Video #1: Water Pump Replacement

Description: This video provides operators with steps to properly replace a water pump.

Summary: To begin the procedure, isolate the cooling system and then close the coolant valves. Once this is done, loosen all pulley bolts and remove the accessory belt. Following completion of the remaining steps indicated; make any required replacements to complete the replacement of a water pump.

Video #2: Power Plant Ventilation System

Description: This video provides a detailed overview of the ventilation located in power plants.

Summary: The ventilation system located in the power plant consists of intake and exhaust. All building walls within the power plant are equipped with motorized dampers, which are necessary for the fire suppression system to be effective. Fresh air enters the building through the two intake ducts.

Video #3: Engine Valve Adjust

Description: This video explains the proper way to adjust an engine valve while making sure the unit is locked out.

Summary: To begin valve adjustment, adjust injector preload. To perform the procedure, the flywheel turning tool will be necessary.

Video #4: Turbocharger Replacement

Description: This video explains the procedure to test if your turbocharger operates properly and if it does not, how to fix it.

Summary: Before beginning repair work, lock unit out. To replace the turbocharger, you must remove the intake bellows, the exhaust pipe, the turbo from the exhaust manifold and the intake manifold. The procedure is relatively simple, one just has to be cognizant of any oil in the area.

Video #5: Thermostat Replacement

Description: This video shows how to replace a cooling system thermostat.

Summary: Before repair work begins, make sure to lock engine out because gensets start automatically. To begin, remove the upper radiator and coolant bypass hoses, as well as the over temperature switch. The cooling system must be isolated in order to perform replacement procedure of thermostat.

Video #6: Starter Motor Test

Description: This video shows how to trouble shoot the starter on the engine.

Summary: Operator should check starter motor when there are issues with slow cranking or no cranking. After checking batteries and other connections, be sure the engine will NOT start during procedure. To do so, operator must remove wire to fuel shutoff. To make sure engine does not work, operator could also trip the emergency air shutdown. After following several steps, the operator should be able to isolate the cause and determine whether or not starter motor will need to be replaced.

Video #7: Switchgear Engine Service

Description: This video gives the operator instructions on what to do on the switchgear side of things when it is time to change the oil of the engine.

Summary: After 250 hours on a unit, or when an operator sees that there is a service warning alarm on their panel, the operator must perform an oil change on the engine to put it back into service. On panel, operator should select ‘manual’ mode. After pressing procedural buttons, a timing sequence will occur to shut unit down. Once unit is turned off, operator should perform oil change. Lock unit, open breaker, and service the engine. After servicing, reset engine.

EASYGEN XT Resetting Service Hours Instructions (PDF)

This PDF walks the operator through how to reset the service hours on a Woodward Easygen XT using pictures of the actual screens and short instructions. YouTube video to be added soon.

Video #8: Switchgear Overview

Description: This video gives the operator a thorough overview of the switchgear and each of its different functions.

Video #9: Switchgear Master Section Faults

Description: This video reviews faults of the master section and the procedure the operator must follow to clear them in order to get plant running.

Summary: When an operator receives an indicator fault in the master section, the entire system will shut down. To clear the fault in the engines, the operator should pull the emergency switch out. Push reset button on master section. Fault indicator will still remain on the other engines. To clear all the engines of fault, press the manual and reset buttons.

Video #10: Switchgear Manual Mode

Description: This video shows how to operate the switchgear in manual mode. Manual mode is only to be used in certain situations such a PLC failure.

Summary: In the event of failure, operator should choose the biggest engine to come online in order to pick up loads of community. On largest generator, select the manual start button.

Video #11: Switchgear Alarms

Description: This video explains the alarms on the switchgear and the differences between hard and soft fault/alarms. Operator also learns to reset alarms on GCPs.

Summary: Across the top of engines, engine related hard and soft shut downs are portrayed. A soft shut down means that when an alarm is indicated, it will start another generator up, bring it online and take one off, allowing for power to never be lost. A hard shut down is a fault that happens instantly and shuts its unit off immediately.

Video #12: Power Plant Switchgear Batteries

Description: This video describes how the engines’ batteries supply power to their specific generator switchgear sections.

Summary: Switchgear batteries are used to crank the engine and supply power to the switchgear. Each section of engine is driven by the set of batteries and their particular generator.

Video #13: Power Plant Switchgear Auto Startup

Description: This video shows the steps to start up a power plant that an operator is to follow in the event of a black start or dead bus.

Summary: A ‘dead bus’ is when an operator comes into a plant and there is no power in the community and no generators are running. First, check engines and oil levels, radiator rooms, and fuel.

Video #14: Voltage Regulator Replacement

Description: This video shows how to manually replace the voltage regulator.

Summary: A new regulator needs to be programmed or your generator will not operate correctly. If a voltage regulator is to fail, you may see that the voltage will not stabilize. Remove screws on the back to remove voltage regulator. Remove regulator and label each wire/connection.

Video #15: Power Plant Overview

Description: This video gives an overview of the power plant and all of its different components and systems.

Summary: In most power plants, bulk fuel tanks exist among many other components. Generally a storage tank is on property and gets filled every month. Inside the power plant there is a day tank, generators, engines, batteries, chargers, piping, valves, radiators, fire suppression system and many more components.

Video #16: Genset Oil Filter Change

Description: This video reviews the procedure of changing the oil and filter on the genset in the power plant.

Summary: Oil should be changed at 200- or 250-hour intervals. To begin, remove old oil filter and funnel into a drip can. Rub finger over filter housing to ensure rubber seal did not stick. Clean filter housing and fill new filter with oil. Lubricate the seal then install new filter.

Video #17: Multimeter Use

Description: This video gives an overview and tutorial of a multimeter.

Summary: The multimeter can measure voltage, resistance, diodes, and current flow. When operating a multimeter, make sure that the meter leads are in the proper holes. The black lead will go in the COM and the red lead will go in the volt-ohm-diode. Be sure to not exceed max voltage when using the multimeter.

Video #18: Power Plant Monthly Inspection

Description: This video reviews that a power plant operator needs to check monthly to keep their plant properly maintained.

Summary: An operator must follow certain procedures in order to keep their plant up and running properly. An operator must be sure that all the warning lights work. Operator must test the alarm horn monthly. It is important for an operator to follow all monthly procedural instructions to maintain power plant.

Video #19: MegOhm Meter Test

Description: This video explains how an operator should test their exciter field on the generator using a megohm meter.

Summary: Meg ohmmeters are designed to test the insulation of the coils of a main generator. By inducing a high voltage, the meter is able to see if the insulation has degraded at all. To test, set meter to 500 volts and wait for reading to appear on screen.

Video #20: Power Plant Intermediate Tank

Description: This video provides an overview of the functions and procedures of the intermediate tank at the power plant.

Summary: Next to the power plant there is a twelve thousand double wall storage tank. The storage tank supplies fuel in to the day tank. On top of the tank there is a clock gauge, which must be maintained at higher than 50% at all times.

Video #21: Fuel Injection Replacement

Description: This video shows how to properly perform a fuel injection replacement.

Summary: Before starting any engine work make sure to lock out unit. Gensets start automatically. Newer gensets also have trim codes that need to be programmed into the injectors by the manufacturer.

Video #22: Heat Recovery System

Description: This video shows the operator the various components of the heat recovery system and how each part works.

Summary: The heat recovery system located in the power plant operates on its own with no control function being required. If service is ever needed, there are three accessible valves to operate on.

Video #23: Removing Water From Fuel

Description: This video explains how an operator should remove water any water from the engines fuel system.

Summary: To drain water from the engines fuel system, begin by opening the drain valve. Once the water has been fully drained, the operator may close the drain valve. After all valves are closed, dispose of water drainage that has dripped in to bucket beneath.

Video #24: Fuel Pump Replacement

Description: This video shows and explains how to properly change a mechanical fuel pump on the engine.

Summary: To begin the procedure, isolate the fuel system and shut the fuel valve off. Follow procedure in order to successfully replace the fuel pump.

Video #25: Fuel Filter Replacement

Description: This video provides the operator with the proper procedure to follow to replace the fuel filter on the engine.

Summary: Fuel filters do need to be changed periodically. To begin, isolate fuel system and close fuel valves. Make sure drip can is underneath to catch fuel drainage. Unscrew top, remove old filter, and install new fuel filter.

Video #26: Power Plant Fire Suppression System

Description: This video provides extensive information on the fire suppression system in your power plant.

Summary: Each power plant is equip with a fire suppression system. In the event of a fire, a compressed gaseous agent would be discharged upwards out of cylinders and put the fire out immediately. All components of the fire suppression system in the power plant are identified as red.

Video #27: Power Plant Engine Description

Description: This video goes over the various components of the generator set and their functions.

Summary: A generator set is composed of many different parts. The engine and generator are mounted on compression legs. The complex components of the machinery are explained in the video.

Video #28: How to Test Diodes in Your Generator

Description: This video shows how to bench test the diodes on your generator.

Summary: Before opening up the generator housing make sure to lock that specific unit out so that it can't start. To begin, remove cover off of the generator. Once inside, disconnect wires to regulator. Remove a flying diode from the generator and test it on diode test position. Read voltage on meter and determine whether or not diode is shorted or useable.

Video #29: Power Plant Day Tank

Description: This video describes the different components and each of their functions in the day tank, its panel and its associated fill piping.

Summary: Fuel enters the day tank through the pipe coming from the intermediate tank outside. Operators must check the filter on the day tank daily to ensure that no water is inside of it. The numerous components of the day tank are thoroughly explained as the video progresses.

Video #30: Power Plant Daily Inspection

Description: This video thoroughly outlines what a power plant operator must inspect daily.

Summary: When entering power plant, operator must check overall security of property and building. Operator must then check engine exhaust cooler. The operator must inspect for any fuel leaks and be sure that fuel levels are appropriate. Once inside, the operator must check the generator room and check which generator is online. Wake up the main generator in order to turn on. Operator then must complete operator log sheet for the duration of their inspection.

Video #31: Cooling System Tools

Description: This video provides a brief overview of the tools that a power plant operator needs on hand to service or test the coolant at their plant.

Summary: An operator must refer to the service manual to ensure that they have the correct tools for the power plant. A power plant operator is going to need a hydrometer, PH test strips, and a pressure test kit.

Video #32: Power Plant Cooling System

Description: This video explains the numerous components of the cooling system in a power plant and their individual functions.

Summary: In the generation room there are two pipes that help to cool the system. The upper pipe is the hot coolant from the engines going to the radiator. The lower pipe is the return coolant coming back from the radiators to the engines.

Video #33: Coolant Services

Description: This video demonstrates the different ways of testing the quality and freeze points of your coolant and how to test for leaks.

Summary: Utilize a hydrometer to take small sample of mixture to test its freeze point. Draw a small sample of the mixture in to hydrometer and look at eye level what the hydrometer reads. Following this procedure, determine the coolant after reading what is appears as.

Video #34: Used Oil Blender

Description: This videos explains how the used oil hopper and blender operate, allowing the engines to burn the oil rather than dispose of it.

Summary: When an oil change is performed, the excess oil is pumped in to the storage container called the hopper. There is another compartment on top of the hopper designed to hold used filters. The oil then goes through three stages of being filtered and blended with diesel fuel. The final blended filtered product fills back in to the day tank.

Video #35: Engine Belt Replacement

Description: This video describes the procedure involved with changing out the accessory belt on your engine.

Summary: To begin procedure, remove the accessory belt cover. Then use ½ inch ratchet to loosen tensioner. After this is loosened, slide the belt into place and apply tension to the tensioner.

Video #36: Battery Service

Description: This video shows how to properly service your battery in order to maintain its functions.

Summary: Before beginning service to the battery, ensure that personal protective equipment is worn. Before beginning procedure, visually inspect batteries condition. To begin battery service, check the voltage and make sure it is in the range of 13.5 to 14 volts. To continue service of battery, continue to inspect for possible causes of damage.

Video #37: Battery Chargers

Description: This video describes the basic functions of the battery chargers inside each power plant.

Summary: Most generator systems have battery chargers that charge up the batteries for the system. The typical battery will have an AC button, an equalized button, a low DC power and a high DC power. If a battery voltage dips too low, a yellow equalizing light will come on and boost the batteries up to a level capable of operating.

Video #38: State of Charge- Battery Test

Description: In this video, the operator is shown how to text each cell of their battery to determine how well the battery can take a charge using a refractometer.

Summary: To measure the specific gravity of battery fluid, extract a small portion of battery acid and put it on refractometer. Once acid is inside the, check the gravity on the window inside the refractometer. Operator must see a gravity that is greater than 1.225.

Video #39: Battery Capacity Test

Description: This video explains how to test your engine batteries using a battery capacity tester.

Summary: To test a batteries capacity to perform, isolate the battery first. Once the cable is removed from battery and is isolated, hook red to positive terminal and black to the negative terminal. Proceed to use battery tester machine.

Video #40: Air Filter Replacement

Description: This video reviews the procedure on how to determine if you need to replace your air filter and if so, how.

Summary: Although most new plants have electronic alarms and warnings that alert the operator when the filter needs to be replaced, it is still important to check the air filter every 1000 engine hours. If the restriction on the air cleaner exceeds 25 inches of water, it is time for replacement.

Video #41: 2000 Engine Hour Service

Description: This video overviews what the operator is required to check every 2000 hours in addition to the 250-hour and 1000-hour service.

Summary: At 2000 hours operator should do everything the same from the 1000-hour check. Must change air filter at 2000 hours and pull valves off to adjust.

Video #42: 1000 Engine Hour Service

Description: This video details what is needed to do on the 1000 engine hour service. This is in addition to the 250-hour service.

Summary: At the 1000-hour service you do everything the same from the 250-hour service. You must change fuel filters, inspect the air filter, inspect crank vent filter, and change coolant filter.

Video #43: 250 Engine Hour Service

Description: This video details what the operator needs to do to their engine at each 250-hour mark.

Summary: 250 hours is the typical time interval for changing oil on the engines. Keep in mind that your plant might use 300-hour or 500-hour service intervals depending on what engines and their configurations may be. Go by the service hours on your engine controller.

Video #44: Power Plant 12 Month Maintenance Inspection

Description: In this video, the operator learns what is needed to inspect and maintain a power plant once a year. This inspection can be combined with the 6-month inspection.

Summary: Once a year, a power plant’s fire system must be checked and re-certified in order to maintain fire code and protect the building. This procedure requires a certified technician.

Video #45: Power Plant 6 Month Maintenance Inspection

Description: This video shows the power plant operator what needs to be inspected and maintained every six months.

Summary: Every six months, check all air filters in the power plant, clean all light fixtures, vent air from closed loop piping, and test the coolant.