THAT THE CABLES ARE DE ENERGIZED FAILURE TO COMPLY MAY CAUSE PERMANENT INJURY OR DEATH Standards Safely and accurately locate an underground cable or fault according to the manufacturer s literature Performance Steps 1 Review danger warning and caution notices 2 Perform lockout and tagout procedures oO Determine the best test method for locating the cable or fault inductive flexible coupler direct connect Perform preoperational checks on the test equipment according to the manufacturer s literature Connect the test set to the cable Locate the underground cable by tracing it from the source to t
270. ent Performance Measures 1 O a A W N N Established a point of contact Determined the original use of the facility Determined the intended use of the facility Extracted data from specific sources Defined the four critical load areas Determined the lighting load by obtaining values from blueprints specifications or direct visual inspection Determined the receptacle outlet load Used 5 amperes for each heavy duty outlet or mogul sized lamp holder to calculate the load Determined the load of major appliances and loads over 5 amperes each 10 11 12 13 14 15 16 17 Determined the motor loads Calculated the total load per building Determined the maximum demand Calculated the demand factor Considered other factors on the load survey Calculated the emergency generation load Determined the location to connect emergency power generation equipment Determined the location to emplace emergency power generation equipment 31 March 2009 STP 5 21P2 SM TG Chapter 3 Performance Measures GO NO GO 18 Determined DA Form 2702 information 19 Completed the assessment data form by hard copy or on the ENG LINK Web site Evaluation Guidance Score the Soldier GO if all measures are passed P Score the Soldier NO GO if any measure is failed F If the Soldier fails any measure show him how to do it correctly References Required Related FM 5 424
271. equipment in advance to ensure that task standards can be met Brief Soldier Direct the Soldier to install a medium voltage nonaerial air switch Performance Measures 1 Reviewed danger warning and caution notices 2 Reviewed the manufacturer s literature electrical construction prints and wiring diagrams 3 Identified the best location for the switch such as a secure area with minimal traffic to ensure easy access during emergencies 4 Selected equipment that was appropriate for the environment and weather when installing a switch outdoors Followed specific guidelines when installing a switch indoors Selected a switch that met safety mission and load requirements 5 6 7 De energized the circuit where the switch was to be installed 8 Isolated the equipment in the work area 9 Performed lockout and tagout procedures 0 Installed personal protective grounds 11 Placed the switch on a level surface 12 Installed the grounding for case and neutral grounds 13 Installed the equipment to the load 14 Installed the equipment to the power source 15 Verified the correct phase sequence 16 Removed personal protective grounds 17 Closed out lockout and tagout procedures by removing locking and tagging devices 18 Performed a functions check on the switch 31 March 2009 STP 5 21P2 SM TG 3 199 Chapter 3 Performance Measures GO NO GO 19 Ensured that the items listed in the conditi
272. er use of safe clearance procedures 7 Remove the equipment and tag the leads 8 Inspect the equipment for damage 31 March 2009 STP 5 21P2 SM TG 3 115 Chapter 3 Performance Steps 9 10 11 12 13 14 15 16 17 18 Test the equipment according to the manufacturer s literature Compare the results with the manufacturer s specifications and take appropriate action Reinstall or replace the equipment Test the circuit for voltage presence a Proceed to step 13 if there is no voltage present b Stop if there is voltage present and perform the following checks until the voltage is no longer present 1 Check the schematics for proper circuit identification 2 Check for back fed circuits 3 Check for the proper use of safe clearance procedures Tag the equipment with the appropriate calibration sticker including the name and testing date Reinstall the equipment a Attach tagged leads b Verify connections Close out lockout and tagout procedures by removing locking and tagging devices Energize the circuit and ensure that it is operating properly Keep a record of results and actions taken Ensure that the items listed in the conditions are properly cleaned and stored Evaluation Preparation Setup Provide the Soldier with the items listed in the conditions Give the Soldier a safety briefing before starting the test and ensure that safety precautions are followed Prepare the testing area and
273. erature Reinstall or repair the circuit breaker based on the test results Performance Steps NOTE Conduct tests according to the manufacturer s literature Use industry standards when the manufacturer s literature cannot be obtained 1 Review danger warning and caution notices 2 Review the manufacturer s literature and wiring diagrams 3 Review maintenance logbooks and historical data pertaining to the equipment 4 Perform lockout and tagout procedures 5 Inspect the condition of the SF6 circuit breaker visually and manually NOTE Microhm or millivolt drop values should not exceed the high levels of the normal range as indicated in the manufacturer s literature If the manufacturer s literature is not available investigate the values that deviate from adjacent poles or similar breakers by more than 50 percent of the lowest value a Clean the circuit breaker before testing unless as found and as left tests are required b Keep a record as left and as found operation counter readings if applicable c Inspect the anchorage and grounding d Inspect and verify mechanism adjustments according to the manufacturer s literature e Inspect and service the air compressor according to the manufacturer s literature f Inspect and service the hydraulic system according to the manufacturer s literature g Test for gas leaks according to the manufacturer s literature h Verify the correct operation of air and SF6 gas pressure alarms an
274. ersonal protective equipment PPE electrical construction prints wiring diagrams and insulating protective equipment DANGER 1 THIS TASK SHOULD ONLY BE PERFORMED BY QUALIFIED PERSONNEL KNOWLEDGEABLE IN THE INSTALLATION AND MAINTENANCE OF ELECTRICAL DISTRIBUTION SYSTEMS AND POWER EQUIPMENT AND THE ASSOCIATED HAZARDS FAILURE TO COMPLY MAY CAUSE PERMANENT INJURY OR DEATH 2 A VOLTAGE DETECTOR SHOULD BE USED TO ENSURE THAT THE CABLES ARE NOT ENERGIZED MATERIAL SUCH AS A LEAD SHEATH THAT ACTS AS A SHIELD MUST NOT BE BETWEEN THE TESTER AND THE CONDUCTORS OF THE CIRCUIT BEING TESTED FAILURE TO TEST THE CABLES MAY CAUSE PERMANENT INJURY OR DEATH 3 REMOVE RINGS NECKLACES OTHER JEWELRY AND LOOSE CLOTHING FAILURE TO COMPLY MAY CAUSE PERMANENT INJURY OR DEATH 4 DO NOT TOUCH EXPOSED ELECTRICAL CONNECTIONS WHEN A SOURCE OF POWER IS CONNECTED TO THE DISTRIBUTION SYSTEM FAILURE TO COMPLY MAY CAUSE PERMANENT INJURY OR DEATH 5 THIS TASK SHOULD ONLY BE PERFORMED ON EQUIPMENT THAT DOES NOT CONTAIN POLYCHLORINATED BIPHENYL PCB FAILURE TO COMPLY MAY CAUSE SKIN AILMENTS REPRODUCTIVE DISORDERS LIVER DISEASE AND OTHER ADVERSE HEALTH CONDITIONS RESULTING IN PERMANENT INJURY OR DEATH 6 DO NOT EXCEED THE MAXIMUM VOLTAGE STIPULATED FOR SPECIFIC TESTS FAILURE TO COMPLY WITH RATED VOLTAGES MAY CAUSE EQUIPMENT DAMAGE AND RESULT IN PERMANENT INJURY OR DEATH 7 THE INSULATION TESTER PRODUCES A HIGH VOLTAGE TO AVOID PERSONAL INJURY DURIN
275. ersonnel were notified when the lockout and tagout devices were ready for removal Closed out lockout and tagout procedures by removing locking and tagging devices Ensured that personnel were safely positioned or were removed from the area needing to be reenergized Completed and filed all necessary forms Ensured that the items listed in the conditions were properly cleaned and stored Evaluation Guidance Score the Soldier GO if all measures are passed P Score the Soldier NO GO if any measure is failed F If the Soldier fails any measure show him how to do it correctly References Required Related ENG FORM 1925 EM 385 1 1 ENG FORM 1927 R 3 22 STP 5 21P2 SM TG 31 March 2009 References Required Related ENG FORM 2198 ER 385 1 31 OSHA REG 1910 147 TM 5 682 31 March 2009 STP 5 21P2 SM TG MOS Skill Level Tasks Chapter 3 Operate a Mobile Electric Power MEP 810A or B Generator 052 244 2114 Conditions As a power plant operator in a tactical or nontactical environment after the completion of a power plant installation you are given an MEP 810A or B generator an operator s manual the appropriate technical manuals and the required accessories for initial start up DANGER 1 THIS TASK SHOULD ONLY BE PERFORMED BY QUALIFIED PERSONNEL WHO ARE KNOWLEDGEABLE IN THE INSTALLATION OPERATION AND MAINTENANCE OF MEDIUM VOLTAGE ELECTRICAL POWER GENERATION EQUIPMENT AND ITS ASSOCIATED HAZARDS FAILURE TO COMPL
276. esistance exceeded the required resistance levels repeated step 10 12 Ensured that the testing equipment and tools were properly cleaned and stored Evaluation Guidance Score the Soldier GO if all measures are passed P Score the Soldier NO GO if any measure is failed F If the Soldier fails any measure show him how to do it correctly References Required Related EM 385 1 1 IEEE GREEN BOOK LCH NEC HANDBOOK NESC 3 74 STP 5 21P2 SM TG 31 March 2009 MOS Skill Level Tasks Repair a Low Voltage Control Cable 052 244 2141 Conditions As a power plant operator in a tactical or nontactical environment when a low voltage control cable has failed you are given a voltage detector a voltmeter a multimeter an insulation resistance test device a lockout and tagout kit a general mechanic s tool box the manufacturer s literature electrical construction prints wiring diagrams appropriate technical manuals personal protective equipment and other materials needed to repair cables DANGER 1 THIS TASK SHOULD ONLY BE PERFORMED BY QUALIFIED PERSONNEL WHO ARE KNOWLEDGEABLE IN THE OPERATION AND MAINTENANCE OF ELECTRICAL POWER GENERATION EQUIPMENT AND ITS ASSOCIATED HAZARDS FAILURE TO COMPLY MAY CAUSE PERMANENT INJURY OR DEATH 2 ENSURE THAT THE SYSTEM IS PROPERLY LOCKED OUT AND TAGGED OUT FAILURE TO COMPLY MAY CAUSE PERMANENT INJURY OR DEATH 3 REMOVE RINGS NECKLACES OTHER JEWELRY AND LOOSE CLOTHING
277. ess than 1 000 megohms at a DC test voltage of 2 500 volts unless otherwise specified in the manufacturer s literature Performed insulation resistance tests on the control wiring according to the manufacturer s literature ensured that the control wiring insulation resistance was a minimum of 2 megohms and for units with solid state components parts followed the manufacturer s recommendations Performed tests with the circuit breaker in the TEST position and ensured that trip and close operations for the circuit breaker worked properly Performed a power factor and dissipation factor test on the breaker compared the results of the power factor and dissipation factor test to the manufacturer s specifications and if the manufacturer s specifications were not available compared the test results to similar circuit breakers Performed an overpotential test according to the manufacturer s literature and ensured that the insulation withstood the applied overpotential test voltage Kept a record of the test results Closed out logout and tagout procedures by removing locking and tagging devices Ensured that the items listed in the conditions were properly cleaned and stored Evaluation Guidance Score the Soldier GO if all measures are passed P Score the Soldier NO GO if any measure is failed F If the Soldier fails any measure show him how to do it correctly References Required Related FM 3 34 480 NETA 3 232 STP
278. esting equipment and tools are correctly cleaned and stored 31 March 2009 STP 5 21P2 SM TG 3 91 Chapter 3 Evaluation Preparation Setup Provide the Soldier with the items listed in the conditions Give the Soldier a safety briefing before starting the test and ensure that safety precautions are followed Prepare the testing area and equipment in advance to ensure that task standards can be met Brief Soldier Direct the Soldier to troubleshoot a nonorganic prime mover Performance Measures 1 2 O oa A O N 13 14 15 Reviewed danger warning and caution notices Reviewed the appropriate technical manuals construction prints wiring diagrams manufacturer s literature or industry standards maintenance logbook and historical data pertaining to the equipment Ensured that the PPE was correctly tested and was fully operable Inspected the tools and testing equipment for serviceability Determined which systems were critical to the operation Identified the fault locations by checking the fault indicator panel or each critical system for obvious malfunctions Isolated the system in which the fault was found Conducted further testing to identify defective components parts if necessary Performed lockout and tagout procedures Repaired or replaced defective components parts when possible Performed a functions check on the affected system Closed out lockout and tagout procedures by removin
279. esults 13 Closed out lockout and tagout procedures by removing locking and tagging devices 14 Ensured that the items listed in the conditions were properly cleaned and stored Evaluation Guidance Score the Soldier GO if all measures are passed P Score the Soldier NO GO if any measure is failed F If the Soldier fails any measure show him how to do it correctly References Required Related FM 3 34 480 NESC NETA 3 246 STP 5 21P2 SM TG 31 March 2009 MOS Skill Level Tasks Perform an Insulation Resistance Test 052 206 2136 Conditions As a power station electrician in a tactical or nontactical environment during maintenance or when electrical equipment is initially installed you are given a megohmmeter or direct current DC high potential test set an electrician s tool kit a voltage detector wire markers a hot stick grounding equipment applicable manufacturer s literature or industry standards a lockout and tagout kit and applicable personal protective equipment DANGER 1 REMOVE RINGS NECKLACES OTHER JEWELRY AND LOOSE CLOTHING FAILURE TO COMPLY MAY CAUSE PERMANENT INJURY OR DEATH 2 USE THE PROPER TEST EQUIPMENT TO TEST FOR VOLTAGE BEFORE CONTACTING THE COMPONENTS PARTS FAILURE TO COMPLY MAY CAUSE PERMANENT INJURY OR DEATH 3 THE INSULATION TESTER PRODUCES HIGH VOLTAGE DO NOT TOUCH THE CABLE BEING TESTED OR THE TEST LEADS REMOVE THE POWER AND DISCHARGE AND G
280. eter an electrician s tool kit electrical construction prints wiring diagrams and a lockout and tagout kit DANGER 1 THIS TASK SHOULD ONLY BE PERFORMED BY QUALIFIED PERSONNEL WHO ARE KNOWLEDGEABLE IN THE OPERATION AND MAINTENANCE OF ELECTRICAL EQUIPMENT AND ITS ASSOCIATED HAZARDS FAILURE TO COMPLY MAY CAUSE PERMANENT INJURY OR DEATH 2 ENSURE THAT THE SYSTEM IS PROPERLY LOCKED OUT AND TAGGED OUT IF NECESSARY FAILURE TO COMPLY MAY CAUSE PERMANENT INJURY OR DEATH 3 REMOVE RINGS NECKLACES OTHER JEWELRY AND LOOSE CLOTHING FAILURE TO COMPLY MAY CAUSE PERMANENT INJURY OR DEATH Standards Install low voltage wiring according to the NEC Handbook without causing injury or equipment damage Performance Steps NOTE Always operate in teams when working with electrical equipment or installing electrical circuits 1 Review danger warning and caution notices 2 Review the manufacturer s literature electrical construction prints and wiring diagrams 3 Create a wiring diagram or a schematic of the circuit to be installed 4 Identify the equipment to be used a Ensure that tools are serviceable b Ensure that equipment is suitable for installation Perform lockout and tagout procedures Install the low voltage wiring according to the NEC Handbook and the wiring diagram or schematic Inspect the work before energizing the circuit to ensure proper installation Close out the lockout and tagout procedures by removin
281. etup Provide the Soldier with the items listed in the conditions Give the Soldier a safety briefing before starting the test and ensure that safety precautions are followed Prepare the testing area and equipment in advance to ensure that task standards can be met Brief Soldier Direct the Soldier to troubleshoot the improper operation of an electrical motor Performance Measures GO NO GO 1 Reviewed danger warning and caution notices 2 Reviewed the manufacturer s literature and wiring diagrams 3 Reviewed maintenance logbooks and historical data pertaining to the equipment 4 Recorded critical data from the motor manufacturer s data plate 5 Performed a visual inspection of the motor 6 Started the motor to perform checks 7 Disconnected the motor leads and ensured that they were isolated and marked 8 Disassembled the motor and labeled the bell ends 9 Cleaned the motor 10 Identified the type of electric motor series shunt compound 11 Tested motor components parts N Reassembled the motor ow Adjusted and lubricated the motor as needed P Returned the motor to operation testing it for proper operating parameters according to the manufacturer s literature 15 Ensured that the items listed in the conditions were properly cleaned and stored Evaluation Guida
282. etup Provide the Soldier with the items listed in the conditions Give the Soldier a safety briefing before starting the test and ensure that safety precautions are followed Prepare the testing area and equipment in advance to ensure that the task standards can be met Brief Soldier Direct the Soldier to identify the hazards of a power generation and distribution system Performance Measures GO NO GO 1 Identified possible mechanical hazards 2 Identified possible electrical hazards 3 Identified possible chemical hazards 4 Identified possible fire hazards Evaluation Guidance Score the Soldier GO if all measures are passed P Score the Soldier NO GO if any measure is failed F If the Soldier fails any measure show him how to do it correctly References Required Related EM 385 1 1 FM 5 19 NFPA 70E TM 5 682 31 March 2009 STP 5 21P2 SM TG 3 49 Chapter 3 Troubleshoot a Direct Current DC Voltage System 052 244 2128 Conditions As a power plant operator in a tactical or nontactical environment while a DC voltage system is malfunctioning you are given Ugly s Electrical Reference a general mechanic s tool box a maintenance logbook and the manufacturer s literature with schematics DANGER 1 THIS TASK SHOULD ONLY BE PERFORMED BY QUALIFIED PERSONNEL WHO ARE KNOWLEDGEABLE IN THE INSTALLATION AND OPERATION OF ELECTRICAL POWER GENERATION EQUIPMENT DC SYSTEMS AND THEIR ASSOCIATE
283. ety precautions are followed Prepare the testing area and equipment in advance to ensure that task standards can be met Brief Soldier Direct the Soldier to service bus bars Performance Measures GO NO GO 1 Reviewed danger warning and caution notices 2 Reviewed the manufacturer s literature electrical construction prints and wiring diagrams 3 Performed lockout and tagout procedures 4 Removed barriers and covers to gain access to the bus bars S Ensured that the grounding cluster was installed and that the equipment being tested was properly grounded Inspected the bus bars Tested electrical connections using a digital low resistance ohmmeter 6 7 8 Kept a record of the findings from the inspection 9 Cleaned the bus bars 0 10 Cleaned the nonconductive material such as the insulators and standoffs 11 Corrected deficiencies if possible 12 Kept a record of deficiencies that could not be corrected 13 Removed the grounding cluster 14 Replaced barriers and covers 15 Closed out lockout and tagout procedures by removing locking and tagging devices 16 Reenergized the equipment 17 Ensured that the items listed in the conditions were properly cleaned and stored Evaluation Guidance Score the Soldier GO if all measures are passed P
284. f Soldier Direct the Soldier to produce an electronic circuit Performance Measures GO NO GO 1 Identified circuit components correctly 2 Inspected components for damage and serviceability 31 March 2009 STP 5 21P2 SM TG 3 95 Chapter 3 Performance Measures GO NO GO 3 Installed components in the circuit board as specified in schematics 4 Inspected the final product for flaws or damage 5 Tested the circuit for proper operation 6 Ensured that the items listed in the conditions were properly cleaned and stored Evaluation Guidance Score the Soldier GO if all measures are passed P Score the Soldier NO GO if any measure is failed F If the Soldier fails any measure show him how to do it correctly References Required Related TM 5 704 TC 9 60 3 96 STP 5 21P2 SM TG 31 March 2009 MOS Skill Level Tasks Perform Electronic Troubleshooting Procedures 052 207 2101 Conditions As a power station instrument technician in a tactical or nontactical environment during scheduled maintenance or when a control system with electronic circuits requires troubleshooting you are given safety standing operating procedures SOPs a lockout and tagout kit a multimeter an oscilloscope an electronic tool kit appropriate technical manuals the applicable manufacturer s literature with schematics maintenance logbooks and wiring diagrams DANGER 1 SOME TROUBLESHOOTING TASKS
285. fluoride SF6 Switch ee ceeeeeeeeeeeeeeeeeeteeeeeeeeeeeeeeeae Service a Vacuum Circuit Breaker 0 00 0 ecceeceeeeeeeeeeeeeeeeeeneeeeeteeeeeteeeeeetieeeeeeaa Perform an Insulation Resistance Test cccceeseeeeceeeeeeeeeeeeneeeeeeeneeeeeeenaeeeeeeaaes Subject Area 5 U4 Power Line Distribution Tasks Inspect Safety EquipMent cececceccecceeeeeeeeeeecaeceeeeeeesececaeceeeeeeesenenneueaeeeeeess Prepare a Manhole for Safe Entry ccceeeeeseeeeeesneeeeeeeneeeeeeneeeeeecaeeeeeeneeeeeeeaes Rescue an Injured Victim From a Utility Pole oo eee center eeenteeeeeetteeeeeeeaes Rescue an Injured Victim From a Manhole c ccescceceeeeeeteeeeeeseeeeeeenieeeeeenaaes Rescue an Injured Victim From an Aerial Bucket Truck c ceeeeeeeeeeeeeeeeeeeees Inspect Hot Line Equipment cccceccececeeeeeeeeeeeceeeeeeesecaaeeeeeeeeesetsesieaeeeeeess Maintain Climbing and Rigging Equipment 0 c ce eecceeeeeneeeeeeneeeeeenteeeeeeaes Perform Operator Preventive Maintenance Checks and Services PMCS on a Line Truck With Auxiliary Equipment ccccceceeeeeeeeeeeeeeeeeeeseeeetnanaeeeeeees Install a Grounding Set cence cece ee eeeeceeeeeeaeeeeeeaeeeeeeaeeeseeiaeeeeeeneeeeneeaes Install High Intensity Lights and Ballasts 0 ccccceeeeeeeeeeeeeeeeeeneeeeeeeneeeeeeaes Install Distribution Equipment De energiZed ceeeeceeeeeeeeeeeeeteeeeeetteeeeeeaes Secure Conductor to In
286. for enlarged eyelet holes 4 Check for stretching 5 Check for hard or dry leather b Check stitched areas for broken ragged or rotted threads 31 March 2009 STP 5 21P2 SM TG 3 263 Chapter 3 Performance Steps 4 Inspect metal products a Check the metal products for faults 1 Check for rust 2 Check for cracks 3 Check for breaks 4 Check for loose attachments 5 Check for wear that might affect overall product strength b Check the gaffs to determine if the cutting edges have been sharpened and shaped 5 Inspect the hard hat a Check the hard hat for cracks burns and overall cleanliness b Inspect the suspension system for fraying and broken suspension components c Inspect the chin strap for elasticity d Check the expiration date 6 Inspect the protective eyewear 7 Maintain leather products a Clean leather surfaces 1 Wipe off surface dirt using a neutral soap and moist sponge 2 Wipe off soap with a clean cloth b Rub the leather with saddle soap 1 Work up a good lather 2 Clean the surface with a sponge 3 Ensure that the saddle soap thoroughly penetrates the surface areas 4 Wipe off excess saddle soap with a clean cloth c Apply neat s foot oil to the leather parts using your hands 1 Ensure that the leather parts are oiled sufficiently 2 Allow the leather to dry in a cool shady area for 24 hours 3 Remove excess oil by rubbing vigorously with a clean cloth
287. formance Steps 13 Ensure that the items listed in the conditions are properly cleaned and stored Evaluation Preparation Setup Provide the Soldier with the items listed in the conditions Give the Soldier a safety briefing before starting the test and ensure that safety precautions are followed Prepare the testing area and equipment in advance to ensure that task standards can be met Brief Soldier Direct the Soldier to service a governor for generating equipment Performance Measures GO NO GO 1 Reviewed maintenance logbooks and historical data pertaining to the equipment to verify that the governor system needed to be serviced Performed lockout and tagout procedures Performed a visual inspection of the governor exterior for obvious faults Removed the governor Cleaned the governor Inspected the governor by taking measurements Repaired components parts that were not within tolerance oN O oO A W N Replaced components parts when repairs did not return the governor to operation Reinstalled the governor on the generator or the designated test stand 10 Closed out lockout and tagout procedures by removing locking and tagging devices 11 Started the unit and observed it for proper operation or observed the results while the governor was on a designated test stand 12 Recorded actions taken on DA For
288. formation that provide additional training support information e Appendix A Metric Conversion Chart This appendix provides a metric measurement conversion chart e Appendix B Wire Gauge Size Conversions This appendix provides conversions for wire gauge sizes Glossary The glossary is a comprehensive list of acronyms abbreviations terms definitions and letter symbols used in this STP e References This section contains two lists of references required and related that support the training of all tasks in this STP Required references are listed in the conditions and are required for the Soldier to do the task Related references are materials that provide more detailed information and a more thorough explanation of task performance b The NCO trainer can use DA Form 5164 R Hands On Evaluation to set up the leader book as described in FM 7 1 The use of this form may help preclude writing the Soldier tasks associated with the unit METL and DA Form 5164 R can become a part of the leader book The use of this form is optional but highly encouraged This evaluation allows you to maintain and track Soldier proficiency at the performance level This form can be obtained electronically and may be reproduced locally Follow these instructions when completing DA Form 5164 R 1 2 STP 5 21P2 SM TG 31 March 2009 Introduction Enter the title and number of the task to be evaluated at the top of the form Enter the number of e
289. from service Inspected the relay for damage Cleaned the relay with a soft brush or noncompressed air Set up the relay test set according to the instruction manual Performed an insulation resistance test on the relay testing from the output connection to the relay case ground by using the insulation resistance output on the relay test set Performed a zero check on the time dial ensuring that the relay contacts only made contact when the time dial read zero and made necessary adjustments when this did not occur Performed a pickup test according to the manufacturer s literature Performed a time curve verification test on the as found time dial setting Tested the DC target and sealed in the unit according to the relay instruction booklet Ensured that the trip circuit remained energized after removing the fault current from the main coil Made adjustments based on the test results Performed a pickup test of the instantaneous unit according to the manufacturer s 3 110 STP 5 21P2 SM TG 31 March 2009 MOS Skill Level Tasks Performance Measures GO NO GO literature 18 Returned relay settings to the correct parameters 19 Tagged the relay with the appropriate calibration sticker including the name and testing date 20 Ensured that flags were reset 21 Replaced the window cover and cleaned and inspected the seal for serviceability 22 Returned the relay to serv
290. function 4 Governor malfunction 5 Crankcase breather restriction 6 Fuel injector malfunction 7 Incorrect valve timing 8 Worn camshaft or bushings 3 Repair or replace defective components when possible 4 Record actions taken on DA Form 2404 or DA Form 5988 E and maintenance logbooks 5 Ensure that the items listed in the conditions are properly cleaned and stored Evaluation Preparation Setup Provide the Soldier with the items listed in the conditions Give the Soldier a safety briefing before starting the test and ensure that safety precautions are followed Prepare the testing area and equipment in advance to ensure that task standards can be met Brief Soldier Direct the Soldier to troubleshoot a diesel engine for unusual smoking 31 March 2009 STP 5 21P2 SM TG 3 133 Chapter 3 Performance Measures 1 Reviewed maintenance logbooks and historical data pertaining to the equipment 2 Identified the smoke color to determine the cause of the malfunction 3 Repaired or replaced defective components when possible 4 Recorded actions taken on DA Form 2404 or DA Form 5988 E and maintenance logbooks 5 Ensured that the items listed in the conditions were properly cleaned and stored Evaluation Guidance Score the Soldier GO if all measures are passed P Score the Soldier NO GO if any measure is failed F If the Soldier fails any measure show him how to do it correctly References Required Related D
291. g MEP 029 generator operation Added fuel as needed during MEP 029 generator operation Inspected the exhaust system after MEP 029 generator operation Inspected the fuel system after MEP 029 generator operation Recorded actions taken on DA Form 2404 or DA Form 5988 E and the maintenance logbook Evaluation Guidance Score the Soldier GO if all measures are passed P Score the Soldier NO GO if any measure is failed F If the Soldier fails any measure show him how to do it correctly References Required Related DA FORM 2404 EM 385 1 1 DA FORM 5988 E TM 5 6115 593 12 3 82 STP 5 21P2 SM TG 31 March 2009 MOS Skill Level Tasks Read a Schematic 052 244 2144 Conditions You are a power plant operator in a tactical or nontactical environment when there is a fault in a system Scheduled services are due or an upgrade to the system is needed or proposed You are given equipment specific schematics for an electrical application Standards Read and interpret the schematic information to identify normal current flow and possible faulty circuit components parts Performance Steps 1 Identify the proper schematic for the appropriate application 2 Orient the schematic to the actual layout 3 Identify the proper current flow through a circuit 4 Identify the alternate current flows within the circuit a Identify the current flow within different switch positions b Identify the current flow within a faulty c
292. g all locking and tagging devices Put the system back into service Recorded faults and repairs in the maintenance logbook Ensured that the PPE testing equipment and tools were correctly cleaned and stored Evaluation Guidance Score the Soldier GO if all measures are passed P Score the Soldier NO GO if any measure is failed F If the Soldier fails any measure show him how to do it correctly References Required Related EM 385 1 1 FM 5 424 LCH TM 5 682 TM 5 684 TM 5 811 1 TM 5 811 3 3 92 STP 5 21P2 SM TG 31 March 2009 MOS Skill Level Tasks Perform Power Plant Battle Damage Assessment and Repair BDAR 052 244 2148 Conditions As a power plant operator in a tactical or nontactical environment after a power plant has been damaged you are given one line diagrams electrical construction prints the applicable BDAR repair kit appropriate technical manuals wiring diagrams DA Form 2404 or DA Form 5988 E the manufacturer s literature with schematics a multimeter maintenance logbooks a general mechanic s tool box a lockout and tagout kit and personal protective equipment DANGER 1 THIS TASK SHOULD ONLY BE PERFORMED BY QUALIFIED PERSONNEL WHO ARE KNOWLEDGEABLE IN THE INSTALLATION AND OPERATION OF ELECTRICAL POWER GENERATION EQUIPMENT AND ITS ASSOCIATED HAZARDS FAILURE TO COMPLY MAY CAUSE PERMANENT INJURY OR DEATH 2 ALWAYS WEAR THE PERSONAL PROTECTIVE EQUIPMENT REQUIRED FOR INSPECTIONS IN HAZARD
293. g locking and tagging devices Reenergize the circuit O O N OQ O 10 Test the circuit for the desired function 11 Ensure that the items listed in the conditions are properly cleaned and stored Evaluation Preparation Setup Provide the Soldier with the items listed in the conditions Give the Soldier a safety briefing before starting the test and ensure that safety precautions are followed Prepare the testing area and equipment in advance to ensure that task standards can be met Brief Soldier Direct the Soldier to install low voltage wiring 3 70 STP 5 21P2 SM TG 31 March 2009 MOS Skill Level Tasks Performance Measures GO NO GO 1 Reviewed danger warning and caution notices 2 Reviewed the manufacturer s literature electrical construction prints and wiring diagrams Created a wiring diagram or a schematic of the circuit to be installed Identified the equipment to be used Performed lockout and tagout procedures O oa A O Installed the low voltage wiring according to the NEC Handbook and the wiring diagram or schematic N Inspected the work before energizing the circuit to ensure proper installation 8 Closed out the lockout and tagout procedures by removing locking and tagging devices 9 Reenergized the circuit 10 Tested the circuit for the desired function 11 Ensured that the items listed
294. gbooks and historical data pertaining to the equipment Identified portions of the circuit or system that were without power or had improper voltage levels Checked and reset tripped protective devices circuit breakers fuses protective relays Checked voltage levels Checked conductor ends Checked conductors electrically for shorts and opens Performed underground cable and or fault procedures if necessary Checked the physical condition of the conductors Conducted a load assessment to find the initial cause of the fault Replaced defective components parts Monitored the circuits 14 Ensured that the items listed in the conditions were properly cleaned and stored Evaluation Guidance Score the Soldier GO if all measures are passed P Score the Soldier NO GO if any measure is failed F If the Soldier fails any measure show him how to do it correctly References Required Related EM 385 1 1 31 March 2009 STP 5 21P2 SM TG 3 327 Chapter 3 Determine the Transformer Polarity 052 264 2110 Conditions As a power station electrician or instrument technician in a tactical or nontactical environment during scheduled or unscheduled maintenance intervals you are given an electrician s tool kit a variable voltage source alternating current AC a multimeter a 0 to 10 volt AC ammeter a milliammeter a 12 volt battery a switch varying lengths of Number 12 American wire gauge for co
295. gine tor Loss of Power ar an 2 059 205 2035 Troubleshoot a Diesel Engine for Unusual Smoka ar aw gt 0522052100 Service a Diese Engine Oyinaereea mr aN gt 052 205 2105 Perform ostec m mwm 0522052109 Senice aPiping System m mw 0522052110 Service Diesel Engine Lue GiSysem ar w gt 0522052111 Service Diesel Engine Cooing System nr aw gt 052 205 2116 Troubleshoot the Cause of an Unexpected Shutdown of a Diesel Engine lafofol Z AIT AIT AIT p Pa a Zi Z Z 052 205 2125 Service a Governor for Generating Equipment 052 205 2126 Service an Internal Fuel System for a Diesel Engine 052 205 2127 Service an External Fuel System for a Diesel Engine gt Z A 052 205 2128 Service a Diesel Engine Starting System A 052 205 2129 Troubleshoot a Diesel Engine Lube Oil System rjr Zz Z Al l l l 052 205 2130 Troubleshoot a Diesel Engine Cooling System 052 205 2131 Troubleshoot a Diesel Engine Air Intake and or Exhaust System 052 205 2132 Repair a Diesel Engine Lube Oil System 052 205 2133 Repair a Diesel Engine Cooling System 052 205 2134 Repair an Engine Air Intake and or Exhaust System A Subject Area 4 S3 Electrical Equipment Maintenance Power Station Tasks 052 206 2100 Service a Low Voltage Circuit Breaker 052 206 2101 Install a Medium Voltage Nonaerial Air Switch gt Z Z2 Zz ziz gt Z A A A A A A A A T IT IT IT T IT IT
296. he equipment Determined what caused the malfunction De energized the circuit before applying safe clearance procedures Performed lockout and tagout procedures Identified the malfunction Repaired or replaced defective components parts when possible N DO oO FB W N Closed out lockout and tagout procedures by removing locking and tagging devices 0 0 Energized the circuit and ensured that it was operating properly 9 Recorded actions taken on DA Form 2404 or DA Form 5988 E and maintenance logbooks 10 Ensured that the items listed in the conditions were properly cleaned and stored Evaluation Guidance Score the Soldier GO if all measures are passed P Score the Soldier NO GO if any measure is failed F If the Soldier fails any measure show him how to do it correctly 31 March 2009 STP 5 21P2 SM TG 3 131 Chapter 3 References Required DA FORM 2404 DA FORM 5988 E 3 132 Related TM 5 6115 456 34P TM 5 6115 593 12 TM 5 6115 593 34 TM 9 6115 604 12 STP 5 21P2 SM TG 31 March 2009 MOS Skill Level Tasks Troubleshoot a Diesel Engine for Unusual Smoking 052 205 2035 Conditions As a power station mechanic in a tactical or nontactical environment when unusual smoke is coming from the exhaust stack of a diesel engine you are given the applicable manufacturer s literature maintenance logbooks a general m
297. he load Mark the path of the cable with flags Perform a preoperational check on the test equipment according to the manufacturer s literature Connect the fault locator to the cable being tested O OoOo N O ON A Set up the fault locator for surge tracing 11 Operate the surge detector and follow the marked cable path until a thump indicates the location of the fault 12 Locate the fault by tracing it from the source to the fault location 13 Repair the fault in the cable 14 Test the repairs 31 March 2009 STP 5 21P2 SM TG 3 301 Chapter 3 Performance Steps 15 16 17 Close out lockout and tagout procedures by removing locking and tagging devices Mark the cable location from the source to the load Remove the test equipment from the circuit being tested Evaluation Preparation Setup Provide the Soldier with the items listed in the conditions Give the Soldier a safety briefing before starting the test and ensure that safety precautions are followed Prepare the testing area and equipment in advance to ensure that task standards can be met Brief Soldier Direct the Soldier to locate an underground cable and or fault Performance Measures 1 2 3 oOo N O A 12 13 14 15 16 17 Reviewed danger warning and caution notices Performed lockout and tagout procedures Determined the best test method for locating the cable or fault inductive flexible coupler direct connect
298. heck the electrical system a Check the battery voltage b Check for loose terminals and harnesses c Check for corrosion d Check the starter Check the engine for seizure Lift the clearance for testing Test the suspected fault to determine if it is the cause of the malfunction Repair the fault if possible O O N O Close out the lockout and tagout procedures by removing locking and tagging devices 11 Attempt to start the generator 12 Record malfunctions and corrections made in the maintenance logbook 13 Record actions taken on the maintenance logbook 14 Ensure that the items listed in the conditions are properly cleaned and stored 31 March 2009 STP 5 21P2 SM TG 3 59 Chapter 3 Evaluation Preparation Setup Provide the Soldier with the items listed in the conditions Give the Soldier a safety briefing before starting the test and ensure that safety precautions are followed Prepare the testing area and equipment in advance to ensure that the task standards can be met Brief Soldier Direct the Soldier to troubleshoot an engine failure to crank Performance Measures GO NO GO 1 Reviewed danger warning and caution notices 2 Reviewed the manufacturer s literature electrical construction prints and wiring diagrams 3 Reviewed the maintenance logbook and historical data pertaining to the equipment Ensured that the generator prime mover was locked out and t
299. hecks in the order listed 1 Inspect the battery compartment a Check the batteries for sufficient electrolyte levels b Ensure that the battery cables are securely tightened c Ensure that the battery cover plate is securely fastened 2 Inspect the exhaust system a Check the mufflers for serviceability b Ensure that the rain caps move freely c Check the turbocharger assembly for leaks and damage 3 Inspect the ground terminals for tight connections 4 Inspect the controls and instruments on the engine panel 3 80 STP 5 21P2 SM TG 31 March 2009 MOS Skill Level Tasks Performance Steps a Inspect for damage and loose mounts b Operate the press to test indicator to ensure that all fault indicators light up c Ensure that the battery charger volts and amperes register in the green portion of the scale d Inspect the fuel level gauge for the proper fuel level 5 Inspect the air cleaner to ensure that the service indicator is not red 6 Inspect the radiator assembly a Relieve the pressure by loosening the radiator cap and waiting 2 minutes before removing the cap b Check the cooling system for leaks c Ensure that the coolant is visible in the sight glass and add coolant if necessary d Check the radiator louvers for unrestricted operation e Check the fan belts for wear and proper tension f Check the radiator fins for damage or obstruction 7 Inspect the fuel system a Check the fuel lines for lea
300. htness Inspected the magnetic pickup for tightness proper clearance and proper voltage Checked for proper voltages on related electronic governor circuitry according to the TM or manufacturer s literature Tested the governor system components parts according to the TM or manufacturer s literature Repaired faulty electronic governor system components parts if possible Replaced faulty electronic governor system components parts that could not be repaired Adjusted the electronic governor for gain stability frequency and droop Closed out lockout and tagout procedures by removing locking and tagging devices Energized the circuit and checked for proper operation Verified adjustments made to the governor during operation Performed a load test on the generator to ensure proper operation 3 340 STP 5 21P2 SM TG 31 March 2009 MOS Skill Level Tasks Performance Measures GO NO GO 17 Kept a record of the test results and actions taken 18 Ensured that the items listed in the conditions were properly cleaned and stored Evaluation Guidance Score the Soldier GO if all measures are passed P Score the Soldier NO GO if any measure is failed F If the Soldier fails any measure show him how to do it correctly References Required Related TM 9 6115 604 12 EM 385 1 1 TM 9 6115 604 34 31 March 2009 STP 5 21P2 SM TG 3 341 Chapter 3 Troubleshoot the Improper Operation of an E
301. ical 3 Attempt to raise the victim out of the manhole using the extraction system for confined space entry and rescue a Remove obstructions that could interfere with the removal of the victim b Raise the victim until his buttocks clear the rim of the manhole 4 Assist the victim out of the manhole a Position the victim on his back b Administer first aid 5 Continue administering first aid until qualified medical personnel arrive Evaluation Preparation Setup Provide the Soldier with the items listed in the conditions Give the Soldier a safety briefing before starting the test and ensure that safety precautions are followed Prepare the testing area and equipment in advance to ensure that task standards can be met Brief Soldier Direct the Soldier to rescue an injured victim from a manhole Performance Measures GO NO GO 1 Evaluated the situation by calling to the victim 2 Ensured your own protection 3 Attempted to raise the victim out of the manhole using the extraction system for confined space entry and rescue 4 Assisted the victim out of the manhole 31 March 2009 STP 5 21P2 SM TG 3 257 Chapter 3 Performance Measures G NO GO 5 Continued administering first aid until qualified medical personnel arrived Evaluation Guidance Score the Soldier GO if all measures are passed P Score the Soldier NO GO if any measure is failed F If the Soldier fails an
302. ical environment an incapacitated individual is in contact with a nonaerial electrical conductor You are given a variety of conductive and nonconductive implements found in the power plant area DANGER 1 DO NOT TOUCH THE VICTIM OR CONDUCTOR WITH YOUR BARE HANDS DO NOT USE IMPLEMENTS CONTAMINATED WITH FOREIGN MATTER MUD OIL WATER FAILURE TO COMPLY MAY CAUSE PERMANENT INJURY OR DEATH 2 DO NOT ATTEMPT TO ADMINISTER FIRST AID OR INITIATE PHYSICAL CONTACT WITH AN ELECTRIC SHOCK VICTIM BEFORE THE POWER IS SHUT OFF OR BEFORE THE VICTIM IS REMOVED FROM THE POWER SOURCE FAILURE TO COMPLY MAY CAUSE PERMANENT INJURY OR DEATH Standards Rescue a victim without causing harm to the rescuer or other personnel Attempt to resuscitate the victim and provide first aid measures as needed Performance Steps NOTES 1 For training purposes simulate a situation where a victim is in contact with a power source Position the victim and conductor so that the Soldier must decide whether to remove the power source from the victim or remove the victim from the power source Provide a variety of conductive and nonconductive implements that the Soldier can select to rescue the victim 2 Members of the power plant team should become familiar with the location of all electrical circuit disconnect points such as air switches and fuse cutouts Knowing the locations of these devices will expedite shutting off the power in emergency situations 3 Hot st
303. ical interlock systems for correct operation and sequencing KH TO 31 March 2009 STP 5 21P2 SM TG 3 241 Chapter 3 Performance Steps 6 Perform resistance measurements through each pole using a low resistance ohmmeter and compare contact resistances of electrical connections to the values of similar connections and to the values specified in the manufacturer s literature 7 Verify that the open and close operations from control devices are operational if applicable 8 Perform insulation resistance tests pole to pole pole to ground and across open poles and ensure that insulation resistance test values at 1 minute are no less than 1 000 megohms at a direct current DC test voltage of 2 500 volts unless otherwise specified in the manufacturer s literature WARNING SOME DC HIGH POTENTIAL TEST SETS ARE HALF WAVE RECTIFIED AND MAY PRODUCE PEAK VOLTAGES IN EXCESS OF THE MANUFACTURER S RECOMMENDED MAXIMUM FOR THE SWITCH FAILURE TO FOLLOW TEST SET INSTRUCTIONS MAY CAUSE IMMEDIATE PERSONAL INJURY OR EQUIPMENT DAMAGE 9 Perform an overpotential test according to the manufacturer s literature 10 Keep a record of the test results 11 Close out lockout and tagout procedures by removing locking and tagging devices 12 Ensure that the items listed in the conditions are properly cleaned and stored Evaluation Preparation Setup Provide the Soldier with the items listed in the conditions Give the Soldier a safety briefing before starti
304. ically 1 Verify that the control alarm and trip settings on the temperature indicators are correct according to the manufacturer s literature 2 Verify that the cooling fans and pumps operate correctly 3 Inspect the bolted electrical connections for high resistance and compare the resistances to values of similar connections 4 Verify that the bolt torque levels are correct according to the manufacturer s literature Verify that the liquid levels in the tanks and bushings are correct Verify that positive pressures are maintained on nitrogen blanketed transformers Perform specific inspections and mechanical tests recommended by the manufacturer Verify that the equipment grounding is correct Verify the presence of transformer surge arresters Measure the insulation resistance of each winding at the designated tap position Remove a sample of insulating liquid according to ASTM D923 and test the sample for the 1 Dielectric breakdown voltage specified in ASTM D877 or ASTM D1816 2 Acid neutralization number specified in ASTM D974 3 Interfacial tension specified in ASTM D971 4 Color specified in ASTM D1500 5 Visual condition specified in ASTM D1524 Remove a sample of insulating liquid and have a dissolved gas analysis performed according to ASTM D3612 TsoQ 9AaA00D 6 Perform electrical tests a Perform resistance measurements on the bolted connections using a low resistance ohmmeter b Perform
305. ication 1 Review danger warning and caution notices Review the manufacturer s literature and wiring diagrams Review maintenance logbooks and historical data pertaining to the equipment Identify the circuit connected to the voltage regulator by using schematics Perform lockout and tagout procedures O oa A W N Test the circuit for voltage a Proceed to step 7 if no voltage is present b Stop if voltage is present and perform checks until the voltage is no longer present 1 Check the schematics for proper circuit identification 2 Check for back fed circuits 3 Check for the proper installation of safe clearance procedures 4 Check for violations of safe clearance procedures 7 Remove the voltage regulator and tag attached leads 8 Inspect the voltage regulator for damage 9 Test the voltage regulator according to the manufacturer s literature and record the results a Test the regulator output with no voltage at sensing inputs b Test the regulator output with the correct voltage at sensing inputs c Test the regulator output with high and low voltage at sensing inputs 3 334 STP 5 21P2 SM TG 31 March 2009 MOS Skill Level Tasks Performance Steps 10 11 12 13 14 15 16 d Check for the proper operation of the manual voltage adjustment Compare the results with the manufacturer s specifications and correct them as necessary a Calibrate the regulator b Reinstall the r
306. ications forms gt Operation Log lt http 140 194 76 129 publications forms gt Safety amp Occupational Health The Control of Hazardous Energy Safe Clearance 1 August 1994 lt http 140 194 76 129 publications eng regs er385 1 31 toc htm gt IEEE Green Book Standard 142 IEEE Recommended Practice for Grounding of Industrial and Commercial Power Systems 1991 The Lineman s and Cableman s Handbook 11th Edition McGraw Hill 2007 National Electrical Code Handbook 2008 lt http code necplus org gt Maintenance Testing Specifications for Electrical Power Distribution Equipment amp Systems 2007 lt http Awww netaworld org gt Standard for Electrical Safety Requirements for Employee Workplaces 2004 The Control of Hazardous Energy Lockout Tagout 1 September 1989 lt http www osha gov index html gt Ugly s Electrical References 2005 Soldier s Manual of Common Tasks Skill Level 1 14 December 2007 Soldier s Manual of Common Tasks SMCT Warrior Leader Skill Level 2 3 and 4 9 September 2008 Interactive Electronic Technical Manual IETM for Calibration and Repair Requirements for the Maintenance of Army Materiel 1 January 2009 Plumbing and Pipefitting TO 40P 1 131 29 July 1971 Operator and Organizational Maintenance Manual for Generator Set Diesel Engine Driven Tactical Skid Mounted 500 kW 3 Phase 4 Wire 120 208 and 240 416 Volts DOD Model MEP 029A Class Utility Hertz 50 60 NSN 6115 01 318 6302 Inc
307. ice 23 Ensured that the items listed in the conditions were properly cleaned and stored Evaluation Guidance Score the Soldier GO if all measures are passed P Score the Soldier NO GO if any measure is failed F If the Soldier fails any measure show him how to do it correctly References Required Related FM 3 34 480 31 March 2009 STP 5 21P2 SM TG 3 111 Chapter 3 Service a Programmable Logic Controller PLC 052 207 2119 Conditions As a power station instrument technician in a tactical or nontactical environment during scheduled maintenance or if a PLC is suspected of being defective you are given a lockout and tagout kit a multimeter a power supply an oscilloscope an electronic tool kit wiring diagrams maintenance logbooks and the applicable manufacturer s literature with schematics DANGER 1 ENSURE THAT POWER TO THE CONTROLLER IS DISCONNECTED BEFORE SERVICING APPLY SAFE CLEARANCE PROCEDURES TO ASSOCIATED CIRCUITS FAILURE TO COMPLY MAY CAUSE PERMANENT INJURY OR DEATH 2 ENSURE THAT CURRENT TRANSFORMERS SUPPLYING CURRENT TO THE CONTROLLER ARE DE ENERGIZED AND ELECTRICALLY SHORTED BEFORE SERVICING THE CONTROLLER IF ENERGIZED AN OPEN CURRENT TRANSFORMER CIRCUIT WILL PRODUCE VERY HIGH VOLTAGES FAILURE TO COMPLY MAY CAUSE PERMANENT INJURY OR DEATH 3 ENSURE THAT POTENTIAL TRANSFORMERS FEEDING THE CONTROLLER ARE DE ENERGIZED BEFORE SERVICING THE CONTROLLER FAILURE TO COMPLY MAY CAUSE PERMAN
308. icks and rubber gloves with leather gauntlets should be readily accessible to all personnel within the power plant for use in emergency situations 1 Assess the situation and take prompt action a Determine if it is a life threatening situation b Evacuate the area if the potential for an explosion exists 2 Disconnect or shut off the power if possible NOTE The use of rubber gloves with leather gauntlets and a hot stick is the preferred method of manually opening air switches or disconnecting fuses 3 Select a nonconductive or insulated implement such as a hot stick a wooden pole or protective rubber gloves with leather gauntlets to remove the conductor from the victim or remove the victim from the conductor 4 Isolate the victim from the source of the electric shock by removing the conductor from the victim or removing the victim from the conductor 5 Evaluate the victim 6 Perform first aid treatment 7 Contact emergency medical personnel 3 10 STP 5 21P2 SM TG 31 March 2009 MOS Skill Level Tasks Evaluation Preparation Setup Provide the Soldier with the items listed in the conditions Give the Soldier a safety briefing before starting the test and ensure that safety precautions are followed Prepare the testing area and equipment in advance to ensure that task standards can be met Brief Soldier Direct the Soldier to rescue a victim from a nonaerial electrical conductor Performance Measures GO NO GO 1 A
309. iefing before starting the test and ensure that all safety precautions are followed Prepare the testing area and equipment in advance to ensure that task standards can be met Brief Soldier Direct the Soldier to operate an MEP 810A or B generator Performance Measures GO NO GO 1 N O Oo FB W ND 10 11 12 Performed preoperational checks according to the TM Performed a preoperational run according to the TM Performed an operator remote terminal setup according to the TM Completed the switch arrangements Verified the lamp indicators Placed the engine control switch in MANUAL mode Ensured that the generator started and accelerated to the correct operating voltage and frequency Placed the synchronous source switch at the master control panel in the G1 position Closed the G1 breaker by cycling the breaker control switch to the CLOSE position Ensured that the breaker control switch closed Returned the synchronous source switch to the OFF position Placed the engineer control switch in the MANUAL position at G2 31 March 2009 STP 5 21P2 SM TG 3 25 Chapter 3 Performance Measures 13 14 15 16 17 18 19 20 21 22 23 24 25 26 Placed the synchronous source switch at the master control panel in the G2 position Closed the G2 breaker by cycling the bre
310. ier Direct the Soldier to manage a power line crew Performance Measures 1 Reviewed danger warning and caution notices 2 Ensured that the PPE was correctly tested and fully operable 3 Ensured that DA Form 2702 included all items necessary to perform the task 4 Inspected tools and climbing and rigging equipment for serviceability 5 Developed a plan for obtaining nonorganic tools and equipment necessary to perform any mission 6 Issued a safety briefing that highlighted safety precautions and the concept of the operation 7 Assigned personnel positions and ensured that they understood roles 8 Supervised the operation of a line truck with auxiliary equipment 9 Ensured that tasks were performed to standard and that safety procedures were followed 10 Ensured that PPE climbing and rigging equipment and tools were correctly cleaned and stored Evaluation Guidance Score the Soldier GO if all measures are passed P Score the Soldier NO GO if any measure is failed F If the Soldier fails any measure show him how to do it correctly References Required Related DA FORM 2702 EM 385 1 1 LCH ER 385 1 31 FM 3 34 480 FM 5 412 NESC NETA TM 5 682 TM 5 684 TM 5 686 TM 5 811 1 TM 5 811 3 3 310 STP 5 21P2 SM TG 31 March 2009 MOS Skill Level Tasks Supervise the Installation of Underground Cable 052 204 2218 Conditions As a power line distribution supervisor in a tactical or nontactical
311. ier GO if all measures are passed P Score the Soldier NO GO if any measure is failed F If the Soldier fails any measure show him how to do it correctly References Required Related DA FORM 2404 EM 385 1 1 DA FORM 5988 E 31 March 2009 STP 5 21P2 SM TG 3 3 Chapter 3 Splice a Medium Voltage Power Cable 052 244 2102 Conditions As a power plant operator in a tactical or nontactical environment during an initial installation of cables where the power cables must be joined or a power cable is damaged beyond repair you are given a splice kit with instructions the tools specified in the instructions an electricians tool kit a lockout and tagout kit grounding equipment a megohmmeter test set a voltage detector manufacturer s literature and personal protective equipment PPE DANGER A VOLTAGE DETECTOR SHOULD BE USED TO ENSURE THAT THE CABLES ARE NOT ENERGIZED THERE MUST BE NO MATERIALS SUCH AS A LEAD SHEATH THAT ACTS AS A SHIELD BETWEEN THE TESTER AND THE CONDUCTORS OF THE CIRCUIT BEING TESTED FAILURE TO COMPLY MAY CAUSE IMMEDIATE DEATH OR PERMANENT INJURY WARNING 1 THE SPLICER S TOOLS HANDS AND MATERIALS MUST BE KEPT CLEAN DURING THE CONSTRUCTION OF A SPLICE FAILURE TO KEEP THE SPLICER S TOOLS HANDS AND MATERIALS CLEAN MAY CAUSE IMMEDIATE PERSONAL INJURY OR EQUIPMENT DAMAGE 2 UTILIZE EVERY AVAILABLE RESOURCE TO PREVENT MOISTURE DRIPPINGS CONDENSATION PERSPIRATION FROM ENTERING THE JOINT INSULATION FAILURE
312. iesel Engine for Loss of POWE 0 cccceeeeeeeeeeeeeteeeeeenteeeeeeenaes 3 130 052 205 2035 Troubleshoot a Diesel Engine for Unusual SMOKING ccccceeeeeeeteeeteeeeeeeees 3 133 052 205 2100 Service a Diesel Engine Cylinder Head 0 ee eccceceeeeeeeeeeeneeeeeeeneeeeeeneeeeeeeaes 3 135 052 205 2104 Perform Electric Arc Welding ccceeeceeceeeeeeeeeceeneeeeeeaeeeeeeaeeeeseeaeeeseeneeeeseaaes 3 138 052 205 2105 Perform Oxyfuel Cutting 20 0 cece eee eaa EE AEAEE EEA RRE 3 141 052 205 2109 Service a Piping Systemi neiitran sinira ke Aane Faan AERAR RE ENEE ARRE FEARN ARENAEN rA 3 145 052 205 2110 Service a Diesel Engine Lube Oil System e ssssesssssrresesrrssrrrrsstrrrsssrrrrssrrrnssne 3 148 052 205 2111 Service a Diesel Engine Cooling System eeeceeceeeeeeeeeeeeeeeeeeeenneeeeeeeneeeeeeaes 3 151 052 205 2113 Service an Engine Air Intake and or Exhaust System cccceeeeeeeeeeteeeeeenaes 3 154 052 205 2116 Troubleshoot the Cause of an Unexpected Shutdown of a Diesel Engine 3 157 052 205 2118 Troubleshoot an Engine Failure to Start eccceeeeseeeeeeeeneeeeeeseeeeeeeseeeeeeaes 3 159 052 205 2119 Replace a Diesel Engine Piston Assembly 00 00 ccccceeeeeeeeeneeeeeeenneeeeeeneeeeeeeaaes 3 161 052 205 2120 Service a Hydraulic System eee eeeeeeeeeeneeeeeeeaeeeeeeaeeeeeeeaeeeeeeaeeeeeenaneeeeeaes 3 164 052 205 2123 Produce a Mechanical Drawing cccccceeseeceeeeeeeeeeeeneeeeeeneeeeeeaeeeeeett
313. in a tactical or nontactical environment during maintenance you are given a multimeter a relay test set an oscilloscope an electronic tool kit applicable manufacturer s literature with schematics appropriate technical manuals with schematics maintenance logbooks and wiring diagrams DANGER 1 SERVICING AND TESTING A UPS MUST BE DONE WITH THE COMPONENTS PARTS ENERGIZED CARE MUST BE TAKEN TO AVOID TOUCHING THE ENERGIZED EQUIPMENT FAILURE TO COMPLY MAY CAUSE PERMANENT INJURY OR DEATH 2 REMOVE RINGS NECKLACES OTHER JEWELRY AND LOOSE CLOTHING FAILURE TO COMPLY MAY CAUSE PERMANENT INJURY OR DEATH Standards Safely service a UPS according to the manufacturer s literature and record the results Performance Steps 1 Review danger warning and caution notices Review the manufacturer s literature and wiring diagrams Review maintenance logbooks and historical data pertaining to the equipment Measure the power supplied to the load from the primary source Identify inputs and outputs of the UPS Isolate the UPS and the supplied load from the incoming power supply N DO Oo FB W DN Compare the UPS output with specified parameters a Determine the current UPS output b Check for voltage sag in the UPS output c Compare the power supplied to the measurement from steps 7a and 7b d Proceed to step 10 if the output is acceptable 8 Check for proper battery charging a Check the voltage level of the rectifier out
314. in the conditions were properly cleaned and stored Evaluation Guidance Score the Soldier GO if all measures are passed P Score the Soldier NO GO if any measure is failed F If the Soldier fails any measure show him how to do it correctly References Required Related NEC HANDBOOK EM 385 1 1 FM 3 34 480 31 March 2009 STP 5 21P2 SM TG 3 71 Chapter 3 Improve Grounding Electrode Resistance 052 244 2140 Conditions As a power plant operator in a nontactical environment when ground resistance tests indicate that resistance does not meet the required parameters you are given a ground rod assembly a measuring tape a hammer a shovel a ground resistance tester applicable manufacturer s literature and magnesium sulfate bentonite clay or rock salt DANGER WHEN PERFORMING A GROUND RESISTANCE TEST THE FAULT IN THE POWER SYSTEM MAY CAUSE A HIGH CURRENT FLOW INTO THE GROUND SYSTEM WHILE THE TEST IS IN PROGRESS THIS MAY CAUSE UNEXPECTED HIGH VOLTAGES AT THE CURRENT AND VOLTAGE PROBES ALWAYS WEAR PROTECTIVE GLOVES WHILE HANDLING THE CONNECTIONS AT THE TERMINALS OF THE TEST SET AND USE A RUBBER SAFETY MAT WHILE OPERATING THE TEST SET FAILURE TO COMPLY MAY CAUSE PERMANENT INJURY OR DEATH NOTES 1 When using chemicals to reduce soil resistivity users must follow Environmental Protection Agency EPA and local environmental regulations Failure to comply may cause legal issues 2 Factors that should be considere
315. in the manufacturer s literature 7 Ensured that the items listed in the conditions were properly cleaned and stored Evaluation Guidance Score the Soldier GO if all measures are passed P Score the Soldier NO GO if any measure is failed F If the Soldier fails any measure show him how to do it correctly References Required Related DA FORM 2404 EM 385 1 1 31 March 2009 STP 5 21P2 SM TG 3 169 Chapter 3 References Required Related DA FORM 5988 E 3 170 STP 5 21P2 SM TG 31 March 2009 MOS Skill Level Tasks Service a Governor for Generating Equipment 052 205 2125 Conditions As a power station mechanic in a nontactical environment when symptoms of governor faults occur you are given a lockout and tagout kit a general mechanic s tool box the applicable manufacturer s literature maintenance logbooks DA Form 2404 Equipment Inspection and Maintenance Worksheet or DA Form 5988 E Equipment Inspection Maintenance Worksheet and the battalion standing operating procedure DANGER 1 ENSURE THAT EQUIPMENT IS PROPERLY LOCKED OUT AND TAGGED OUT FAILURE TO COMPLY MAY CAUSE PERMANENT INJURY OR DEATH 2 REMOVE RINGS NECKLACES OTHER JEWELRY AND LOOSE CLOTHING FAILURE TO COMPLY MAY CAUSE PERMANENT INJURY OR DEATH WARNING WHEN DISCONNECTING BATTERY CABLES ALWAYS DISCONNECT THE NEGATIVE TERMINAL FIRST WHEN RECONNECTING CONNECT THE POSITIVE TERMINAL FIRST FAILURE TO COMPLY MAY RESULT IN SPARKING OR BATTERY E
316. ines have been properly sagged de energized you are given a conductor appropriately sized clips ties for the conductors applicable climbing and rigging equipment safety standing operating procedures SOPs the Lineman s and Cableman s Handbook LCH hot line tools a voltage detector grounding equipment the applicable personal protective equipment PPE and a lockout and tagout kit DANGER 1 THIS TASK SHOULD ONLY BE PERFORMED BY QUALIFIED PERSONNEL KNOWLEDGEABLE IN THE INSTALLATION AND MAINTENANCE OF ELECTRICAL DISTRIBUTION SYSTEMS AND POWER EQUIPMENT AND THE ASSOCIATED HAZARDS FAILURE TO COMPLY MAY CAUSE PERMANENT INJURY OR DEATH 2 ENSURE THAT THE CIRCUIT IS COMPLETELY DE ENERGIZED AND CORRECTLY GROUNDED BEFORE PERFORMING ANY WORK FAILURE TO COMPLY MAY CAUSE PERMANENT INJURY OR DEATH 3 A VOLTAGE DETECTOR SHOULD BE USED TO ENSURE THAT THE CABLES ARE NOT ENERGIZED MATERIAL SUCH AS A LEAD SHEATH THAT ACTS AS A SHIELD MUST NOT BE BETWEEN THE TESTER AND THE CONDUCTORS OF THE CIRCUIT BEING TESTED FAILURE TO TEST THE CABLES MAY CAUSE PERMANENT INJURY OR DEATH 4 REMOVE RINGS NECKLACES OTHER JEWELRY AND LOOSE CLOTHING FAILURE TO COMPLY MAY CAUSE PERMANENT INJURY OR DEATH Standards Secure the conductor to the insulator de energized Ensure that phases are level and conductors are not stressed Performance Steps 1 Perform lockout and tagout procedures 2 Ascend the pole to the required height if necessary 3 Tes
317. ing diagrams Reviewed maintenance logbooks and historical data pertaining to the equipment Performed lockout and tagout procedures Inspected the condition of the SF6 circuit breaker visually and manually Performed resistance measurements through the bolted connections using a low resistance ohmmeter and compared contact resistances of electrical connections to the values of similar connections and to the values specified in the 31 March 2009 STP 5 21P2 SM TG 3 237 Chapter 3 Performance Measures 7 10 11 12 13 14 manufacturer s literature Performed insulation resistance tests pole to pole pole to ground and across open poles and ensured that the insulation resistance test values at 1 minute were no less than 1 000 megohms at a DC voltage of 2 500 volts unless otherwise specified in the manufacturer s literature Performed insulation resistance tests on the control wiring according to the manufacturer s literature ensured that the insulation resistance of the control wiring was a minimum of 2 megohms and for units with solid state components parts followed the manufacturer s recommendations Performed a power factor and dissipation factor test on the breaker and bushings compared the results to the manufacturer s specifications and if the manufacturer s literature was not available compared the test results to similar circuit breakers
318. ing equipment for serviceability Develop a plan for obtaining nonorganic tools and the equipment necessary to perform the mission Issue a safety briefing that highlights safety precautions and the concept of the operation Assign personnel positions and ensure that they understand their role in accomplishing this task Inspect the hole to ensure that is the appropriate depth O Oo N O a A OO N _ Ensure that rigging is done so that the pole does not slip m Ensure that the pole is lowered into the center of the hole N Inspect the pole while it is in the hole to ensure that the hole is the proper depth and that the pole is centered facing the correct direction and correctly aligned 13 Ensure that the pole is tamped 14 Ensure that a watershed was created at the pole base 15 Recheck the pole depth centering facing and alignment before mounting the hardware 16 Ensure that guys and anchors are installed as stated in the electrical construction prints 17 Ensure that the items listed in the conditions are properly cleaned and stored 3 316 STP 5 21P2 SM TG 31 March 2009 MOS Skill Level Tasks Evaluation Preparation Setup Provide the Soldier with the items listed in the conditions Give the Soldier a safety briefing before starting the test and ensure that safety precautions are followed Prepare the testing area and equipment in advance to ensure that task standards can be met Bri
319. ing maintenance or when electrical equipment is initially installed you are given a power factor test set a general mechanic s tool box a voltage detector a hot stick ground cables with clamps a grounding stick safety standing operating procedures electrical construction prints wiring diagrams the applicable manufacturer s literature and a lockout and tagout kit DANGER 1 REMOVE RINGS NECKLACES OTHER JEWELRY AND LOOSE CLOTHING FAILURE TO COMPLY MAY CAUSE PERMANENT INJURY OR DEATH 2 USE THE PROPER TEST EQUIPMENT TO TEST FOR VOLTAGE BEFORE CONTACTING COMPONENTS PARTS FAILURE TO COMPLY MAY CAUSE PERMANENT INJURY OR DEATH WARNING THIS TASK SHOULD NOT BE PERFORMED ON EQUIPMENT THAT CONTAINS POLYCHLORINATED BIPHENYL PCB FAILURE TO COMPLY MAY CAUSE SKIN AILMENTS REPRODUCTIVE DISORDERS LIVER DISEASE AND OTHER ADVERSE HEALTH CONDITIONS Standards Perform a power factor and dissipation factor test to determine the condition of the insulation Verify that the test results are sufficient according to the manufacturer s literature or industry standards before reenergizing the equipment Performance Steps NOTE Power factor and dissipation factor test results are important for tracking the deterioration of insulation While single tests are useful it is critical to keep records of the tests This will help track the insulation and show if drastic changes in insulation values over a short period of time 1 Review danger wa
320. ing the schematics Performed lockout and tagout procedures Tested the circuit for voltage presence Removed the current boost module and tagged the leads Inspected the current boost module for damage Tested the current boost module according to the manufacturer s literature 3 104 STP 5 21P2 SM TG 31 March 2009 MOS Skill Level Tasks Performance Measures GO NO GO 10 Compared the results with the manufacturer s specifications and took appropriate action 11 Calibrated or replaced the current boost module 12 Tested the circuit for voltage presence 13 Tagged the current boost module with the appropriate calibration sticker including the name and testing date 14 Reinstalled the current boost module 15 Closed out lockout and tagout procedures by removing locking and tagging devices 16 Energized the circuit and ensured that it was operating properly 17 Kept a record of results and actions taken 18 Ensured that the items listed in the conditions were properly cleaned and stored Evaluation Guidance Score the Soldier GO if all measures are passed P Score the Soldier NO GO if any measure is failed F If the Soldier fails any measure show him how to do it correctly References Required Related FM 3 34 480 31 March 2009 STP 5 21P2 SM TG 3 105 Chapter 3 Ser
321. ing the estimated load 16 Determine the location to connect emergency power generation equipment 17 Determine the location to emplace emergency power generation equipment 18 Determine DA Form 2702 information 3 56 STP 5 21P2 SM TG 31 March 2009 MOS Skill Level Tasks Performance Steps NOTE DA Form 2702 should include a minimum of the items listed below plus any additional special items needed to connect the power generation equipment to the facility and properly ground any equipment such as fuel storage and power generation equipment a Include load cables size and length of each cable and total amount of runs required to power 19 the facility b Include equipment ground cables ground rods and connection devices such as split bolt connectors c Include other material needed to connect power generation equipment to the facility Complete the assessment data form by hard copy or on the ENG LINK Web site a Include the calculated load b Include DA Form 2702 c Include special considerations d Include a site map e Include a strip map to the location Evaluation Preparation Setup Provide the Soldier with the items listed in the conditions Give the Soldier a safety briefing before starting the test and ensure that safety precautions are followed Prepare the testing area and equipment in advance to ensure that the task standards can be met Brief Soldier Direct the Soldier to perform a load assessm
322. ing the test and ensure that safety precautions are followed Prepare the testing area and equipment in advance to ensure that task standards can be met Brief Soldier Direct the Soldier to service an engine air intake and or exhaust system Performance Measures 1 O o N O a A OO N lt A _ 12 13 14 Reviewed maintenance logbooks and historical data pertaining to the equipment to verify that the air intake and or exhaust system needed to be serviced Performed lockout and tagout procedures Inspected air filters Inspected the air filter housing Inspected air restriction indicators Ensured that air intake mechanisms were clean and serviceable Checked for air leaks in the air box and intake manifold Inspected the exhaust manifold for cracks and leaks Inspected mufflers for cracked welds and leaks Inspected the turbocharger or air blower Closed out lockout and tagout procedures by removing locking and tagging devices Started the unit and observed it for proper operation Recorded actions taken on DA Form 2404 or DA Form 5988 E and maintenance logbooks Ensured that the items listed in the conditions were properly cleaned and stored Evaluation Guidance Score the Soldier GO if all measures are passed P Score the Soldier NO GO if any measure is failed F If the Soldier fails any measure show him how to do it correctly 31 March 2009 STP 5 21P2 SM TG 3 155 Chapter
323. insulation resistance tests winding to winding and winding to ground on each phase and ensure that the test values at 1 minute meet the manufacturer s specifications If not stated compare the results by voltage to the NETA Maintenance Testing Specifications for Electrical Power Distribution Equipment and Systems c Perform a turn to turn ratio test on each tap setting and ensure that the test results do not deviate more than 1 2 percent from the adjacent coils or calculated ratio d Perform power factor and dissipation factor tests on the bushings using the ambient temperature and ensure that the maximum power factor is corrected to 20 C according to the manufacturer s literature e Perform an excitation test using the test equipment according to the manufacturer s literature f Measure the resistance of each winding at the designated tap position and compare the measurements within 1 percent of previously obtained results after factoring in temperature corrections 7 Reconnect the isolated equipment 8 Close out lockout and tagout procedures by removing locking and tagging devices 9 Reenergize the de energized equipment 10 Check the primary and secondary sides of the transformer for the proper voltages listed on the equipment data plate 11 Ensure that the items listed in the conditions are properly cleaned and stored 31 March 2009 STP 5 21P2 SM TG 3 219 Chapter 3 Evaluation Preparation Setup Provide the Soldier with
324. ion prints and wiring diagrams Performed lockout and tagout procedures Conducted voltage tests with the appropriate voltage detector in the order listed in the substeps Inspected the exterior of the switchgear enclosure Inspected the interior of the switchgear enclosure Cleaned and wiped down the interior and exterior of the switchgear enclosure Corrected deficiencies if possible and recorded uncorrectable deficiencies on DA Form 2404 Performed an inventory of cleaning supplies and tools 10 11 12 Reconnected the isolated equipment Closed the door or replaced the access panel Closed out lockout and tagout procedures by removing locking and tagging 31 March 2009 STP 5 21P2 SM TG 3 225 Chapter 3 Performance Measures GO NO GO devices 13 Reenergized the de energized equipment 14 Ensured that the items listed in the conditions were properly cleaned and stored Evaluation Guidance Score the Soldier GO if all measures are passed P Score the Soldier NO GO if any measure is failed F If the Soldier fails any measure show him how to do it correctly References Required Related DA FORM 2404 NESC S AND C HANDBOOK TM 5 684 TM 9 6115 604 12 3 226 STP 5 21P2 SM TG 31 March 2009 MOS Skill Level Tasks Perform a Power Factor and Dissipation Factor Test 052 206 2123 Conditions As a power station electrician in a tactical or nontactical environment dur
325. ions Applied the connector using the correct compression tool 10 11 12 13 Ensured that overhead conductors were resagged Spliced overhead medium voltage cables Cleaned surfaces with an approved solvent to remove carbon dust and residue Replaced the high voltage insulation layer according to the manufacturer s literature Applied a semiconductive layer from the edge of the shielding tape to the edge of the opposing shield according to the manufacturer s literature Recreated a shield layer across the splice connector according to the manufacturer s literature Attached a ground to the shield according to the manufacturer s literature and left the ground long enough to reach the grounding point Applied an outer jacket to the power cable according to the manufacturer s literature to prevent moisture from entering Tested the splice to ensure that it met the cable rating Closed out lockout and tagout procedures by removing locking and tagging devices 3 290 STP 5 21P2 SM TG 31 March 2009 MOS Skill Level Tasks Evaluation Guidance Score the Soldier GO if all measures are passed P Score the Soldier NO GO if any measure is failed F If the Soldier fails any measure show him how to do it correctly References Required Related EM 385 1 1 FM 3 34 480 FM 5 412 LCH NESC TM 5 682 TM 5 684 TM 5 686 TM 5 811 1 TM 5 811 3 31 March 2009 STP 5 21P2 SM TG 3 291 Chapter 3 Terminate a Medium V
326. ions are followed Prepare the testing area and equipment in advance to ensure that task standards can be met Brief Soldier Direct the Soldier to service a PLC Performance Measures GO NO GO 1 O o N O Oa A W N _ Reviewed danger warning and caution notices before proceeding Reviewed the manufacturer s literature with schematics and wiring diagrams Reviewed maintenance logbooks and historical data pertaining to the equipment Identified the circuit connected to the PLC by using the schematics Performed lockout and tagout procedures Tested the circuit for voltage presence Removed the controller and tagged the leads Inspected the controller for damage Tested the controller according to the manufacturer s literature Compared the results with the manufacturer s specifications and took appropriate action Reinstalled or replaced the controller 31 March 2009 STP 5 21P2 SM TG 3 113 Chapter 3 Performance Measures 12 13 14 15 16 17 18 Tested the circuit for voltage presence Tagged the controller with the appropriate calibration sticker including the name and testing date Reinstalled the controller Closed out lockout and tagout procedures by removing locking and tagging devices Energized the circuit and ensured that it was operating properly Kept a record of
327. ipment in advance to ensure that task standards can be met Brief Soldier Direct the Soldier to service a vacuum switch Performance Measures GO NO GO 1 2 Reviewed danger warning and caution notices Reviewed the manufacturer s literature electrical construction prints and wiring diagrams Performed lockout and tagout procedures Inspected the condition of the vacuum switch visually and manually Performed resistance measurements on the bolted connections using a low resistance ohmmeter and ensured that the bolt torque levels matched the manufacturer s specifications 31 March 2009 STP 5 21P2 SM TG 3 205 Chapter 3 Performance Measures 6 10 11 12 13 Performed a contact resistance test and compared the contact resistances of the electrical connections to the values of similar connections according to the manufacturer s literature Verified that open and close control devices were operational and functional according to the manufacturer s specifications Performed insulation resistance tests pole to pole pole to ground and across the open poles and ensured that the test values were not less than 1 000 megohms at a DC test voltage of 2 500 volts minimum unless otherwise stated in the manufacturer s literature Performed a vacuum bottle integrity test across each vacuum bottle with the switch in the OPEN position according to the manufa
328. ir wattage ratings Incandescent lighting rating represents the total wattage Fluorescent 3 54 STP 5 21P2 SM TG 31 March 2009 MOS Skill Level Tasks Performance Steps lights are specified and the load per outlet is calculated by using one of the methods listed below a Use the ampere rating of ballast directly for the most accurate method It is referenced in the NEC Handbook EXAMPLE When a building has 150 fluorescent light fixtures each fixture consisting of two lamps 40 watts per lamp with a single 120 volt ballast rated at 1 1 ampere the lighting load is calculated as follows FORMULA 150 fixtures x 1 1 ampere per ballast 165 amperes 165 amperes x 120 volts 19 800 watts b Use the wattage of the lamps and increase the wattage by 20 percent to account for the ballast load that can be used when the ampere rating of the ballast is unknown This method is referenced in FM 5 424 EXAMPLE When a building has 150 fluorescent light fixtures each fixture consisting of two lamps 40 watts per lamp with a single 120 volt ballast the total lighting load is calculated as follows FORMULA 2 lamps x 40 watts x 150 fixtures 12 000 watts 12 000 watts x 1 2 which is 120 percent 14 400 watts 14 400 watts 120 volts 120 amperes 7 Determine the receptacle outlet load using one of the following methods a Calculate other outlets in the ceiling and walls and compute the wattage drain at 1 5 amperes per outlet b Determine
329. ired Related DA FORM 2404 DA FORM 5988 E 3 18 STP 5 21P2 SM TG 31 March 2009 MOS Skill Level Tasks Perform Lockout and Tagout Procedures 052 244 2112 Conditions As a power plant operator in a tactical or nontactical environment with a system that must be de energized for troubleshooting or maintenance you are given Occupational Safety and Health Administration OSHA Regulation 1910 147 TM 5 682 ER 385 1 31 Eng Form 1925 Danger Main Hold Card ENG Form 1927 R Safe Clearance Request Eng Form 2198 Operation Log a lockout and tagout kit a voltage detector a two way radio or telephone communication equipment other appropriate TMs and schematics or prints for the equipment to be locked out or tagged out DANGER 1 THIS TASK SHOULD ONLY BE PERFORMED BY QUALIFIED PERSONNEL WHO ARE KNOWLEDGEABLE IN THE INSTALLATION OPERATION AND MAINTENANCE OF MEDIUM VOLTAGE ELECTRICAL POWER GENERATION EQUIPMENT AND ITS ASSOCIATED HAZARDS FAILURE TO COMPLY MAY CAUSE PERMANENT INJURY OR DEATH 2 A VOLTAGE DETECTOR SHOULD BE USED TO ENSURE THAT THE CABLES ARE NOT ENERGIZED MATERIAL SUCH AS A LEAD SHEATH THAT ACTS AS A SHIELD MUST NOT BE BETWEEN THE DETECTOR AND THE CONDUCTORS OF THE CIRCUIT BEING TESTED FAILURE TO COMPLY MAY CAUSE PERMANENT INJURY OR DEATH 3 ALL SYSTEMS ARE CONSIDERED ENERGIZED UNTIL THE ENERGY SOURCE IS REMOVED LOCKED OUT WHEN POSSIBLE AND TAGGED OUT WHEN ENERGY ISOLATING DEVICES CANNOT BE PHYSICALLY LOCKED OUT
330. is appropriate contact lubricant on moving and sliding surfaces twos 3_ sxa Perform insulation resistance tests pole to pole pole to ground and across the open contacts of each phase using the voltage specified in the manufacturer s literature and ensure that the insulation resistance test values are not less than 1 000 megohms at a direct current DC test voltage of 2 500 volts unless otherwise stated in the manufacturer s literature Perform overpotential tests pole to pole pole to ground and across the open contacts of each phase using the voltage specified in the manufacturer s literature and ensure that the insulation withstands the voltage applied during the test Perform resistance measurements on the bolted connections using a low resistance ohmmeter and ensure that the bolt torque levels match the manufacturer s literature Measure the contact resistance across each switchblade and fuse holder and compare the contact resistances of the electrical connections to the values of similar connections and the manufacturer s literature Measure the resistance across each fuse and verify that the fuse resistance values do not deviate from each other by more than 15 percent Perform corrective action as necessary Close out lockout and tagout procedures by removing locking and tagging devices Reconnect the air switch to the system Perform a functions check on the nonaerial air switch Reenergize the powe
331. is no voltage present 4 Connect one end of the grounding conductor to an established ground usually the grounded neutral conductor NOTE A driven ground rod at the work site connected to the neutral conductor provides additional protection 5 Install a grounding cluster block on the pole below the work area if work is to be performed on a wooden pole NOTE Ensure that the grounding cluster is physically and electrically connected to the established ground before moving to the next step 6 Connect the other end of the grounding conductor using a hot line tool to the bottom conductor on vertical constructions or the closest conductor on horizontal constructions 7 Install grounds or jumpers from a grounded conductor to the ungrounded conductor in sequence until all conductors are grounded and short circuited together 8 Double check connections to ensure that they are clean and tight 9 Ensure that all parts of the grounding circuit have adequate current carrying capacity for the distribution system to be grounded 10 Remove the grounds when work is complete in the exact reverse sequence of installation 31 March 2009 STP 5 21P2 SM TG 3 269 Chapter 3 Performance Steps ensuring that established ground connection removal was last 11 Close out lockout and tagout procedures by removing locking and tagging devices WARNING BEFORE THE LOCKOUT OR TAGOUT DEVICES ARE REMOVED AND ELECTRIC CIRCUITS OR EQUIPMENT ARE REENERG
332. items listed in the conditions are properly cleaned and stored Evaluation Preparation Setup Provide the Soldier with the items listed in the conditions Give the Soldier a safety briefing before starting the test and ensure that safety precautions are followed Prepare the testing area and equipment in advance to ensure that task standards can be met Brief Soldier Direct the Soldier to troubleshoot a diesel engine air intake and or exhaust system Performance Measures GO NO GO 1 Reviewed TMs manufacturer s literature or industry standards maintenance logbooks and historical data pertaining to the equipment Ensured that PPE was correctly tested and fully mission capable Inspected tools and testing equipment for serviceability Performed lockout and tagout procedures a A O N Identified fault locations by checking the equipment fault indicator panel or the engine air intake and exhaust system for obvious malfunctions O Conducted further testing to identify specific defective components if necessary 7 Recorded actions taken on DA Form 2404 or DA Form 5988 E and maintenance logbooks 8 Ensured that the items listed in the conditions were properly cleaned and stored Evaluation Guidance Score the Soldier GO if all measures are passed P Score the Soldier NO GO if any measure is failed F If the Soldier fails any measure show him how to do
333. iterature if applicable e Verify the correct adjustments and operation of the motor operator limit switches and mechanical interlocks if applicable 31 March 2009 STP 5 21P2 SM TG 3 201 Chapter 3 Performance Steps 10 11 12 13 14 f Verify the correct blade alignment and penetration travel stops arc interrupter and mechanical operation g Inspect the insulating assemblies for evidence of physical damage and surface contamination h Check each fuse holder for adequate support and contact i Verify that the fuse sizes and types correspond to the drawings j Test the electrical and mechanical interlock systems for correct operation and sequencing k Verify that the insulating oil level is correct l Inspect and replace gaskets according to the manufacturer s literature as required m Verify that there is appropriate contact lubricant on moving current carrying parts Perform resistance measurements on the bolted connections using a low resistance ohmmeter and ensure that the bolt torque levels match the manufacturer s specifications Remove a sample of the insulating oil according to ASTM D923 a Test it for the correct dielectric breakdown voltage according to ASTM D877 b Test it for the correct color according to ASTM D1500 c Test it for the correct visual condition according to ASTM D1524 Perform a contact resistance test and compare the contact resistances of the electrical connections to the
334. ity DC negative electrode or DC positive electrode a Consider the nature of the base metal b Consider the position to be welded c Consider the type of welding machine available 6 Determine the approximate welding amperage required a Consider the nature of the base metal b Consider the position to be welded c Consider the type and size of the electrodes 7 Energize the welding machine and adjust the amperage a Perform a test weld on a metal similar to the metal being welded b Adjust the welding amperage to produce suitable weld beads 8 Perform one or more SMAW weld types depending on the items to be welded a Perform butt welds b Perform inside corner welds c Perform outside corner welds in flat d Perform out of position orientation welds 9 Inspect the weld for proper penetration 10 Shut down and properly store the welding equipment a Shut off the power switch to the welding machine b De energize the breaker to the welder if present c Coil electrode cables and store them in a secure location to prevent damage Evaluation Preparation Setup Provide the Soldier with the items listed in the conditions Give the Soldier a safety briefing before starting the test and ensure that safety precautions are followed Prepare the testing area and equipment in advance to ensure that task standards can be met Brief Soldier Direct the Soldier to perform electric arc welding Performance Measures GO NO GO
335. iven safety standing operating procedures SOPs a lockout and tagout kit a multimeter an alternating current AC power supply an electronic tool kit wiring diagrams maintenance logbooks and the applicable manufacturer s literature with schematics DANGER 1 ENSURE THAT POWER TO THE MODULE IS DISCONNECTED BEFORE SERVICING APPLY SAFE CLEARANCE PROCEDURES TO THE ASSOCIATED CIRCUITS FAILURE TO COMPLY MAY CAUSE PERMANENT INJURY OR DEATH 2 ENSURE THAT CURRENT TRANSFORMERS SUPPLYING CURRENT TO THE MODULE ARE DE ENERGIZED AND ELECTRICALLY SHORTED BEFORE SERVICING THE MODULE IF ENERGIZED AN OPEN CURRENT TRANSFORMER CIRCUIT WILL PRODUCE VERY HIGH VOLTAGES FAILURE TO COMPLY MAY CAUSE PERMANENT INJURY OR DEATH 3 ENSURE THAT POTENTIAL TRANSFORMERS FEEDING THE MODULE ARE DE ENERGIZED BEFORE SERVICING THE METER FAILURE TO COMPLY MAY CAUSE PERMANENT INJURY OR DEATH AND EQUIPMENT DAMAGE 4 REMOVE RINGS NECKLACES OTHER JEWELRY AND LOOSE CLOTHING FAILURE TO COMPLY MAY CAUSE PERMANENT INJURY OR DEATH WARNING KEEP THE WORK AREA NEAT AND ORGANIZED KEEP THE METER AND EQUIPMENT STABLE WHILE PERFORMING THIS TASK FAILURE TO COMPLY MAY LEAD TO UNRELIABLE TEST READINGS Standards Service the current boost module by safely testing and calibrating it according to the manufacturer s literature Reinstall or replace the module based on the test results Performance Steps NOTE The low voltage side of the potential transformer that sup
336. k fed circuits 3 Check for the proper use of safe clearance procedures Tag the equipment with the appropriate calibration sticker including the name and testing date Reinstall the meter a Attach tagged leads b Verify connections Close out lockout and tagout procedures by removing locking and tagging devices Energize the circuit and check for proper meter operation Keep a record of results and actions taken Ensure that the items listed in the conditions are properly cleaned and stored Evaluation Preparation Setup Provide the Soldier with the items listed in the conditions Give the Soldier a safety briefing before starting the test and ensure that safety precautions are followed Prepare the testing area and equipment in advance to ensure that task standards can be met Brief Soldier Direct the Soldier to service a meter Performance Measures GO NO GO 1 O oa A W N Reviewed danger warning and caution notices before proceeding Reviewed the manufacturer s literature with schematics and wiring diagrams Reviewed maintenance logbooks and historical data pertaining to the equipment Identified which circuit needed to be tested using the appropriate schematics Performed lockout and tagout procedures Tested the circuit for voltage presence 31 March 2009 STP 5 21P2 SM TG 3 125 Chapter 3 Performance Measures 7 8 9 10 11 13 14
337. ks WARNING WHEN HANDLING DIESEL FUEL PROVIDE METAL TO METAL CONTACT BETWEEN THE CONTAINER AND THE FUEL TANK FAILURE TO COMPLY MAY CAUSE IMMEDIATE PERSONAL INJURY OR EQUIPMENT DAMAGE b Check the valve location to ensure that it is in the OPEN position on the inside of the fuel filler neck cap c Add fuel if necessary d Drain the water and sediment from the filters e Inspect the filters 8 Inspect the muffler and exhaust during MEP 029 generator operation a Check for leaks in the turbocharger and exhaust stack b Inspect the muffler for unusual smoking 9 Inspect the engine panel controls and instruments during MEP 029 generator operation a Ensure that battery charging volts and amperes register in the green portion of the scale b Ensure that the coolant temperature gauge is between 180 and 200 F c Ensure that the oil pressure gauge is between 30 and 55 pounds per square inch 10 Inspect the generator panel during MEP 029 generator operation a Ensure that the voltmeter reads 120 phase to neutral and 208 phase to phase when in the United States When not in the United States ensure that the voltmeter reads 240 phase to neutral and 416 phase to phase Ensure that the alternating current AC ammeter does not exceed 100 percent Ensure that the kilowatt meter does not exceed 100 percent Ensure that the frequency meter reads 50 or 60 hertz e Ensure that the fault indicator lights are extinguished aoo
338. l are notified that the distribution system will soon be reenergized 5 Ensure that each lockout and tagout device is removed by the installer or designated representative if the installer is not available DANGER BEFORE LOCKOUT OR TAGOUT DEVICES ARE REMOVED AND ELECTRICAL CIRCUITS OR EQUIPMENT ARE REENERGIZED APPROPRIATE TESTS AND VISUAL INSPECTIONS WILL BE CONDUCTED BY THE INSTALLER THE INSTALLER WILL VERIFY THAT PERSONNEL TOOLS MECHANICAL RESTRAINTS ELECTRICAL JUMPERS SHORTS AND GROUNDS HAVE BEEN REMOVED THE ENTIRE WORK AREA WILL BE INSPECTED AND NONESSENTIAL ITEMS WILL BE REMOVED FROM THE SYSTEM FAILURE TO COMPLY MAY CAUSE PERMANENT INJURY OR DEATH 6 Ensure that personnel PPE hot line equipment climbing and rigging equipment and tools are safely positioned or removed from the area to be reenergized 7 Reenergize the distribution system 8 Perform a functions check on the electrical distribution system Evaluation Preparation Setup Provide the Soldier with the items listed in the conditions Give the Soldier a safety briefing before starting the test and ensure that safety precautions are followed Prepare 31 March 2009 STP 5 21P2 SM TG 3 299 Chapter 3 the testing area and equipment in advance to ensure that task standards can be met Brief Soldier Direct the Soldier to energize an electrical distribution system Performance Measures GO NO GO 1 Reviewed danger warning and caution notices
339. l data pertaining to the equipment to verify that the diesel engine starting system needed to be serviced 2 Inspected the starting system 3 Corrected the appropriate malfunction 4 Recorded actions taken on DA Form 2404 or DA Form 5988 E and maintenance logbooks 5 Ensured that the items listed in the conditions were properly cleaned and stored Evaluation Guidance Score the Soldier GO if all measures are passed P Score the Soldier NO GO if any measure is failed F If the Soldier fails any measure show him how to do it correctly References Required Related DA FORM 2404 EM 385 1 1 DA FORM 5988 E 3 180 STP 5 21P2 SM TG 31 March 2009 MOS Skill Level Tasks Troubleshoot a Diesel Engine Lube Oil System 052 205 2129 Conditions As a power station mechanic in a nontactical environment when a diesel engine lube oil system malfunctions you are given a lockout and tagout kit a general mechanic s tool box the applicable technical manuals TMs the applicable manufacturer s literature or industry standards a maintenance logbook DA Form 2404 Equipment Inspection and Maintenance Worksheet or DA Form 5988 E Equipment Inspection Maintenance Worksheet and applicable personal protective equipment PPE DANGER 1 REMOVE RINGS NECKLACES OTHER JEWELRY AND LOOSE CLOTHING FAILURE TO COMPLY MAY CAUSE PERMANENT INJURY OR DEATH 2 EXERCISE EXTREME CAUTION WHEN WORKING IN THE AREA
340. lant from exterior electrical connections Disconnected or removed batteries according to the shipping requirements Removed ground connections Drained fluids to the allowable levels according to the shipping requirements Prepared the generator accessories for movement Prepared the basic initial issue Inspected the tools and rigging and lifting equipment for serviceability Installed the lifting rigging and positioning equipment as necessary Supervised the loading of the generator onto the transport vehicle 15 Ensured that the items listed in the conditions were properly cleaned and stored Evaluation Guidance Score the Soldier GO if all measures are passed P Score the Soldier NO GO if any measure is failed F If the Soldier fails any measure show him how to do it correctly 3 78 STP 5 21P2 SM TG 31 March 2009 MOS Skill Level Tasks References Required Related EM 385 1 1 31 March 2009 STP 5 21P2 SM TG 3 79 Chapter 3 Perform Preventive Maintenance Checks and Services PMCS on a Mobile Electric Power MEP 029 Generator 052 244 2143 Conditions As a power plant operator in a tactical or nontactical environment you are given an MEP 029 generator TM 5 6115 593 12 DA Form 2404 Equipment Inspection and Maintenance Worksheet or DA Form 5988 E Equipment Inspection Maintenance Worksheet a general mechanic s tool box a wiping cloth a maintenance logbook and personal protective equip
341. ldier to operate a multiunit power plant Performance Measures GO NO GO 1 Performed preoperational PMCS 2 Started the units and conducted preoperation checks 31 March 2009 STP 5 21P2 SM TG 3 41 Chapter 3 Performance Measures 3 N O oO A ee 10 11 12 13 14 15 Adjusted the frequency adjustment rheostat for a frequency meter reading of 50 or 60 hertz Adjusted the voltage adjustment rheostat for an AC reading of the desired value Performed isolated or parallel operations Performed grid or parallel operations Determined the proper number of generators required to handle the assessed load Operated the generators in different modes of operation Paralleled the generators on and off the bus as directed by a shift supervisor or as needed Maintained the operator s logbook according to the SOP Monitored engine and generator indicators to ensure continued operation through various load changes Maintained an hourly reading log detailing the engine and electrical parameters of the equipment online and off line Performed during operation PMCS according to the TM Conducted unit shutdown operations Conducted postoperation PMCS according to the TM Evaluation Guidance Score the Soldier GO if all measures are passed P Score the Soldier NO GO if any measure is failed F If the Soldier fails any measure show him how to do it correctly Referen
342. le investigate values that deviate from adjacent poles or similar breakers by more than 50 percent of the lowest value 3 244 STP 5 21P2 SM TG 31 March 2009 MOS Skill Level Tasks Performance Steps 10 11 Thoroughly clean the unit before testing unless as found or as left tests are required Keep a record of as left and as found operation counter readings if applicable Inspect the anchorage alignment and grounding Perform mechanical operational tests on the circuit breaker and its operating mechanism Measure critical distances such as the contact gap according to the manufacturer s literature f Verify that lubrication is present on moving sliding surfaces oaoa Perform resistance measurements through the bolted connections with a low resistance ohmmeter and ensure that the bolt torque levels match the manufacturer s literature Perform a contact resistance test and compare contact resistances of electrical connections to the values of similar connections and to the values specified in the manufacturer s literature Verify that trip close trip free and antipump functions operate properly Trip the circuit breaker by operating each protective device to verify that open and close protective devices are operational and function according to the recommended values specified in the manufacturer s literature Perform insulation resistance tests pole to pole pole to ground and across open p
343. le personal protective equipment PPE DANGER FAILURE TO FOLLOW PROPER MAINTENANCE PROCEDURES MAY CAUSE PERMANENT INJURY OR DEATH WARNING 1 ONLY APPROVED CLEANING MATERIALS SHOULD BE USED TO CLEAN LEATHER PRODUCTS FAILURE TO COMPLY MAY CAUSE IMMEDIATE PERSONAL INJURY OR EQUIPMENT DAMAGE 2 INCORRECT MAINTENANCE OF RIGGING EQUIPMENT MAY CAUSE IMMEDIATE PERSONAL INJURY OR EQUIPMENT DAMAGE WARNING CARE SHOULD BE TAKEN WHILE SHARPENING GAFFS TO AVOID INJURY NOTES 1 Defective equipment should not be used It should be repaired or replaced immediately 2 There are several different manufacturers of climbing equipment Ensure that the appropriate manufacturer s literature is referenced before performing equipment maintenance Standards Maintain climbing and rigging equipment by inspecting it performing maintenance on it and storing it as stated in the applicable manufacturer s literature Performance Steps 1 Inventory the climbing and rigging equipment 2 Ensure that all items are included in the inventory a Include climber gaffs two each b Include a safety strap c Include a body belt d Include a hard hat e Include a pair of gloves f Include safety glasses g Include a climbing equipment storage bag h Include a handline i Include a block and tackle j Include a chain hoist 3 Inspect leather products a Check leather products for faults 1 Check for tears 2 Check for cracks 3 Check
344. leather gloves a welder s leather cape and bib a chipping hammer a wire brush work gloves safety glasses hearing protection and a fire extinguisher DANGER 1 EXTREME CAUTION SHOULD BE EXERCISED WHEN USING WELDING EQUIPMENT INJURY CAN RESULT FROM FIRE EXPLOSION OR HARMFUL AGENTS GENERATED BY WELDING FAILURE TO COMPLY MAY CAUSE PERMANENT INJURY OR DEATH 2 REMOVE FLAMMABLE MATERIALS SUCH AS BUTANE CIGARETTE LIGHTERS FROM THE CUTTING AREA AND THE WELDER S POCKETS FAILURE TO COMPLY MAY CAUSE PERMANENT INJURY OR DEATH 3 PROTECTIVE GUARDS COVERS AND INSULATORS MUST BE MAINTAINED IN THEIR PROPER POSITIONS AND CONDITION FAILURE TO COMPLY MAY CAUSE PERMANENT INJURY OR DEATH 4 IF THE WELDER MUST LEAN SIT OR KNEEL ON THE WORKTABLE DURING THE WELDING PROCESS A NONCONDUCTIVE FIRE RESISTANT INSULATING PAD SHOULD BE USED BETWEEN THE WELDER AND THE MATERIAL FAILURE TO COMPLY MAY CAUSE PERMANENT INJURY OR DEATH 5 ENSURE THAT WELDING OCCURS IN AN ADEQUATELY VENTILATED AREA FAILURE TO COMPLY MAY CAUSE PERMANENT INJURY OR DEATH WARNING WELDING BY PRIME POWER MECHANICS IS INTENDED TO SUPPORT NONCRITICAL WELDS USED IN THE INSTALLATION AND MAINTENANCE OF PRIME POWER GENERATION EQUIPMENT WELDING OF CRITICAL WELDS USED TO LIFT EQUIPMENT SHOULD BE DEFERRED TO PROFESSIONAL WELDERS POSSESSING THE SPECIAL EQUIPMENT AND QUALIFICATIONS TO PERFORM TEST AND CERTIFY THOSE WELDS FAILURE TO COMPLY MAY CAUSE IMMEDIATE INJURY TO PERSONNEL
345. lectric Power Plants DED Skid MTD 1500 KW 4160 V AC Electromotive Model MP36A 60 HZ NSN 6115 00 250 4402 1250 KW 4160 V AC MP36A 50 HZ 6115 00 250 4403 15 February 1980 STP 5 21P2 SM TG References 3 References TM 5 684 TM 5 686 TM 5 811 3 Training Aids 5180 02 502 9507 Training Circulars TC 9 510 TC 9 60 References 4 Facilities Engineering Electrical Exterior Facilities NAVFAC MO 200 AFJMAN 32 1082 29 November 1996 Power Transformer Maintenance and Acceptance Testing 16 November 1998 Electrical Design Lightning and Static Electricity Protection AFM 88 9 Chap 3 29 March 1985 BDAR Maintainer Kit Metal Body Repair and Related Operations 30 September 1993 Communications Electronics Fundamentals Basic Principles of Alternating Current and Direct Current 30 August 2004 STP 5 21P2 SM TG 31 March 2009 STP 5 21P2 SM TG 31 March 2009 By Order of the Secretary of the Army GEORGE W CASEY JR General United States Army Chief of Staff Official are a JOYCE E MORROW Administrative Assistant to the Secretary of the Army 0902203 DISTRIBUTION Active Army Army National Guard and United States Army Reserve Not to be distributed Electronic media only PIN 083036 000
346. lectrical Motor 052 264 2115 Conditions As a power station electrician or mechanic in a nontactical environment when an electric motor needs service you are given the manufacturer s literature with schematics wiring diagrams a megohmmeter a multimeter maintenance logbooks a steel brush contact cleaner compressed air and a general mechanic s tool box DANGER 1 THIS TASK SHOULD ONLY BE PERFORMED BY QUALIFIED INDIVIDUALS WHO ARE KNOWLEDGEABLE IN THE INSTALLATION AND OPERATION OF ELECTRICAL MOTORS ALTERNATING CURRENT AC SYSTEMS AND DIRECT CURRENT DC SYSTEMS AND THEIR ASSOCIATED HAZARDS FAILURE TO COMPLY MAY CAUSE PERMANENT INJURY OR DEATH 2 ALWAYS WEAR THE PERSONAL PROTECTIVE EQUIPMENT REQUIRED FOR INSPECTIONS IN HAZARDOUS AREAS FAILURE TO COMPLY MAY CAUSE PERMANENT INJURY OR DEATH 3 REMOVE RINGS NECKLACES OTHER JEWELRY AND LOOSE CLOTHING FAILURE TO COMPLY MAY CAUSE PERMANENT INJURY OR DEATH 4 ELECTRICAL CIRCUITS CONDUCTORS COMPONENTS PARTS AND EQUIPMENT SHOULD BE CONSIDERED ELECTRICALLY ENERGIZED UNTIL THE ENERGY SOURCE IS REMOVED FAILURE TO COMPLY MAY CAUSE PERMANENT INJURY OR DEATH WARNING COMPRESSED AIR USED FOR CLEANING OR DRYING CAN CREATE AIRBORNE PARTICLES THAT MAY ENTER THE EYES PRESSURE SHOULD NOT EXCEED 30 POUNDS PER SQUARE INCH GOGGLES ARE REQUIRED FAILURE TO COMPLY MAY CAUSE IMMEDIATE PERSONAL INJURY OR EQUIPMENT DAMAGE Standards Safely service an electrical motor by inspecting and testing
347. listed in the conditions are properly cleaned and stored 31 March 2009 STP 5 21P2 SM TG 3 75 Chapter 3 Evaluation Preparation Setup Provide the Soldier with the items listed in the conditions Give the Soldier a safety briefing before starting the test and ensure that safety precautions are followed Prepare the testing area and equipment in advance to ensure that task standards can be met Brief Soldier Direct the Soldier to repair a low voltage control cable Performance Measures 1 2 12 13 Reviewed danger warning and caution notices Reviewed the manufacturer s literature electrical construction prints and wiring diagrams Ensured that personal protective equipment was properly tested and was fully operable Performed lockout and tagout procedures Prepared an as found wiring diagram to ensure the correct reinstallation of the cable Ensured that no voltage was present by using a voltage detector and voltmeter Disconnected the damaged cable from the equipment to perform repairs as necessary Repaired the damaged cable using the splice mechanical type connector or termination method Reinstalled the cable using the as found wiring diagram 10 11 Tested the cable Closed out lockout and tagout procedures by removing locking and tagging devices Ensured that voltage was present by using a voltage detector and voltmeter Ensured that the items listed in the conditio
348. listed in the conditions are properly cleaned and stored Evaluation Preparation Setup Provide the Soldier with the items listed in the conditions Give the Soldier a safety briefing before starting the test and ensure that safety precautions are followed Prepare the testing area and equipment in advance to ensure that task standards can be met Brief Soldier Direct the Soldier to service an internal fuel system for a diesel engine Performance Measures GO NO GO 1 Reviewed maintenance logbooks and historical data pertaining to the equipment to verify that the internal fuel system needed to be serviced Performed lockout and tagout procedures Shut off fuel supply lines Depressurized and drained the affected portion of the system if required for a 3 174 STP 5 21P2 SM TG 31 March 2009 MOS Skill Level Tasks Performance Measures GO NO GO specific system service 5 Drained the water from the fuel water separator as applicable 6 Removed fuel filters and strainers for replacement or cleaning as required by the maintenance schedule 7 Inspected pickup pumps and engine mounted fuel pumps 8 Cleaned debris from in line strainers located on the inlet side of the pumps 9 Performed a detailed inspection of all portions of the system 10 Inspected connection points closely for signs of leakage 11 Inspected valves closely
349. listed in the conditions are properly cleaned and stored Evaluation Preparation Setup Provide the Soldier with the items listed in the conditions Give the Soldier a safety briefing before starting the test and ensure that safety precautions are followed Prepare the testing area and equipment in advance to ensure that task standards can be met Brief Soldier Direct the Soldier to supervise the installation of underground cable Performance Measures GO NO GO 1 Reviewed danger warning and caution notices before proceeding 2 Reviewed the manufacturer s literature electrical construction prints and wiring diagrams 3 Ensured that PPE was correctly tested and fully mission capable 4 Completed DA Form 2702 for the tools and equipment necessary to perform the task 5 Inspected tools and rigging equipment for serviceability 6 Developed a plan for obtaining nonorganic tools and the equipment necessary to perform the mission 7 Issued a safety briefing that highlighted safety precautions and the concept of the operation 8 Assigned personnel positions and ensured that they understood their role in accomplishing the task 9 Determined if the mobile or stationary reel method of reeling out the conductors would be used 10 Inspected conductors to ensure that they were not damaged during reeling out 11 Ensured that cond
350. literature 15 Applied an outer jacket to prevent moisture from entering the power cable according to the manufacturer s literature 16 Tested the splice to ensure that it met the cable rating 17 Closed out lockout and tagout procedures by removing locking and tagging devices Evaluation Guidance Score the Soldier GO if all measures are passed P Score the Soldier NO GO if any measure is failed F If the Soldier fails any measure show him how to do it correctly References Required Related EM 385 1 1 FM 3 34 480 FM 5 412 LCH NESC TM 5 682 TM 5 684 TM 5 686 TM 5 811 1 TM 5 811 3 3 294 STP 5 21P2 SM TG 31 March 2009 MOS Skill Level Tasks Conduct a Safety Briefing 052 204 2207 Conditions As a power line distribution supervisor in a tactical or nontactical environment before work begins on a jobsite you are given a detailed job description and applicable safety standing operating procedures SOPs Standards Conduct a safety briefing to inform personnel of dangers warnings cautions and risks related to the jobsite based on the detailed job description and applicable safety SOPs Performance Steps 1 Perform an initial walk through of the jobsite 2 Note possible hazards and associated risks 3 Inform personnel verbally of possible hazards and associated risks 4 Remind personnel that everyone at the jobsite is a safety officer who has the responsibility of
351. literature electrical construction prints and wiring diagrams 3 Perform lockout and tagout procedures 4 Service a dry type distribution transformer a Inspect the condition of the transformer visually and mechanically 1 Clean the unit before testing it unless as found and as left tests are required 2 Inspect the bolted electrical connections for high resistance and compare the resistances to values of similar connections 3 Verify that the cooling fans operate correctly 4 Verify that the bolt torque levels are correct according to the manufacturer s literature b Perform electrical tests 1 Perform resistance measurements on the bolted connections using a low resistance ohmmeter 2 Perform insulation resistance tests winding to winding and winding to ground on each phase and ensure that the test values at 1 minute meet the manufacturer s specifications If not stated compare the results by voltage to the NETA Maintenance Testing 3 218 STP 5 21P2 SM TG 31 March 2009 MOS Skill Level Tasks Performance Steps Specifications for Electrical Power Distribution Equipment and Systems 3 Perform a turn to turn ratio test on each tap setting and ensure that the test results do not deviate more than 1 2 percent from the adjacent coils or calculated ratio 4 Check the pressure of the transformer surge arrestor 5 Service a liquid filled distribution transformer a Inspect the condition of the transformer visually and mechan
352. load requirements Prepared the engine Grounded the generator unit Attached fuel lines if necessary Tested generator breakers to ensure proper operation Started the generator Performed a walk around inspection to ensure that there were no major mechanical defects or malfunctions before proceeding to the next step Checked the output voltage and frequency Stopped the generator 3 44 STP 5 21P2 SM TG 31 March 2009 MOS Skill Level Tasks Performance Measures GO NO GO 10 Prepared load cables 11 Energized the system 12 Made necessary changes to achieve the proper output voltage and frequency 13 Ensured that the items listed in the conditions were properly cleaned and stored Evaluation Guidance Score the Soldier GO if all measures are passed P Score the Soldier NO GO if any measure is failed F If the Soldier fails any measure show him how to do it correctly References Required Related FM 3 34 480 31 March 2009 STP 5 21P2 SM TG 3 45 Chapter 3 Operate a Nonorganic Generator 052 244 2125 Conditions As a power plant operator in a tactical or nontactical environment after a nonorganic generator has been successfully installed you are given the manufacturer s literature and personal protective equipment DANGER 1 THIS TASK SHOULD ONLY BE PERFORMED BY QUALIFIE
353. locking and tagging devices 16 Energized the circuit and ensured that it was operating properly 17 Kept a record of results and actions taken 18 Ensured that the items listed in the conditions were properly cleaned and stored Evaluation Guidance Score the Soldier GO if all measures are passed P Score the Soldier NO GO if any measure is failed F If the Soldier fails any measure show him how to do it correctly References Required Related TM 5 6115 593 12 TM 5 6115 593 34 31 March 2009 STP 5 21P2 SM TG 3 123 Chapter 3 Service a Meter 052 207 2125 Conditions As a power plant instrument technician in a tactical or nontactical environment during scheduled maintenance or if a meter is suspected of being defective you are given safety standing operating procedures SOPs a lockout and tagout kit a multimeter a relay test set with three phase voltage current capability and manual a variable frequency generator an oscilloscope or digital equivalent an electronic tool kit appropriate equipment technical manuals and schematics wiring diagrams maintenance logbooks and the applicable manufacturer s literature with schematics DANGER 1 ENSURE THAT POWER TO THE METER IS DISCONNECTED BEFORE SERVICING APPLY SAFE CLEARANCE PROCEDURES TO ASSOCIATED CIRCUITS FAILURE TO COMPLY MAY CAUSE PERMANENT INJURY OR DEATH 2 ENSURE THAT CURRENT TRANSFORMERS ARE DE ENERGIZED AND ELECTRICAL
354. luding Optional KTS DOD Models MEP 029AHK Nomenclature Housing Kit NSN 6115 01 070 7550 MEP 029ACM Automatic Control Module NSN 6115 01 275 7912 MEP 029ARC Remote Control Module NSN 6115 01 070 7553 MEP 029ACC Remote control Cable NSN 6115 01 087 4127 TO 35C2 3 463 1 17 July 1990 Facilities Engineering Electrical Facilities Safety 8 November 1999 Construction Print Reading in the Field AFM 85 27 2 January 1969 Electric Power Supply and Distribution AFJMAN 32 1080 28 February 1995 Operator and Unit Maintenance Manual for Generator Set Diesel Engine Driven Air Transportable Skid Mounted 750 kW 3 Phase 4 Wire 2400 4160 and 2200 3800 Volts DOD Model MEP 208A Class Prime Utility Hz 50 60 NSN 6115 00 450 5881 NAVFAC P 8 6 33 12 31 August 1995 STP 5 21P2 SM TG 31 March 2009 TM 9 61 15 604 34 Direct Support General Support and Depot Level Maintenance Manual for Generator Set Diesel Engine Driven Air Transportable Skid MTD 750 KW 3 PHASE 4 WIRE 2400 4160 AND 2200 3800 VOLTS DOD MODEL MEP 208A PRIME UTILITY CLASS 50 60 HERTZ NSN 6115 00 450 5881 NAVFAC P 8 633 34 30 August 1996 Related Publications Related publications are sources of additional information They are not required in order to understand this publication Army Regulations AR 385 10 Field Manuals FM 10 67 1 FM 3 34 471 FM 3 34 480 FM 4 25 11 FM 4 30 31 FM 5 125 FM 5 412 FM 55 509 1 Other Product Types AEH
355. ly operable Inspected the tools and testing equipment for serviceability Determined which systems were due for service Performed lockout and tagout procedures Inspected tested cleaned repaired or replaced system components parts 3 88 STP 5 21P2 SM TG 31 March 2009 MOS Skill Level Tasks Performance Measures GO NO GO according to the manufacturer s literature 8 Performed a functions check on serviced systems 9 Closed out lockout and tagout procedures by removing all locking and tagging devices 10 Put the system back into service 11 Recorded faults and repairs in the maintenance logbook 12 Ensured that the items listed in the conditions were properly cleaned and stored Evaluation Guidance Score the Soldier GO if all measures are passed P Score the Soldier NO GO if any measure is failed F If the Soldier fails any measure show him how to do it correctly References Required Related EM 385 1 1 FM 3 34 480 LCH TM 5 682 TM 5 684 TM 5 811 1 TM 5 811 3 31 March 2009 STP 5 21P2 SM TG 3 89 Chapter 3 Troubleshoot a Nonorganic Prime Mover 052 244 2147 Conditions As a power plant operator in a tactical or nontactical environment when a nonorganic prime mover fails to maintain the normal operating speed you are given a prime mover a lockout and tagout kit grounding equipment safety standing operati
356. m 2404 or DA Form 5988 E and maintenance logbooks 13 Ensured that the items listed in the conditions were properly cleaned and stored Evaluation Guidance Score the Soldier GO if all measures are passed P Score the Soldier NO GO if any measure is failed F If the Soldier fails any measure show him how to do it correctly References Required Related DA FORM 2404 DA FORM 5988 E 3 172 STP 5 21P2 SM TG 31 March 2009 MOS Skill Level Tasks Service an Internal Fuel System for a Diesel Engine 052 205 2126 Conditions As a power station mechanic in a tactical or nontactical environment during maintenance you are given a lockout and tagout kit a general mechanic s tool box Environmental Protection Agency EPA guidelines the applicable manufacturer s literature maintenance logbooks and DA Form 2404 Equipment Inspection and Maintenance Worksheet or DA Form 5988 E Equipment Inspection Maintenance Worksheet DANGER 1 THIS TASK SHOULD ONLY BE PERFORMED BY QUALIFIED PERSONNEL WHO ARE KNOWLEDGEABLE IN THE INSTALLATION OPERATION AND MAINTENANCE OF ELECTRICAL POWER GENERATION EQUIPMENT AND THE ASSOCIATED HAZARDS FAILURE TO COMPLY MAY CAUSE PERMANENT INJURY OR DEATH 2 DO NOT TOUCH EXPOSED ELECTRICAL CONNECTIONS WHEN A POWER SOURCE SUCH AS UTILITY POWER OR ANOTHER GENERATOR SET IS CONNECTED TO LOAD TERMINALS FAILURE TO COMPLY MAY CAUSE PERMANENT INJURY OR DEATH 3 REMOVE RINGS NECKLACES OTHER JEWEL
357. m that allows individuals to make informed conscious decisions about acceptable risk levels to reduce injury and equipment damage Performance Steps NOTE Each step contains examples of common hazards and is not intended to be an all inclusive list 1 Identify possible mechanical hazards a Consider noises b Consider high temperature equipment c Consider compressed air d Consider pressurized liquids e Consider heavy objects f Consider grinding operations g Consider moving parts h Consider tools i Consider hazardous objects j Consider hydraulically operated equipment k Consider pneumatically operated equipment 2 Identify possible electrical hazards a Check for loose wiring b Check for energized equipment c Check for capacitive charges d Check for ungrounded systems or equipment e Check ground resistance and ensure that resistance is under 25 ohms 3 Identify possible chemical hazards a Check for chemical solvents b Check welding operations c Check batteries d Check exhaust gases e Check for polychlorinated biphenyl PCB f Check fuels g Check for hazardous waste 3 48 STP 5 21P2 SM TG 31 March 2009 MOS Skill Level Tasks Performance Steps 4 Identify possible fire hazards a Check generator equipment b Check electrical switchgears c Check petroleum oil and lubricant facilities d Check maintenance shops e Check ignitable substances Evaluation Preparation S
358. mark the cable b Inspect the cable for carbon particles and remove any that are found c Inspect the primary insulation of the cable for nicks and remove any that are found d Cut the cable to the proper length 31 March 2009 STP 5 21P2 SM TG 3 7 Chapter 3 Performance Steps 4 9 10 11 12 13 14 15 16 17 Remove the jacket using the distance indicated in the manufacturer s literature and ensure that the length required for the lug is added to the measure back distance Remove the shield using the distance indicated in the manufacturer s literature Remove the semiconductor using the distance indicated in the manufacturer s literature Remove the high voltage insulation layer using the distance indicated in the manufacturer s literature Install the termination lug using the correct compression tool a Place two crimps on the lug and rotate it approximately 90 between each crimp b Remove any sharp edges Clean all surfaces using an approved solvent to remove any carbon dust or residue Replace the high voltage layer as specified in the manufacturer s literature Apply a semiconductive layer as specified in the manufacturer s literature Recreate a shield layer as specified in the manufacturer s literature Attach a ground as specified in the manufacturer s literature leaving it long enough to reach the grounding point Apply a high voltage insulation layer as specified in the manufact
359. matics for proper circuit identification 2 Check for back fed circuits 3 Check for the proper use of safe clearance procedures 7 Remove the relay and tag the leads 3 118 STP 5 21P2 SM TG 31 March 2009 MOS Skill Level Tasks Performance Steps 8 9 10 11 12 13 14 15 16 Test the relay according to the manufacturer s literature Compare the results with the manufacturer s specifications and take appropriate action Calibrate reinstall or replace the relay Test the circuit for voltage presence a Proceed to step 12 if there is no voltage present b Stop if there is voltage present and perform the following checks until voltage is no longer present 1 Check the schematics for proper circuit identification 2 Check for back fed circuits 3 Check for the proper use of safe clearance procedures Reinstall the relay a Attach tagged leads b Verify connections Close out lockout and tagout procedures by removing locking and tagging devices Energize the circuit and ensure that it is operating properly Keep a record of results and actions taken Ensure that the items listed in the conditions are properly cleaned and stored Evaluation Preparation Setup Provide the Soldier with the items listed in the conditions Give the Soldier a safety briefing before starting the test and ensure that safety precautions are followed Prepare the testing area and equipment in advance to ensure that task st
360. mechanic s tool box DANGER 1 THIS TASK SHOULD ONLY BE PERFORMED BY QUALIFIED PERSONNEL WHO ARE KNOWLEDGEABLE IN THE INSTALLATION OPERATION AND MAINTENANCE OF MEDIUM VOLTAGE ELECTRICAL POWER GENERATION EQUIPMENT AND ITS ASSOCIATED HAZARDS FAILURE TO COMPLY MAY CAUSE PERMANENT INJURY OR DEATH 2 ELECTRICAL CIRCUITS CONDUCTORS COMPONENTS PARTS AND EQUIPMENT MUST BE CONSIDERED ELECTRICALLY ENERGIZED UNTIL THE ENERGY SOURCE IS REMOVED FAILURE TO COMPLY MAY CAUSE PERMANENT INJURY OR DEATH 3 DO NOT OPERATE THE GENERATOR SET UNLESS IT HAS BEEN PROPERLY GROUNDED FAILURE TO COMPLY COULD RESULT IN ELECTROCUTION AND MAY CAUSE PERMANENT INJURY OR DEATH 4 STATIC CHARGE MAY BE ON THE GENERATOR LINES WHEN THE GENERATOR SET IS SHUT DOWN USING AN INSULATED ROD WITH A GROUNDED METAL TIP DISCHARGE THE GENERATOR LEADS TO THE GROUND BEFORE WORKING ON THEM FAILURE TO COMPLY MAY CAUSE PERMANENT INJURY OR DEATH 5 REMOVE RINGS NECKLACES OTHER JEWELRY AND LOOSE CLOTHING FAILURE TO COMPLY MAY CAUSE PERMANENT INJURY OR DEATH CAUTION NOISE LEVELS IN EXCESS OF 85 DECIBELS EXIST WITHIN A 50 FOOT RADIUS OF OPERATING EQUIPMENT ALWAYS WEAR SINGLE HEARING PROTECTION WITHIN A 50 FOOT RADIUS OF OPERATING EQUIPMENT FAILURE TO COMPLY MAY CAUSE INJURY Standards Troubleshoot a generator s improper voltage output according to the corresponding technical manual or manufacturer s literature ensuring that the problem is identified and corrected Pe
361. ment DANGER 1 THIS TASK SHOULD ONLY BE PERFORMED BY QUALIFIED PERSONNEL WHO ARE KNOWLEDGEABLE IN THE INSTALLATION OPERATION AND MAINTENANCE OF LOW VOLTAGE ELECTRICAL POWER GENERATION EQUIPMENT AND ITS ASSOCIATED HAZARDS FAILURE TO COMPLY MAY CAUSE PERMANENT INJURY OR DEATH 2 DO NOT TOUCH EXPOSED ELECTRICAL CONNECTIONS WHEN A POWER SOURCE SUCH AS A UTILITY POWER OR ANOTHER GENERATOR SET IS CONNECTED TO THE LOAD TERMINALS FAILURE TO COMPLY MAY CAUSE PERMANENT INJURY OR DEATH 3 DO NOT OPERATE THE GENERATOR SET UNLESS IT HAS BEEN PROPERLY GROUNDED FAILURE TO COMPLY MAY CAUSE PERMANENT INJURY OR DEATH 4 REMOVE RINGS NECKLACES OTHER JEWELRY AND LOOSE CLOTHING FAILURE TO COMPLY MAY CAUSE PERMANENT INJURY OR DEATH WARNING 1 AVOID CONTACT WITH BATTERY ELECTROLYTES THEY CONTAIN SULFURIC ACID THAT CAN CAUSE SEVERE CHEMICAL BURNS SKIN AND EYE PROTECTION IS REQUIRED FAILURE TO COMPLY MAY CAUSE IMMEDIATE PERSONAL INJURY OR EQUIPMENT DAMAGE 2 DO NOT ATTEMPT TO SERVICE ADJUST CONNECT OR RECONNECT WIRES OR CABLES UNTIL THE GENERATOR SET IS SHUT DOWN AND COMPLETELY DE ENERGIZED FAILURE TO COMPLY MAY CAUSE IMMEDIATE PERSONAL INJURY OR EQUIPMENT DAMAGE Standards Perform PMCS on an MEP 029 generator according to TM 5 6115 593 12 without causing personal injury or equipment damage Ensure that the system parameters are met Performance Steps NOTE Perform steps 1 through 7 before starting the MEP 029 generator Perform c
362. mponents and protective devices within the electronic system 3 Identify the correct electronic symbols for the components and protective devices for the electronic schematic 4 Illustrate the electronic schematic a Organize the correct sequence of the electrical and protective device symbols b Determine the current path c Label the current path amperage voltage and components 5 Perform a complete system trace using the created electronic schematic to check for accuracy Evaluation Preparation Setup Provide the Soldier with the items listed in the conditions Give the Soldier a safety briefing before starting the test and ensure that safety precautions are followed Prepare the testing area and equipment in advance to ensure that task standards can be met Brief Soldier Direct the Soldier to produce an electronic schematic Performance Measures GO NO GO 1 Determined which electronic system needed the electronic schematic 2 Identified electronic components and protective devices within the electronic system 3 Identified the correct electronic symbols for the components and protective devices for the electronic schematic 4 Illustrated the electronic schematic 5 Performed a complete system trace using the created electronic schematic to check for accuracy Evaluation Guidance Score the Soldier GO if all measures are passed P Score the Soldier NO GO if any meas
363. mponents parts are present 3 Prepare the cable and splice it according to the manufacturer s literature a Measure and mark the cable b Inspect the cable for carbon particles and remove those that are found c Inspect the cable jacket for nicks and remove those that are found 4 Align cables so that the ends of the conductors conjoin squarely a Ensure that cuts are squarely made and leave a smooth edge b Perform ring cuts as needed without causing damage to other cable parts 3 288 STP 5 21P2 SM TG 31 March 2009 MOS Skill Level Tasks Performance Steps 5 Remove the jacket using the distance indicated by the splice kit instructions NOTES 1 Cuts should be made square to the conductor 2 Steps 6 through 9 are used for splicing underground medium voltage cable only 6 Remove the cable metallic shield using the distance indicated in the splice kit instructions NOTE Do not ring cut into the metallic shielding or insulation when removing the jacket 7 Remove the high voltage insulation layer using the distance indicated in the splice kit instructions 8 Remove the semiconductor from the metallic shield edge using the distance indicated in the splice kit instructions 9 Apply the connector using the correct compression tool a Measure back the depth needed for the conductor to penetrate the connector plus the distance indicated by the splice kit b Clean the entire area of the splice with cable cleaning sol
364. n the unit before testing it unless as found and as left tests are required Verify the appropriate anchorage and area clearing Verify the appropriate equipment grounding Check the blade for the correct 1 Alignment 2 Penetration 3 Travel stops 4 Mechanical operation 5 Contact pressure Verify that the fuse sizes and types are correct according to the manufacturer s literature f Verify that the expulsion limiting devices are in place on holders that have expulsion type elements a008 9 31 March 2009 STP 5 21P2 SM TG 3 209 Chapter 3 Performance Steps 10 11 12 13 14 15 g Verify that each fuse holder has adequate mechanical support h Inspect the bolted electrical connections for high resistance 1 Test by using a low resistance ohmmeter 2 Verify the tightness of the bolted connections using a calibrated torque wrench according to the manufacturer s literature 3 Perform a thermographic survey Test the interlocking systems for correct sequencing and operation Inspect the insulating assemblies for evidence of physical damage or contamination Exercise the mechanical components parts Compare the switchblade clearances with the industry standards Ensure that the indicating and control devices operate correctly Verify the operation of the heaters if applicable Verify that there is appropriate contact lubricant on the moving current carrying parts Verify that there
365. nce Score the Soldier GO if all measures are passed P Score the Soldier NO GO if any measure is failed F If the Soldier fails any measure show him how to do it correctly 31 March 2009 STP 5 21P2 SM TG 3 343 Chapter 3 Subject Area 8 S2 and E5 Combined Tasks Service an Auxiliary and or an Instrumentation Sensing Device 052 264 2104 Conditions As a power station instrument technician or power station mechanic in a tactical or nontactical environment during maintenance intervals you are given a lockout and tagout kit a multimeter an oscilloscope maintenance logbooks wiring diagrams appropriate technical manuals an electronic tool kit and the applicable manufacturer s literature with schematics DANGER 1 ENSURE THAT POWER TO THE SENSING DEVICE IS DISCONNECTED BEFORE SERVICING APPLY SAFE CLEARANCE PROCEDURES TO ASSOCIATED CIRCUITS FAILURE TO COMPLY MAY CAUSE PERMANENT INJURY OR DEATH 2 REMOVE RINGS NECKLACES OTHER JEWELRY AND LOOSE CLOTHING FAILURE TO COMPLY MAY CAUSE PERMANENT INJURY OR DEATH CAUTION KEEP THE WORK AREA NEAT AND ORGANIZED WHILE PERFORMING THIS TASK FAILURE TO COMPLY MAY CAUSE IMMEDIATE PERSONAL INJURY OR EQUIPMENT DAMAGE Standards Safely service auxiliary and sensing devices by testing and calibrating or replacing them Test the devices according to the manufacturer s literature and record the results Reinstall or replace the auxiliary or sensing device based on the test results Perf
366. nce Testing Specifications for Electrical Power Distribution Equipment and Systems and the applicable manufacturer s literature DANGER 1 THIS TASK SHOULD ONLY BE PERFORMED BY QUALIFIED PERSONNEL WHO ARE KNOWLEDGEABLE IN THE INSTALLATION AND MAINTENANCE OF TRANSFORMERS AND POWER EQUIPMENT AND THEIR ASSOCIATED HAZARDS FAILURE TO COMPLY MAY CAUSE PERMANENT INJURY OR DEATH 2 DO NOT TOUCH EXPOSED ELECTRICAL CONNECTIONS WHILE A POWER SOURCE IS CONNECTED TO THE TRANSFORMER FAILURE TO COMPLY MAY CAUSE PERMANENT INJURY OR DEATH 3 REMOVE RINGS NECKLACES OTHER JEWELRY AND LOOSE CLOTHING FAILURE TO COMPLY MAY CAUSE PERMANENT INJURY OR DEATH WARNING THIS TASK SHOULD ONLY BE PERFORMED ON EQUIPMENT THAT DOES NOT CONTAIN POLYCHLORINATED BIPHENYL PCB FAILURE TO COMPLY MAY CAUSE SKIN AILMENTS REPRODUCTIVE DISORDERS LIVER DISEASE AND OTHER ADVERSE HEALTH CONDITIONS Standards Safely service a power transformer by inspecting and testing it according to the manufacturer s literature Reinstall or repair the transformer based on the test results Performance Steps NOTE Conduct tests according to the manufacturer s literature when available Use industry standards when the manufacturer s literature cannot be obtained 1 Review danger warning and caution notices 2 Review the manufacturer s literature electrical construction prints and wiring diagrams 3 Perform lockout and tagout procedures 4 Service a dry type power transfo
367. nches 2 54000 Centimeters Inches 0 02540 Meters Inches 25 40010 Millimeters Miles statute 1 60930 Kilometers Miles nautical 1 85320 Kilometers Yards 0 91400 Meters Square inches 6 45160 Square centimeters Square feet 0 09290 Square meters Square yards 0 83610 Square meters Cubic inches 16 38720 Cubic centimeters Cubic feet 0 02830 Cubic meters Cubic yards 0 76460 Cubic meters Gallons 3 78540 Liters Fluid ounces 29 57300 Milliliters Quarts 0 94600 Liters Ounces 28 34900 Grams Pounds 453 59000 Grams Pounds 0 45359 Kilograms Short tons 0 90700 Metric tons Long tons 1 01600 Metric tons Foot pounds 1 38300 Newton meters Pounds per square inch 6 90000 Kilopascals 31 March 2009 STP 5 21P2 SM TG Appendix A Metric Units Multiplied By Table A 1 Metric Conversion Chart continued Equals U S Units Centimeters Meters per second Length 0 39370 2 23700 Inches Miles per hour Millimeters 0 03937 Inches Area Square centimeters Square meters Square meters 0 15500 10 76400 1 19600 Volume Square inches Square feet Square yards Cubic centimeters Cubic meters Cubic meters Milliliters Liters Liters 0 06100 35 31440 1 30790 0 03380 1 05700 0 26420 Cubic inches Cubic feet Cubic yards Fluid ounces Quarts Gallons Grams Kilograms Metric tons Metric tons Newton meters 0 03527
368. nd historical data pertaining to the equipment to verify that the diesel engine cooling system needs to be serviced 2 Perform lockout and tagout procedures NOTE The following inspections and checks are guidelines and may be done in any order If defective components parts are found replace or repair them as necessary 3 Inspect the water pump a Check for secure installation b Check for obvious damage c Check for signs of leakage d Check the weep hole for leaks 4 Inspect the radiator cap for signs of rust a degraded seal and leaks NOTE There are no coolant filters on a mobile electric power MEP 810A MEP 810B or MEP 36A generator 5 Inspect the coolant filter for damage leaks and a secure mounting 6 Inspect radiator pipes hoses and clamps for security signs of rust and other signs of leakage 31 March 2009 STP 5 21P2 SM TG 3 151 Chapter 3 Performance Steps 7 Inspect the sight gauge for damage leaks and a secure mounting 8 Inspect radiator fans 9 Inspect the fan belt for tension and signs of excessive wear glazing dry rotting fraying 10 Inspect the radiator a Check for leaks or damage b Use a strong light to examine the core from the front and back side of the radiator NOTE If damage is found to the radiator core refer it to the next higher maintenance level 11 Check the coolant for the proper antifreeze level and add coolant or additives as needed NOTE Different units and u
369. nd testing equipment for serviceability Performed lockout and tagout procedures Verified the defective components parts Repaired or replaced the defective components parts using the appropriate TM applicable manufacturer s literature or industry standards Closed out lockout and tagout procedures by removing locking and tagging devices Performed a functions check on the diesel engine cooling system Recorded actions taken on DA Form 2404 or DA Form 5988 E and maintenance logbooks Ensured that the items listed in the conditions were properly cleaned and stored 31 March 2009 STP 5 21P2 SM TG 3 191 Chapter 3 Evaluation Guidance Score the Soldier GO if all measures are passed P Score the Soldier NO GO if any measure is failed F If the Soldier fails any measure show him how to do it correctly References Required Related DA FORM 2404 EM 385 1 1 DA FORM 5988 E 3 192 STP 5 21P2 SM TG 31 March 2009 MOS Skill Level Tasks Repair an Engine Air Intake and or Exhaust System 052 205 2134 Conditions As a power station mechanic in a nontactical environment when a diesel engine air intake and or exhaust system needs repair you are given a lockout and tagout kit a general mechanic s tool box the applicable technical manuals TMs the applicable manufacturer s literature or industry standards maintenance logbooks DA Form 24
370. ng and replacing the defective components parts Annotate repairs on DA Form 2404 or DA Form 5988 E Performance Steps 1 Review the appropriate TMs manufacturer s literature or industry standards maintenance logbooks and historical data pertaining to the equipment malfunction Ensure that PPE is correctly tested and fully mission capable Inspect tools and testing equipment for serviceability Perform lockout and tagout procedures Verify the defective components parts O oa A W N Repair or replace the defective components parts using the appropriate TM applicable manufacturer s literature or industry standards 31 March 2009 STP 5 21P2 SM TG 3 193 Chapter 3 Performance Steps 7 Close out lockout and tagout procedures by removing locking and tagging devices 8 Perform a functions check on the diesel engine air intake and or exhaust system 9 Record actions taken on DA Form 2404 or DA Form 5988 E and maintenance logbooks 10 Ensure that the items listed in the conditions are properly cleaned and stored Evaluation Preparation Setup Provide the Soldier with the items listed in the conditions Give the Soldier a safety briefing before starting the test and ensure that safety precautions are followed Prepare the testing area and equipment in advance to ensure that task standards can be met Brief Soldier Direct the Soldier to repair an engine air intake and or exhaust system Performance Measures GO NO GO
371. ng leg Ensure that your weight remains on your heel aim your gaff toward the heart of the pole below your body and let your body weight aid in your descent as the gaff penetrates the pole Ensure that your uppermost leg is horizontal with the ground each time you drop Remove the upper gaff by moving your upper knee away from the pole and ensure that your last step is approximately 6 inches above the ground Evaluation Preparation Setup Provide the Soldier with the items listed in the conditions Give the Soldier a safety briefing before starting the test and ensure that safety precautions are followed Prepare the testing area and equipment in advance to ensure that task standards can be met Brief Soldier Direct the Soldier to climb a utility pole Performance Measures GO NO GO 1 Performed a utility pole serviceability inspection 2 Inspected equipment 3 Laid out the handline and attached it to the body belt 4 Ascended the utility pole until he was eye level with the lag screw and then belted in 31 March 2009 STP 5 21P2 SM TG 3 281 Chapter 3 Performance Measures GO NO GO 5 Hitchhiked down 5 feet and then hitchhiked back up until he was eye level with the lag screw 6 Circled to the right until he was positioned directly below the crossarm 7 Assumed a good working position that allowed him to reach the end of the crossarm and then returned to
372. ng procedures the appropriate technical manuals construction prints wiring diagrams the applicable manufacturer s literature or industry standards a maintenance logbook a general mechanic s tool box a multimeter and personal protective equipment PPE DANGER 1 THIS TASK SHOULD ONLY BE PERFORMED BY QUALIFIED PERSONNEL WHO ARE KNOWLEDGEABLE IN THE INSTALLATION AND MAINTENANCE OF ELECTRICAL DISTRIBUTION SYSTEMS AND POWER EQUIPMENT AND THEIR ASSOCIATED HAZARDS FAILURE TO COMPLY MAY CAUSE PERMANENT INJURY OR DEATH 2 REMOVE RINGS NECKLACES OTHER JEWELRY AND LOOSE CLOTHING FAILURE TO COMPLY MAY CAUSE PERMANENT INJURY OR DEATH 3 EXERCISE EXTREME CARE WHEN WORKING AROUND ROTATING ENGINE COMPONENTS PARTS FAILURE TO COMPLY MAY CAUSE PERMANENT INJURY OR DEATH 4 ALWAYS WEAR THE PPE REQUIRED FOR INSPECTIONS IN HAZARDOUS AREAS FAILURE TO COMPLY MAY CAUSE PERMANENT INJURY OR DEATH 5 ISOLATION VERIFICATION AND SYSTEM DE ENERGIZING MUST BE ACCOMPLISHED BY ATTEMPTING TO OPERATE THE ENERGY ISOLATING DEVICES AND DISCONNECTING MEANS FAILURE TO COMPLY MAY CAUSE PERMANENT INJURY OR DEATH CAUTION 1 NOISE LEVELS IN EXCESS OF 85 DECIBELS EXIST WITHIN A 50 FOOT RADIUS OF OPERATING EQUIPMENT PERSONNEL MUST WEAR SINGLE HEARING PROTECTION WITHIN A 50 FOOT RADIUS FAILURE TO COMPLY MAY CAUSE PERSONAL INJURY 2 EQUIPMENT WITH A CLASS III LEAK SHOULD NOT BE OPERATED AND MUST BE REPAIRED OR SENT FOR REPAIR IMMEDIATELY FAILURE TO COMPLY MAY
373. ng the test and ensure that safety precautions are followed Prepare the testing area and equipment in advance to ensure that task standards can be met Brief Soldier Direct the Soldier to service an SF6 switch Performance Measures GO NO GO 1 Reviewed danger warning and caution notices Reviewed the manufacturer s literature and wiring diagrams Reviewed maintenance logbooks and historical data pertaining to the equipment Performed lockout and tagout procedures Inspected the condition of the SF6 switch visually and manually O a A W N Performed resistance measurements through each pole using a low resistance ohmmeter and compared contact resistances of electrical connections to the values of similar connections and to the values specified in the manufacturer s literature 7 Verified that the open and close operations from control devices were operational if applicable 8 Performed insulation resistance tests pole to pole pole to ground and across open poles and ensured that insulation resistance test values at 1 minute were less than 1 000 megohms at a DC test voltage of 2 500 volts unless otherwise specified in the manufacturer s literature 9 Performed an overpotential test according to the manufacturer s literature 10 Kept a record of the test results 11 Closed out lockout and tagout procedures by removing locking and t
374. ngs loose fittings and leakage 5 Inspect drive belts between the motor and pump or compressor for dry rotting cracking and glazing 6 Inspect the motor and pump or compressor sheave alignment using a straightedge along the outside edge of the sheave to ensure that the motor and pump or compressor have not slipped out of alignment 7 Inspect the belt tension by deflecting the belt one belt thickness for every 48 inches of unsupported length using your thumb to apply moderate pressure 8 Replace belt sets if necessary as a complete set 31 March 2009 STP 5 21P2 SM TG 3 145 Chapter 3 Performance Steps 9 Inspect compressor lubrication fluid levels 10 Observe several pumping mechanism cycles of operation a Ensure that the unit starts properly and comes up to speed indicating that the unloaders are working properly b Ensure that the pumping mechanism is capable of bringing the system to its designed working pressure within the time parameters c Ensure that the system shuts down properly with the unloaders properly depressurizing the pump or compressor d Ensure that the pumping mechanism cycles on and off at the pressures specified in the appropriate TM e Check the cycle time between the end of one cycle and the beginning of the next on the system with no usage demands which will establish if there are internal or external leaks that need to be corrected 11 Check the piping system for leaks by pressurizing
375. nit shutdown operations a Place the breaker control switch in the TRIP position b Allow the engine to operate for 5 minutes at no load c Place the master switch in the STOP position Perform after operation PMCS Evaluation Preparation Setup Provide the Soldier with the items listed in the conditions Give the Soldier a safety briefing before starting the test and ensure that safety precautions are followed Prepare the testing area and equipment in advance to ensure that task standards can be met Brief Soldier Direct the Soldier to operate an MEP 012 or 208 generator Performance Measures 1 2 3 4 5 O 11 12 13 14 Performed before operation PMCS Placed the 24 volt DC control power circuit breaker in the ON position Placed the maintenance lockout switch in the MANUAL position Placed the operation selector switch in the MANUAL position Placed the parallel switch in the appropriate position for the operating conditions and ensured that the indicator light was illuminated Placed the local remote switch in the LOCAL position Held the prelube system switch in the ON position and observed the lube oil pressure gauge for rising oil pressure Released the switch when the pressure stabilized the pressure should have stabilized within 2 minutes Placed the master switch in the START position and released it to the RUN position Released the prelube system switch Adj
376. nits at different locations require different types of coolant or different mixes of coolant Refer to the appropriate TM for the correct type of coolant 12 Close out lockout and tagout procedures by removing locking and tagging devices 13 Start the unit and observe it for proper operation 14 Record actions taken on DA Form 2404 or DA Form 5988 E and maintenance logbooks 15 Ensure that the items listed in the conditions are properly cleaned and stored Evaluation Preparation Setup Provide the Soldier with the items listed in the conditions Give the Soldier a safety briefing before starting the test and ensure that safety precautions are followed Prepare the testing area and equipment in advance to ensure that task standards can be met Brief Soldier Direct the Soldier to service a diesel engine cooling system Performance Measures GO NO GO 1 Reviewed maintenance logbooks and historical data pertaining to the equipment to verify that the diesel engine cooling system needed to be serviced Performed lockout and tagout procedures Inspected the water pump Inspected the radiator cap for signs of rust a degraded seal and leaks Inspected the coolant filter for damage leaks and a secure mounting O oa A W N Inspected radiator pipes hoses and clamps for security signs of rust and other signs of leakage N Inspected the sight gauge for damage leaks
377. nizing circuitry 2 Ensure that the rotation is going slow in the fast direction 3 Adjust the incoming frequency of the generator to a slightly higher frequency than that of the bus 4 Adjust the incoming voltage of the generator to a slightly higher voltage than that of the bus Close the circuit breaker at a synchronous moment to assume the load De energize the synchronizing circuit Maintain a proportional balance in kilowatt and kilovar loads Bring the unit online and off line as determined by the load conditions or directed by a supervisor 9 Remove the load and open the circuit breaker 5 6 7 8 3 46 STP 5 21P2 SM TG 31 March 2009 MOS Skill Level Tasks Performance Steps 4 Perform during operation checks according to the manufacturer s literature and record operational and maintenance data 5 Conduct unit shutdown operations 6 Perform after operation checks Evaluation Preparation Setup Provide the Soldier with the items listed in the conditions Give the Soldier a safety briefing before starting the test and ensure that safety precautions are followed Prepare the testing area and equipment in advance to ensure that task standards can be met Brief Soldier Direct the Soldier to operate a nonorganic generator Performance Measures GO NO GO 1 Performed before operation checks 2 Started the generator 3 Performed an isolated or parallel operating procedure 4
378. nnecting meters a variable voltage source battery or direct current DC a lockout and tagout kit a grounding stick high voltage gloves safety standing operating procedures maintenance logbooks and transformers to be tested DANGER 1 REMOVE RINGS NECKLACES OTHER JEWELRY AND LOOSE CLOTHING FAILURE TO COMPLY MAY CAUSE PERMANENT INJURY OR DEATH 2 USE PROPER TEST EQUIPMENT TO TEST FOR VOLTAGE BEFORE CONTACTING COMPONENTS PARTS FAILURE TO COMPLY MAY CAUSE PERMANENT INJURY OR DEATH WARNING THIS TASK SHOULD NOT BE PERFORMED ON EQUIPMENT THAT CONTAINS POLYCHLORINATED BIPHENYL PCB FAILURE TO COMPLY MAY CAUSE SKIN AILMENTS REPRODUCTIVE DISORDERS LIVER DISEASE OR IMMEDIATE PERSONAL INJURY Standards Determine the polarity of a transformer and mark the transformer accordingly Performance Steps NOTE An additive single phase power or potential transformer will have the high voltage terminal H1 opposite the low voltage terminal X2 and the H2 opposite the X1 When a single phase power or potential transformer is said to be subtractive the high voltage terminal H1 is opposite X1 and H2 is opposite X2 Current transformers CTs will normally have the polarity marked on the X1 or X2 terminals but they still have to be tested and verified 1 Review danger warning and caution notices 2 Review the manufacturer s literature electrical construction prints and wiring diagrams 3 Review maintenance logbooks and historical dat
379. not applicable nation assistance national archives not available noncommissioned officer Noncommissioned Officer Education System National Electrical Code National Electrical Safety Code InterNational Electrical Testing Association National Fire Protection Association Operational Safety and Health Act Occupational Safety and Health Administration needs practice pass passed barometric pressure mean radius of curvature pamphlet polychlorinated biphenyl private first class provisional load class programmable logic controller Primary Leadership Development Course preventive maintenance checks and services part number petroleum oils and lubricants STP 5 21P2 SM TG Glossary 3 Glossary PPE PU PVC PVT QC QT reg S AND C SA SD SF6 SFC SGM SGT sig SL SM SMAW SMCT SOP SPC SSG STP sust TB Glossary 4 protective posture equipment personal protective equipment power unit point of vertical curvature polyvinyl chloride private point of vertical tangency positioning velocity timing pressure volume temperature quality assurance quality control quart quarterly qualification test regiment regulation register switchgear and control Secretary of the Army semiannually situational awareness security assistance staging area solvent dry cleaning self destruct special duty slope distance sulfur hexafluoride special forces command sergeant first class sergeant
380. ns were properly cleaned and stored Evaluation Guidance Score the Soldier GO if all measures are passed P Score the Soldier NO GO if any measure is failed F If the Soldier fails any measure show him how to do it correctly References Required Related EM 385 1 1 NEC HANDBOOK 3 76 STP 5 21P2 SM TG 31 March 2009 MOS Skill Level Tasks Prepare a Power Plant for Movement 052 244 2142 Conditions As a power plant operator in a tactical or nontactical environment when the power plant needs to be moved from one location to another you are given a general mechanic s tool box appropriate technical manuals the manufacturer s literature electrical construction prints wiring diagrams and an electrician s tool kit DANGER REMOVE RINGS NECKLACES OTHER JEWELRY AND LOOSE CLOTHING FAILURE TO COMPLY MAY CAUSE PERMANENT INJURY OR DEATH WARNING 1 DO NOT PERFORM MAINTENANCE ON THE ENGINE EXHAUST SYSTEM WHILE THE SYSTEM IS HOT FAILURE TO COMPLY MAY CAUSE IMMEDIATE PERSONAL INJURY 2 EXERCISE EXTREME CAUTION WHEN INSPECTING OR DRAINING ENGINE FLUIDS THEY MAY BE EXCESSIVELY HOT OR UNDER PRESSURE FAILURE TO COMPLY MAY CAUSE IMMEDIATE PERSONAL INJURY 3 ALWAYS DISCONNECT BATTERIES BEFORE A GENERATOR IS MOVED FAILURE TO COMPLY MAY CAUSE IMMEDIATE PERSONAL INJURY OR EQUIPMENT DAMAGE Standards Prepare the power plant for movement Pack the generator in the same manner that it was originally shipped conforming to loc
381. nspect air filters a Clean oil bath filters with solvent and ensure that the solvent is completely removed before putting the filter back into service b Use compressed air to clean paper filters from the inside out WARNING WHEN CLEANING THE FILTERS WITH AN AIR COMPRESSOR WEAR EYE PROTECTION AND DO NOT EXCEED MORE THAN 15 POUNDS PER SQUARE INCH FAILURE TO COMPLY MAY CAUSE THE AIR FILTER ELEMENT TO BE DAMAGED c Clean cotton filters according to the manufacturer s literature 4 Inspect the air filter housing 5 Inspect air restriction indicators 6 Ensure that air intake mechanisms are clean and serviceable a Check the cyclonic air intake 3 154 STP 5 21P2 SM TG 31 March 2009 MOS Skill Level Tasks Performance Steps 7 8 9 10 11 12 13 14 b Check dust boots c Check the piping Check for air leaks in the air box and intake manifold Inspect the exhaust manifold for cracks and leaks Inspect mufflers for cracked welds and leaks Inspect the turbocharger or air blower Close out lockout and tagout procedures by removing locking and tagging devices Start the unit and observe it for proper operation Record actions taken on DA Form 2404 or DA Form 5988 E and maintenance logbooks Ensure that the items listed in the conditions are properly cleaned and stored Evaluation Preparation Setup Provide the Soldier with the items listed in the conditions Give the Soldier a safety briefing before start
382. nts the manufacturer s literature a two way radio or telephone communication equipment safety standing operating procedures SOPs the Lineman s and Cableman s Handbook LCH and applicable personal protective equipment PPE DANGER 1 THIS TASK SHOULD ONLY BE PERFORMED BY QUALIFIED PERSONNEL WHO ARE KNOWLEDGEABLE IN THE INSTALLATION OPERATION AND MAINTENANCE OF MEDIUM VOLTAGE ELECTRICAL POWER GENERATION EQUIPMENT AND ITS ASSOCIATED HAZARDS FAILURE TO COMPLY MAY CAUSE PERMANENT INJURY OR DEATH 2 SYSTEMS WILL BE CONSIDERED ENERGIZED UNTIL THE SOURCE OF ENERGY IS REMOVED LOCKED OUT WHEN POSSIBLE TAGGED OUT AND GROUNDED WHEN ENERGY ISOLATING DEVICES CANNOT BE PHYSICALLY LOCKED OUT USE TAGOUT PROCEDURES FAILURE TO COMPLY MAY CAUSE PERMANENT INJURY OR DEATH 3 REMOVE RINGS NECKLACES OTHER JEWELRY AND LOOSE CLOTHING FAILURE TO COMPLY MAY CAUSE PERMANENT INJURY OR DEATH Standards Energize an electrical distribution system following the one line diagram safety SOPs LCH and applicable manufacturer s literature Performance Steps 1 Review danger warning and caution notices 2 Review the electrical one line diagrams electrical construction prints and manufacturer s literature 3 Request permission from the project supervisor to energize the electrical distribution system 4 Perform an inspection with the project supervisor and personnel who performed work on the distribution system to ensure that all personne
383. nufacturer s literature and wiring diagrams Reviewed maintenance logbooks and historical data pertaining to the equipment Performed lockout and tagout procedures Tested the circuit for voltage Inspected the condition of the CT visually and manually to ensure that mechanical functions operated smoothly and that there was no physical damage Performed a continuity check on the transformer winding to ensure that the winding resistance was consistent with the manufacturer s specifications Verified the CT ratio Performed an insulation resistance test on the transformer and connected a megohmmeter across the lead terminal or a to ground terminal at a test voltage specified in the manufacturer s literature to ensure that insulation resistance readings were a minimum of 100 megohms Reconnected the isolated equipment Closed out lockout and tagout procedures by removing locking and tagging devices Ensured that the equipment was operating as designed Kept a record of the test results and actions taken Ensured that the items listed in the conditions were properly cleaned and stored Evaluation Guidance Score the Soldier GO if all measures are passed P Score the Soldier NO GO if any measure is failed F If the Soldier fails any measure show him how to do it correctly 3 322 STP 5 21P2 SM TG 31 March 2009 MOS Skill Level Tasks References Required Related NETA TM 5 686 31 March 2009 STP
384. o the manufacturer s specifications 3 Perform a thermographic survey h Test interlocking systems for correct operation and sequencing i Inspect insulating assemblies for evidence of physical damage or contaminated surfaces j Exercise mechanical components parts k l Q Maana oow Compare switchblade clearances with industry standards Verify that indicating and control devices are operating correctly 31 March 2009 STP 5 21P2 SM TG 3 331 Chapter 3 Performance Steps 10 11 12 13 14 15 m Verify the operation of heaters if applicable n Clean the unit before testing unless as found and as left tests are required o Verify contact lubrication on moving current carrying components parts p Verify lubrication on moving sliding surfaces Check for proper control function according to the manufacturer s literature a Test the automatic control b Test the manual control Perform insulation resistance tests pole to pole pole to ground and across open contacts of each phase and ensure that test values are not less than 1 000 megohms at a direct current DC test voltage of 2 500 volts or at the voltage recommended by the manufacturer Perform overpotential tests pole to pole pole to ground and across open contacts of each phase at the voltage recommended by the manufacturer Perform resistance measurements through the bolted connections using a low resistance ohmmeter to ensu
385. ocedures SOPs DANGER SAFETY EQUIPMENT MUST BE INSPECTED AS SPECIFIED IN THE APPLICABLE EQUIPMENT TM OR MANUFACTURER S LITERATURE FAILURE TO PERFORM A REQUIRED INSPECTION MAY CAUSE PERMANENT INJURY OR DEATH Standards Inspect safety equipment using the manufacturer s literature applicable equipment TMs and applicable SOPs Remove unsafe equipment from the inventory Performance Steps 1 Determine the personal protective equipment PPE required for each specific job Inspect the equipment visually for cracks rips tears and excessive wear Inspect the equipment manually for cracks rips tears and excessive wear Check for valid calibration stamps if applicable Record deficiencies on DA Form 2404 O oa A W N Remove unsafe equipment from the inventory Evaluation Preparation Setup Provide the Soldier with the items listed in the conditions Give the Soldier a safety briefing before starting the test and ensure that safety precautions are followed Prepare the testing area and equipment in advance to ensure that task standards can be met Brief Soldier Direct the Soldier to inspect safety equipment Performance Measures GO NO GO 1 Determined the PPE required for each specific job Inspected the equipment visually for cracks rips tears and excessive wear Inspected the equipment manually for cracks rips tears and excessive wear Checked for valid calibration stamps if ap
386. oil rings Low oil consumption may be caused by water or fuel leaking into the oil 6 Conduct further testing to identify specific defective components if necessary 7 Record actions taken on DA Form 2404 or DA Form 5988 E and maintenance logbooks 8 Ensure that the items listed in the conditions are properly cleaned and stored Evaluation Preparation Setup Provide the Soldier with the items listed in the conditions Give the Soldier a safety briefing before starting the test and ensure that safety precautions are followed Prepare the testing area and equipment in advance to ensure that task standards can be met Brief Soldier Direct the Soldier to troubleshoot a diesel engine lube oil system Performance Measures GO NO GO 1 Reviewed TMs manufacturer s literature or industry standards maintenance logbooks and historical data pertaining to the equipment Ensured that PPE was correctly tested and fully mission capable Inspected tools and testing equipment for serviceability Performed lockout and tagout procedures ao A OO N Identified fault locations by checking the equipment fault indicator panel or the engine lube oil system for obvious malfunctions O Conducted further testing to identify specific defective components if necessary 7 Recorded actions taken on DA Form 2404 or DA Form 5988 E and maintenance logbooks 8 Ensured that the items li
387. oles and ensure that insulation resistance test values are no less than 1 000 megohms at a DC voltage of 2 500 volts unless otherwise specified in the manufacturer s literature Perform a vacuum bottle integrity test across each vacuum bottle with the switch in the OPEN position and according to the manufacturer s literature a Ensure that the test set does not trip when the overpotential voltage is applied b Provide adequate barriers and protection against x radiation during the test NOTE Do not perform this test unless the contact displacement of each interrupter is within the tolerance specified in the manufacturer s literature 12 13 14 Keep a record of the test results Close out lockout and tagout procedures by removing locking and tagging devices Ensure that the items listed in the conditions are properly cleaned and stored Evaluation Preparation Setup Provide the Soldier with the items listed in the conditions Give the Soldier a safety briefing before starting the test and ensure that safety precautions are followed Prepare the testing area and equipment in advance to ensure that task standards can be met Brief Soldier Direct the Soldier to service a vacuum circuit breaker Performance Measures GO NO GO 1 O oa A W N Reviewed danger warning and caution notices Reviewed the manufacturer s literature and wiring diagrams Reviewed maintenance logbooks and historical data pert
388. oltage Power Cable 052 204 1130 Conditions As a power line distribution specialist in a tactical or nontactical environment during an initial installation of cables when power cables must be terminated or when an existing power cable termination is damaged beyond repair you are given an electrician s tool kit a lockout and tagout kit grounding equipment a megohmmeter test set a voltage detector an applicable termination kit with instructions applicable tools specified in the termination kit instructions applicable manufacturer s literature and applicable personal protective equipment DANGER A VOLTAGE DETECTOR SHOULD BE USED TO ENSURE THAT CABLES ARE NOT ENERGIZED MATERIAL SUCH AS A LEAD SHEATH THAT ACTS AS A SHIELD MUST NOT BE BETWEEN THE TESTER AND THE CONDUCTORS OF THE CIRCUIT BEING TESTED FAILURE TO COMPLY MAY CAUSE PERMANENT INJURY OR DEATH WARNING 1 THE SPLICER S TOOLS HANDS AND TERMINATION MATERIALS MUST BE CLEAN DURING CONSTRUCTION FAILURE TO COMPLY MAY CAUSE IMMEDIATE PERSONAL INJURY OR EQUIPMENT DAMAGE 2 EMPLOY EVERY RESOURCE TO PREVENT MOISTURE DRIPPINGS CONDENSATION PERSPIRATION FROM ENTERING THE JOINT INSULATION FAILURE TO COMPLY MAY CAUSE IMMEDIATE PERSONAL INJURY OR EQUIPMENT DAMAGE NOTE There are several different types of termination kits available for use with a medium voltage power cable Each kit contains specific instructions on how to construct the termination Always follow the manufacturer
389. oming operating parameters of the generator or the plant as determined by the isolated or infinite grid Maintain the frequency at a specified value in an isolated mode of operation for a non 810 series k Maintain the voltage at a specified value in an isolated mode of operation for a non 810 series Maintain a proportional balance in kilowatt and kilovar loads ooaoogogg im e 3 40 STP 5 21P2 SM TG 31 March 2009 MOS Skill Level Tasks Performance Steps m Bring the units online and off line as determined by the load conditions 6 Perform grid or parallel operations Adjust the incoming frequency of the generator to the approximate frequency of the bus Adjust the incoming voltage of the generator to the approximate voltage of the bus Energize the synchronizing circuitry Ensure that the phase rotation is going slow in the fast direction Adjust the incoming frequency of the generator to a frequency that is slightly higher than that of the bus Adjust the incoming voltage of the generator to a voltage that is slightly higher than that of the bus g Close the circuit breaker at a synchronous moment to assume the load h De energize the synchronizing circuit Stabilize the incoming operating parameters of the generator or the plant as determined by the isolated or infinite grid Maintain the prescribed kilowatt and kilovar loads k Maintain a proportional balance in the kilowatt and kilovar loads
390. omponent 1 Check for a blown fuse 2 Check for shorts 3 Check for opens 4 Check for defective or burned components parts 5 Identify the circuit components parts 6 Identify the characteristics of the circuit components parts Evaluation Preparation Setup Provide the Soldier with the items listed in the conditions Give the Soldier a safety briefing before starting the test and ensure that safety precautions are followed Prepare the testing area and equipment in advance to ensure that task standards can be met Brief Soldier Direct the Soldier to read a schematic Performance Measures GO NO GO 1 Identified the proper schematic for the appropriate application Oriented the schematic to the actual layout Identified the proper current flow through a circuit Identified the alternate current flows within the circuit Identified the circuit components parts O o A W N Identified the characteristics of the circuit components parts Evaluation Guidance Score the Soldier GO if all measures are passed P Score the Soldier NO GO if any measure is failed F If the Soldier fails any measure show him how to do it correctly References Required Related TM 5 811 1 31 March 2009 STP 5 21P2 SM TG 3 83 Chapter 3 Operate a Line Truck with Auxiliary Equipment 052 244 2145 Conditions As a power plant operator in a tactical or nontactical environment when
391. on equipment by inspecting and testing it according to the applicable manufacturer s literature Recorded the inspection and test results 11 Repaired or replaced equipment based on the inspection and test results 31 March 2009 STP 5 21P2 SM TG 3 307 Chapter 3 Performance Measures GO NO GO 12 Removed personal protective grounds 13 Closed out lockout and tagout procedures by removing locking and tagging devices 14 Performed a functions check on the electrical distribution system 15 Ensured that the items listed in the conditions were properly cleaned and stored Evaluation Guidance Score the Soldier GO if all measures are passed P Score the Soldier NO GO if any measure is failed F If the Soldier fails any measure show him how to do it correctly References Required Related LCH EM 385 1 1 ER 385 1 31 FM 3 34 480 FM 5 412 NESC NETA TM 5 682 TM 5 684 TM 5 686 TM 5 811 1 TM 5 811 3 3 308 STP 5 21P2 SM TG 31 March 2009 MOS Skill Level Tasks Manage a Power Line Crew 052 204 2217 Conditions As a power line distribution supervisor in a tactical or nontactical environment when work must be performed on electrical distribution equipment you are given a power line distribution crew a line truck with a cable trailer safety standing operating procedures SOPs applicable manufacturer s literature the Lineman s and Cableman
392. ons were properly cleaned and stored Evaluation Guidance Score the Soldier GO if all measures are passed P Score the Soldier NO GO if any measure is failed F If the Soldier fails any measure show him how to do it correctly References Required Related EM 385 1 1 NESC S AND C HANDBOOK TM 5 684 3 200 STP 5 21P2 SM TG 31 March 2009 MOS Skill Level Tasks Service an Oil Switch 052 206 2102 Conditions As a power station electrician in a tactical or nontactical environment during maintenance you are given safety standing operating procedures a general mechanic s tool box a digital low resistance ohmmeter a megohmmeter an oil test set electrical construction prints wiring diagrams a high potential test set grounding equipment applicable manufacturer s literature and ASTM D877 D923 1500 and D1524 standards DANGER 1 THIS TASK SHOULD ONLY BE PERFORMED BY QUALIFIED PERSONNEL WHO ARE KNOWLEDGEABLE IN THE INSTALLATION AND MAINTENANCE OF OIL SWITCHES AND POWER EQUIPMENT AND THEIR ASSOCIATED HAZARDS FAILURE TO COMPLY MAY CAUSE PERMANENT INJURY OR DEATH 2 DO NOT TOUCH EXPOSED ELECTRICAL CONNECTIONS WHILE A POWER SOURCE IS CONNECTED TO THE SWITCH FAILURE TO COMPLY MAY CAUSE PERMANENT INJURY OR DEATH 3 REMOVE RINGS NECKLACES OTHER JEWELRY AND LOOSE CLOTHING FAILURE TO COMPLY MAY CAUSE PERMANENT INJURY OR DEATH WARNING THIS TASK SHOULD ONLY BE PERFORMED ON EQUIPMENT THAT DOES NOT CONTAIN POLYCHL
393. oot an Alternating Current AC Control Voltage Circuit 052 244 2130 Perform a Load Assessment 052 244 2131 Troubleshoot an Engine Failure to Crank Maintain a Rated Speed 052 244 2135 Troubleshoot a Generators Improper Vollage Output AT AN 2 0522442136 Instali Low Voltage Organic Equipment oar AN 2 052 244 2137 Record Maintenance andlor Operational Daa at w 2 052 244 2138 instal Low Voltage Wiring m an 052 244 2140 Improve Grounding Electrode Resistance AIT mw 2 0522442141 RepairaLow Voltage Convoi Cae nm m 0522442142 Prepare a Power PlantforMovement m m Perform Preventive Maintenance Checks and Services E E PMCS on a Mobile Electric Power MEP 029 Generator zaza ReadaSchematc O O O wa 052 244 2146 Service a Nonorganic Prime Mover UNIT 052 244 2147 Troubleshoot a Nonorganic Prime Mover UNIT Repair BDAR NPM MTM MIM MT NM 052 207 2121 Service a Solid State Relay 052 207 2123 Service a Digital Synchronizer and Load Controller DSLC 052 207 2126 Produce an Electronic Schematic 2 2 31 March 2009 STP 5 21P2 SM TG 2 3 Chapter 2 Table 2 1 MOS 21P2 Critical Tasks continued Task Number Title Training Sust Sust Location Tng Tng SL Freq Subject Area 3 S2 Mechanical Equipment Maintenance Power Station Tasks 052 205 2052 Troubleshoot a Diesel Engine fora Mistring Gyinder ar AN 2 052 205 2084 Troubleshoot Diesel En
394. open contacts of each phase and ensured that test values were not less than 1 000 megohms at a DC test voltage of 2 500 volts or at the voltage recommended by the manufacturer 3 332 STP 5 21P2 SM TG 31 March 2009 MOS Skill Level Tasks Performance Measures 8 10 11 12 13 14 15 Performed overpotential tests pole to pole pole to ground and across open contacts of each phase at the voltage recommended by the manufacturer Performed resistance measurements through the bolted connections using a low resistance ohmmeter to ensure that bolt torque levels were according to the manufacturer s literature Measured the contact resistance across each switchblade and fuse holder according to the manufacturer s literature Measured resistance across each fuse to ensure that values did not deviate from each other by more than 15 percent Performed corrective actions as necessary Closed out lockout and tagout procedures by removing locking and tagging devices Performed a function check on the ATS Ensured that the items listed in the conditions were properly cleaned and stored Evaluation Guidance Score the Soldier GO if all measures are passed P Score the Soldier NO GO if any measure is failed F If the Soldier fails any measure show him how to do it correctly 31 March 2009 STP 5 21P2 SM TG 3 333 Chapter 3 Service a Voltage Regulator 052 264 2113 Conditions As a power station instr
395. operly 17 Kept a record of results and actions taken 18 Ensured that the items listed in the conditions were properly cleaned and stored Evaluation Guidance Score the Soldier GO if all measures are passed P Score the Soldier NO GO if any measure is failed F If the Soldier fails any measure show him how to do it correctly References Required Related TM 5 6115 593 12 TM 5 6115 593 34 31 March 2009 STP 5 21P2 SM TG 3 117 Chapter 3 Service a Solid State Relay 052 207 2121 Conditions As a power station instrument technician in a tactical or nontactical environment during scheduled maintenance or if the relay is suspected of being defective you are given a lockout and tagout kit a multimeter a relay test set with manual an electronic tool kit wiring diagrams maintenance logbooks and the applicable manufacturer s literature with schematics DANGER 1 ENSURE THAT POWER TO THE RELAY IS DISCONNECTED BEFORE SERVICING APPLY SAFE CLEARANCE PROCEDURES TO ASSOCIATED CIRCUITS FAILURE TO COMPLY MAY CAUSE PERMANENT INJURY OR DEATH 2 ENSURE THAT CURRENT TRANSFORMERS SUPPLYING CURRENT TO THE RELAY ARE DE ENERGIZED AND ELECTRICALLY SHORTED BEFORE SERVICING THE RELAY IF ENERGIZED AN OPEN CURRENT TRANSFORMER CIRCUIT WILL PRODUCE VERY HIGH VOLTAGES FAILURE TO COMPLY MAY CAUSE PERMANENT INJURY OR DEATH 3 ENSURE THAT POTENTIAL TRANSFORMERS FEEDING THE RELAY ARE DE ENERGIZED BEFORE SERVICING THE M
396. or equipment damage Performance Steps 1 Prepare the MEP 029 generator for start up a Perform preventive maintenance checks and services PMCS and prestart checks b Check the air box damper position and reset it manually if required c Check the battery terminals and ensure that the negative is connected to a ground d Place the 24 volt direct current DC control circuit breaker on the generator panel to the ON position e Ensure that the maintenance switch on the alternating current AC DC control panel is in the OPERATION position Check the fuel level and the side door shutter operation by placing the battle short switch on the generator panel to the ON position Then switch the master switch on the engine panel to the START position g Return the master switch to the STOP position and the battle short switch to the Pal 3 30 STP 5 21P2 SM TG 31 March 2009 MOS Skill Level Tasks Performance Steps OFF position h Check the engine fault indicators and the annunciator by placing the annunciator test switch on the generator panel to the TEST position If none of the lights are on after being tested proceed with the next step If a light comes on correct the indicated fault before proceeding i Check the voltage and frequency requirements of the load against the voltage and frequency connection of the generator set j Place the AUTO TRIP MAN switch to the MAN position 2 Start the MEP 029 generator a Ensu
397. or medium voltage splices only 17 Apply an outer jacket to the power cable according to the manufacturer s literature to prevent moisture from entering 31 March 2009 STP 5 21P2 SM TG 3 289 Chapter 3 Performance Steps 18 19 Close out lockout and tagout procedures by removing locking and tagging devices Test the splice to ensure that it meets the cable rating Evaluation Preparation Setup Provide the Soldier with the items listed in the conditions Give the Soldier a safety briefing before starting the test and ensure that safety precautions are followed Prepare the testing area and equipment in advance to ensure that task standards can be met Brief Soldier Direct the Soldier to splice a medium voltage power cable Performance Measures 1 O oa A OO N 14 15 16 17 18 19 Performed lockout and tagout procedures Inspected the splice kit Prepared the cable and spliced it according to the manufacturer s literature Aligned cables so that the ends of the conductors conjoined squarely Removed the jacket using the distance indicated by the splice kit instructions Removed the cable metallic shield using the distance indicated in the splice kit instructions Removed the high voltage insulation layer using the distance indicated in the splice kit instructions Removed the semiconductor from the metallic shield edge using the distance indicated in the splice kit instruct
398. ormance Steps 1 Review TMs manufacturer s literature or industry standards maintenance logbooks and historical data pertaining to the equipment 2 Ensure that PPE is correctly tested and fully mission capable 31 March 2009 STP 5 21P2 SM TG 3 181 Chapter 3 Performance Steps 3 Inspect tools and testing equipment for serviceability 4 Perform lockout and tagout procedures 5 Identify fault locations by checking the equipment fault indicator panel or the engine lube oil system for obvious malfunctions NOTE The following substeps are a guideline and are not all inclusive Check for the most obvious and easily corrected problems first a Check the oil level NOTE The reading should be taken when the oil is hot b Check for low oil pressure NOTE This may be caused by a stuck oil relief valve foreign material on the valve seat that is holding the valve open broken oil lines clogged strainers or filters excessive bearing wear low oil viscosity a faulty pump or diluted or insufficient oil c Check for pump failure NOTE This may be caused by sheared pump gear keys a broken housing or damaged gears d Check for oil dilution NOTE This may be caused by water or fuel leaking into the oil e Check oil consumption NOTE Excessive oil consumption may be caused by oil leaks broken or stuck piston rings worn cylinder liners a clogged oil separator screen improper oil grade or clogged oil drain holes under piston
399. ormance Steps NOTE Direct current DC control voltage for sensing devices may be removed by opening the circuit breaker and disconnecting the batteries Verify by using the schematics 1 Review danger warning and caution notices Review the manufacturer s literature and wiring diagrams Review maintenance logbooks and historical data pertaining to the equipment Use the schematics to identify the circuit of the sensing device being tested Perform lockout and tagout procedures O oa A OO N Test the circuit for voltage a Proceed to step 7 if no voltage is present b Stop if voltage is present and do not proceed to step 7 until voltage is no longer present 1 Check the schematics for proper circuit identification 2 Check for possible back fed circuits 3 Check for the proper installation of safe clearances 7 Remove the sensing device and tagged leads 8 Test the sensing device according to the manufacturer s literature and record the results a Test the speed switches for continuity switching on contacts b Check the pickups with the engine running if possible c Check the pressure and temperature sensors for continuity within specified ranges 9 Compare the test results with the manufacturer s specifications and take proper action a Calibrate the sensing device b Reinstall the sensing device 3 344 STP 5 21P2 SM TG 31 March 2009 MOS Skill Level Tasks Performance Steps 10 11 12 1
400. orrectly References Required Related FM 3 34 480 3 240 STP 5 21P2 SM TG 31 March 2009 MOS Skill Level Tasks Service a Sulfur Hexafluoride SF6 Switch 052 206 2134 Conditions As a power plant electrician in a tactical or nontactical environment during maintenance you are given safety standing operating procedures a general mechanic s tool box a digital low resistance ohmmeter a megohmmeter a high potential test set grounding equipment and the applicable manufacturer s literature DANGER 1 THIS TASK SHOULD ONLY BE PERFORMED BY QUALIFIED PERSONNEL WHO ARE KNOWLEDGEABLE IN THE INSTALLATION AND MAINTENANCE OF SF6 SWITCHES AND POWER EQUIPMENT AND THEIR ASSOCIATED HAZARDS FAILURE TO COMPLY MAY CAUSE PERMANENT INJURY OR DEATH 2 DO NOT TOUCH EXPOSED ELECTRICAL CONNECTIONS WHILE A POWER SOURCE IS CONNECTED TO THE SF6 SWITCH FAILURE TO COMPLY MAY CAUSE PERMANENT INJURY OR DEATH 3 REMOVE RINGS NECKLACES OTHER JEWELRY AND LOOSE CLOTHING FAILURE TO COMPLY MAY CAUSE PERMANENT INJURY OR DEATH 4 DO NOT EXCEED THE MAXIMUM VOLTAGE STIPULATED FOR THIS TEST FAILURE TO COMPLY MAY CAUSE PERMANENT INJURY OR DEATH Standards Safely service an SF6 switch by inspecting and testing it Test the SF6 switch according to the manufacturer s literature Reinstall or repair the SF6 switch based on the test results Performance Steps NOTE Conduct tests according to the manufacturer s literature Use industry standards when the m
401. ors or equipment using rubber gloves and hot sticks 4 Determine the victim s condition a Check him for responsiveness if he is responsive 1 Ask him to define the problem 2 Reassure him 3 Assist him in descending the utility pole if possible 4 Prepare to lower him to the ground if he cannot descend the utility pole without assistance 5 Administer first aid as needed b Check his breathing if he is unresponsive 1 Provide an open airway and administer two short breaths if he is not breathing 2 Lower him to the ground if he is breathing 5 Lower the victim to the ground a Position the rescue line over the crossarm for a clear path to the ground and wrap the short end of the line around the fall line two or more times so that you have a mechanical advantage NOTE It is best to anchor the rescue line 2 to 3 feet out on the crossarm to help maintain the victim s clearance from the utility pole upon descent If no crossarm is available place the rescue 31 March 2009 STP 5 21P2 SM TG 3 255 Chapter 3 Performance Steps line over any other substantial piece of equipment strong enough to support the victim s weight b Pass the free end of the rescue line around the victim s chest tying three half hitches with the knot in the front near one armpit and snug the knot c Remove the slack in the rescue line d Grip the rescue line firmly and securely NOTE If the victim is not breathing give him two more quick
402. osest conductor on horizontal constructions 7 Installed grounds or jumpers from a grounded conductor to the ungrounded conductor in sequence until all conductors were grounded and short circuited together 8 Double checked connections to ensure that they were clean and tight 9 Ensured that all parts of the grounding circuit had adequate current carrying capacity for the distribution system to be grounded 10 Removed the grounds when work was completed in the exact reverse sequence of installation ensuring that established ground connection removal was last 11 Closed out lockout and tagout procedures by removing locking and tagging devices 12 Ensured that the items listed in the conditions were properly cleaned and stored Evaluation Guidance Score the Soldier GO if all measures are passed P Score the Soldier NO GO if any measure is failed F If the Soldier fails any measure show him how to do it correctly 3 270 STP 5 21P2 SM TG 31 March 2009 MOS Skill Level Tasks References Required Related LCH EM 385 1 1 TM 5 684 TM 5 811 3 31 March 2009 STP 5 21P2 SM TG 3 271 Chapter 3 Install High Intensity Lights and Ballasts 052 204 1121 Conditions As a power line distribution specialist in a tactical or nontactical environment at a site needing illumination you are given electrical construction prints poles mounting brackets high intensity lights b
403. otices 2 Review the manufacturer s literature electrical construction prints and wiring diagrams 3 Perform lockout and tagout procedures 4 Inspect the condition of the vacuum switch visually and manually a Clean the unit thoroughly before testing it unless as found or as left tests are required b Keep a record of as found and as left operation counter readings if applicable c Inspect the anchorage alignment and grounding 3 204 STP 5 21P2 SM TG 31 March 2009 MOS Skill Level Tasks Performance Steps 10 11 12 13 d Perform the mechanical operator tests according to the manufacturer s literature if applicable e Verify the correct adjustments and operation of the motor operator limit switches and mechanical interlocks if applicable f Measure the contact erosion according to the manufacturer s literature g Inspect the insulating assemblies for evidence of physical damage or contamination h Check each fuse holder for adequate support and contact i Verify that the fuse sizes and types correspond to the drawings j Test the electrical and mechanical interlock systems for correct operation and sequencing k Verify that there is appropriate contact lubricant on moving and sliding surfaces Perform resistance measurements on the bolted connections using a low resistance ohmmeter and ensure that the bolt torque levels match the manufacturer s specifications Perform a contact resistance test and comp
404. parameters 19 Tag the relay with the appropriate calibration sticker including the name and testing date 31 March 2009 STP 5 21P2 SM TG 3 109 Chapter 3 Performance Steps 20 21 22 23 Ensure that flags are reset Replace the window cover and clean and inspect the seal for serviceability Return the relay to service a Replace the relay inside the case b Reconnect GE type relays by slowly sliding the connecting block back in c Reconnect Westinghouse type relays by first returning the black connecting levers and then the red lever Ensure that the items listed in the conditions are properly cleaned and stored Evaluation Preparation Setup Provide the Soldier with the items listed in the conditions Give the Soldier a safety briefing before starting the test and ensure that safety precautions are followed Prepare the testing area and equipment in advance to ensure that task standards can be met Brief Soldier Direct the Soldier to service an induction disk and or electromagnetic relay Performance Measures 1 O N O a A W N _ 11 12 13 14 15 16 17 Reviewed danger warning and caution notices before proceeding Reviewed the manufacturer s literature with schematics and wiring diagrams Reviewed maintenance logbooks and historical data pertaining to the equipment Reviewed the relay instruction booklet Recorded the relay information Removed the relay
405. pection Maintenance Worksheet and applicable personal protective equipment PPE DANGER 1 REMOVE RINGS NECKLACES OTHER JEWELRY AND LOOSE CLOTHING FAILURE TO COMPLY MAY CAUSE PERMANENT INJURY OR DEATH 2 EXERCISE EXTREME CAUTION WHEN WORKING IN THE AREA OF ROTATING ENGINE COMPONENTS FAILURE TO COMPLY MAY CAUSE PERMANENT INJURY OR DEATH 3 ALWAYS WEAR PPE AS REQUIRED FOR INSPECTIONS IN HAZARDOUS AREAS FAILURE TO COMPLY MAY CAUSE PERMANENT INJURY OR DEATH WARNING ENGINE EXHAUST GETS VERY HOT DURING OPERATION DO NOT REMOVE ANY EXHAUST SYSTEM COMPONENTS UNTIL THE ENGINE HAS COOLED FAILURE TO COMPLY MAY CAUSE IMMEDIATE PERSONAL INJURY CAUTION NOISE LEVELS IN EXCESS OF 85 DECIBELS EXIST WITHIN A 50 FOOT RADIUS OF OPERATING EQUIPMENT PERSONNEL MUST WEAR SINGLE HEARING PROTECTION WITHIN A 50 FOOT RADIUS FAILURE TO COMPLY MAY CAUSE INJURY NOTE 1 All equipment is not the same and may function differently depending on the make model and manufacturer Troubleshooting steps are similar but may vary Always consult the applicable manufacturer s literature for each piece of equipment 2 All tests should be conducted according to the manufacturer s literature when available Use industry standards when the manufacturer s literature cannot be obtained 3 Defective equipment should not be used it should be repaired or replaced immediately Standards Troubleshoot a diesel engine air intake and or exhaust system through in
406. personal protective grounds 17 Close out lockout and tagout procedures by removing locking and tagging devices 18 Perform a functions check on the electrical distribution system 19 Ensure that the items listed in the conditions are properly cleaned and stored Evaluation Preparation Setup Provide the Soldier with the items listed in the conditions Give the Soldier a safety briefing before starting the test and ensure that safety precautions are followed Prepare the testing area and equipment in advance to ensure that task standards can be met Brief Soldier Direct the Soldier to install distribution equipment de energized Performance Measures GO NO GO 1 Reviewed danger warning and caution notices before proceeding 2 Reviewed the manufacturer s literature electrical construction prints and wiring diagrams Ensured that PPE was properly tested and fully mission capable Inspected tools and climbing and rigging equipment for serviceability Performed lockout and tagout procedures Ascended the pole to the desired height if necessary Tested phases to ensure that there was no voltage present Installed personal protective grounds Installed rigging equipment as necessary O OoOo OA N O oO A QOQ _ Raised and positioned safely the distribution equipment to be installed 11 Installed mounting hardware as s
407. pickup test according to the manufacturer s literature 13 Perform a time curve verification test on the as found time dial setting a Determine if the pickup is as specified in the manufacturer s literature b Select three test currents that fall along the knee of the curve for the particular relay being tested c Perform a test at each current to verify the curve d Verify that the relay performs within the manufacturer s specifications and make necessary adjustments to meet these specifications CAUTION THE APPLIED TEST CURRENTS SHOULD ONLY BE APPLIED MOMENTARILY FAILURE TO COMPLY MAY CAUSE EXCESSIVE HEATING OF THE MAIN COIL NOTE Ensure that the relay disk has returned to a rested position before performing each consecutive test Perform each test at least twice for each current to verify the results 14 Test the direct current DC target and seal in the unit according to the relay instruction booklet 15 Ensure that the trip circuit remains energized after removing the fault current from the main coil 16 Make adjustments based on the test results 17 Perform a pickup test of the instantaneous unit according to the manufacturer s literature CAUTION HIGH AMOUNTS OF FAULT CURRENT ARE REQUIRED TO PERFORM THIS TEST THE APPLIED TEST CURRENT SHOULD ONLY BE ALLOWED TO TRAVEL THROUGH THE INSTANTANEOUS UNIT COIL AND NOT THROUGH THE MAIN COIL FAILURE TO COMPLY MAY RESULT IN EQUIPMENT DAMAGE 18 Return relay settings to the correct
408. plicable Recorded deficiencies on DA Form 2404 O a A W N Removed unsafe equipment from the inventory Evaluation Guidance Score the Soldier GO if all measures are passed P Score the Soldier NO GO if any measure is failed F If the Soldier fails any measure show him how to do it correctly 3 250 STP 5 21P2 SM TG 31 March 2009 MOS Skill Level Tasks References Required Related DA FORM 2404 EM 385 1 1 LCH TM 5 682 TM 5 684 31 March 2009 STP 5 21P2 SM TG 3 251 Chapter 3 Prepare a Manhole for Safe Entry 052 204 1113 Conditions As a power line distribution specialist in a tactical or nontactical environment when a manhole needs to be prepared for safe entry you are given a three person team consisting of an entry supervisor an attendant and an entrant You are also given traffic control equipment a manhole lid removal device an extraction system for confined space entry and rescue a manhole ventilator a submersible water pump with a hose a power source for a submersible pump an air quality tester with the manufacturer s instructions and the applicable personal protective equipment DANGER 1 IF A MANHOLE COVER IS ENCASED IN ICE DO NOT STRIKE IT WITH STEEL OR IRON THE STRIKING OF STEEL OR IRON AGAINST A STEEL COVER MAY RESULT IN AN EXPLOSION IF COMBUSTIBLE GAS IS PRESENT IN THE MANHOLE FAILURE TO COMPLY MAY CAUSE PERMANENT INJURY OR DEATH 2 NEVER ENTER A MANHOLE UNTIL ATM
409. plies voltage to the module may be fuse protected To further isolate the circuit electrically and as an additional safety measure this fuse may be removed Check the schematics for verification 1 Review danger warning and caution notices before proceeding Review the manufacturer s literature with schematics and wiring diagrams Review maintenance logbooks and historical data pertaining to the equipment Identify the circuit connected to the current boost module by using the schematics Perform lockout and tagout procedures O oa A W N Test the circuit for voltage presence a Proceed to step 7 if there is no voltage present b Stop if there is voltage present and perform the following checks until voltage is no longer present 1 Check the electrical schematics for proper circuit identification 2 Check for back fed circuits 3 Check for the proper use of safe clearance procedures 31 March 2009 STP 5 21P2 SM TG 3 103 Chapter 3 Performance Steps 7 8 9 10 11 12 13 14 15 16 17 18 Remove the current boost module and tag the leads Inspect the current boost module for damage Test the current boost module according to the manufacturer s literature Compare the results with the manufacturer s specifications and take appropriate action Calibrate or replace the current boost module Test the circuit for voltage presence a Proceed to step 13 if there is no voltage present
410. posure to sources of electrical and mechanical energy hazards 7 Identify other energy sources in the immediate area to determine possible exposure to stored or residual energy 8 Ensure that potentially hazardous stored or residual energy is relieved discharged or otherwise rendered safe 9 Establish energy control methods to regulate other hazardous energy sources in the area 10 Test each phase conductor or circuit part using a voltage detector to verify that it is de energized a Check an energized circuit to ensure that the voltage detector is working b Check for the presence of voltage on the de energized circuit c Check the energized circuit again to verify that the voltage detector is working properly 11 Install lockout devices on the energy isolating mechanisms and disconnectors so that they are maintained in an open or de energized position NOTE The person performing the work retains the keys to the lockout devices until the work is complete 12 Attach Eng Form 1925 as a main hold card for the primary means of energy isolation a Ensure that the person installing the lockout device signs the lockout tag with the 1 Printed name of the installer 2 Date 3 Time 4 Clearance number b Ensure that the main hold card lists all locations of the auxiliary hold cards 13 Attach Eng Form 1925 as an auxiliary hold card for the secondary means of energy isolation a Ensure that the person installing the locko
411. products Inspected the hard hat Inspected the protective eyewear Maintained leather products Maintained climber gaffs Tested climber gaffs O o OA N O o A W N Maintained the handline 31 March 2009 STP 5 21P2 SM TG 3 265 Chapter 3 Performance Measures GO NO GO 11 Maintained the block and tackle 12 Maintained the chain hoist 13 Ensured that the items listed in the conditions were properly cleaned and stored Evaluation Guidance Score the Soldier GO if all measures are passed P Score the Soldier NO GO if any measure is failed F If the Soldier fails any measure show him how to do it correctly References Required Related FM 5 125 LCH TM 5 682 TM 5 684 3 266 STP 5 21P2 SM TG 31 March 2009 MOS Skill Level Tasks Perform Operator Preventive Maintenance Checks and Services PMCS on a Line Truck With Auxiliary Equipment 052 204 1119 Conditions As a power line distribution specialist in a tactical or nontactical environment performing before during after and weekly line truck operations or when PMCS on a line truck with auxiliary equipment needs to be done you are given the technical or user s manuals for the truck being inspected maintenance logbooks and DA Form 2404 Equipment Inspection and Maintenance Worksheet or DA Form 5988 E Equipment Inspection Maintenance Worksheet CAUTION VEHI
412. put b Check the waveform of the rectifier output for the proper direct current DC c Replace or repair the malfunctioning rectifier or filter if necessary 9 Check for proper inverter operation a Check the voltage level of the inverter output b Check the waveform output of the inverter for the proper sine wave c Replace or repair the inverter if necessary 10 Service the batteries 11 Return the UPS and load to the incoming power supply 12 Perform a functions check on the UPS 13 Ensure that the items listed in the conditions are properly cleaned and stored Evaluation Preparation Setup Provide the Soldier with the items listed in the conditions Give the Soldier a safety briefing before starting the test and ensure that safety precautions are followed Prepare 31 March 2009 STP 5 21P2 SM TG 3 337 Chapter 3 the testing area and equipment in advance to ensure that task standards can be met Brief Soldier Direct the Soldier to service a UPS Performance Measures 1 O Oo N O oO A W N ii aak a k N Reviewed danger warning and caution notices Reviewed the manufacturer s literature and wiring diagrams Reviewed maintenance logbooks and historical data pertaining to the equipment Measured the power supplied to the load from the primary source Identified inputs and outputs of the UPS Isolated the UPS and the supplied load from the incoming power supply Compared the UPS output with
413. quipment cc ececeeceeeeeeeeeeneeeeeeeneeeeeeeeaeereeeaeees 3 66 052 244 2137 Record Maintenance and or Operational Data 0 cccccceeeeeecteceeeeeeeeteesnaeees 3 68 052 244 2138 Install Low Voltage WING eee eeeeeeeeeeeeeeeeeeeeeeeeeeeeeaeeeeeeeaeeeeeeeaaeeeseeeaeeeseeaaeees 3 70 052 244 2140 Improve Grounding Electrode ReSisStance ccccccceeseeeeeeeeeeeeeeeneeeeteeneeeeeeeatees 3 72 052 244 2141 Repair a Low Voltage Control Cable eeccccceeeeeeeeeeceeeeeeeeeeeeeeeaeeeseeeeeeeeeaeees 3 75 052 244 2142 Prepare a Power Plant for Movement ccccceeeeeeeceeceeeeeeeeseeeeneeeeeeeeeneeeseaeess 3 77 052 244 2143 Perform Preventive Maintenance Checks and Services PMCS on a Mobile Electric Power MEP 029 Generator cceccceceeeeeteee eee eeneeeeeeneeeeetieeeeetneeeeeeae 3 80 052 244 2144 Read a Schematic eee etree ee eeneee terete ee eee ne ee ee teeeeeteeeeeetaeeeeetieeeeesnaeeee 3 83 052 244 2145 Operate a Line Truck with Auxiliary Equipment cccccccseeeeceeeceeeeeeeseeseaeees 3 84 052 244 2146 Service a Nonorganic Prime MOVE cceeceecceeeeeeeeeeeneeeeeeeeeeeseeeaeeeseeaeeeseeaaees 3 87 052 244 2147 Troubleshoot a Nonorganic Prime MOVEe ccecececeeeeeeeeeneeeeeseeeeeeseenaeeeseeaeees 3 90 052 244 2148 Perform Power Plant Battle Damage Assessment and Repair BDAR 3 93 Subject Area 2 E5 Instrument Maintenance Power Station Tasks 052 207 2
414. r DA Form 5988 E Equipment Inspection Maintenance Worksheet DANGER 1 THIS TASK SHOULD ONLY BE PERFORMED BY QUALIFIED PERSONNEL WHO ARE KNOWLEDGEABLE IN THE OPERATION AND MAINTENANCE OF ELECTRICAL POWER GENERATION EQUIPMENT AND ITS ASSOCIATED HAZARDS FAILURE TO COMPLY MAY CAUSE PERMANENT INJURY OR DEATH 2 REMOVE RINGS NECKLACES OTHER JEWELRY AND LOOSE CLOTHING FAILURE TO COMPLY MAY CAUSE PERMANENT INJURY OR DEATH 3 EXERCISE EXTREME CARE WHEN WORKING AROUND ROTATING ENGINE COMPONENTS PARTS FAILURE TO COMPLY MAY CAUSE PERMANENT INJURY OR DEATH WARNING DIESEL FUEL IS FLAMMABLE AND MODERATELY TOXIC USE SKIN AND EYE PROTECTION WHEN CHECKING THE FUEL SYSTEM FAILURE TO COMPLY MAY CAUSE INJURY CAUTION NOISE LEVELS IN EXCESS OF 85 DECIBELS EXIST WITHIN A 50 FOOT RADIUS OF OPERATING EQUIPMENT ALWAYS WEAR SINGLE HEARING PROTECTION WITHIN A 50 FOOT RADIUS FAILURE TO COMPLY MAY CAUSE PERSONAL INJURY Standards Troubleshoot an engine that fails to accelerate or maintain a rated speed by identifying the fault and testing the fault to verify that it is the cause of the malfunction Performance Steps 1 Review danger warning and caution notices 2 Review the manufacturer s literature electrical construction prints and wiring diagrams 3 Review the maintenance logbook and historical data pertaining to equipment 4 Identify the location of the fault a Check the fuel system b Check the governor c Check the air sys
415. r NO GO if any measure is failed F If the Soldier fails any measure show him how to do it correctly References Required Related DA FORM 2404 EM 385 1 1 DA FORM 5988 E TM 9 6115 604 12 31 March 2009 STP 5 21P2 SM TG 3 163 Chapter 3 Service a Hydraulic System 052 205 2120 Conditions As a power station mechanic in a nontactical environment when maintenance on a hydraulic system is required you are given a generator with hydraulic system and the applicable technical manual TM personal protective equipment PPE a general mechanic s tool kit maintenance logbooks DA Form 2404 Equipment Inspection and Maintenance Worksheet or DA Form 5988 E Equipment Inspection Maintenance Worksheet and a lockout and tagout kit DANGER 1 ENSURE THAT EQUIPMENT IS PROPERLY LOCKED OUT AND TAGGED OUT FAILURE TO COMPLY MAY CAUSE PERMANENT INJURY OR DEATH 2 REMOVE RINGS NECKLACES OTHER JEWELRY AND LOOSE CLOTHING FAILURE TO COMPLY MAY CAUSE PERMANENT INJURY OR DEATH WARNING HYDRAULIC FLUID PRESSURES CAN REACH 3 000 POUNDS PER SQUARE INCH WHILE THE PRIME UNIT IS OPERATING DO NOT TOUCH SUSPECTED HYDRAULIC SYSTEM LEAKS FAILURE TO COMPLY MAY CAUSE SERIOUS INJURIES TO UNPROTECTED SKIN OR EYES CAUTION 1 NOISE LEVELS IN EXCESS OF 85 DECIBELS EXIST WITHIN A 50 FOOT RADIUS OF OPERATING EQUIPMENT PERSONNEL MUST WEAR SINGLE HEARING PROTECTION WITHIN A 50 FOOT RADIUS FAILURE TO COMPLY MAY CAUSE INJURY 2 DO NOT OVERFILL THE HYDRA
416. r head Inspected the cylinder head by measuring and inspecting it according to the manufacturer s literature Repaired or replaced the cylinder head depending on the test results Reinstalled the cylinder head according to the manufacturer s literature Referred to the manufacturer s literature for proper torque specifications and the correct torque sequence Closed out lockout and tagout procedures by removing locking and tagging devices Started the unit and observed it for proper operation Recorded actions taken on DA Form 2404 or DA Form 5988 E and maintenance logbooks Ensured that the items listed in the conditions were properly cleaned and stored 3 136 STP 5 21P2 SM TG 31 March 2009 MOS Skill Level Tasks Evaluation Guidance Score the Soldier GO if all measures are passed P Score the Soldier NO GO if any measure is failed F If the Soldier fails any measure show him how to do it correctly References Required Related DA FORM 2404 DA FORM 5988 E 31 March 2009 STP 5 21P2 SM TG 3 137 Chapter 3 Perform Electric Arc Welding 052 205 2104 Conditions As a power station mechanic in a nontactical environment when a piece of metal must be welded and it is determined that electric arc welding is the best available method you are given the appropriate technical manuals TMs a shielded metal arc welding SMAW machine the applicable welding electrodes an arc welder s 9 Lens shade helmet
417. r to the equipment Ensure that the items listed in the conditions are properly cleaned and stored Evaluation Preparation Setup Provide the Soldier with the items listed in the conditions Give the Soldier a safety briefing before starting the test and ensure that safety precautions are followed Prepare the testing area and equipment in advance to ensure that task standards can be met Brief Soldier Direct the Soldier to service a nonaerial air switch Performance Measures GO NO GO 1 2 Reviewed danger warning and caution notices Reviewed the manufacturer s literature electrical construction prints and wiring diagrams 3 210 STP 5 21P2 SM TG 31 March 2009 MOS Skill Level Tasks Performance Measures GO NO GO 3 Performed lockout and tagout procedures 4 Performed visual and manual inspections of the nonaerial air switch to identify and correct deficiencies 5 Performed insulation resistance tests pole to pole pole to ground and across the open contacts of each phase using the voltage specified in the manufacturer s literature and ensured that the insulation resistance test values were not less than 1 000 megohms at a DC test voltage of 2 500 volts unless otherwise stated in the manufacturer s literature 6 Performed overpotential tests pole to pole pole to ground and across the open contacts of each phase using the voltage specified in the m
418. raining and evaluation This section may contain a training information outline evaluation preparation and or evaluation guide The training information outline includes detailed training information The evaluation preparation subsection indicates the necessary modifications to task performance to train and evaluate a task that cannot be trained to the wartime standard under wartime conditions The evaluation preparation may also include special training and evaluation preparation instructions to accommodate these modifications and any instruction that should be given to the Soldier before evaluation The evaluation guide identifies the specific actions known as performance measures that the Soldier must do to successfully complete the task These actions are listed in a pass fail format for easy evaluation Each evaluation guide contains a feedback statement that indicates the requirements for receiving a GO on the evaluation 31 March 2009 STP 5 21P2 SM TG 1 1 Chapter 1 References This section identifies references that provide more detailed and thorough explanations of task performance requirements than those given in the task summary description 1 4 Safety Some task summaries include safety statements and notes Safety statements danger warning and caution notices alert users to the possibility of death personal injury or equipment damage Notes provide an explanation or hint relative to the performance measures 1 5 Soldier
419. ransformer Performed electrical tests Reconnected the isolated equipment oN O oO A O Closed out lockout and tagout procedures by removing locking and tagging devices Ko Reenergized the de energized equipment 10 Checked the primary and secondary sides of the transformer for the proper voltages listed on the equipment data plate 11 Ensured that the items listed in the conditions were properly cleaned and stored Evaluation Guidance Score the Soldier GO if all measures are passed P Score the Soldier NO GO if any measure is failed F If the Soldier fails any measure show him how to do it correctly References Required Related ASTM D1500 NESC ASTM D1524 TM 5 686 ASTM D1816 ASTM D3612 ASTM D877 ASTM D923 ASTM D971 ASTM D974 3 216 STP 5 21P2 SM TG 31 March 2009 MOS Skill Level Tasks References Required Related NETA 31 March 2009 STP 5 21P2 SM TG 3 217 Chapter 3 Service a Distribution Transformer 052 206 2115 Conditions As a power station electrician in a tactical or nontactical environment during maintenance you are given safety standing operating procedures a grounding cluster a general mechanic s tool box a digital low resistance ohmmeter a megohmmeter a transformer turn to turn ratio test set an oil test set a power factor test set ASTM D877 D923 D971 D974 D1500 D1524 D1816 D2285 D3612 and D3613 stand
420. raps and two more close wraps around the conductor 3 Bend the ends back and cut off excess tie wire 6 Inspect the ties to ensure that conductors remain secure 7 Ensure that the items listed in the conditions are properly cleaned and stored Evaluation Preparation Setup Provide the Soldier with the items listed in the conditions Give the Soldier a safety briefing before starting the test and ensure that safety precautions are followed Prepare the testing area and equipment in advance to ensure that task standards can be met Brief Soldier Direct the Soldier to secure a conductor to an insulator de energized Performance Measures GO NO GO 1 Performed lockout and tagout procedures Ascended the pole to the required height if necessary Tested phases to ensure that there was no voltage present Installed personal protective grounds Determined the best tie method for each location Inspected the ties to ensure that conductors remained secure N O Oo A W DN Ensured that the items listed in the conditions were properly cleaned and stored Evaluation Guidance Score the Soldier GO if all measures are passed P Score the Soldier NO GO if any measure is failed F If the Soldier fails any measure show him how to do it correctly References Required Related LCH EM 385 1 1 TM 5 682 TM 5 684 TM 5 811 1 TM 5 811 3 31 March 2009 STP 5 21P2 SM
421. rcent of the name plate rating for the bushings WARNING SOME DC HIGH POTENTIAL TEST SETS ARE HALF WAVE RECTIFIED AND MAY PRODUCE PEAK VOLTAGES IN EXCESS OF THE MANUFACTURER S RECOMMENDED MAXIMUM FOR THE CIRCUIT BREAKER FAILURE TO FOLLOW TEST SET INSTRUCTIONS MAY CAUSE IMMEDIATE PERSONAL INJURY OR EQUIPMENT DAMAGE 10 11 12 13 14 Perform an overpotential test according to the manufacturer s literature and ensure that the insulation withstands the applied overpotential test voltage Verify that the trip close trip free and antipump functions operate properly and ensure that the minimum pickup for the trip and close coils conforms to the specifications in the manufacturer s literature Trip the circuit breaker by operating each protective device Close out lockout and tagout procedures by removing locking and tagging devices Ensure that the items listed in the conditions are properly cleaned and stored Evaluation Preparation Setup Provide the Soldier with the items listed in the conditions Give the Soldier a safety briefing before starting the test and ensure that safety precautions are followed Prepare the testing area and equipment in advance to ensure that task standards can be met Brief Soldier Direct the Soldier to service an SF6 circuit breaker Performance Measures GO NO GO 1 O oa A W N Reviewed danger warning and caution notices Reviewed the manufacturer s literature and wir
422. rch 2009 STP 5 21P2 SM TG 3 285 Chapter 3 References Required Related LCH TM 5 684 3 286 STP 5 21P2 SM TG 31 March 2009 MOS Skill Level Tasks Interpret an Electrical One Line Diagram 052 204 1128 Conditions As a power line distribution specialist in a tactical or nontactical environment where there is a system fault scheduled services due or a needed or proposed system upgrade you are given an electrical one line diagram for an electrical distribution system Standards Interpret an electrical one line diagram by identifying the electrical flow and electrical symbols and their relationships Performance Steps 1 Identify the correct electrical one line diagram for the electrical system 2 Identify the lines and symbols on the diagram 3 Determine the functions of symbols on the one line diagram and the relationships between electrical devices 4 Identify possible electrical paths depending on switchgear positioning Evaluation Preparation Setup Provide the Soldier with the items listed in the conditions Give the Soldier a safety briefing before starting the test and ensure that safety precautions are followed Prepare the testing area and equipment in advance to ensure that task standards can be met Brief Soldier Direct the Soldier to interpret an electrical one line diagram Performance Measures GO NO GO 1 Identified the correct electrical one line diagram for the electrical system 2 Identifie
423. rcuit Performed a circuit trace if needed oN O o A O Ensured that the items listed in the conditions were properly cleaned and stored Evaluation Guidance Score the Soldier GO if all measures are passed P Score the Soldier NO GO if any measure is failed F If the Soldier fails any measure show him how to do it correctly 3 98 STP 5 21P2 SM TG 31 March 2009 MOS Skill Level Tasks References Required Related FM 3 34 480 31 March 2009 STP 5 21P2 SM TG 3 99 Chapter 3 Service a Timing Relay 052 207 2106 Conditions As a power station instrument technician in a tactical or nontactical environment during scheduled maintenance or if a timing relay is suspected of being defective you are given safety standing operating procedures SOPs a lockout and tagout kit a multimeter a relay test set and manual an electronic tool kit maintenance logbooks wiring diagrams and the applicable manufacturer s literature with schematics DANGER 1 ENSURE THAT POWER TO THE RELAY IS DISCONNECTED BEFORE SERVICING APPLY SAFE CLEARANCE PROCEDURES TO THE ASSOCIATED CIRCUITS FAILURE TO COMPLY MAY CAUSE PERMANENT INJURY OR DEATH 2 ENSURE THAT CURRENT TRANSFORMERS ARE DE ENERGIZED AND ELECTRICALLY SHORTED BEFORE SERVICING THE METER IF ENERGIZED AN OPEN CURRENT TRANSFORMER CIRCUIT WILL PRODUCE VERY HIGH VOLTAGES FAILURE TO COMPLY MAY CAUSE PERMANENT INJURY OR DEATH 3 ENSURE THAT POTENTIAL TRANSFORME
424. re or industry standards Close out lockout and tagout procedures by removing locking and tagging devices Perform a functions check on the diesel engine lube oil system Record actions taken on DA Form 2404 or DA Form 5988 E and maintenance logbooks Ensure that the items listed in the conditions are properly cleaned and stored Evaluation Preparation Setup Provide the Soldier with the items listed in the conditions Give the Soldier a safety briefing before starting the test and ensure that safety precautions are followed Prepare the testing area and equipment in advance to ensure that task standards can be met Brief Soldier Direct the Soldier to repair a diesel engine lube oil system Performance Measures GO NO GO 1 O oa A W N 10 Reviewed the TMs manufacturer s literature or industry standards maintenance logbooks and historical data pertaining to the equipment malfunction Ensured that PPE was correctly tested and fully mission capable Inspected tools and testing equipment for serviceability Performed lockout and tagout procedures Verified the defective components parts Repaired or replaced the defective components parts using the applicable TM applicable manufacturer s literature or industry standards Closed out lockout and tagout procedures by removing locking and tagging devices Performed a functions check on the diesel
425. re that bolt torque levels are according to the manufacturer s literature Measure the contact resistance across each switchblade and fuse holder according to the manufacturer s literature Measure resistance across each fuse to ensure that values did not deviate from each other by more than 15 percent Perform corrective actions as necessary Close out lockout and tagout procedures by removing locking and tagging devices Perform a function check on the ATS Ensure that the items listed in the conditions are properly cleaned and stored Evaluation Preparation Setup Provide the Soldier with the items listed in the conditions Give the Soldier a safety briefing before starting the test and ensure that safety precautions are followed Prepare the testing area and equipment in advance to ensure that task standards can be met Brief Soldier Direct the Soldier to service an ATS Performance Measures GO NO GO 1 N DO Oo FBP W DN Reviewed danger warning and caution notices Reviewed the manufacturer s literature and wiring diagrams Reviewed maintenance logbooks and historical data pertaining to the equipment Performed lockout and tagout procedures Performed a visual and manual inspection of the ATS Checked for proper control function according to the manufacturer s literature Performed insulation resistance tests pole to pole pole to ground and across
426. re that the preheat system has operated at least 6 hours before starting If the ambient temperature is below 40 F operate the preheat system as follows 1 Ensure that the jumper is connected between terminals 1 and 3 on Terminal Board 20 NOTE Terminal Board 20 is located in the AC DC control box The jumpers are needed only if the generator is permanently connected to the external power to permit battery operation 2 Connect the 120 or 240 volt AC external power source to the external power receptacle on the external power box control panel 3 Switch the external power breaker to the ON position 4 Switch the preheat switch to the ON position b Toggle the master switch on the engine panel to the START position Adjust the frequency and voltage to the desired values when the engine starts Check the generator fault indicators by placing the annunciator test switch to the TEST position before closing the main circuit breaker 1 Proceed with step 2e if no lights are on after being tested 2 Correct the indicated fault before proceeding if a light comes on e Place the parallel single unit operation switch to the SINGLE UNIT position f Place the AC power circuit breaker to the CLOSE position for about 2 or 3 seconds to close the main circuit breaker Ensure that the closed indicator light comes on 3 Operate the MEP 029 generator a Monitor the engine and generator indicators to ensure that the MEP 029 generator continues to oper
427. re the torch for lighting a Open the torch oxygen valve on the cutting torch NOTE On combination welding and cutting torch assemblies that are screwed together in the middle two oxygen valves will be present Open both valves DANGER WHILE OPENING THE TANK SUPPLY VALVES ON THE REGULATOR PERSONNEL SHOULD STAND TO THE SIDE OF THE REGULATOR FACE FAULTY REGULATORS MAY DETONATE INTERNALLY PROJECTING THE REGULATOR FACE OUTWARD FAILURE TO COMPLY MAY CAUSE PERMANENT INJURY OR DEATH b Standing to the side of the oxygen regulator slowly open the oxygen tank valve about one quarter to one half turn until the dial on the high pressure gauge moves indicating tank pressure 1 Monitor the high and low pressure regulator for signs of malfunction 2 Open the oxygen supply valve fully if there are no signs of problems NOTE Fully opening the oxygen valve will cause it to back seat against a stem seal in order to prevent valve stem pressure leaks while in operation c Adjust the oxygen regulator working pressure as necessary for cutting NOTES 1 See the manufacturer s literature to determine the proper pressure for the cutting torch tip size being used The size is indicated on the side of the cutting tip 2 Oxygen gas will flow out of the torch tip while the working pressure is being adjusted The open flow will allow proper adjustment in the flowing condition and purge the oxygen hose to obtain a 3 142 STP 5 21P2 SM TG 31 March 20
428. readings are a minimum of 20 megohms from the secondary lead to the ground terminal c Ensure that insulation resistance readings are a minimum of 20 megohms from the primary lead to the secondary lead terminal 31 March 2009 STP 5 21P2 SM TG 3 319 Chapter 3 Performance Steps 9 10 11 Close out lockout and tagout procedures by removing locking and tagging devices 12 Perform a transformer turn to turn ratio test Reconnect the isolated equipment Ensure that the items listed in the conditions are properly cleaned and stored Evaluation Preparation Setup Provide the Soldier with the items listed in the conditions Give the Soldier a safety briefing before starting the test and ensure that safety precautions are followed Prepare the testing area and equipment in advance to ensure that task standards can be met Brief Soldier Direct the Soldier to service a potential transformer Performance Measures 1 12 Reviewed danger warning and caution notices Reviewed the manufacturer s literature and wiring diagrams Reviewed maintenance logbooks and historical data pertaining to the equipment 2 3 4 5 Performed lockout and tagout procedures Inspected the condition of the potential transformer visually and manually to ensure that mechanical functions operated smoothly and that there was no physical damage to the oil switch Tested the fuses Performed individual continuity checks on prim
429. removed Check the appropriate schematics for verification 1 Review danger warning and caution notices before proceeding 2 Review the manufacturer s literature with schematics and wiring diagrams 3 Review maintenance logbooks and historical data pertaining to the equipment 4 Identify which circuit needs to be tested by using the appropriate schematics 5 Perform lockout and tagout procedures 3 124 STP 5 21P2 SM TG 31 March 2009 MOS Skill Level Tasks Performance Steps 6 11 12 13 14 15 16 17 Test the circuit for voltage presence a Proceed to step 7 if there is no voltage present b Stop if there is voltage present and perform the following checks until voltage is no longer present 1 Check appropriate schematics for proper circuit identification 2 Check for back fed circuits 3 Check for the proper use of safe clearance procedures Remove the meter and tag attached leads Inspect the meter for physical damage Test the meter according to the manufacturer s literature Compare the results with the manufacturer s specifications and take appropriate action by calibrating or replacing the meter Test the circuit for voltage presence a Proceed to step 12 if there is no voltage present b Stop if there is voltage present and perform the following checks until voltage is no longer present 1 Check appropriate schematics for proper circuit identification 2 Check for bac
430. res are passed P Score the Soldier NO GO if any measure is failed F If the Soldier fails any measure show him how to do it correctly References Required Related DA FORM 2404 EM 385 1 1 DA FORM 5988 E 3 166 STP 5 21P2 SM TG 31 March 2009 MOS Skill Level Tasks Produce a Mechanical Drawing 052 205 2123 Conditions As a power station mechanic in a tactical or nontactical environment when a mechanical drawing is needed for a prime mover system you are given graph paper colored pencils and the appropriate technical manual or manufacturer s literature Standards Produce a mechanical drawing that accurately depicts a mechanical system that can be used for planning future missions or troubleshooting Performance Steps 1 Identify the mechanical system to be depicted as a drawing 2 Identify key items in the system to be produced a Identify valves b Identify pumps c Identify filters d Identify screens e Identify fluid flows f Identify additional components 3 Represent equipment with correct symbols and color schemes 4 Create an illustration of the mechanical system 5 Use the mechanical drawing for a briefing or post drawing Evaluation Preparation Setup Provide the Soldier with the items listed in the conditions Give the Soldier a safety briefing before starting the test and ensure that safety precautions are followed Prepare the testing area and equipment in advance to ensure that task standards c
431. resent and perform the following checks until voltage is no longer present a Check schematics for proper circuit identification b Check for back fed circuits c Check for the proper use of safe clearance procedures Trace the circuit using schematics and wiring diagrams Test each wire for continuity and secure the electrical connection Isolate each component and test for proper electrical parameters Test switches for proper operation Test relays for proper contact transfer when the coil is energized Test resistors for rated values TO a0 AO 8 Ensure that the items listed in the conditions are properly cleaned and stored Evaluation Preparation Setup Provide the Soldier with the items listed in the conditions Give the Soldier a safety briefing before starting the test and ensure that safety precautions are followed Prepare the testing area and equipment in advance to ensure that task standards can be met Brief Soldier Direct the Soldier to perform electronic troubleshooting procedures Performance Measures GO NO GO 1 Reviewed danger warning and caution notices before proceeding 2 Reviewed the manufacturer s literature with schematics electrical construction prints and wiring diagrams Reviewed maintenance logbooks and historical data pertaining to the equipment Checked for obvious malfunctions Ensured that the power was on Sectionalized the ci
432. results and actions taken Ensured that the items listed in the conditions were properly cleaned and stored Evaluation Guidance Score the Soldier GO if all measures are passed P Score the Soldier NO GO if any measure is failed F If the Soldier fails any measure show him how to do it correctly References Required Related FM 3 34 480 3 114 STP 5 21P2 SM TG 31 March 2009 MOS Skill Level Tasks Service Optoelectronic Equipment 052 207 2120 Conditions As a power station instrument technician in a tactical or nontactical environment during scheduled maintenance or if optoelectronic equipment is suspected of being defective you are given a lockout and tagout kit a multimeter a power supply an oscilloscope an electronic tool kit wiring diagrams maintenance logbooks and the applicable manufacturer s literature with schematics DANGER 1 ENSURE THAT POWER TO THE EQUIPMENT IS DISCONNECTED BEFORE SERVICING APPLY SAFE CLEARANCE PROCEDURES TO ASSOCIATED CIRCUITS FAILURE TO COMPLY MAY CAUSE PERMANENT INJURY OR DEATH 2 ENSURE THAT CURRENT TRANSFORMERS SUPPLYING CURRENT TO EQUIPMENT ARE DE ENERGIZED AND ELECTRICALLY SHORTED BEFORE SERVICING EQUIPMENT IF ENERGIZED AN OPEN CURRENT TRANSFORMER CIRCUIT WILL PRODUCE VERY HIGH VOLTAGES FAILURE TO COMPLY MAY CAUSE PERMANENT INJURY OR DEATH 3 ENSURE THAT POTENTIAL TRANSFORMERS FEEDING EQUIPMENT ARE DE ENERGIZED BEFORE SERVICING THE EQUIPMENT FAILURE TO COMPLY MAY CA
433. rformance Steps 6 Inspect the interior of the switchgear enclosure a Check for moisture b Check the condition of weather seals c Check for the presence of animal remains d Check for grounding connection quality e Check for broken bolts and missing or loose bolts nuts and washers f Check for dirt debris or anything that might infringe upon the safe operation of the switchgear assembly Clean and wipe down the interior and exterior of the switchgear enclosure Perform an inventory of cleaning supplies and tools Reconnect the isolated equipment Close the door or replace the access panel Close out lockout and tagout procedures by removing locking and tagging devices Reenergize the de energized equipment 14 Ensure that the items listed in the conditions are properly cleaned and stored Correct deficiencies if possible and record uncorrectable deficiencies on DA Form 2404 Evaluation Preparation Setup Provide the Soldier with the items listed in the conditions Give the Soldier a safety briefing before starting the test and ensure that safety precautions are followed Prepare the testing area and equipment in advance to ensure that task standards can be met Brief Soldier Direct the Soldier to service a switchgear enclosure Performance Measures 1 2 A N OQ A Reviewed danger warning and caution notices Reviewed the manufacturer s literature electrical construct
434. rformance Steps 1 Review danger warning and caution notices Review the manufacturer s literature electrical construction prints and wiring diagrams Review the maintenance logbook and historical data pertaining to equipment Perform lockout and tagout procedures Isolate the system and system circuits that need troubleshooting O oa A W N Identify fault indicators a Check for failure to produce voltage b Check for low voltage c Check for high voltage d Check for fluctuating voltage e Check for slow load change recovery f Check for blown fuses 31 March 2009 STP 5 21P2 SM TG 3 63 Chapter 3 Performance Steps 7 10 11 12 13 14 15 16 17 18 Ensure that the voltage detector functions properly a Check an energized circuit to ensure that the voltage detector is working properly b Check for the presence of voltage on the de energized circuit c Check the energized circuit again to verify that the voltage detector is working properly Test the voltage regulator for proper settings Ensure that the voltage regulator is receiving the proper amount of voltage from the power transformers and current transformers Ensure that the prime mover of the generator is operating at the proper revolutions per minute Test relays associated with the alternator Test the rotating rectifier Replace faulty components parts Close out the lockout and tagout procedures by removing locking and
435. rgize the equipment 17 Ensure that the items listed in the conditions are properly cleaned and stored Evaluation Preparation Setup Provide the Soldier with the items listed in the conditions Give the Soldier a safety briefing before starting the test and ensure that safety precautions are followed Prepare the testing area and equipment in advance to ensure that task standards can be met Brief Soldier Direct the Soldier to perform an insulation resistance test Performance Measures GO NO GO 1 Reviewed danger warning and caution notices 2 Performed lockout and tagout procedures on the system where the equipment was installed 3 Used a voltage detector to verify that there was no voltage at connection points 4 Installed safety grounds 5 Prepared an as found wiring diagram that showed the connection configuration used to attach the equipment to the system 6 Marked cable ends to identify their connection points and designated phases 7 Cleaned the equipment to be tested 8 Determined which type of insulation test such as the megohmmeter or high potential to use 9 Disconnected cables from the equipment terminals as necessary to perform the test 3 248 STP 5 21P2 SM TG 31 March 2009 MOS Skill Level Tasks Performance Measures GO NO GO 10 Employed the test equipment and performed the insulation resistance test
436. rical data pertaining to the equipment 2 Identify the cause of the diesel engine shutdown a Check for low oil pressure caused by one or more of the following 1 Low oil level 2 Thick oil 3 Faulty oil pressure sensor b Check for high coolant temperature caused by one or more of the following 1 Clogged radiator 2 Faulty radiator fans 3 Low coolant level 4 High coolant temperature c Check for low fuel pressure caused by one or more of the following 1 Air in the fuel lines 2 Low fuel level d Check for low boost pressure e Check for overspeed due to switch or sensor malfunction f Check for low hydraulic pressure g Check for wiring harnesses that are not connected correctly NOTE Check for warning or shutdown lights on the equipment being used h Check for catastrophic engine failure that caused a broken rod piston valve timing gear or train 3 Perform on site corrections when possible 4 Record actions taken on DA Form 2404 or DA Form 5988 E and maintenance logbooks 5 Ensure that the items listed in the conditions are properly cleaned and stored 31 March 2009 STP 5 21P2 SM TG 3 157 Chapter 3 Evaluation Preparation Setup Provide the Soldier with the items listed in the conditions Give the Soldier a safety briefing before starting the test and ensure that safety precautions are followed Prepare the testing area and equipment in advance to ensure that task standards can be met
437. rmance Measures GO NO GO 1 Prepared the cutting area and the material to be cut Inspected oxyacetylene equipment Prepared the torch for lighting Lit and adjusted the torch flame Cut the material using the correct cutting techniques O oa A W N Shut down and properly stored the cutting equipment Evaluation Guidance Score the Soldier GO if all measures are passed P Score the Soldier NO GO if any measure is failed F If the Soldier fails any measure show him how to do it correctly References Required Related EM 385 1 1 TC 9 510 3 144 STP 5 21P2 SM TG 31 March 2009 MOS Skill Level Tasks Service a Piping System 052 205 2109 Conditions As a power station mechanic in a nontactical environment when maintenance on general piping systems is required you are given TM 5 551K the applicable equipment specific TMs a general mechanic s tool box specialized piping system maintenance and repair tools maintenance logbooks DA Form 2404 Equipment Maintenance and Inspection Worksheet or DA Form 5988 E Equipment Maintenance Inspection Worksheet and a lockout and tagout kit DANGER 1 ENSURE THAT THE SECTION OF THE PIPING SYSTEM BEING SERVICED IS PROPERLY ISOLATED LOCKED OUT TAGGED OUT DEPRESSURIZED AND DRAINED BEFORE BEGINNING MAINTENANCE FAILURE TO COMPLY MAY CAUSE PERMANENT INJURY OR DEATH 2 ENSURE THAT ELECTRICAL POWER TO THE PUMPING UNIT IS DE ENE
438. rmer a Inspect the condition of the transformer visually and mechanically 1 Clean the unit before testing it unless as found and as left tests are required 2 Inspect the bolted electrical connections for high resistance and compare the resistances to the values of similar connections 3 Verify that the cooling fans operate correctly 4 Verify that the bolt torque levels are correct according to the manufacturer s literature b Perform electrical tests 1 Perform resistance measurements on the bolted connections using a low resistance ohmmeter 2 Perform insulation resistance tests winding to winding and winding to ground on each phase and ensure that the test values at 1 minute meet the manufacturer s specifications If not stated compare the results by voltage to the NETA Maintenance Testing 3 214 STP 5 21P2 SM TG 31 March 2009 MOS Skill Level Tasks Performance Steps Specifications for Electrical Power Distribution Equipment and Systems 3 Perform a turn to turn ratio test on each tap setting and ensure that the test results do not deviate more than 1 2 percent from the adjacent coils or calculated ratio 4 Check the pressure of the transformer surge arrestor NOTE Microhm or millivolt drop values should not exceed the high levels of the normal range as indicated in the manufacturer s literature If the manufacturer s literature is not available investigate the values that deviate from similar connections by more than 50
439. rmer terminals Remove the variable AC source and jumper wire 10 Mark the appropriate polarity on the transformer 11 Test for polarity on a CT using the current or inductive kick method DANGER THE SECONDARY WINDINGS OF CTs SHOULD HAVE A CLOSED CIRCUIT ACROSS THEIR SECONDARY TERMINALS WHEN POWER IS APPLIED TO THE PRIMARY TERMINALS FAILURE TO COMPLY MAY CAUSE PERMANENT INJURY OR DEATH a Connect a 12 volt battery to the primary conductor of the CT and a switch in series with the battery The positive side of the battery should be on the load side H1 terminal and the negative side should be on the H2 terminal Connect a milliammeter across the secondary winding of the transformer The positive lead of the milliammeter should be connected to the appropriate polarity mark if indicated or to the X1 terminal if not indicated Connect the negative lead to the remaining secondary terminal Close the switch momentarily and note the movement of the ammeter The transformer is connected in subtractive polarity if the ammeter moves in the positive direction It is connected in additive polarity if the ammeter moves in the negative direction 12 Record the test results 13 Mark the appropriate polarity on the CT 14 Remove the grounds from incoming and load cables 15 Reconnect the transformer 16 Close out lockout and tagout procedures by removing locking and tagging devices 17 Ensure that the items listed in
440. rning and caution notices Review the manufacturer s literature electrical construction prints and wiring diagrams Perform lockout and tagout procedures Use a voltage detector to verify that no voltage exists at equipment connection points Install safety grounds O oa A W N Prepare an as found wiring diagram that shows the connection configuration used to attach the equipment to the system N Disconnect the cables from the equipment terminals as necessary to perform the test 8 Mark the cable ends to identify connection points and designated phases 9 Clean the equipment to be tested after the as found test is completed if the as found readings are needed 10 Employ the test equipment and perform a power factor and dissipation factor test according to the manufacturer s literature 11 Keep a record of the test results 12 Keep a record of the environmental conditions 13 Determine the status of the insulation by interpreting the test 31 March 2009 STP 5 21P2 SM TG 3 227 Chapter 3 Performance Steps 14 15 16 17 18 a Proceed to step 14 if the test results are acceptable b Repair or replace the insulation if the test results are unacceptable c Retest the insulation after repairing or replacing it Reconnect and torque the cables if necessary Uninstall the safety grounds Remove the safety clearance Close out lockout and tagout procedures by removing locking and tagging devi
441. rnor speed control system Check the hydraulic system Check the pneumatic system Check the alternating current AC control system Check the direct current DC control system wT O 0Q000fM Identify the fault locations by checking the fault indicator panel or each critical system for obvious malfunctions NOTE This list is meant to be a guideline and is not all inclusive Check for the most obvious and easily corrected problems first a Identify incorrectly positioned control switches b Identify lighted control panel warnings c Identify improper meter readings d Identify tripped circuit breakers and reset buttons and blown fuses e Identify fluid leaks f Identify loose or burnt wiring g Identify excessively worn components parts h Identify burnt components parts by sight and smell i Identify out of tolerance service requirements j Identify low fluid levels k Identify the restricted flows of fluids and gases Isolate the system in which the fault was found Conduct further testing to identify defective components parts if necessary Perform lockout and tagout procedures Repair or replace defective components parts when possible Perform a functions check on the affected system Close out lockout and tagout procedures by removing all locking and tagging devices Put the system back into service Record faults and repairs in the maintenance logbook Ensure that the PPE t
442. rol switch in the MANUAL position at G2 o Place the synchronous source switch at the master control panel in the G2 position _ A Close the G2 breaker by cycling the breaker control switch to the CLOSE position when the two green triangular light emitting diodes LEDs that show 12 o clock on the synchroscope are energized 15 Ensure that the breaker control switch closes 3 24 STP 5 21P2 SM TG 31 March 2009 MOS Skill Level Tasks Performance Steps 16 17 18 19 20 21 22 23 24 25 26 Return the synchronous source switch to the OFF position Close the required feeder tie breaker s from the local control panel and allow it run for 20 minutes through various load changes Shut down the generator according to the TM Perform a preoperational run according to the TM Perform an operator remote terminal setup according to the TM Ensure that Generator 1 automatically starts and accelerates to the correct operating voltage and frequency Ensure that Generator 1 automatically closes to the system bus Ensure that the tie breaker automatically closes Ensure that Generator 2 automatically starts and accelerates to the correct operating voltage and frequency Ensure that Generator 2 automatically parallels the system bus Shut down the generator according to the TM Evaluation Preparation Setup Provide the Soldier with the items listed in the conditions Give the Soldier a safety br
443. rts are found replace or repair them as necessary 3 Inspect the oil level 4 Check oil viscosity and color NOTE If oil contamination is suspected and a Joint Oil Analysis Program JOAP is not readily available change the oil and filters It is preferred that a JOAP be conducted before putting the unit back into operation to ensure the worthiness of the oil 5 Check oil filters and filter housings 6 Check the filter bypass and differential bypasses 7 Check oil lines and oil rifles if needed 8 Check the oil sump or oil pan seal for cleanliness and leaks 9 Ensure that the oil pump is secure inlet screen is clear gear teeth are in good condition and backlash is within tolerance 10 Close out lockout and tagout procedures by removing locking and tagging devices 11 Start the unit and observe it for proper operation 12 Record actions taken on DA Form 2404 or DA Form 5988 E and maintenance logbooks 13 Ensure that the items listed in the conditions are properly cleaned and stored Evaluation Preparation Setup Provide the Soldier with the items listed in the conditions Give the Soldier a safety briefing before starting the test and ensure that safety precautions are followed Prepare the testing area and equipment in advance to ensure that task standards can be met 31 March 2009 STP 5 21P2 SM TG 3 149 Chapter 3 Brief Soldier Direct the Soldier to service a diesel engine lube oil system Performance Mea
444. s maintenance logbooks and historical data pertaining to the equipment malfunction Ensure that PPE is correctly tested and fully mission capable Inspect tools and testing equipment for serviceability Perform lockout and tagout procedures Verify the defective components parts Repair or replace the defective components parts using the appropriate TM applicable manufacturer s literature or industry standards Close out lockout and tagout procedures by removing locking and tagging devices Perform a functions check on the diesel engine cooling system 9 10 Record actions taken on DA Form 2404 or DA Form 5988 E and maintenance logbooks Ensure that the items listed in the conditions are properly cleaned and stored Evaluation Preparation Setup Provide the Soldier with the items listed in the conditions Give the Soldier a safety briefing before starting the test and ensure that safety precautions are followed Prepare the testing area and equipment in advance to ensure that task standards can be met Brief Soldier Direct the Soldier to repair a diesel engine cooling system Performance Measures GO NO GO 1 O oa A W N 10 Reviewed the appropriate TMs applicable manufacturer s literature or industry standards maintenance logbooks and historical data pertaining to the equipment malfunction Ensured that PPE was correctly tested and fully mission capable Inspected tools a
445. s and the applicable personal protective equipment PPE DANGER TIME IS EXTREMELY CRITICAL THROUGHOUT THIS TASK FAILURE TO RESCUE A VICTIM IN A TIMELY MANNER MAY RESULT IN PERMANENT INJURY OR DEATH Standards Rescue an injured victim from a utility pole by lowering him to the ground within 1 minute of reaching the victim on the pole Administer first aid until he is in stable condition or qualified medical personnel arrive Performance Steps 1 Evaluate the situation by calling to the victim a Determine the victim s level of injury or illness before climbing the utility pole NOTE If the victim is conscious and responds in an understanding voice attempt to talk him down the utility pole b Prepare to climb the utility pole and aid the victim if he is unconscious does not respond or appears to be stunned or dazed 2 Ensure your own protection a Contact emergency response personnel b De energize the circuit if necessary or practical c Ensure that rescue line tools hot sticks and rubber gloves are properly rated d Ensure that the utility pole is not energized e Ensure that the utility pole is not on fire and that there are no damaged conductors or equipment 3 Climb to the rescue position a Leap onto the utility pole ensuring that no part of your body touches the pole and the ground at the same time b Belt in slightly above and to one side of the victim c Clear the victim and yourself from energized conduct
446. s a power station electrician in a tactical or nontactical environment during maintenance you are given applicable safety standing operating procedures a general mechanic s tool box a digital low resistance ohmmeter a megohmmeter a current injection test set grounding equipment electrical construction prints wiring diagrams and the appropriate manufacturer s literature DANGER 1 THIS TASK SHOULD ONLY BE PERFORMED BY QUALIFIED PERSONNEL WHO ARE KNOWLEDGEABLE IN THE INSTALLATION AND MAINTENANCE OF CIRCUIT BREAKERS AND POWER EQUIPMENT AND THEIR ASSOCIATED HAZARDS FAILURE TO COMPLY MAY CAUSE PERMANENT INJURY OR DEATH 2 DO NOT TOUCH EXPOSED ELECTRICAL CONNECTIONS WHILE A POWER SOURCE IS CONNECTED TO THE CIRCUIT BREAKER FAILURE TO COMPLY MAY CAUSE PERMANENT INJURY OR DEATH 3 REMOVE RINGS NECKLACES OTHER JEWELRY AND LOOSE CLOTHING FAILURE TO COMPLY MAY CAUSE PERMANENT INJURY OR DEATH Standards Safely service the circuit breaker by inspecting and testing it according to the manufacturer s literature Reinstall or repair the circuit breaker based on the test results Performance Steps NOTES 1 Conduct tests according to the manufacturer s literature when available Use industry standards when the manufacturer s literature cannot be obtained 2 Microhm or millivolt drop values should not exceed the high levels of the normal range as indicated in the manufacturer s literature If the manufacturer s literature is not available
447. s if required b Use BDAR procedures to rapidly repair damages c Use field expedient materials to make repairs if required d Use field expedient POL if required 8 Record actions taken on DA Form 2404 or DA Form 5988 E and maintenance logbooks 31 March 2009 STP 5 21P2 SM TG 3 93 Chapter 3 Performance Steps 9 10 11 12 13 Notify the change of command of destruction procedures if required Prepare the equipment for destruction if required according to the BDAR manual Close out lockout and tagout procedures by removing locking and tagging devices Perform a functions check on the repaired equipment Ensure that the items listed in the conditions are properly cleaned and stored Evaluation Preparation Setup Provide the Soldier with the items listed in the conditions Give the Soldier a safety briefing before starting the test and ensure that safety precautions are followed Prepare the testing area and equipment in advance to ensure that task standards can be met Brief Soldier Direct the Soldier to perform power plant BDAR Performance Measures 1 2 oN O oO A O 10 11 12 13 Reviewed danger warning and caution notices Reviewed the manufacturer s literature electrical construction prints and wiring diagrams Reviewed maintenance logbooks and historical data pertaining to the equipment Performed lockout and tagout procedures Performed an equipment inspection Determined
448. s were properly cleaned and stored Evaluation Guidance Score the Soldier GO if all measures are passed P Score the Soldier NO GO if any measure is failed F If the Soldier fails any measure show him how to do it correctly References Required Related FM 3 34 480 31 March 2009 STP 5 21P2 SM TG 3 67 Chapter 3 Record Maintenance and or Operational Data 052 244 2137 Conditions As a power plant operator in a tactical or nontactical environment where equipment is being operated and maintained you are given a maintenance logbook operational logbook and corresponding technical manual Standards Record the maintenance and operational data in maintenance and operational logbooks while equipment is being operated and maintained Performance Steps 1 Identify the type of work logged as maintenance or operational 2 Record information in the maintenance logbook a Document hourly services b Document completed repairs c Document annual services d Document noticeable abnormalities e Document part replacements 3 Record information in the operational logbook a Document current shift operator names b Document current cautions and clearances c Document the plant status during shift changes 1 Log engine hours 2 Log circuit breaker trips 3 Log kilowatt hours 4 Log bumper numbers of current online units 5 Log plant loads d Document added fuel e Document added oil f Document br
449. serviceability inspection a Visually inspect the pole for 1 Shell rot 2 Large cracks or splits Signs of soil erosion around the pole base Hollow spots Woodpecker holes 6 Burned spots b Perform a sound test with a 2 pound hammer and check for butt rot shell rot and heart rot WARNING ALWAYS BE AWARE OF OBJECTS THAT ARE OVERHEAD WHEN SOUNDING THE POLE LOOSE OR ROTTED ITEMS MAY FALL AND CAUSE IMMEDIATE PERSONAL INJURY OR EQUIPMENT DAMAGE we YS Dm wa 3 4 5 NOTE Strike the pole in several different locations and at different heights A good pole will sound solid when struck with a hammer A decayed pole will sound hollow or like a drum c Perform a probe test with the brace and bit if necessary 1 Remove the dirt around the pole to a depth of 12 to 18 inches and an area wide enough to operate the brace and bit 2 Drill a 3 8 inch hole below the ground line into the butt of the pole at a downward angle of 30 to 45 Ensure that you drill deep enough to reach the center of the pole Check the wood shavings for decay Plug the drilled hole with a 3 8 inch wooden dowel to prevent further decay Fill the hole in with dirt and tamp it d Mark the poles that do not pass the tests so that they are easily identified 3 4 5 6 3 280 STP 5 21P2 SM TG 31 March 2009 MOS Skill Level Tasks Performance Steps 2 Inspect equipment a Inspect PPE b Inspect climbing equipment c Inspect
450. spection fault identification and fault testing to verify the cause of malfunction Performance Steps 1 Review TMs manufacturer s literature or industry standards maintenance logbooks and historical data pertaining to the equipment Ensure that PPE is correctly tested and fully mission capable Inspect tools and testing equipment for serviceability Perform lockout and tagout procedures ao fF O N Identify fault locations by checking the equipment fault indicator panel or the engine air intake and exhaust system for obvious malfunctions 3 186 STP 5 21P2 SM TG 31 March 2009 MOS Skill Level Tasks Performance Steps a Check for the engine not starting when turned over at the proper speed NOTE This may be due to exhaust valves stuck open or not at proper clearance b Check for engine loss of power NOTE This may be due to a clogged air intake or air filters stuck exhaust valves obstructions in the exhaust or a faulty turbocharger c Check for an engine knock NOTE This may be due to exhaust valves being out of adjustment d Check for a smoky exhaust NOTE This may be due to dirty air intake filters an exhaust obstruction or low compression e Check for a cylinder misfire NOTE This may be due to stuck exhaust valves 6 Conduct further testing to identify specific defective components if necessary 7 Record actions taken on DA Form 2404 or DA Form 5988 E and maintenance logbooks 8 Ensure that the
451. ssessed the situation and took prompt action 2 Disconnected or shut off the power if possible 3 Selected a nonconductive or insulated implement such as a hot stick a wooden pole or protective rubber gloves with leather gauntlets to remove the conductor from the victim or remove the victim from the conductor 4 Isolated the victim from the source of the electric shock by removing the conductor from the victim or removing the victim from the conductor 5 Evaluated the victim 6 Performed first aid treatment er 7 Contacted emergency medical personnel Evaluation Guidance Score the Soldier GO if all measures are passed P Score the Soldier NO GO if any measure is failed F If the Soldier fails any measure show him how to do it correctly References Required Related EM 385 1 1 FM 4 25 11 TB 385 4 TM 5 315 31 March 2009 STP 5 21P2 SM TG 3 11 Chapter 3 Perform Preventive Maintenance on Safety Equipment 052 244 2106 Conditions As a power plant operator in a tactical or nontactical environment during scheduled and unscheduled maintenance you are given the manufacturer s literature DA Form 2404 equipment technical manuals cleaning materials electrician tools equipment specified in the manufacturer s maintenance instructions and standing operating procedures DANGER ALL SAFETY EQUIPMENT MUST BE MAINTAINED ACCORDING TO THE MANUFACTURER S MAINTENANCE IN
452. staller or by a designated representative if the installer is unavailable 21 Ensure that personnel are safely positioned or are removed from the area needing to be reenergized 22 Complete and file all necessary forms a Complete Eng Form 1927 R b Annotate the completed work on Eng Form 2198 c File the completed Eng Form 1927 R 23 Ensure that the items listed in the conditions are properly cleaned and stored Evaluation Preparation Setup Provide the Soldier with the items listed in the conditions Give the Soldier a safety briefing before starting the test and ensure that safety precautions are followed Prepare the testing area and equipment in advance to ensure that task standards can be met Brief Soldier Direct the Soldier to perform lockout and tagout procedures Performance Measures GO NO GO 1 Notified the project supervisor of the work areas requiring lockout and tagout procedures Initiated a safe clearance request Reviewed the schematics and prints of the system Isolated systems operated by remote controlled power sources a A O N Created a list of energy isolating devices and disconnecting equipment to be locked and tagged 31 March 2009 STP 5 21P2 SM TG 3 21 Chapter 3 Performance Measures 6 10 11 12 13 14 15 16 17 18 19 20 21 22 23 Reviewed other work areas to identify possible exposure
453. starting the test and ensure that safety precautions are followed Prepare the testing area and equipment in advance to ensure that task standards can be met Brief Soldier Direct the Soldier to operate a line truck with auxiliary equipment Performance Measures GO NO GO 1 Prepared a line truck for operation 2 Operated the truck boom using the primary and secondary controls while paying close attention to the hand and arm signals of the ground guide 3 Operated the line truck boom while paying close attention to the hand and arm signals of the ground guide 4 Operated the digger or auger on a line truck while paying close attention to the hand and arm signals of the ground guide 5 Operated the auxiliary line truck equipment 6 Secured the line truck with the auxiliary equipment Evaluation Guidance Score the Soldier GO if all measures are passed P Score the Soldier NO GO if any measure is failed F If the Soldier fails any measure show him how to do it correctly 31 March 2009 STP 5 21P2 SM TG 3 85 Chapter 3 References Required Related EM 385 1 1 LCH TM 5 684 TM 5 811 1 3 86 STP 5 21P2 SM TG 31 March 2009 MOS Skill Level Tasks Service a Nonorganic Prime Mover 052 244 2146 Conditions As a power plant operator in a tactical or nontactical environment when a nonorganic prime mover has been identified for service or when symptoms indicate one or
454. sted in the conditions were properly cleaned and stored 13 Ensured that deficiencies and troubleshooting procedures were recorded in the maintenance logbook Evaluation Guidance Score the Soldier GO if all measures are passed P Score the Soldier NO GO if any measure is failed F If the Soldier fails any measure show him how to do it correctly References Required Related UGLYS DA FORM 2404 EM 385 1 1 31 March 2009 STP 5 21P2 SM TG 3 53 Chapter 3 Perform a Load Assessment 052 244 2130 Conditions As a power plant operator in a tactical or nontactical environment when data is needed for a distribution design generator selection disaster relief or other electrical missions of a facility you are given FM 5 424 the National Electrical Code NEC Handbook Ugly s Electrical Reference a calculator DA Form 2702 Bill of Materials a multimeter and access to the ENG LINK website NOTE In some situations Soldiers may not have access to the ENG LINK website In these situations Soldiers may have to rely on hard copies DANGER 1 DO NOT TOUCH EXPOSED ELECTRICAL CONNECTIONS WHEN A SOURCE OF POWER SUCH AS UTILITY POWER OR ANOTHER GENERATOR SET IS CONNECTED TO THE LOAD TERMINALS FAILURE TO COMPLY MAY CAUSE PERMANENT INJURY OR DEATH 2 REMOVE RINGS NECKLACES OTHER JEWELRY AND LOOSE CLOTHING FAILURE TO COMPLY MAY CAUSE PERMANENT INJURY OR DEATH 3 ALWAYS WEAR THE PERSONAL PROTECTIVE EQUI
455. sted in the conditions were properly cleaned and stored 3 182 STP 5 21P2 SM TG 31 March 2009 MOS Skill Level Tasks Evaluation Guidance Score the Soldier GO if all measures are passed P Score the Soldier NO GO if any measure is failed F If the Soldier fails any measure show him how to do it correctly References Required Related DA FORM 2404 EM 385 1 1 DA FORM 5988 E 31 March 2009 STP 5 21P2 SM TG 3 183 Chapter 3 Troubleshoot a Diesel Engine Cooling System 052 205 2130 Conditions As a power station mechanic in a tactical or nontactical environment when a diesel engine cooling system malfunctions you are given a lockout and tagout kit a general mechanic s tool box the applicable technical manuals TMs the applicable manufacturer s literature or industry standards maintenance logbooks DA Form 2404 Equipment Inspection and Maintenance Worksheet or DA Form 5988 E Equipment Inspection Maintenance Worksheet and the applicable personal protective equipment PPE DANGER 1 REMOVE RINGS NECKLACES OTHER JEWELRY AND LOOSE CLOTHING FAILURE TO COMPLY MAY CAUSE PERMANENT INJURY OR DEATH 2 EXERCISE EXTREME CAUTION WHEN WORKING IN THE AREA OF ROTATING ENGINE COMPONENTS FAILURE TO COMPLY MAY CAUSE PERMANENT INJURY OR DEATH 3 ALWAYS WEAR PPE AS REQUIRED FOR INSPECTIONS IN HAZARDOUS AREAS FAILURE TO COMPLY MAY CAUSE PERMANENT INJURY OR DEATH 4 ENGINE COOLANT GETS VERY HOT DURING OPERATION DO NOT
456. stem if there is no obvious malfunction b Check for a complete operation cycle c Listen for unusual operating sounds DANGER DE ENERGIZE IMMEDIATELY AT THE FIRST SIGN OF AN ELECTRICAL SHORT OR SMOKE FAILURE TO COMPLY MAY CAUSE IMMEDIATE INJURY AND SEVERE DAMAGE TO EQUIPMENT d Check the system by sectionalizing the circuit if the fault cannot be identified 6 Sectionalize the circuit a Study schematics and wiring diagrams b Take measurements at each end of the circuit 31 March 2009 STP 5 21P2 SM TG 3 97 Chapter 3 Performance Steps c Begin sectionalizing the circuit if the desired values are not obtained 1 Identify the point where the circuit can be approximately sectionalized in half to determine if the circuit is working up to that point 2 Divide the circuit closest to the output voltage approximately in half again if the values obtained indicate that the circuit is working up to that point 3 Divide the circuit closest to the power source approximately in half again if the values obtained indicate that the circuit is not working up to that point d Continue sectionalizing the circuit until the component that is causing the fault is identified e Perform a circuit trace and component test if the fault cannot be located 7 Perform a circuit trace if needed a De energize the inoperative circuit b Test the circuit for voltage 1 Proceed to step 7c if there is no voltage present 2 Stop if there is voltage p
457. sulator De energiZed 0 0 eeceeeeeeeeeeeeeeeteeeeeee tennessee Climbza Utility Role i 3 442 a T E ee aa tee ee eee Perform a Crossarm Change Out ceccceeeeeeeeeeeeeeeeeeeeneeeeeeaaeeeeeeaeeeeesnaeeeeeeaes Perform Groundman DUtICS raria a cnet ee ee tenets eeeaeeeeeeeaeeeeeenaeeeeeenneeeeeaes Interpret an Electrical One Line Diagram ccccccceeneeeeeeeeeeeeeeeneeeeeeeeeeeteeaaees STP 5 21P2 SM TG Contents 052 204 1129 Splice a Medium Voltage Power Cable eecececeeeeseeeeeeeneeeeeentaeeeeeeneeeeeeaaes 3 288 052 204 1130 Terminate a Medium Voltage Power Cable 0 cc ccccceeeeeeeeneeeeeeeneeeeseeeeeeeeenaees 3 292 052 204 2207 Conduct a Safety Briefing ec eeceeeeeeeeeeneeeeeeeneeeeeeaeeeeeeaeeeeeeaeeeeeeenaeeeeeeaes 3 295 052 204 2208 Conduct a Safety Inspection 00 0 eee eeeeeee eee eeeeeeeeeeeeeeeeteeeaeeeseeeaeeeeeeaaeeeeeeaaees 3 296 052 204 2211 Develop a Bill of Materials BOM List ee eeeeeeeeeeneeeeeeneeeeeeenaeeeeeeaaes 3 297 052 204 2212 Energize an Electrical Distribution SyStem cece eeeeeeeeeneeeeeenteeeeeeeteeeeeeaaes 3 299 052 204 2213 Locate an Underground Cable and or a Fault ceececeeeesneeeeeeeeeeeeeenaeeeeeeeaes 3 301 052 204 2214 Perform Live Line Testing 0 0 0 ceeccceeeeeeceeeeeeeeeeeeeeeeenaeeeeeeceeeeseenaeeeeeeneeeeneaes 3 304 052 204 2216 Perform Maintenance on Electrical Distribution Equipment cceee 3 306 052 204 2217 Manage a Power Line Crew
458. sures 1 oO ON OOA W ND O 11 12 13 Reviewed maintenance logbooks and historical data pertaining to the equipment to verify that the diesel engine lube oil system needed to be serviced Performed lockout and tagout procedures Inspected the oil level Checked oil viscosity and color Checked oil filters and filter housings Checked the filter bypass and differential bypasses Checked oil lines and oil rifles if needed Checked the oil sump or oil pan seal for cleanliness and leaks Ensured that the oil pump was secure inlet screen was clear gear teeth were in good condition and backlash was within tolerance Closed out lockout and tagout procedures by removing locking and tagging devices Started the unit and observed it for proper operation Recorded actions taken on DA Form 2404 and DA Form 5988 E and maintenance logbooks Ensured that the items listed in the conditions were properly cleaned and stored Evaluation Guidance Score the Soldier GO if all measures are passed P Score the Soldier NO GO if any measure is failed F If the Soldier fails any measure show him how to do it correctly References Required Related DA FORM 2404 DA FORM 5988 E 3 150 STP 5 21P2 SM TG 31 March 2009 MOS Skill Level Tasks Service a Diesel Engine Cooling System 052 205 2111 Conditions As a power station mechanic in a nontactical environment when a diesel engine cooling syst
459. sures GO NO GO 1 2 3 4 11 Performed lockout and tagout procedures Inspected the termination kit Prepared the cable and termination according to the manufacturer s literature Removed the jacket using the distance indicated in the manufacturer s literature and ensured that the length required for the lug was added to the measure back distance Removed the shield using the distance indicated in the manufacturer s literature Removed the semiconductor using the distance indicated in the manufacturer s literature Removed the high voltage insulation layer using the distance indicated in the manufacturer s literature Installed the termination lug using the correct compression tool Cleaned surfaces using an approved solvent to remove carbon dust and residue Replaced the high voltage insulation layer according to the manufacturer s literature Applied a semiconductive layer according to the manufacturer s literature 31 March 2009 STP 5 21P2 SM TG 3 293 Chapter 3 Performance Measures GO NO GO 12 Recreated a shield layer according to the manufacturer s literature 13 Attached a ground according to the manufacturer s literature and ensured that it was long enough to reach the grounding point 14 Applied a high voltage insulation layer according to the manufacturer s
460. t a valid DA Label 80 stamped with Calibration Not Required was attached to the test equipment not requiring calibration 5 Placed a valid DA Label 80 stamped with Calibrate Before Use on the TMDE that had not been calibrated Submitted defective and delinquent equipment for calibration or repair Cleaned test equipment as necessary 6 7 8 Performed PMCS on electrical mechanical and instrumentation TMDE 9 Recorded actions taken on DA Form 2404 or DA Form 5988 E 10 Ensured that the items listed in the conditions were properly cleaned and stored Evaluation Guidance Score the Soldier GO if all measures are passed P Score the Soldier NO GO if any measure is failed F If the Soldier fails any measure show him how to do it correctly References Required Related DA FORM 2404 LCH DA FORM 3758 R DA FORM 5988 E DA LABEL 80 TB 43 180 3 16 STP 5 21P2 SM TG 31 March 2009 MOS Skill Level Tasks Troubleshoot an Engine Failure to Stop 052 244 2111 Conditions As a power plant operator in a tactical or nontactical environment you are given an engine that fails to stop the technical manual for the engine a general mechanic s tool box a multimeter a maintenance logbook and DA Form 2404 Equipment Inspection and Maintenance Worksheet or DA Form 5988 E Equipment Inspection Maintenance Worksheet DANGER 1 THIS TASK SHOULD ONLY BE PERFORME
461. t phases to ensure that there is no voltage present 4 Install personal protective grounds 5 Determine the best tie method for each location a Use preformed tie wires if available NOTE Preformed tie wires are not one size fits all They must match the application and the conductor size b Use armor rod ties when applicable NOTES 1 Armor rod ties are used to protect conductors from damage due to vibration and are placed on the conductors the same way as preformed tie wires 2 Never cross tie wires c Use a top tie when the conductor is in the top groove of the insulator 1 Center the tie wire on the top of the insulator pulling one end toward you and one end away from you Both sides of the wire should be of equal length and positioned under the conductor Wrap both ends halfway around the insulator 3 278 STP 5 21P2 SM TG 31 March 2009 MOS Skill Level Tasks Performance Steps 2 Tighten both wire ties against the insulator and wrap two close wraps three spaced wraps and two more close wraps around the conductor 3 Bend the ends back and cut off excess tie wire d Use a side tie when the conductor pulls against the side of the insulator 1 Center the tie wire on the back side of the insulator pulling the ends toward you forming a U Both sides of the wire should be equal in length and positioned under the conductor 2 Tighten the wire ties against the insulator and wrap two close wraps three spaced w
462. t the system NOTE Resistance values between each bonded frame and ground should be less than 5 ohms If there is a long distance from the frame and main ground connection point the total resistance could be over 1 ohm so it is important to test section by section or point to point a Proceed to the next step if the test results are acceptable b Test individual sections to identify and correct deficiencies if the test results are unacceptable 7 Keep a record of the test results 8 Close out lockout and tagout procedures by removing locking and tagging devices 9 Perform a functions check on the electrical equipment grounding system 10 Ensure that the items listed in the conditions are properly cleaned and stored Evaluation Preparation Setup Provide the Soldier with the items listed in the conditions Give the Soldier a safety briefing before starting the test and ensure that safety precautions are followed Prepare the testing area and equipment in advance to ensure that task standards can be met Brief Soldier Direct the Soldier to service an electrical equipment grounding system 3 212 STP 5 21P2 SM TG 31 March 2009 MOS Skill Level Tasks Performance Measures 1 O oa A O 9 10 Reviewed danger warning and caution notices Reviewed the manufacturer s literature electrical construction prints and wiring diagrams Performed lockout and tagout procedures Conducted a visual inspection Serviced
463. t the polarity sensitive components parts are properly oriented e Place heat sink clips on the leads for temperature sensitive components f Secure electrical components to minimize movement during the soldering process 4 Solder the components parts together using the appropriate technique a Ensure good thermal contact between the tip of the soldering iron and the components parts b Melt the solder directly to the components parts allowing the solder to flow into the connection c Remove the soldering iron and solder when enough solder has filled the area to create a good electrical and secure union between the two components parts d Ensure that the components parts do not move during or after the soldering process until the solder cools 5 Inspect the final product for flaws and damage 6 Test the connection using a multimeter to ensure that the resistance measures 0 ohms Evaluation Preparation Setup Provide the Soldier with the items listed in the conditions Give the Soldier a safety briefing before starting the test and ensure that safety precautions are followed Prepare the testing area and equipment in advance to ensure that task standards can be met Brief Soldier Direct the Soldier to solder an electrical or electronic component 3 324 STP 5 21P2 SM TG 31 March 2009 MOS Skill Level Tasks Performance Measures GO NO GO 1 Identified components parts to be soldered Inspected components parts for dam
464. t up and operation DANGER 1 THIS TASK SHOULD ONLY BE PERFORMED BY QUALIFIED PERSONNEL WHO ARE KNOWLEDGEABLE IN THE INSTALLATION OPERATION AND MAINTENANCE OF ELECTRICAL POWER GENERATION EQUIPMENT AND ITS ASSOCIATED HAZARDS FAILURE TO COMPLY MAY CAUSE PERMANENT INJURY OR DEATH 2 DO NOT OPERATE THE GENERATOR SET UNLESS IT HAS BEEN PROPERLY GROUNDED FAILURE TO COMPLY MAY CAUSE PERMANENT INJURY OR DEATH 3 REMOVE RINGS NECKLACES OTHER JEWELRY AND LOOSE CLOTHING FAILURE TO COMPLY MAY CAUSE PERMANENT INJURY OR DEATH WARNING 1 ENSURE THAT NO TOOLS PARTS OR LOOSE ITEMS TOUCH THE ENGINE FAILURE TO COMPLY MAY CAUSE INJURY 2 SHUTTERS WILL RAPIDLY SNAP SHUT WITH CONSIDERABLE FORCE WHEN THE GENERATOR SET IS STOPPED ENSURE THAT PERSONNEL ARE CLEAR OF THE SHUTTERS BEFORE STOPPING THE GENERATOR FAILURE TO COMPLY MAY CAUSE INJURY 3 IF THE ENGINE DOES NOT START IN 45 SECONDS OVERCRANK PROTECTION WILL TERMINATE THE CRANKING CYCLE RESET THE ENGINE AND ALLOW IT TO REST FOR 1 MINUTE BEFORE STARTING ANOTHER CRANK CYCLE FAILURE TO COMPLY MAY CAUSE DAMAGE TO THE CRANK CIRCUIT CAUTION NOISE LEVELS IN EXCESS OF 85 DECIBELS EXIST WITHIN A 50 FOOT RADIUS OF OPERATING EQUIPMENT ALWAYS WEAR SINGLE HEARING PROTECTION WITHIN A 50 FOOT RADIUS OF OPERATING EQUIPMENT FAILURE TO COMPLY MAY CAUSE INJURY Standards Operate an MEP 029 generator according to TM 5 6115 593 12 Ensure that the system parameters are met without causing injury
465. tach fuel lines if necessary Test generator breakers to ensure proper operation Start the generator Perform a walk around inspection to ensure that there are no major mechanical defects or malfunctions before proceeding to the next step Check the output voltage and frequency Stop the generator Prepare load cables Test cables according to the manufacturer s standard Connect load break elbows Use a phase rotation meter to ensure primary phasing Mark connections with colored tape to differentiate between phases Trace cables from the generator to the load to ensure that cables are correctly marked and connected O09QAaq oo Energize the system a Start the generator b Check the voltage at the breaker with the breaker open c Close the breaker d Check the voltage at the load Make necessary changes to achieve the proper output voltage and frequency Ensure that the items listed in the conditions are properly cleaned and stored Evaluation Preparation Setup Provide the Soldier with the items listed in the conditions Give the Soldier a safety briefing before starting the test and ensure that safety precautions are followed Prepare the testing area and equipment in advance to ensure that task standards can be met Brief Soldier Direct the Soldier to install a nonorganic generator Performance Measures GO NO GO 1 N DO Oo FB W ND ee Ensured that the generator set met the
466. tains a list of training locations and their corresponding brevity codes ASI SD Additional skill identifier special duty AIT Advanced individual training ANCOC Advanced Noncommissioned Officer Course BNCOC Basic Noncommissioned Officer Course UNIT Trained in the unit Figure 2 1 Training Locations Sustainment training frequency column This column indicates the recommended frequency at which the tasks should be trained to ensure that Soldiers maintain task proficiency Figure 2 2 identifies the frequency codes used in this column Biannually Annually Semiannually Quarterly Monthly Biweekly Weekly Figure 2 2 Sustainment Training Frequency Codes Sustainment training skill level column This column lists the skill levels of the MOS for which Soldiers must receive sustainment training to ensure that they maintain proficiency to SM standards 31 March 2009 STP 5 21P2 SM TG 2 1 Chapter 2 Subject area codes Tasks are grouped into numbered areas and are broken down by subject area skill level See Figure 2 3 Overall 21P30 Tasks Additional Skill Identifier Tasks Power Line Distribution Tasks Overall 21P40 Tasks kh OND Figure 2 3 Subject Area Codes 2 3 Critical Tasks List See Table 2 1 for critical tasks for this STP Table 2 1 MOS 21P2 Critical Tasks Task Number Training Sust Sust Location Tng Tng SL Freq Skill Level 2 Subject Area 1 Overall 21P20 Tasks 052 244 2101
467. tated in the applicable manufacturer s literature 12 Removed rigging equipment 13 Connected the distribution equipment electrically according to the applicable manufacturer s literature 14 Verified the correct phase sequence 3 276 STP 5 21P2 SM TG 31 March 2009 MOS Skill Level Tasks Performance Measures GO NO GO 15 Positioned or sagged conductors to the appropriate clearance according to the applicable manufacturer s literature 16 Removed personal protective grounds 17 Closed out lockout and tagout procedures by removing locking and tagging devices 18 Performed a functions check on the electrical distribution system 19 Ensured that the items listed in the conditions were properly cleaned and stored Evaluation Guidance Score the Soldier GO if all measures are passed P Score the Soldier NO GO if any measure is failed F If the Soldier fails any measure show him how to do it correctly References Required Related LCH EM 385 1 1 ER 385 1 31 FM 3 34 480 FM 5 125 FM 5 412 FM 5 424 NESC NETA TM 5 682 TM 5 684 TM 5 686 TM 5 811 1 TM 5 811 3 31 March 2009 STP 5 21P2 SM TG 3 277 Chapter 3 Secure Conductor to Insulator De energized 052 204 1123 Conditions As a power line distribution specialist in a tactical or nontactical environment when a conductor needs to be secured to an insulator after the l
468. tated in the electrical construction prints Ensured that the items listed in the conditions were properly cleaned and stored Evaluation Guidance Score the Soldier GO if all measures are passed P Score the Soldier NO GO if any measure is failed F If the Soldier fails any measure show him how to do it correctly 31 March 2009 STP 5 21P2 SM TG 3 317 Chapter 3 References Required DA FORM 2702 LCH 3 318 Related AR 385 10 EM 385 1 1 ER 385 1 31 FM 3 34 480 TM 5 682 TM 5 684 TM 5 811 1 TM 5 811 3 STP 5 21P2 SM TG 31 March 2009 MOS Skill Level Tasks Subject Area 6 S3 and E5 Combined Tasks Service a Potential Transformer 052 264 2106 Conditions As a power station electrician in a tactical or nontactical environment during maintenance you are given a general mechanic s tool box a digital low resistance ohmmeter a megohmmeter a transformer turn to turn ratio tester grounding equipment applicable safety standing operating procedures wiring diagrams maintenance logbooks and the manufacturer s literature with schematics DANGER 1 THIS TASK SHOULD ONLY BE PERFORMED BY QUALIFIED PERSONNEL WHO ARE KNOWLEDGEABLE IN THE INSTALLATION AND MAINTENANCE OF TRANSFORMERS AND POWER EQUIPMENT AND THEIR ASSOCIATED HAZARDS FAILURE TO COMPLY MAY CAUSE PERMANENT INJURY OR DEATH 2 DO NOT TOUCH EXPOSED ELECTRICAL CONNECTIONS WHEN THE POWER SOURCE IS CONNECTED TO THE TRANSFORMER FAILURE TO COMPLY MAY CAU
469. tem d Check the engine electrical components parts 5 Check the fuel system a Ensure that there is fuel in the system b Ensure that the fuel system is on c Check the fuel for contamination d Check fuel filters for restrictions e Check the fuel pump for proper operation f Check the fuel system for the presence of air g Check the injector flow 6 Check the governor for proper operation 31 March 2009 STP 5 21P2 SM TG 3 61 Chapter 3 Performance Steps 7 8 9 10 11 Check air filters for restrictions Check the engine electrical components parts a Check the system for proper direct current DC voltage control b Check relays for proper operation c Check speed sensors Test the engine to ensure that the suspected fault is the cause of the malfunction Repair the fault if possible Ensure that the items listed in the conditions are properly cleaned and stored Record actions taken on DA Form 2404 or DA Form 5988 E and the maintenance logbook 12 Evaluation Preparation Setup Provide the Soldier with the items listed in the conditions Give the Soldier a safety briefing before starting the test and ensure that safety precautions are followed Prepare the testing area and equipment in advance to ensure that task standards can be met Brief Soldier Direct the Soldier to troubleshoot an engine failure to accelerate and or maintain a rated speed Performance Measures 1 2 o ON O
470. testing equipment for serviceability 4 Perform lockout and tagout procedures 5 Identify fault locations by checking the equipment fault indicator panel or the engine cooling system for obvious malfunctions NOTE The following substeps are a guideline and are not all inclusive Check for the most obvious and easily corrected problems first a Check for a hot engine NOTE This may be due to broken fan belts plugged radiator core or air passages or a defective thermostat or temperature switch b Check for low water pressure NOTE This may be due to coolant loss pump inlet cavitation a plugged oil cooler or clogged piping to the pump inlet 6 Conduct further testing to identify specific defective components if necessary 7 Record actions taken on DA Form 2404 or DA Form 5988 E and maintenance logbooks 8 Ensure that the items listed in the conditions are properly cleaned and stored Evaluation Preparation Setup Provide the Soldier with the items listed in the conditions Give the Soldier a safety briefing before starting the test and ensure that safety precautions are followed Prepare the testing area and equipment in advance to ensure that task standards can be met Brief Soldier Direct the Soldier to troubleshoot a diesel engine cooling system Performance Measures GO NO GO 1 Reviewed TMs manufacturer s literature or industry standards maintenance logbooks and historical data pertaining to the equipment
471. the ends of the conductors conjoined squarely 31 March 2009 STP 5 21P2 SM TG 3 5 Chapter 3 Performance Measures 5 6 9 10 11 12 13 14 15 16 17 18 Removed the jacket using the distance indicated in the splice kit instructions Removed the metallic shield of the cable from the edge of the jacket using the distance indicated in the splice kit instructions Removed the high voltage insulation layer using the distance indicated in the splice kit instructions Removed the semiconductor from the edge of the metallic shield using the distance indicated in the splice kit instructions Applied the connector using the correct compression tool Cleaned surfaces with an approved solvent to remove carbon dust or residue Replaced the high voltage layer according to the manufacturer s literature Applied a semiconductive layer from the edge of the shielding tape to the edge of the opposing shield according to the manufacturer s literature Recreated a shield layer across the splice connector according to the manufacturer s literature Attached a ground to a shield according to the manufacturer s literature Left the ground long enough to reach the grounding point Applied an outer jacket to the cable according to the manufacturer s literature to prevent moisture from entering the cable Tested the splice to ensure that it met the rating of the cable Closed out lockout and tagout procedures
472. the extent of the equipment damage Performed expedient repairs Recorded actions taken on DA Form 2404 or DA Form 5988 E and maintenance logbooks Notified the change of command of destruction procedures if required Prepared equipment for destruction if required according to the BDAR manual Closed out lockout and tagout procedures by removing locking and tagging devices Performed a functions check on the repaired equipment Ensured that the items listed in the conditions were properly cleaned and stored Evaluation Guidance Score the Soldier GO if all measures are passed P Score the Soldier NO GO if any measure is failed F If the Soldier fails any measure show him how to do it correctly References Required Related DA FORM 2404 5180 02 502 9507 DA FORM 5988 E EM 385 1 1 FM 3 34 480 FM 4 30 31 TM 5 811 1 UGLYS 3 94 STP 5 21P2 SM TG 31 March 2009 MOS Skill Level Tasks Subject Area 2 E5 Instrument Maintenance Power Station Tasks Produce an Electronic Circuit 052 207 2100 Conditions As a power station instrument technician in a tactical or nontactical environment you are given safety standing operating procedures SOPs an empty circuit board the required electronic components a soldering iron a solder and rosin flux a multimeter an oscilloscope with manual an electronic tool kit TM 5 704 electrical schematics and the applicable manufacturer s literature with schematics DANG
473. the items listed in the conditions are properly cleaned and stored 13 Ensure that deficiencies and troubleshooting procedures are recorded in the maintenance logbook 3 52 STP 5 21P2 SM TG 31 March 2009 MOS Skill Level Tasks Evaluation Preparation Setup Provide the Soldier with the items listed in the conditions Give the Soldier a safety briefing before starting the test and ensure that safety precautions are followed Prepare the testing area and equipment in advance to ensure that task standards can be met Brief Soldier Direct the Soldier to troubleshoot an AC control voltage circuit Performance Measures GO NO GO 1 Reviewed danger warning and caution notices 2 Reviewed the manufacturer s literature electrical construction prints and wiring diagrams 3 Reviewed the maintenance logbook and historical data pertaining to the equipment Isolated the system circuits that needed troubleshooting Performed lockout and tagout procedures Identified the symptoms of the problem Located the fault or problem Repaired or replaced defective components parts when possible Verified that the fault was corrected O OO OA N O ON A Closed out lockout and tagout procedures by removing locking and tagging devices 11 Performed a functions check on the AC control voltage circuit 12 Ensured that the items li
474. the proper inspection of the detector and for proper test performance 2 Different depths of the manhole should be tested The sampling tube should not come into 3 252 STP 5 21P2 SM TG 31 March 2009 MOS Skill Level Tasks Performance Steps contact with the ground or any other foreign object 3 While work is being performed in the manhole the air quality tester should constantly be in use to monitor gases 6 Test atmospheric conditions using the air quality tester a Test for combustible gases b Test for toxic gases c Test for oxygen deficiency 7 Pump out water 8 Ventilate the manhole a Use the forced air method b Use the natural method c Use the sail method 9 Install the extraction system for confined space entry and rescue 10 Suit the entrant with the safety harness and attach it to the extraction system for confined space entry and rescue 11 Assist the entrant into the manhole Evaluation Preparation Setup Provide the Soldier with the items listed in the conditions Give the Soldier a safety briefing before starting the test and ensure that safety precautions are followed Prepare the testing area and equipment in advance to ensure that task standards can be met Brief Soldier Direct the Soldier to prepare a manhole for safe entry Performance Measures GO NO GO 1 Ensured that tools and equipment were in proper working condition Conducted a safety briefing Set
475. the total outlet load using the watts per square foot method according to FM 5 424 This includes lighting and general purpose receptacles 1 Use the outside building dimensions to determine the total area in square feet 2 Multiply the area by the standard watts per square foot requirement which is a constant based on the type of building See FM 5 424 EXAMPLE When a store is 200 feet by 200 feet the total outlet load is calculated as follows FORMULA 200 feet x 200 feet 40 000 square feet 40 000 square feet x 3 120 kilowatts 8 Use 5 amperes for each heavy duty outlet or mogul sized lamp holder to calculate the load 9 Determine the load of major appliances and loads over 5 amperes each a Use the data plate wattage when available b Use the average wattage consumption data in FM 5 424 when the data plates are unavailable c Use the load conversion table in FM 5 424 when only partial data is available 10 Determine the motor loads a Locate the motor data plate to determine the rated voltage the full load amperes FLA the locked rotor amperes LRA and the rated horsepower b Determine the FLA when not given by referencing FM 5 424 c Use the motor code letter to determine the LRA and the corresponding LRA values to each motor code by referencing the NEC Handbook NOTE You must calculate in the extra wattage needed for starting electric motors Depending on the type of motor it may require from three to ten times
476. tics for proper circuit identification 2 Check for back fed circuits 3 Check for the proper use of safe clearance procedures Tag the timing relay with the appropriate calibration sticker to include the name and testing date Reinstall the timing relay Close out lockout and tagout procedures by removing locking and tagging devices Energize the circuit and check for proper timing relay operation Keep a record of results and actions taken Ensure that the items listed in the conditions are properly cleaned and stored Evaluation Preparation Setup Provide the Soldier with the items listed in the conditions Give the Soldier a safety briefing before starting the test and ensure that safety precautions are followed Prepare the testing area and equipment in advance to ensure that task standards can be met Brief Soldier Direct the Soldier to service a timing relay Performance Measures GO NO GO 1 Reviewed danger warning and caution notices before proceeding Reviewed the manufacturer s literature with schematics and wiring diagrams Reviewed maintenance logbooks and historical data pertaining to the equipment 2 3 4 5 Identified which circuit needed to be tested using schematics Performed lockout and tagout procedures 31 March 2009 STP 5 21P2 SM TG 3 101 Chapter 3 Performance Measures 6 7 8 9 10 11 12 13 14 15 16 17 18
477. tions Give the Soldier a safety briefing before starting the test and ensure that safety precautions are followed Prepare the testing area and equipment in advance to ensure that task standards can be met Brief Soldier Direct the Soldier to service a low voltage circuit breaker Performance Measures GO NO GO 1 2 Reviewed danger warning and caution notices Reviewed the manufacturer s literature electrical construction prints and wiring diagrams Performed lockout and tagout procedures Inspected the circuit breaker to ensure that the mechanical functions operated smoothly and that there was no physical damage Performed resistance measurements through the bolted connections using a low 3 196 STP 5 21P2 SM TG 31 March 2009 MOS Skill Level Tasks Performance Measures GO NO GO resistance ohmmeter 6 Performed insulation resistance tests pole to pole pole to ground and across the open contacts of each phase 7 Performed an insulation resistance test on the control wiring 8 Performed longtime delay time current characteristic tests by passing 300 percent of the rated current through each pole separately unless series testing was required to defeat the ground fault functions Ensured that the circuit breaker trip times fell within the guidelines specified in the manufacturer s literature 9 Determined the short time pickup
478. to sergeant major SGM However the EPMS is useless if the Soldier does not understand and use it Part of the trainer s job is to ensure that the Soldier understands and uses the EPMS As an aid Figure 1 1 page 1 4 provides the trainer with a career management field CMF map for the Soldier Along with information contained in AR 614 200 the Soldier can use the CMF map to develop goals early in his career and plan accordingly 31 March 2009 STP 5 21P2 SM TG 1 3 Chapter 1 NCOES Civilian schools ME E ae i iy Other schools Encouraged assignments Key leadership assignments Years of service High school GED diploma Drill sergeant school Recruiting school Battle staff course 1SG course Retention recruiter Drill sergeant Instructor Operations intelligence sergeant Senior power plant operator Prime power supervisor CMF 21 staff assignments Technician Team Squad Platoon leader leader section SGT section leader Figure 1 1 CMF Map 1 10 Skill Progression Chart Similar or related education training and experience are grouped into CMFs The career progression path for MOS 21P CMF 21 prime power production specialist is shown in Table 1 1 Table 1 1 Career Progression Sequence for Prime Power Production Specialist CMF 21 CSM E8 and E9 Power Station Sergeant E7 Prime Power Supervisor E6 Senior Power Plant Operator E5 Power Plant Operator E1 through E4 NA STP 5 21P2 SM TG 31 March
479. to sources of electrical and mechanical energy hazards Identified other energy sources in the immediate area to determine possible exposure to stored or residual energy Ensured that potentially hazardous stored or residual energy was relieved discharged or otherwise rendered safe Established energy control methods to regulate other hazardous energy sources in the area Tested each phase conductor and circuit part using a voltage detector to verify that it was de energized Installed lockout devices on the energy isolating mechanisms and disconnectors so that they were maintained in an open or de energized position Attached Eng Form 1925 as a main hold card for the primary means of energy isolation Attached Eng Form 1925 as an auxiliary hold card for the secondary means of energy isolation Attached Eng Form 1925 as a tagout device for the energy isolating mechanisms and disconnectors that could not be physically locked Performed an inspection with personnel in the work area and the project supervisor Tested each phase conductor or circuit part with an adequately rated voltage detector to verify that they were de energized Performed maintenance and service on the phase conductor or circuit part Requested permission from the project supervisor to close out lockout and tagout procedures Performed an inspection with the personnel performing the work and the project supervisor to ensure that all affected p
480. tor level troubleshooting Correct on the spot deficiencies o ON DODO A W N Report deficiencies to the plant supervisor 31 March 2009 STP 5 21P2 SM TG 3 37 Chapter 3 Evaluation Preparation Setup Provide the Soldier with the items listed in the conditions Give the Soldier a safety briefing before starting the test and ensure that safety precautions are followed Prepare the testing area and equipment in advance to ensure that task standards can be met Brief Soldier Direct the Soldier to perform PMCS on an MEP 012 or 208 generator Performance Measures GO NO GO 1 Reviewed danger warning and caution notices _ Performed before operation PMCS Performed preoperational checks and started the generator Performed during operation PMCS Performed after operation PMCS Recorded actions taken on DA Form 2404 or DA Form 5988 E Performed operator level troubleshooting Corrected on the spot deficiencies o ON DO a A OO DN Reported deficiencies to the plant supervisor Evaluation Guidance Score the Soldier GO if all measures are passed P Score the Soldier NO GO if any measure is failed F If the Soldier fails any measure show him how to do it correctly References Required Related DA FORM 2404 DA FORM 5988 E TM 9 6115 604 12 3 38 STP 5 21P2 SM TG 31 March 2009 MOS Skill Level Tasks Read an Electrical One Line
481. ts pole to pole pole to ground and across open poles and ensure that insulation resistance test values at 1 minute are no less than 1 000 megohms at a direct current DC test voltage of 2 500 volts unless otherwise specified in the manufacturer s literature Perform an insulation resistance test on the control wiring according to the manufacturer s literature Perf lat t test on th trol ding to th facturer s literat ensure that the control wiring insulation resistance is a minimum of 2 megohms and for units with solid state components parts follow the manufacturer s recommendations Perform tests with the circuit breaker in the TEST position and ensure that trip and close operations for the circuit breaker work properly a Trip and close the circuit breaker with the control switch b Trip the breaker by operating each protective relay c Verify that the trip free and antipump functions work properly Perform a power factor and dissipation factor test on the breaker compare the results of the power factor and dissipation factor test to the manufacturer s specifications and if the manufacturer s specifications are not available compare the test results to similar circuit breakers Perform an overpotential test according to the manufacturer s literature and ensure that the insulation withstands the applied overpotential test voltage Keep a record of the test results Close out logout and tagout procedures by removing locking an
482. ture Record the inspection and test results Repair or replace equipment based on the inspection and test results Remove personal protective grounds Close out lockout and tagout procedures by removing locking and tagging devices Perform a functions check on the electrical distribution system 15 Ensure that the items listed in the conditions are properly cleaned and stored Evaluation Preparation Setup Provide the Soldier with the items listed in the conditions Give the Soldier a safety briefing before starting the test and ensure that safety precautions are followed Prepare the testing area and equipment in advance to ensure that task standards can be met Brief Soldier Direct the Soldier to perform maintenance on electrical distribution equipment Performance Measures GO NO GO 1 2 o ON DOD a FF Q Reviewed danger warning and caution notices before proceeding Reviewed the manufacturer s literature electrical construction prints and wiring diagrams Ensured that PPE was correctly tested and fully mission capable Inspected tools and testing equipment for serviceability Performed lockout and tagout procedures Ascended the pole to the required height if necessary Tested the phases to ensure that there was no voltage present Installed personal protective grounds Performed maintenance on electrical distributi
483. tylene equipment a Inspect the welding equipment to ensure that there are no obvious deficiencies b Ensure that tanks are secured by a retaining chain c Verify that nonreturn valves are installed NOTE Nonreturn valves must be installed at the torch handle and hoses connection Optional nonreturn valves may be connected on the hoses and regulator connections d Back out both oxygen and acetylene pressure setscrews counterclockwise until no resistance is felt DANGER FAILURE TO BACK OUT THE OXYGEN AND ACETYLENE PRESSURE SETSCREWS MAY CAUSE THE ACETYLENE TO BE PRESSURIZED BEYOND ITS STABILITY POINT OF 15 POUNDS PER SQUARE INCH AND DETONATE UPON OPENING THE TANK MAIN SUPPLY VALVES FAILURE TO COMPLY MAY CAUSE PERMANENT INJURY OR DEATH e Determine the cutting tip size as needed for the brand of cutting torch being used and based on the thickness of the steel being cut and determine the required cutting pressures for acetylene and oxygen WARNING AN ACETYLENE REGULATOR IS DEFECTIVE IF IT SHOWS SIGNS OF CREEPING OR A STEADY RISE IN PRESSURE ON THE PRESSURE GAUGE A SINGLE MOMENTARY RISE IN PRESSURE UP TO 1 POUND PER SQUARE INCH IS ACCEPTABLE WHEN SHUTTING THE FLOW OF THE GAS AT THE TORCH A CREEPING ACETYLENE GAUGE WILL ALLOW THE ACETYLENE PRESSURE TO RISE TO A LEVEL THAT WILL CAUSE SPONTANEOUS DETONATION OF THE ACETYLENE IN THE HOSE AND REGULATOR FAILURE TO COMPLY MAY RESULT IN IMMEDIATE PERSONAL INJURY AND EQUIPMENT DAMAGE 3 Prepa
484. uctors were placed on conductor support devices in the proper sequence 12 Ensured that the underground cable was installed according to electrical construction prints 13 Ensured that the items listed in the conditions were properly cleaned and stored Evaluation Guidance Score the Soldier GO if all measures are passed P Score the Soldier NO GO if any measure is failed F If the Soldier fails any measure show him how to do it correctly References Required Related DA FORM 2702 AR 385 10 LCH EM 385 1 1 ER 385 1 31 FM 3 34 480 TM 5 682 TM 5 684 TM 5 811 1 3 312 STP 5 21P2 SM TG 31 March 2009 MOS Skill Level Tasks References Required Related TM 5 811 3 31 March 2009 STP 5 21P2 SM TG 3 313 Chapter 3 Supervise the Loading and Unloading of Utility Poles 052 204 2219 Conditions As a power line distribution supervisor in a tactical or nontactical environment when utility poles need to be loaded and unloaded you are given a line truck with auxiliary equipment a pole trailer a cant hook lifting tongs chains hoists cable slings wheel chocks ground guides safety standing operating procedures SOPs the applicable personal protective equipment PPE and DA Form 2702 Bill of Materials DANGER 1 NEVER LIFT OBJECTS WITHOUT A GROUND GUIDE TO ASSIST IN FINDING THE LOCATION OF THE ITEMS BEING LIFTED AND ANOTHER INDIVIDUAL TO HELP ENSURE THAT THE OBJECT DOES NOT BEGIN TO SWAY OU
485. uel quality f Check for excessive fuel inlet restriction g Check the overspeed trip device h Check for open exhaust valves i Ensure that reset buttons have been reset j Check injector operation and timing k Check for incorrect power assembly components Check for starter malfunction 1 Check electrical connections 2 Test the solenoid 31 March 2009 STP 5 21P2 SM TG 3 159 Chapter 3 Performance Steps m Check electrical harnesses and connections for loose connections or cable corrosion 6 Perform corrections on site when possible 7 Record actions taken on DA Form 2404 or DA Form 5988 E and maintenance logbooks 8 Ensure that the items listed in the conditions are properly cleaned and stored Evaluation Preparation Setup Provide the Soldier with the items listed in the conditions Give the Soldier a safety briefing before starting the test and ensure that safety precautions are followed Prepare the testing area and equipment in advance to ensure that task standards can be met Brief Soldier Direct the Soldier to troubleshoot an engine failure to start Performance Measures GO NO GO 1 Reviewed maintenance logbooks manufacturer s literature and historical data pertaining to the equipment 2 Identified warning lights on the generator set through visual inspection 3 Connected the Caterpillar ET tool and hardware to the engine and ran a diagnostic test if the engine was eq
486. ufacturer s literature Determine the short time pickup and time delay of the circuit breaker by using the primary current injection test method and ensuring that the times fall within the guidelines specified in the manufacturer s literature Determine the ground fault pickup and time delay of the circuit breaker by using the primary current injection test method and ensuring that the times fall within the guidelines specified in the manufacturer s literature Test the instantaneous pickup using the primary current injection method Apply current using the run up or pulse method to ensure that the instantaneous trip times of the circuit breaker fall within the guidelines specified in the manufacturer s literature Ensure that the trip characteristics of the breakers fall within the manufacturer s published time current characteristic tolerance band including adjustment factors Verify the correct operation of the auxiliary features a Check the trip and pickup indicators b Check the zone interlocking c Check the electrical close d Check the trip operation e Check the trip free f Check the antipump function Close out lockout and tagout procedures by removing locking and tagging devices Reenergize the circuit Ensure that the circuits work as designed Ensure that the items listed in the conditions are properly cleaned and stored Evaluation Preparation Setup Provide the Soldier with the items listed in the condi
487. uipment in advance to ensure that task standards can be met Brief Soldier Direct the Soldier to service a piping system Performance Measures GO NO GO 1 Reviewed maintenance logbooks and historical data pertaining to the equipment to verify that the piping system needed to be serviced 2 Ensured that service tools and parts were on hand before servicing the system 3 Performed safety requirements before servicing or repairing the piping system 3 146 STP 5 21P2 SM TG 31 March 2009 MOS Skill Level Tasks Performance Measures 4 12 13 14 15 16 17 18 Inspected pump or compressor drive mechanisms for signs of loose mounting bolts deteriorated couplings loose fittings and leakage Inspected drive belts between the motor and pump or compressor for dry rotting cracking and glazing Inspected the motor and pump or compressor sheave alignment using a straightedge along the outside edge of the sheave to ensure that the motor and pump or compressor had not slipped out of alignment Inspected the belt tension by deflecting the belt one belt thickness for every 48 inches of unsupported length using your thumb to apply moderate pressure Replaced belt sets if necessary as a complete set Inspected compressor lubrication fluid levels 10 11 Observed several pumping mechanism cycles of operation Checked the piping system for leaks by pressurizing the s
488. uipped with an electronic troubleshooting system Checked the engine starter Determined what caused the malfunction Performed corrections on site when possible N O oO A Recorded actions taken on DA Form 2404 or DA Form 5988 E and maintenance logbooks 8 Ensured that the items listed in the conditions were properly cleaned and stored Evaluation Guidance Score the Soldier GO if all measures are passed P Score the Soldier NO GO if any measure is failed F If the Soldier fails any measure show him how to do it correctly References Required Related DA FORM 2404 EM 385 1 1 DA FORM 5988 E TM 9 6115 604 12 3 160 STP 5 21P2 SM TG 31 March 2009 MOS Skill Level Tasks Replace a Diesel Engine Piston Assembly 052 205 2119 Conditions As a power station mechanic in a tactical or nontactical situation when a diesel engine piston assembly has been identified for replacement you are given a lockout and tagout kit a general mechanic s tool box special tools the applicable manufacturer s literature maintenance logbooks and DA Form 2404 Equipment Inspection and Maintenance Worksheet or DA Form 5988 E Equipment Inspection Maintenance Worksheet DANGER 1 ENSURE THAT BATTERIES ARE DISCONNECTED BEFORE SERVICING APPLY SAFE CLEARANCE PROCEDURES TO THE ASSOCIATED CIRCUITS FAILURE TO COMPLY MAY CAUSE PERMANENT INJURY OR DEATH 2 THIS TASK SHOULD ONLY BE PERFORMED BY QUALI
489. uit connected to the voltage regulator by using schematics Performed lockout and tagout procedures Tested the circuit for voltage Removed the voltage regulator and tagged attached leads Inspected the voltage regulator for damage Tested the voltage regulator according to the manufacturer s literature and recorded the results Compared the results with the manufacturer s specifications and corrected them as necessary Tested the circuit for voltage Reinstalled the voltage regulator 31 March 2009 STP 5 21P2 SM TG 3 335 Chapter 3 Performance Measures GO NO GO 13 Closed out lockout and tagout procedures by removing locking and tagging devices 14 Performed a functions check on the voltage regulator 15 Kept a record of the test results and actions taken 16 Ensured that the items listed in the conditions were properly cleaned and stored Evaluation Guidance Score the Soldier GO if all measures are passed P Score the Soldier NO GO if any measure is failed F If the Soldier fails any measure show him how to do it correctly References Required Related TM 5 6115 593 12 TM 5 6115 593 34 3 336 STP 5 21P2 SM TG 31 March 2009 MOS Skill Level Tasks Service an Uninterruptible Power Supply UPS 052 264 2114 Conditions As a power station instrument technician or a power station electrician
490. ument technician or a power station electrician in a tactical or nontactical environment during maintenance you are given a lockout and tagout kit a multimeter a relay test set an electronic phase shifter EPS 1000 an electronic tool kit maintenance logbooks appropriate technical manuals and the manufacturer s literature with schematics DANGER 1 ENSURE THAT THE POWER TO THE VOLTAGE REGULATOR IS DISCONNECTED BEFORE SERVICING APPLY SAFE CLEARANCE PROCEDURES TO ASSOCIATED CIRCUITS FAILURE TO COMPLY MAY CAUSE PERMANENT INJURY OR DEATH 2 ENSURE THAT POTENTIAL TRANSFORMERS FEEDING THE VOLTAGE REGULATOR ARE DE ENERGIZED BEFORE SERVICING FAILURE TO COMPLY MAY CAUSE INJURY OR EQUIPMENT DAMAGE 3 REMOVE RINGS NECKLACES OTHER JEWELRY AND LOOSE CLOTHING FAILURE TO COMPLY MAY CAUSE PERMANENT INJURY OR DEATH NOTE KEEP THE WORK AREA NEAT AND ORGANIZED AND THE REGULATOR STABLE WHILE PERFORMING THIS TASK FAILURE TO COMPLY MAY LEAD TO UNRELIABLE TEST READINGS Standards Safely service a voltage regulator by testing and calibrating it according to the manufacturer s literature and record the results Reinstall or replace the regulator based on the test results Performance Steps NOTE The low voltage side of the potential transformer that supplies voltage to the regulator may be fuse protected To further isolate the circuit electrically and as an additional measure of safety this fuse may be removed Check the schematics for verif
491. up traffic control equipment Removed the manhole cover Tested the air quality tester for proper operation Tested atmospheric conditions using the air quality tester Pumped out water Ventilated the manhole Installed the extraction system for confined space entry and rescue O o N O o A W N Suited the entrant with the safety harness and attached it to the extraction system for confined space entry and rescue 11 Assisted the entrant into the manhole Evaluation Guidance Score the Soldier GO if all measures are passed P Score the Soldier NO GO if any measure is failed F If the Soldier fails any measure show him how to do it correctly 31 March 2009 STP 5 21P2 SM TG 3 253 Chapter 3 References Required Related AR 385 10 LCH TM 5 682 TM 5 684 TM 5 811 1 3 254 STP 5 21P2 SM TG 31 March 2009 MOS Skill Level Tasks Rescue an Injured Victim From a Utility Pole 052 204 1114 Conditions As a power line distribution specialist in a tactical or nontactical environment when an individual is responsive or unresponsive and unable to descend a pole on his own you are given a two way radio or telephone communication equipment personal climbing equipment 1 2 inch diameter rope rescue line that is twice the length of the height from the ground to the highest crossarm plus 10 feet a sharp skinning knife hot line tool
492. upervise the loading and unloading of utility poles Performance Measures GO NO GO 1 Reviewed danger warning and caution notices before proceeding 2 Ensured that PPE was correctly tested and fully mission capable 3 Completed DA Form 2702 for the tools and equipment necessary to perform the task 3 314 STP 5 21P2 SM TG 31 March 2009 MOS Skill Level Tasks Performance Measures 4 Inspected tools and rigging equipment for serviceability 5 Developed a plan for obtaining nonorganic tools and the equipment necessary to perform the mission 6 Issued a safety briefing that highlighted safety precautions and the concept of the operation 7 Assigned personnel positions and ensured that they understood their role in accomplishing the task 8 Ensured that equipment brakes were set and wheels were chocked 9 Ensured that utility poles were loaded and unloaded safely 10 Ensured that the items listed in the conditions were properly cleaned and stored Evaluation Guidance Score the Soldier GO if all measures are passed P Score the Soldier NO GO if any measure is failed F If the Soldier fails any measure show him how to do it correctly References Required Related DA FORM 2702 AR 385 10 EM 385 1 1 ER 385 1 31 FM 3 34 480 LCH TM 5 682 TM 5 684 TM 5 811 1 31 March 2009 STP 5 21P2 SM TG 3 315 Chapter 3 Supervise the Mechanical Erection of a Utility Pole 052 204 2220
493. ure is failed F If the Soldier fails any measure show him how to do it correctly References Required Related FM 55 509 1 INTRO CIRCUIT ANALYSIS TM 5 811 1 TM 5 811 3 31 March 2009 STP 5 21P2 SM TG 3 127 Chapter 3 Subject Area 3 S2 Mechanical Equipment Maintenance Power Station Tasks Troubleshoot a Diesel Engine for a Misfiring Cylinder 052 205 2032 Conditions As a power station mechanic in a tactical or nontactical environment when a diesel engine loses power you are given a general mechanic s tool box appropriate special tools maintenance logbooks and DA Form 2404 Equipment Inspection and Maintenance Worksheet or DA Form 5988 E Equipment Inspection Maintenance Worksheet DANGER REMOVE RINGS NECKLACES OTHER JEWELRY AND LOOSE CLOTHING FAILURE TO COMPLY MAY CAUSE PERMANENT INJURY OR DEATH CAUTION NOISE LEVELS IN EXCESS OF 85 DECIBELS EXIST WITHIN A 50 FOOT RADIUS OF OPERATING EQUIPMENT PERSONNEL MUST WEAR SINGLE HEARING PROTECTION WITHIN A 50 FOOT RADIUS FAILURE TO COMPLY MAY CAUSE PERSONAL INJURY Standards Troubleshoot a diesel engine for a misfiring cylinder by identifying which cylinder is misfiring Test the engine to verify what caused the malfunction annotate the problem in the maintenance logbook and annotate any uncorrectable malfunctions on DA Form 2404 or DA Form 5988 E Performance Steps 1 Review maintenance logbooks and historical data pertaining to the equipment 2 Identify the misfiring
494. urer s literature Apply an outer jacket to prevent moisture from entering the power cable as specified in the manufacturer s literature Test the splice to ensure that it meets the rating of the cable Close out lockout and tagout procedures by removing locking and tagging devices Evaluation Preparation Setup Provide the Soldier with the items listed in the conditions Give the Soldier a safety briefing before starting the test and ensure that safety precautions are followed Prepare the testing area and equipment in advance to ensure that task standards can be met Brief Soldier Direct the Soldier to terminate a medium voltage power cable Performance Measures GO NO GO 1 2 3 4 Performed lockout and tagout procedures Inspected the termination kit Prepared the cable and termination as specified in the manufacturer s literature Removed the jacket using the distance indicated in the manufacturer s literature and ensured that the length required for the lug was added to the measure back distance Removed the shield using the distance indicated in the manufacturer s literature Removed the semiconductor using the distance indicated in the manufacturer s literature Removed the high voltage insulation layer using the distance indicated in the manufacturer s literature Installed the termination lug using the correct compression tool
495. usted the frequency adjustment rheostat for a frequency meter reading of 50 or 60 hertz as applicable Placed the GEN BUS voltmeter switch in the GEN 3 1 position Adjusted the voltage adjustment rheostat for an AC KVA reading of 4 16 for a 60 hertz operation or 3 8 KVA for a 50 hertz operation Verified that the AC KVA reading was the same at all three GEN BUS settings Placed the breaker control switch in the CLOSE position and ensured that the indicator light was illuminated 3 28 STP 5 21P2 SM TG 31 March 2009 MOS Skill Level Tasks Performance Measures GO NO GO 15 Monitored the engine and generator indicators to ensure that the operation continued through the various load changes 16 Performed during operation PMCS 17 Conducted unit shutdown operations 18 Performed after operation PMCS Evaluation Guidance Score the Soldier GO if all measures are passed P Score the Soldier NO GO if any measure is failed F If the Soldier fails any measure show him how to do it correctly References Required Related TM 9 6115 604 12 31 March 2009 STP 5 21P2 SM TG 3 29 Chapter 3 Operate a Mobile Electric Power MEP 029 Generator 052 244 2116 Conditions As a power plant operator in a tactical or nontactical environment after an MEP 029 generator has been fully installed and is operational you are given TM 5 6115 593 12 and personal protective equipment for a routine star
496. ut device signs the lockout tag with the 1 Printed name of the installer 2 Date 3 Time 4 Clearance number b Ensure that the auxiliary hold card number matches the numbered location of the main hold cards 14 Attach Eng Form 1925 as a tagout device for the energy isolating mechanisms and disconnectors that cannot be physically locked a Ensure that the person installing the lockout device signs the lockout tag with the 1 Printed name of the installer 2 Date 3 Time 4 Clearance number b Ensure that the lockout tag is placed directly over the operating controls of the energy isolating mechanisms and disconnectors NOTE The lockout tag should contain a brief statement that prohibits the unauthorized operation of energy isolating devices and disconnectors and removal of the tag It should warn against the hazards of the system being energized and include a legend that contains wording such as Do Not Start Do Not Energize Do Not Open Do Not Close and Do Not Operate 15 Perform an inspection with personnel in the work area and the project supervisor a Verify that the system has been successfully isolated and de energized b Accomplish the inspection before working on the systems that have been locked out or tagged out 3 20 STP 5 21P2 SM TG 31 March 2009 MOS Skill Level Tasks Performance Steps DANGER VERIFICATION OF ISOLATION AND SYSTEM DE ENERGIZING MUST BE ACCOMPLISHED BY ATTEMPTING TO OP
497. ution when removing the relay from the circuit Do not trip the circuit off line DA0CT M 3 108 STP 5 21P2 SM TG 31 March 2009 MOS Skill Level Tasks Performance Steps 6 Remove the relay from service a Remove GE type relays by removing the connection block smoothly b Remove Westinghouse type relays by first releasing the red lever to disarm the trip circuit and then releasing the black levers 7 Inspect the relay for damage a Inspect for signs of overheating b Inspect for loose connections c Inspect for debris d Inspect the disk travel for smooth operation 8 Clean the relay with a soft brush or noncompressed air a Clean relay contacts with a burnishing tool b Clean the magnet with a magnet cleaning tool CAUTION WHILE CLEANING THE RELAY DO NOT USE SOLVENTS OR ABRASIVE MATERIAL AND AVOID TOUCHING THE INDUCTION DISK WITH YOUR FINGERS FAILURE TO COMPLY MAY REDUCE THE LIFE OF THE RELAY 9 Set up the relay test set according to the instruction manual NOTE To ensure accurate relay testing place the device being tested on a level surface 10 Perform an insulation resistance test on the relay testing from the output connection to the relay case ground by using the insulation resistance output on the relay test set 11 Perform a zero check on the time dial ensuring that relay contacts only make contact when the time dial reads zero and make necessary adjustments if this does not occur 12 Perform a
498. valuation Guidance Score the Soldier GO if all measures are passed P Score the Soldier NO GO if any measure is failed F If the Soldier fails any measure show him how to do it correctly References Required Related EM 385 1 1 FM 5 125 LCH TM 5 684 TM 5 811 1 3 284 STP 5 21P2 SM TG 31 March 2009 MOS Skill Level Tasks Perform Groundman Duties 052 204 1127 Conditions As a power line distribution specialist in a tactical or nontactical environment when a lineman needs assistance from a groundman you are given applicable climbing and rigging equipment the required hand tools and the applicable personal protective equipment PPE DANGER A GROUNDMAN MUST ALWAYS BE PREPARED TO RESCUE A VICTIM FROM A UTILITY POLE AND ADMINISTER FIRST AID TIME IS EXTREMELY CRITICAL THE TIME IT TAKES TO RESCUE AN INJURED VICTIM AND THE EXTENT OF HIS INJURIES COULD BE THE DIFFERENCE BETWEEN PERMANENT DISABILITIES OR VICTIM DEATH FAILURE TO COMPLY MAY CAUSE PERMANENT INJURY OR DEATH WARNING WHEN POSSIBLE INDIVIDUALS NOT ASCENDING THE POLE MUST MAINTAIN A 10 FOOT RADIUS FROM THE POLE BASE TO ENSURE THAT THEY ARE NOT STRUCK BY DROPPED OBJECTS FAILURE TO COMPLY MAY CAUSE IMMEDIATE PERSONAL INJURY Standards Perform groundman duties by ensuring that safety precautions are followed supporting the lineman and raising or lowering the equipment and tools as directed by the lineman who is performing tasks on the utility pole Performance Steps
499. vent c Remove sharp edges d Place two crimps on the connector and ensure an offset between each crimp that is approximately 90 NOTE Steps 10 through 12 are used for splicing overhead medium voltage cable only 10 Ensure that overhead conductors are resagged 11 Splice overhead medium voltage cables a Use the automatic sleeve splice 1 Rig as necessary 2 Trim to the desired length 3 Clean and insert conductors into the sleeve ends b Use the compression sleeve splice 1 Rig as necessary 2 Trim to the desired length 3 Clean and insert conductors into the sleeve ends 4 Crimp the sleeve using a compression tool c Use the western union splice 1 Rig as necessary 2 Trim to the desired length 3 Clean and wrap the conductors 12 Clean surfaces with an approved solvent to remove carbon dust and residue NOTE Steps 13 through 16 are used for splicing underground medium voltage cable only 13 Replace the high voltage insulation layer according to the manufacturer s literature 14 Apply a semiconductive layer from the edge of the shielding tape to the edge of the opposing shield according to the manufacturer s literature 15 Recreate a shield layer across the splice connector according to the manufacturer s literature 16 Attach a ground to the shield according to the manufacturer s literature and leave the ground long enough to reach the grounding point NOTE Steps 17 through 19 are used f
500. vice a Signal Transmission Circuit 052 207 2116 Conditions As a power station instrument technician in a tactical or nontactical environment when an unshielded twisted pair UTP communication cable is in need of repair or replacement you are given a UTP cable reel at least Category 5 quality RJ 45 connectors a modular plug crimp tool an electronic tool kit wiring diagrams and the applicable manufacturer s literature with schematics Standards Service a signal transmission circuit by repairing or replacing a damaged connector based on cable inspection Performance Steps 1 Review danger warning and caution notices before proceeding 2 Review the manufacturer s literature with schematics and wiring diagrams 3 Inspect the cable for serviceability a Examine the RJ 45 connectors for proper crimps and solid connections b Perform a visual inspection of the entire length of the cable c Replace the cable if it is damaged anywhere other than the ends near the connectors d Test each conductor for continuity e Test each conductor for isolation from other conductors 4 Repair the cable as needed a Determine if the cable is a crossover cable or a straight through cable NOTE Straight through cables have identical ends End A Crossover cables have one end that is identical to a straight through cable End A and the other end has the green and orange pairs switched End B When other colors are present or in a different order
501. vide the Soldier with the items listed in the conditions Give the Soldier a safety briefing before starting the test and ensure that safety precautions are followed Prepare the testing area and equipment in advance to ensure that task standards can be met Brief Soldier Direct the Soldier to service a hydraulic system Performance Measures 1 Reviewed maintenance logbooks and historical data pertaining to the equipment to verify that the hydraulic system needed to be serviced Ensured that service items were on hand before servicing the system Performed safety requirements before servicing the system Removed unit side panels ao A O N Inspected the hydraulic system by tracing the entire system and checking for leaks loose connections hoses rubbing against each other and dry rotted hoses 31 March 2009 STP 5 21P2 SM TG 3 165 Chapter 3 Performance Measures GO NO GO 6 Serviced filters when the unit reached the required hours of service 7 Reinstalled panels 8 Performed a functions check on the hydraulic system 9 Ensured that lockout and tagout procedures were closed out by removing locking and tagging devices 10 Recorded actions taken on DA Form 2404 or DA Form 5988 E and maintenance logbooks 11 Ensured that the items listed in the conditions were properly cleaned and stored Evaluation Guidance Score the Soldier GO if all measu
502. vironmental conditions Determined the status of the insulation by interpreting the test Reconnected and torqued the cables if necessary Uninstalled the safety grounds Removed the safety clearance Closed out lockout and tagout procedures by removing locking and tagging 3 228 STP 5 21P2 SM TG 31 March 2009 MOS Skill Level Tasks Performance Measures GO NO GO devices 18 Ensured that the items listed in the conditions were properly cleaned and stored Evaluation Guidance Score the Soldier GO if all measures are passed P Score the Soldier NO GO if any measure is failed F If the Soldier fails any measure show him how to do it correctly References Required Related IEEE RED BOOK NETA TM 5 684 31 March 2009 STP 5 21P2 SM TG 3 229 Chapter 3 Service an Air Magnetic Circuit Breaker 052 206 2124 Conditions As a power station electrician in a tactical or nontactical environment during maintenance you are given safety standing operating procedures a general mechanic s tool box a digital low resistance ohmmeter a megohmmeter a high potential test set a power factor test set wiring diagrams maintenance logbooks grounding equipment and the applicable manufacturer s literature with schematics DANGER 1 THIS TASK SHOULD ONLY BE PERFORMED BY QUALIFIED PERSONNEL WHO ARE KNOWLEDGEABLE IN THE INSTALLATION AND MAINTENANCE OF CIRCUIT BREAKERS AND POWER EQUIPMENT AND THEIR ASSOCIATED HAZARD
503. w the type of engine and the serial number NOTE If there is an active diagnostic code refer to Caterpillar part RENR2227 02 Troubleshooting 3406E and 3456 Generator Set Engines for further instructions 4 Interpret the code and correct deficiencies where possible 5 Record actions taken on DA Form 2404 or DA Form 5988 E and maintenance logbooks 6 Disconnect and properly store the Caterpillar ET tool and associated cables as specified in the manufacturer s literature 7 Ensure that the items listed in the conditions are properly cleaned and stored Evaluation Preparation Setup Provide the Soldier with the items listed in the conditions Give the Soldier a safety briefing before starting the test and ensure that safety precautions are followed Prepare the testing area and equipment in advance to ensure that task standards can be met Brief Soldier Direct the Soldier to operate a Caterpillar ET tool Performance Measures GO NO GO 1 Inventoried Caterpillar ET tool parts 2 Connected the Caterpillar ET tool and the Caterpillar communication adaptor to the engine 3 Turned the operator s remote terminal to the ON position 4 Interpreted the code and corrected deficiencies where possible 5 Recorded actions taken on DA Form 2404 or DA Form 5988 E and maintenance logbooks 6 Disconnected and properly stored the Caterpillar ET tool and associated cables as specified
504. wer line distribution supervisor in a tactical or nontactical environment when live line distribution equipment needs to be tested you are given a one line diagram the applicable climbing and rigging equipment hot line tools a voltage detector a clamp on amp meter safety standing operating procedures SOPs the applicable manufacturer s literature the Lineman s and Cableman s Handbook LCH applicable personal protective equipment PPE insulating protective equipment electrical construction prints wiring diagrams and DA Form 2702 Bill of Materials DANGER 1 THIS TASK SHOULD ONLY BE PERFORMED BY QUALIFIED PERSONNEL KNOWLEDGEABLE IN THE INSTALLATION OPERATION AND MAINTENANCE OF MEDIUM VOLTAGE ELECTRICAL POWER GENERATION EQUIPMENT AND THE ASSOCIATED HAZARDS FAILURE TO COMPLY MAY CAUSE PERMANENT INJURY OR DEATH 2 A VOLTAGE DETECTOR SHOULD BE USED TO ENSURE THAT THE CABLES ARE NOT ENERGIZED MATERIAL SUCH AS A LEAD SHEATH THAT ACTS AS A SHIELD MUST NOT BE BETWEEN THE TESTER AND THE CONDUCTORS OF THE CIRCUIT BEING TESTED FAILURE TO TEST THE CABLES MAY CAUSE PERMANENT INJURY OR DEATH Standards Perform live line testing to determine whether the line is energized Performance Steps 1 Review danger warning and caution notices before proceeding 2 Review the manufacturer s literature electrical construction prints and wiring diagrams 3 Ensure that PPE hot line equipment and test equipment is correctly tested and full
505. winch line e Return the boom to its original state 4 Operate the digger or auger on a line truck while paying close attention to the hand and arm signals of the ground guide WARNING THE FOLLOWING PROCEDURES SHOULD BE FOLLOWED AS CLOSELY AS POSSIBLE FAILURE TO COMPLY MAY CAUSE IMMEDIATE PERSONAL INJURY OR EQUIPMENT DAMAGE a Raise the boom 45 above the horizontal position b Rotate the boom 90 to the side of the truck c Verify that the second stage of the boom is fully retracted d Place the two speed digger button in the LOW SPEED position e Move the digger control slightly toward the DIG position and as it rises hold the auger release switch in the RELEASE position f Move the digger control toward the clean position to slowly lower the auger g Move the auger to the desired location and dig a hole to a depth of 8 feet h Return the auger and boom to their cradles 5 Operate the auxiliary line truck equipment a Operate the capstan b Operate the take up reel c Operate the hydraulic tools 6 Secure the line truck with the auxiliary equipment a Secure the loose gear b Raise and store the outriggers c Secure the boom d Turn the truck and machine switch to the TRUCK position e Disengage the power take off f Release the emergency brake before moving the truck Evaluation Preparation Setup Provide the Soldier with the items listed in the conditions Give the Soldier a safety briefing before
506. xyacetylene welding set with hoses acetylene and oxygen cylinders regulators with pressure gauges an oxyacetylene cutting torch an applicable cutting tip sized to the metal being cut a soapstone marker pencil a spark igniter a welder s wrench Shade 5 lens welding goggles work gloves safety glasses a fire extinguisher manufacturers literature and an item to be cut DANGER 1 EXTREME CAUTION SHOULD BE EXERCISED WHEN USING ANY TYPE OF CUTTING EQUIPMENT INJURY CAN RESULT FROM FIRE EXPLOSION OR HARMFUL AGENTS GENERATED BY THE CUTTING PROCESS FAILURE TO COMPLY MAY CAUSE PERMANENT INJURY OR DEATH 2 REMOVE FLAMMABLE MATERIALS SUCH AS BUTANE CIGARETTE LIGHTERS FROM THE CUTTING AREA AND THE WELDER S POCKETS FAILURE TO COMPLY MAY CAUSE PERMANENT INJURY OR DEATH 3 ENSURE THAT THE ACETYLENE OPERATING PRESSURE NEVER EXCEEDS 7 POUNDS PER SQUARE INCH ACETYLENE IS A POTENTIALLY UNSTABLE GAS AT ELEVATED PRESSURES ACETYLENE ABOVE 15 POUNDS PER SQUARE INCH CAN CHEMICALLY BREAK DOWN AND EXPLODE IF SUBJECTED TO HEAT OR SHOCK ACETYLENE ABOVE 29 4 POUNDS PER SQUARE INCH WILL SPONTANEOUSLY COMBUST WITHOUT OUTSIDE FORCE FAILURE TO COMPLY MAY CAUSE PERMANENT INJURY OR DEATH 4 ENSURE THAT THERE ARE NO FAULTY REGULATORS FAULTY REGULATORS MAY ALLOW ACETYLENE TO BE PRESSURIZED ABOVE ITS UNSTABLE POINT AND DETONATE FAILURE TO COMPLY MAY CAUSE PERMANENT INJURY OR DEATH 5 ENSURE THAT CUTTING OCCURS IN AN ADEQUATELY VENTILATED AREA FAILURE T
507. y Engineer School ATTN ATSE DT Individual Training Division 320 MANSCEN Loop Fort Leonard Wood MO 65473 8929 Comments should be keyed to a specific page paragraph and line of text in which the change is recommended Provide reasons for each comment to ensure understanding and complete evaluation Unless this publication states otherwise masculine nouns and pronouns do not refer exclusively to men 31 March 2009 STP 5 21P2 SM TG v This page is intentionally left blank Chapter 1 Introduction 1 1 General This manual identifies the individual MOS training requirements for Soldiers It is designed to be used by commanders trainers and Soldiers to plan conduct and evaluate individual training in units This manual is the primary reference for supporting self development evaluating MOS proficiency and training Soldiers Commanders employ the following two primary methods to evaluate Soldier proficiency Commander s evaluation Commander s evaluations are local tests or assessments of Soldier performance of MOS specific and common tasks critical to the unit mission They may be conducted year round Common task test CTT CTTs are hands on tests used to evaluate proficiency on common tasks Alternate written tests are provided if equipment is not available for hands on testing 1 2 Integration of Individual and Collective Tasks This manual should be used with STP 21 1 SMCT STP 21 24 SMCT Field Manual FM 7 0 FM
508. y checks on the generator set and keep a record of the results on an hourly log sheet Performance Steps NOTES 1 Generator readings are taken hourly to assess the operational condition of the generator and identify degradation trends before a fault occurs 31 March 2009 STP 5 21P2 SM TG 3 1 Chapter 3 Performance Steps 2 Hourly checks applicable to specific equipment should be completed according to the manufacturer s guidelines 1 Review danger warning and caution notices 2 Record administrative data a Record the generator bumper or serial number b Record the name of the person taking hourly readings c Record the date and time of the readings 3 Record instrument panel readings a Record the oil pressure b Record the oil temperature c Record the coolant temperature d Record engine hours e Record kilowatt hours f Record the fuel level g Record ampere meter readings on phases h Record voltage meter readings on phases i Record the exhaust temperature j Record the air filter differential pressure reading k Record the fuel filter differential pressure reading Record the engine oil level reading from the engine compartment oil pan dipstick or sight glass Record the coolant level from the radiator sight glass Record the battery charger voltage and amperes N O oO A Check the generator set for damage excessive or discolored smoke and unusual noise Record unusual con
509. y measure show him how to do it correctly References Required Related EM 385 1 1 FM 4 25 11 LCH TM 5 682 TM 5 684 3 258 STP 5 21P2 SM TG 31 March 2009 MOS Skill Level Tasks Rescue an Injured Victim From an Aerial Bucket Truck 052 204 1116 Conditions As a power line distribution specialist in a tactical or nontactical environment when an individual is responsive or unresponsive and unable to descend from an aerial bucket truck without assistance you are given a two way radio or telephone communication equipment an aerial bucket truck with lower controls a winch line and the applicable personal protective equipment PPE DANGER 1 BEFORE USING THE AERIAL BUCKET TRUCK NEAR ENERGIZED LINES THE TRUCK CHASSIS MUST BE GROUNDED FOR SAFETY 2 OBSTACLES IN THE PATH OF THE AERIAL BUCKET MUST BE AVOIDED FAILURE TO COMPLY MAY CAUSE PERMANENT INJURY OR DEATH 3 THE TRUCK MAY BECOME ENERGIZED AND MUST BE MOUNTED PROPERLY FAILURE TO ENSURE THAT CONTACT IS NOT MADE BETWEEN YOU THE TRUCK AND THE GROUND AT THE SAME TIME MAY CAUSE PERMANENT INJURY OR DEATH NOTE Rescue procedures may vary when using a nonorganic bucket truck Standards Rescue an injured victim from an aerial bucket truck by using the lower controls to lower the bucket to the proper rescue position Remove the victim from the bucket Administer first aid until he is in stable condition or qualified medical personnel arrive Performance Steps 1 Evaluate the
510. y mission capable Complete DA Form 2702 and include the tools and equipment necessary to perform this task Ensure that personnel are safely positioned or removed from the area to be tested Perform an initial equipment self test N O oO A Test each phase conductor or circuit part with adequately rated test equipment a Check a known energized circuit to ensure that the test equipment is working correctly b Check a known de energized circuit to ensure that the test equipment is working correctly c Test the identified energized circuit and verify the test results 8 Ensure that the items listed in the conditions are properly cleaned and stored Evaluation Preparation Setup Provide the Soldier with the items listed in the conditions Give the Soldier a safety briefing before starting the test and ensure that safety precautions are followed Prepare the testing area and equipment in advance to ensure that task standards can be met Brief Soldier Direct the Soldier to perform live line testing Performance Measures GO NO GO 1 Reviewed danger warning and caution notices before proceeding 2 Reviewed the manufacturer s literature electrical construction prints and wiring diagrams 3 304 STP 5 21P2 SM TG 31 March 2009 MOS Skill Level Tasks Performance Measures GO NO GO 3 Ensured that PPE hot line equipment and test equipment was correctly tested and fully mission capable
511. y the normally open 3 100 STP 5 21P2 SM TG 31 March 2009 MOS Skill Level Tasks Performance Steps 9 10 11 12 13 14 15 16 17 18 19 20 c Identify the normally closed Determine time delay types a Determine the pickup time delay proceed to step 10 b Determine the dropout time delay proceed to step 11 skip step 10 Test the relay for proper pickup time delay a Apply the voltage or current to the main coil according the manufacturer s literature b Determine the time between voltage or current application and contact transfer c Remove the voltage or current from the main coil according to the manufacturer s literature d Ensure that auxiliary contacts transfer immediately Test the relay for the proper dropout time delay a Apply voltage or current to the main coil according to the manufacturer s literature b Ensure that auxiliary contacts transfer c Remove the voltage or current from the main coil according to the manufacturer s literature d Determine the time between voltage or current removal and contact transfer Compare test results with the manufacturer s specifications and take appropriate action Calibrate reinstall or replace the timing relay Test the circuit for voltage presence a Proceed to step 15 if there is no voltage present b Stop if there is voltage present and perform the following checks until voltage is no longer present 1 Check the electrical schema
512. ys and broken wires 4 Check hoses for cracks tears breaks and signs of dry rot 5 Check belts for cracks frays missing teeth and signs of dry rot c Inspect the cab interior for damage and deficiencies Check gauges for correct operation Check interior lights for cracks breaks and correct operation Check the horn for correct operation 1 1 1 Ensure that you have basic issue items Inspect seat belts for cracks frays rips and tears and ensure that they lock correctly Inspect the bench seat for cracks rips and tears d Check the hydraulic fluid level 31 March 2009 STP 5 21P2 SM TG 3 267 Chapter 3 Performance Steps 2 Perform during operation PMCS and annotate the deficiencies Check the boom for correct operation Check the digger auger for correct operation Check outriggers for correct operation Check the engine and transmission for correct operation Check the electrical system for correct operation o9naq oa 3 Perform after operation PMCS Ensure that tools are placed in the correct tool bins Ensure that the fuel tank is full Ensure that trash limbs and scrap is removed and correctly discarded Ensure that personal gear is removed from the vehicle Ensure that stock is placed in the stock bins oaao 4 Perform weekly operation PMCS Remove and blow out air filters Wash and clean windows and mirrors Wash th
513. ystem to its full working pressure and performed a full system trace Drained condensation from the volume tanks and in line water separators on compressed air systems Verified that automated condensation drain systems were clean and working as designed Replaced inoperative drain systems Cleaned filters and strainers on the incoming sides of pumps or compressors Replaced the filters that could not be cleaned Recorded actions taken on DA Form 2404 or DA Form 5988 E and maintenance logbooks Ensured that the items listed in the conditions were properly cleaned and stored Evaluation Guidance Score the Soldier GO if all measures are passed P Score the Soldier NO GO if any measure is failed F If the Soldier fails any measure show him how to do it correctly References Required Related DA FORM 2404 EM 385 1 1 DA FORM 5988 E FM 3 34 471 TM 5 551K 31 March 2009 STP 5 21P2 SM TG 3 147 Chapter 3 Service a Diesel Engine Lube Oil System 052 205 2110 Conditions As a power station mechanic in a nontactical environment when a diesel engine lube oil system has been identified for service or symptoms of lube oil system faults occur you are given a lockout and tagout kit a general mechanic s tool box a filter wrench the applicable technical manuals TMs the applicable manufacturer s literature maintenance logbooks and DA Form 2404 Equipment Inspection and Maintenance Worksheet or DA Form 5988 E Equipment Inspe

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