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USAF TO 35C2-3-518-1

USA TM 9-6115-484-14
DRS RADIAN CTM 01646.1R0253/1R0254

12.4.3.10 TRANSDUCER (XD)

The following maintenance procedures are provided for the Transducer (XD):

Inspect
Test
Remove
Install
Service

FIGURE 12.4.3.10-1 TRANSDUCER LOCATION

Transducer converts the 4-20mA output from the RTU to a 0-10VDC signal for use by the LSM during
utility paralleling operations only. It is located on the center section sub panel.

12.4.3.10.1 INSPECT TRANSDUCER (XD)

Inspect the Transducer (XD) for the following:

a. Inspect for proper mounting.

b. Inspect for loose connections.

c. Inspect for physical and heat damage.

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12.4.3.10.2 TEST TRANSDUCER (XD)

To test the Transducer (XD), proceed as follows:

a. There is no testing of the device at this level.

b. When the GMS is in “UTILITY PARALLEL”, the green Power light on the front of the transducer
should be illuminated.

c. Check power supply if the light is not illuminated.

d. Replace the XD if there is 24VDC present. Refer to FO-22 for more information.

12.4.3.10.3 REMOVE TRANSDUCER (XD)

WARNING

REMOVE ALL RINGS, NECKLACES, JEWELERY AND LOOSE CLOTHING.


FAILURE TO DO SO COULD CAUSE SEVERE INJURY OR DEATH.

WARNING

DO NOT PERFORM THE FOLLOWING TASK WHEN THE GENERATOR SET IS


OPERATING. DO NOT TOUCH EXPOSED ELECTRICAL CONNECTION WHEN A
SOURCE OF POWER SUCH AS UTILITY POWER OR ANOTHER GENERATOR SET
IS CONNECTED TO THE LOAD TERMINALS. DEATH OR INJURY MAY RESULT
FROM FAILURE TO OBSERVE THIS WARNING.

WARNING

WHEN POWER GENERATION EQUIPMENT MUST BE IN OPERATION TO MAKE


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

To remove the Transducer (XD), proceed as follows:

a. This maintenance requires that the PU MUST be shutdown, rendered unable to start, cool
enough for the maintenance to be performed, and Communication Cable (A) and (B)
rerouted to the next PU. This is accomplished by performing the following:

(1) Shutdown the PU in accordance with Section 5.1.6.1 Shutdown Generators.


(2) Isolate the PU from any power plant control system in accordance with Note 1.
(3) Pull to open the PU DC Power Control Breaker.
(4) Push to open both Emergency Stop Switches.
(5) Place both Engine Control Switches (ECS) in the OFF position.
(6) Place a DO NOT OPERATE tag on both generator control panels.
(7) Turn the Battery Bank Parallel Switch to the OFF position.

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(8) De-energize both Battery Chargers.


(9) Disconnect the negative and positive cables from both Battery Banks.
(10) Place a DO NOT OPERATE tag on both Battery Banks.
(11) Place all Circuit Breakers in the LOCK OUT position.
(12) Disconnect both 7P1 and 7P2 Connectors located on the inside panel of the PDC.
(13) Close and Lock both generator set control panels.

NOTE 1: When the DC Control Power Circuit Breaker is in the (OFF) position (Pulled – Out), all control
power is turned off to the PU. This will cause the HUB to stop functioning. This causes the
network to not see the equipment shutdown and all PU’s after it. When pulling major
maintenance the (A) (B) Communication Cable must be routed to the next PU in order to
reestablish the communication network.

b. Tag and disconnect the wiring from the Transducer (XD).

FIGURE 12.4.3.10.3-1 TRANSDUCER (XD) CONFIGURATION

c. Remove the Transducer (XD) by using a thin flat tip screwdriver. Insert the screwdriver in the
spring-loaded catch at the bottom of the transducer. Push up on the screwdriver to force the
catch downward then pull out and up to remove the transducer from the DIN rail-mounting
bracket. (See Figure 12.4.3.10.3-1)

12.4.3.10.4 INSTALL TRANSDUCER (XD)

To install Transducer (XD), proceed as follows:

a. This maintenance requires that the PU MUST be shutdown, rendered unable to start, cool
enough for the maintenance to be performed, and Communication Cable (A) and (B)
rerouted to the next PU. See procedures and warnings in paragraph 12.4.3.10.3.

b. Reinstall the Transducer (XD) on the mounting bracket by inserting the flat tip screwdriver in the
spring-loaded catch at the bottom. Hook the top rear of the transducer onto the mounting bracket
and depress the spring-loaded catch. Push in on the bottom of the (XD) and release the catch.

c. Reinstall wiring to the Transducer (XD) and discard tags.

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12.4.3.10.5 SERVICE TRANSDUCER (XD)

To service the Transducer (XD), proceed as follows:

a. Before installing the new transducer, you must first set the two Dual Inline Position (DIP) switches
that are internal to the transducer. Proceed as follows.

FIGURE 12.4.3.10.5-1 OPENING THE TRANSDUCER

b. Open the transducer by using a screwdriver to disengage the top part of the housing on both
sides (See Figure 12.4.3.10.5-1).

FIGURE 12.4.3.10.5-2 SETTING THE DIP SWITCHES

c. Pull out the top part of the housing and the electronics section about 3 cm, to expose the two DIP
switches (Figure 12.4.3.10.5-1 and Figure12.4.3.10.5-2).

d. Set the IN DIP switch (DIP 1) to the following positions. 1-3-6 ON, 2-4-5-7-8 OFF. Reference the
table on the side of the transducer

e. Set the OUT DIP switch (DIP 2) to the following positions. 5-8 ON, 1-2-3-4-6-7-9-10 OFF.
Reference the table on the side of the Transducer.

f. Close the front of the transducer and ensure the locking tabs snap into the closed position.

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12.4.3.11 AC TRANSFORMER BOX (ATB)

The following maintenance procedures are provided for the AC Transformer Box (ATB):

Inspect
Test
Remove
Install

FIGURE 12.4.3.11-1 AC TRANSFORMER BOX (ATB)

These components convert the potential transformer and current transformer signals to levels useable by
associated GSC module. The ATB also provides fused protection for the potential transformer signals.
Each is located on the rear of the associated generator section door.

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12.4.3.11.1 INSPECT AC TRANSFORMER BOX (ATB)

Inspect the AC Transformer Box (ATB) for the following:

a. Inspect for proper mounting.

b. Inspect for loose connections.

c. Inspect for physical and heat damage.

12.4.3.11.2 TEST AC TRANSFORMER BOX (ATB)

To test the AC Transformer Box (ATB), proceed as follows:

See RENR 1200-01 or later version (Electronic Modular Control Panel II+ for EUI Engines) for
troubleshooting procedures. (SMCS Code: 4490-035, “Zero Display of Voltage or Current –
Troubleshoot”).

12.4.3.11.3 REMOVE AC TRANSFORMER BOX (ATB)

WARNING

REMOVE ALL RINGS, NECKLACES, JEWELERY AND LOOSE CLOTHING.


FAILURE TO DO SO COULD CAUSE SEVERE INJURY OR DEATH.

WARNING

DO NOT PERFORM THE FOLLOWING TASK WHEN THE GENERATOR SET IS


OPERATING. DO NOT TOUCH EXPOSED ELECTRICAL CONNECTION WHEN A
SOURCE OF POWER SUCH AS UTILITY POWER OR ANOTHER GENERATOR SET
IS CONNECTED TO THE LOAD TERMINALS. DEATH OR INJURY MAY RESULT
FROM FAILURE TO OBSERVE THIS WARNING.

WARNING

WHEN POWER GENERATION EQUIPMENT MUST BE IN OPERATION TO MAKE


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

To remove the AC Transformer Box (ATB), proceed as follows:

a. This maintenance requires that the PU MUST be shutdown, rendered unable to start, cool
enough for the maintenance to be performed, and Communication Cable (A) and (B)
rerouted to the next PU. This is accomplished by performing the following:

(1) Shutdown the PU in accordance with Section 5.1.6.1 Shutdown Generators.


(2) Isolate the PU from any power plant control system in accordance with Note 1.

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(3) Pull to open the PU DC Power Control Breaker.
(4) Push to open both Emergency Stop Switches.
(5) Place both Engine Control Switches (ECS) in the OFF position.
(6) Place a DO NOT OPERATE tag on both generator control panels.
(7) Turn the Battery Bank Parallel Switch to the OFF position.
(8) De-energize both Battery Chargers.
(9) Disconnect the negative and positive cables from both Battery Banks.
(10) Place a DO NOT OPERATE tag on both Battery Banks.
(11) Place all Circuit Breakers in the LOCK OUT position.
(12) Disconnect both 7P1 and 7P2 Connectors located on the inside panel of the PDC.
(13) Close and Lock both generator set control panels.

NOTE 1: When the DC Control Power Circuit Breaker is in the (OFF) position (Pulled – Out), all control
power is turned off to the PU. This will cause the HUB to stop functioning. This causes the
network to not see the equipment shutdown and all PU’s after it. When pulling major
maintenance the (A) (B) Communication Cable must be routed to the next PU in order to
reestablish the communication network.

b. Ensure that all wires at the terminal strip of the ATB are marked with the respective termination
point.

c. Remove all external wires from the termination strip.

d. Disconnect the ATB connector from the harness connector.

e. Remove all mounting nuts and screws that fasten the ATB to the sub-panel.

f. Remove the ATB.

12.4.3.11.4 INSTALL AC TRANSFORMER BOX (ATB)

To install the AC Transformer Box (ATB), proceed as follows:

a. This maintenance requires that the PU MUST be shutdown, rendered unable to start, cool
enough for the maintenance to be performed, and Communication Cable (A) and (B)
rerouted to the next PU. See procedures and warnings in paragraph 12.4.3.11.3.

b. Reinstall the new ATB in the sub panel, and Reinstall the mounting hardware.

c. Reinstall all wiring and Reinstall the ATB connector.

d. The ATB barcode information must be reinstalled into the GSC+. To enter the information refer
to Caterpillar Manual RENR 1200 –01 or later version. Go to Voltmeter/Ammeter Programming
OP8, SMCS Code: 4490; 7451 and follow the programming procedures.

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CHAPTER 13
COOLING SYSTEM REPAIR
TABLE OF CONTENTS

SECTION TITLE PAGE


13.0 COOLING SYSTEM REPAIR 5

13.1 SAFETY INSTRUCTIONS 5

13.2 BRIEF SYSTEM DESCRIPTION 7

13.3 SERVICE REQUIREMENTS 8

13.3.1 COOLING SYSTEM SCHEDULED MAINTENANCE 10

13.3.2 COOLANT SYSTEM SPECIFICATIONS 11

13.3.2.1 WATER 12

13.3.2.2 ADDITIVES 12

13.3.2.3 ETHYLENE GLYCOL 13

13.3.3 INITIAL COOLANT SYSTEM FILL 13

13.3.4 COOLANT SYSTEM VISUAL INSPECTION 14

13.4 COMPONENT REPAIR PROCEDURES 15

13.4.1 WATER TEMPERATURE REGULATOR & MANIFOLD 15

13.4.1.1 INSPECT WATER TEMPERATURE REGULATOR & MANIFOLD 15

13.4.1.2 TEST WATER TEMPERATURE REGULATOR & MANIFOLD 16

13.4.1.3 REMOVE WATER TEMPERATURE REGULATOR & MANIFOLD 19

13.4.1.4 INSTALL WATER TEMPERATURE REGULATOR & MANIFOLD 22

13.4.2 WATER PUMP 23

13.4.2.1 INSPECT WATER PUMP 23

13.4.2.2 TEST WATER PUMP 24

13.4.2.3 REMOVE WATER PUMP 25

13.4.2.4 INSTALL WATER PUMP 27

13.4.3 FILLER CAP 28

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TABLE OF CONTENTS

SECTION TITLE PAGE


13.4.3.1 INSPECT FILLER CAP 29

13.4.3.2 TEST FILLER CAP 31

13.4.3.3 REMOVE AND INSTALL FILLER CAP 32

13.4.4 ENGINE OIL COOLER 33

13.4.4.1 INSPECT ENGINE OIL COOLER 33

13.4.4.2 TEST ENGINE OIL COOLER 33

13.4.4.3 REMOVE ENGINE OIL COOLER 34

13.4.4.4 INSTALL ENGINE OIL COOLER 36

13.4.5 RADIATOR AND AFTER COOLER ASSEMBLY 38

13.4.5.1 INSPECT RADIATOR AND AFTER COOLER ASSEMBLY 39

13.4.5.2 TEST RADIATOR AND AFTER COOLER ASSEMBLY 39

13.4.5.3 REMOVE RADIATOR AND AFTER COOLER ASSEMBLY 42

13.4.5.4 INSTALL RADIATOR AND AFTER COOLER ASSEMBLY 46

13.4.5.5 SERVICE RADIATOR AND AFTER COOLER ASSEMBLY 47

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LIST OF FIGURES

FIGURE TITLE PAGE


FIGURE 13.2-1 TYPICAL COOLANT SYSTEM OPERATION 7

FIGURE 13.4.1-1 WATER TEMPERATURE REGULATOR & MANIFOLD 15

FIGURE 13.4.1.3-1 WATER TEMPERATURE REGULATOR 19

FIGURE 13.4.1.3-2 THERMOSTAT HOUSING 20

FIGURE 13.4.1.3-3 THERMOSTAT HOUSING 20

FIGURE 13.4.1.3-4 THERMOSTAT HOUSING 20

FIGURE 13.4.1.3-5 DISASSEMBLY OF THERMOSTAT HOUSING 21

FIGURE 13.4.1.3-6 DISASSEMBLED THERMOSTAT HOUSING 21

FIGURE 13.4.2-1 WATER PUMP 23

FIGURE 13.4.2.2-1 WATER PUMP 24

FIGURE 13.4.3-1 FILLER CAP 28

FIGURE 13.4.4-1 ENGINE OIL COOLER 33

FIGURE 13.4.5-1 RADIATOR AND AFTERCOOLER ASSEMBLY 38

FIGURE 13.4.5.5-1 RADIATOR DRAIN 51

FIGURE 13.4.5.5-2 RADIATOR HOSE DRAIN 52

FIGURE 13.4.5.5-3 RADIATOR TANK 53

FIGURE 13.4.5.5-4 COOLANT SYSTEM AIR BLEED VALVE 53

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LIST OF TABLES

TABLE TITLE PAGE


TABLE 13.3.2.1-1 ACCEPTABLE CHARACTERISTICS OF WATER 12

TABLE 13.4.1.2-1 WATER TEMPERATURE REGULATOR 18

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13.0 COOLING SYSTEM REPAIR

Maintenance procedures are provided for the following Cooling System components:

• Water Temperature Regulator & Manifold


• Water Pump
• Filler Cap
• Engine Oil Cooler
• Radiator After Cooler Assembly

13.1 SAFETY INSTRUCTIONS

a. Safety precautions must be observed while any maintenance is being performed. Safety
precautions must be observed to ensure that the operator/technician cannot have contact with the
following:

• Hot engine parts


• Hot engine fluids
• Medium Voltage AC electricity
• Low Voltage AC electricity
• Low Voltage DC electricity
• Rotating Parts
• High noise levels

b. Minor troubleshooting can be performed while both engines are running as long as safety
precautions are taken.

c. Minor maintenance can be performed while one generator set is running and the other
generator set has been shutdown. Some examples of this maintenance are:

• Lubrication System – Oil and Filter Change.


• Hydraulic System – Oil and Filter Change.
• Fuel System – Primary and Secondary Filter Change.
• Coolant System – Coolant Change.
• Minor Troubleshooting.
• Check Fluid levels and add required fluids.

(1) The generator set that has been shut down must be rendered unable to start, and cool
enough for the maintenance to be performed. Procedures to render a generator set
unable to start are:

(a) Shutdown the PU in accordance with Section 5.1.6.1 Shutdown Generators.


(b) Push to OPEN the Emergency Stop Switch.
(c) Place the Engine Control Switch (ECS) in the OFF position.
(d) Place a DO NOT OPERATE tag on the generator control panel.
(e) Turn the Battery Bank Parallel Switch to the OFF position.

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(f) De-energize the Battery Charger.


(g) Disconnect the negative and positive cables from the Battery Bank for the engine
due maintenance.
(h) Place a DO NOT OPERATE tag on the Battery Bank.
(i) Place the generator Circuit Breaker in the LOCK OUT position.
(j) Disconnect the 7P1 and 7P2 Connectors located on the inside panel of the PDC.
(k) Close and Lock the generator set control panel.

NOTE: The fuel transfer pump electrical power is normally fed directly from the G1 generator set
battery bank. If you disconnect the G1 battery bank, the external fuel transfer pump will not
function. Place the Fuel Pump Source Switch (S2) into the (G1 or G2 position). Place the S2
in the (G1 or G2) position, for the generator set not receiving maintenance.

d. Major maintenance or service requires that the PU MUST be shutdown, isolated from any
power plant electrical bus or utility connection, isolated from any power plant control
system, and rendered unable to start. This is accomplished by performing the following:

(1) Shutdown the PU in accordance with Section 5.1.6.1 Shutdown Generators.


(2) Isolate the PU from any power plant or utility connection in accordance with Section
5.9.6.15, Unit Isolation Procedure with PSC. See Note 1 and 2.
(3) Isolate the PU from any power plant control system in accordance with Note 3.
(4) Pull to open the PU DC Power Control Breaker.
(5) Push to OPEN both Emergency Stop Switches.
(6) Place both Engine Control Switches (ECS) in the OFF position.
(7) Place a DO NOT OPERATE tag on both generator control panels.
(8) Turn the Battery Bank Parallel Switch to the OFF position.
(9) De-energize both Battery Chargers.
(10) Disconnect the negative and positive cables from both Battery Banks.
(11) Place a DO NOT OPERATE tag on both Battery Banks.
(12) Place all Circuit Breakers in the LOCK OUT position.
(13) Disconnect both 7P1 and 7P2 Connectors located on the inside panel of the PDC.
(14) Close and Lock both generator set control panels.

NOTE 1: Also the PU must be completely electrically isolated from the power distribution bus and
any other electrical source that can back feed into the PU. All medium voltage cables need to
be placed on the standoff insulators by use of hot sticks and other safety gear.

NOTE 2: Ensure cables are not energized by opening the circuit breaker of the Primary Switching
Center (PSC), then disconnect Load Cables (Using the proper safety gear) on the PU and
place them on the Parking Stands.

NOTE 3: When the DC Control Power Circuit Breaker is in the (OFF) position (Pulled – Out), all control
power is turned off to the PU. This will cause the HUB to stop functioning. This causes the
network to not see the equipment shutdown and all PU’s after it. When pulling major
maintenance the (A) (B) Communication Cable must be routed to the next PU in order to
reestablish the communication network.

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13.2 BRIEF SYSTEM DESCRIPTION

a. The MEP-PU-810 has a pressure type cooling system that is equipped with a vent line. A
pressure type cooling system gives two advantages. First, the cooling system can be operated
safely at a temperature that is higher than the boiling point of water. Next, cavitation in the water
pump is prevented. It is more difficult for air or steam pockets to be made in the cooling system.

FIGURE 13.2-1 TYPICAL COOLANT SYSTEM OPERATION

b. Coolant System Operation: Refer to Figure 13.2-1 for reference. In operation, the Water
Pump sends most of the coolant from the Radiator, to the Oil Cooler, the Cylinder Block,
through a Bonnet and an Elbow. The coolant goes around the Cylinder Liners, through Water
Directors, and into the Cylinder Head. The Water Directors send the flow of coolant around
the Valves and the passages for the exhaust gases in the Cylinder Head. The coolant then flows
to the front of the Cylinder Head. At this point, Water Temperature Regulators (2 EA), controls
the direction of the coolant flow. The Water Temperature Regulators (2 EA) are closed when
the engine is cold. The coolant flows through the Regulator Housing and Elbow back to Water
Pump. If the coolant is at normal operating temperature, the Water Temperature Regulators (2
EA), opens and the coolant flows to the Radiator, through the Outlet Hose. The coolant
becomes cooler as the coolant moves through the Radiator. When the coolant gets to the
bottom of the Radiator, the coolant goes through the Inlet Hose and into the Water Pump.

c. The cooling system for each generator set consists of two separate cooling systems: One
coolant circuit cools the engine block. The other circuit cools the pressurized filtered intake air
after by use of an Air To Air After Cooler (ATAAC). The air is carried in the 4.00-inch diameter
pipes that pass through the top of the interior trailer wall. The engine block is cooled with a water
and anti-freeze mixture from a coolant to air heat exchanger. The coolant is carried in a
combination of 2.50 and 3.00-inch pipes that pass through the center of the interior trailer wall.

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13.3 SERVICE REQUIREMENTS

Service requirements for the coolant system include the following:

• Cooling System Scheduled Maintenance

• Cooling System Specifications

• Initial Coolant System Fill

• Coolant System Visual Inspection

WARNING

ALWAYS WEAR EYE PROTECTION WHEN YOU PERFORM ANY SERVICE WORK
ON A COOLING SYSTEM

WARNING

RELEASE THE PRESSURE IN THE COOLING SYSTEM BEFORE PERFORMING ANY


SERVICE WORK. IF THE PRESSURE IN THE COOLING SYSTEM IS NOT
RELEASED OR THE TEMPERATURE OF THE SYSTEM IS NOT PERMITTED TO
COOL, STEAM OR HOT WATER MAY BE RELEASED WHEN YOU REMOVE THE
FILLER CAP. THIS MAY CAUSE PERSONAL INJURY.

WARNING

TO RELEASE THE PRESSURE IN A COOLING SYSTEM, LET THE SYSTEM COOL,


PUT A HEAVY CLOTH OVER THE CAP AND LOOSEN IT SLOWLY.

WARNING

DO NOT ALLOW UNDILUTED CORROSION INHIBITORS OR DILUTED/UNDILUTED


RADIATOR CLEANERS TO COME IN CONTACT WITH THE SKIN OR EYES.

WARNING

DO NOT USE CHROMATE CORROSION INHIBITORS IN A COOLING SYSTEM.

WARNING

ALWAYS FOLLOW THE MANUFACTURER’S INSTRUCTIONS WHEN HANDLING


CORROSION INHIBITORS, RADIATOR CLEANERS OR ANTIFREEZE BE
ESPECIALLY SURE TO FOLLOW THE MANUFACTURER’S RECOMMENDATIONS
CONCERNING TOXICITY.

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WARNING

ETHYLENE GLYCOL MAY CATCH FIRE WHEN IT IS HOT OR EXPOSED TO AN


OPEN FLAME. DO NOT WELD, CUT OR USE AN OPEN FLAME NEAR LEAKING
COOLANT THAT CONTAINS ANTIFREEZE.

WARNING

DO NOT USE ALCOHOL IN PLACE OF ANTIFREEZE. ALCOHOL HAS A LOWER


BOILING TEMPERATURE AND FLASH POINT.

WARNING

DO NOT ATTEMPT TO TIGHTEN ANY HOSE CLAMPS WHILE THE COOLING


SYSTEM IS HOT OR UNDER PRESSURE. IF THERE IS A FAILURE OF THE HOSE
CLAMP WHEN IT IS TIGHTENED, A SUDDEN LOSS OF HOT COOLANT OR STEAM
COULD RESULT.

WARNING

DO NOT REMOVE FILLER CAP AFTER OPERATION UNTIL SYSTEM HAS COOLED
DOWN. FAILURE TO ALLOW ENGINE COOLANT TO COOL DOWN COULD RESULT
IN SECOND AND THIRD DEGREE BURNS. CAP MAY BE HALF-TURNED TO
RELIEVE PRESSURE AND THEN REMOVED TO INSPECT COOLANT LEVEL.

WARNING

PERSONAL INJURY CAN RESULT FROM HOT COOLANT, STEAM AND ALKALI.

WARNING

AT OPERATING TEMPERATURE, ENGINE COOLANT IS HOT AND UNDER PRESSURE.


THE RADIATOR AND ALL LINES TO THE ENGINE CONTAIN HOT COOLANT OR STEAM.
ANY CONTACT CAN CAUSE SEVERE BURNS.

WARNING

REMOVE FILLER CAP SLOWLY TO RELIEVE PRESSURE ONLY WHEN THE ENGINE IS
STOPPED AND THE FILLER CAP IS COOL ENOUGH TO TOUCH WITH YOUR BARE HAND.

WARNING

COOLING SYSTEM CONDITIONER CONTAINS ALKALI. AVOID CONTACT WITH SKIN AND
EYES.

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CAUTION

CARE MUST BE TAKEN TO ENSURE THAT FLUIDS ARE CONTAINED DURING


PERFORMANCE OF INSPECTION, MAINTENANCE, TESTING, ADJUSTING AND
REPAIR OF THE PU. BE PREPARED TO COLLECT THE FLUID WITH SUITABLE
CONTAINERS BEFORE OPENING ANY COMPARTMENT OR DISASSEMBLY ANY
COMPONENT CONTAINING FLUIDS. DISPOSE OF FLUIDS ACCORDING TO
LOCAL REGULATIONS AND MANDATES.

CAUTION

THE WATER TEMPERATURE REGULATORS (2 EA) ARE AN IMPORTANT PART


OF THE COOLING SYSTEM. THE WATER TEMPERATURE REGULATORS DIVIDE
THE COOLANT FLOW BETWEEN THE RADIATOR AND THE BYPASS ELBOW.
THIS WILL MAINTAIN THE CORRECT ENGINE TEMPERATURE. IF THE WATER
TEMPERATURE REGULATORS ARE NOT INSTALLED IN THE SYSTEM, THERE IS
NO MECHANICAL TEMPERATURE CONTROL. MOST OF THE COOLANT WILL GO
THROUGH THE BYPASS. THIS WILL CAUSE THE ENGINE TO OVERHEAT IN HOT
WEATHER. IF A HIGHER VOLUME OF COOLANT GOES THROUGH THE
RADIATOR, THE ENGINE WILL NOT REACH NORMAL OPERATING
TEMPERATURES. THIS OCCURS DURING COLD WEATHER.

CAUTION

DO NOT USE A COMMERCIAL COOLANT/ANTIFREEZE THAT ONLY MEETS THE


ASTM D3306 OR D4656 SPECIFICATION. THIS TYPE OF COOLANT/ANTIFREEZE
IS MADE FOR LIGHT DUTY AUTOMOTIVE APPLICATIONS.

CAUTION

IF NON ELC COOLANTS HAVE BEEN USED, IMPROPER OR INCOMPLETE


RINSING OF THE COOLING SYSTEM CAN RESULT IN DAMAGE TO COPPER AND
OTHER METAL COMPONENTS. TO AVOID DAMAGE TO THE COOLING SYSTEM,
MAKE SURE TO COMPLETELY FLUSH THE COOLING SYSTEM WITH CLEAN
WATER. CONTINUE TO FLUSH THE SYSTEM UNTIL ALL SIGNS OF THE
CLEANING AGENT ARE GONE.

13.3.1 COOLING SYSTEM SCHEDULED MAINTENANCE

a. 10-HOUR OR DAILY CHECK

(1) Inspect the coolant level in the top tank through the sight glass.

(2) Inspect coolant system and lines for leaks.

(2) Remove foreign material and dirt from outside the radiator core (and between the panels of
folded core radiators).

b. 250-HOUR OR MONTHLY CHECK (Engine is shutdown and cool)

(1) Perform all 10 hour maintenance checks.

(2) Test the coolant for freeze level protection.

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DRS RADIAN CTM 01646.1R0253/1R0254

(3) Inspect the Filler Cap gasket.

(4) Inspect all hoses and coolant pipes for leaks.

c. 3000 HOURS OR 24 MONTHS (whichever occurs first)(engine is shutdown and cool)

(1) Perform all 10, and 250-hour maintenance checks.

(2) Non ELC Coolant Only - Drain, clean and refill the cooling system.

(3) Inspect the condition of fan blades and guards. Inspect the condition of hoses and clamps.
Tighten all clamps.

(4) Obtain a coolant analysis.

(5) Add ELC Extender.

13.3.2 COOLANT SYSTEM SPECIFICATIONS

a. Many engine failures are related to the cooling system. The following problems are related to
cooling system failures:

• Overheating
• Leakage of the water pump
• Plugged radiators or heat exchangers
• Pitting of the cylinder liners

b. These failures can be avoided with proper cooling system maintenance. Cooling system
maintenance is as important as maintenance of the fuel system and the lubrication system.
Quality of the coolant is as important as the quality of the fuel and the lubricating oil.

c. Coolant is normally composed of the following three elements:

• Water
• Additives
• Glycol

NOTE: The DPGDS PU engine-cooling systems were designed, factory filled and intended for the
use of Extended Life Coolant (ELC). Normally, ELC is used in a premixed, full fill mixture.
Use of Coolant other than ELC will require different maintenance requirements.

13-11
USAF TO 35C2-3-518-1
USA TM 9-6115-484-14
DRS RADIAN CTM 01646.1R0253/1R0254

13.3.2.1 WATER

a. ELC premixed, full fill coolant has the correct specification water already included in the ELC
container. This eliminates the following water problems listed below:

• Hard water
• Water that is softened with salt
• Salt water

b. In emergency situations if distilled water or de-ionized water is not available, use water with the
characteristics that are listed in Table 13.3.2.1-1.

TABLE 13.3.2.1-1 ACCEPTABLE CHARACTERISTICS OF WATER


CHARACTERISTIC MAXIMUM LIMIT ASTM TEST
“D512b”
2.4 grains/US gal
CHLORIDE (CI) “D512d”
(40 mg/L)
“D4327”
5.9 grains/US gal “D516b”
SULFATE (SO)
(100 mg/L) “D516d”
10 grains/US gal
TOTAL HARDNESS “D1126b”
(170 mg/L)
20 grain/US gal
TOTAL SOLIDS “D1888a”
(340 mg/L)
PH 5.5 to 9.0 “D1293”

c. For a water analysis, consult one of the following sources:

• Caterpillar dealer
• Local water utility company
• Agricultural agent
• Independent laboratory

13.3.2.2 ADDITIVES

a. ELC does not require any additives accept for the ELC Coolant System Extender Package,
added during the service interval listed in Table 6.3-1. Use of non-compatible additives with the
ELC coolant can lead to loss of the long life effect of the ELC Coolant, or even serious cooling
system damage.

b. ELC helps to protect the metal surfaces of the cooling system. A lack of ELC Coolant, lack of
maintenance or, contamination of the ELC Coolant with standard coolant additives can enable the
following conditions to occur:

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DRS RADIAN CTM 01646.1R0253/1R0254

• Corrosion
• Formation of mineral deposits
• Rust
• Scale
• Corrosion and erosion from cavitation of the cylinder liner
• Foaming of the coolant

c. Portions of the ELC Coolant chemical contents are depleted during engine operation. These
protective properties must be replaced periodically. This can be achieved by adding the ELC
Extender Package to the Extended Life Coolant (ELC) at the proper service interval. ELC
Extender must be added at the proper volume for the PU coolant volume capacity.

13.3.2.3 ETHYLENE GLYCOL

a. The ELC does contain Ethylene Glycol. Ethylene Glycol in the coolant helps to provide protection
against the following conditions:

• Boiling
• Freezing
• Cavitation of the water pump and the cylinder liner

NOTE: For optimum performance, Caterpillar recommends premixed, Extended Life Coolant.
(Contains the proper amount of specified water at a 50/50 mixture).

13.3.3 INITIAL COOLANT SYSTEM FILL

a. Select the ELC Coolant (Premixed or Concentrate).

b. Before the cooling system is filled, close all drain plugs.

c. Remove the Filler Cap and open the Cooling System Air Bleed Valve, located on the Water
Temperature Regulator Housing.

d. Do not fill the cooling system faster than 5 gallons (19 liters) per minute. This prevents air
pockets from developing. Air pockets result in an incomplete fill and could cause damaging
steam.

e. Close the Cooling System Air Bleed Valve after coolant starts to run out. Continue filling until
the expansion tank has been filled to the proper level.

f. After filling the cooling system, run the engine for several minutes with the Filler Cap off. Next,
reinstall the Filler Cap and run the engine until the coolant becomes warm.

g. Check for proper coolant level. If necessary, add coolant and reinstall the Filler Cap. Check all
cooling system components for leaks. If none are found, the engine is ready for service.

13-13
USAF TO 35C2-3-518-1
USA TM 9-6115-484-14
DRS RADIAN CTM 01646.1R0253/1R0254

13.3.4 COOLANT SYSTEM VISUAL INSPECTION

NOTE: The following checks can only be performed while the Power Unit is shut down.

a. If an overheating problem is suspected, first check to see if an overheating problem actually


exists. Look for radiator clogging, low coolant level and low fan rpm. With the engine shutdown,
check for coolant leaks or steam coming out of the overflow on the radiator.

b. If no problem is found after these simple visual checks, the following checks are
necessary:

(1) Check the level of the coolant in the radiator. Make sure the coolant is cool first. A low
coolant level can sometimes cause overheating, but it can also be the result of overheating.
If the coolant begins to boil, the pressure relief valve in the expansion tank cap will open.
This keeps the cooling system pressure constant, but permits loss of coolant. If the level of
the coolant is low, add more as needed. If the engine overheats again, the low coolant level
was not the cause of overheating.

(2) Check for restrictions that can stop the flow of air through the radiator. Check for dirt in the
cores, especially outside of the fan blast area. Use a light to check for plugged areas in the
core. Lower a light on one side of the radiator and visually inspect the opposite side. Check
for radiator fins that are bent, damaged or show signs of leakage from the radiator.

(3) Check the Fan Blades for damage. Check for missing or damaged radiator baffles. The
baffles prevent circulation of air around the sides of the radiator. A missing or damaged
baffle raises the temperature of the air that goes through the radiator.

(4) Check the condition of the shrouds. Check to see they are installed correctly. Also, Check
to make sure all sealing gaskets are in good condition. Fan and radiator shrouds increase
the efficiency of the fan by helping to move air through the radiator. The fan shroud must be
near the outer edges of the fan blade to prevent re-circulation of air around the ends of the
fan.

(5) Check the air inlet system. Ensure there are no restrictions in the air cleaner, air inlet and
exhaust lines, or to the flow of air through the cooling system.

(6) Check the condition of all hoses. A collapsed hose is an indication that the water pump
cannot pump enough coolant because of a restriction in the radiator.

(7) Check for leaks around the water pump, there is a drain hole between the coolant seal and
the bearing seal in the water pump. Without this drain hole, coolant can get into the oil if
there is a failure of the seals in the water pump. Check for signs of coolant or oil leaks at the
junction of the cylinder head and cylinder block. Leaks in this area are an indication of head
gasket failure.

c. Engine Overcooling: Overcooling can damage an engine just as overheating can. Overcooling
occurs when the normal temperature at which the engine operates cannot be reached. This
condition is most severe with the use of high sulfur fuel. High sulfur fuel increases wear if the
temperature is not over 175°F (80°C). Overcooling is the result of coolant bypassing the water
temperature regulators and flowing directly to the radiator.

d. Causes of Overcooling: The most common cause of overcooling is from water temperature
regulators that are held open because of a defect. It is possible for coolant to flow around a water
temperature regulator that is in good condition. This too will give an indication of overcooling.

13-14
USAF TO 35C2-3-518-1
USA TM 9-6115-484-14
DRS RADIAN CTM 01646.1R0253/1R0254

13.4 COMPONENT REPAIR PROCEDURES

13.4.1 WATER TEMPERATURE REGULATOR & MANIFOLD

The following maintenance procedures are provided for the Water Temperature Regulator & Manifold:

Inspect
Test
Remove
Install

COOLANT THERMOSTAT HOUSING

FIGURE 13.4.1-1 WATER TEMPERATURE REGULATOR & MANIFOLD

13.4.1.1 INSPECT WATER TEMPERATURE REGULATOR & MANIFOLD

Inspect the water pump and thermostat for the following conditions:

a. Check for security of attachment.

b. Check for evidence of damage or leakage.

c. Check for missing or damaged mounting hardware.

13-15
USAF TO 35C2-3-518-1
USA TM 9-6115-484-14
DRS RADIAN CTM 01646.1R0253/1R0254

13.4.1.2 TEST WATER TEMPERATURE REGULATOR & MANIFOLD

WARNING

ALWAYS WEAR EYE PROTECTION WHEN YOU PERFORM ANY SERVICE WORK
ON A COOLING SYSTEM

WARNING

RELEASE THE PRESSURE IN THE COOLING SYSTEM BEFORE PERFORMING ANY


SERVICE WORK. IF THE PRESSURE IN THE COOLING SYSTEM IS NOT
RELEASED OR THE TEMPERATURE OF THE SYSTEM IS NOT PERMITTED TO
COOL, STEAM OR HOT WATER MAY BE RELEASED WHEN YOU REMOVE THE
FILLER CAP. THIS MAY CAUSE PERSONAL INJURY.

WARNING

TO RELEASE THE PRESSURE IN A COOLING SYSTEM, LET THE SYSTEM COOL,


PUT A HEAVY CLOTH OVER THE CAP AND LOOSEN IT SLOWLY.

WARNING

DO NOT ALLOW UNDILUTED CORROSION INHIBITORS OR DILUTED/UNDILUTED


RADIATOR CLEANERS TO COME IN CONTACT WITH THE SKIN OR EYES.

WARNING

ALWAYS FOLLOW THE MANUFACTURER’S INSTRUCTIONS WHEN HANDLING


CORROSION INHIBITORS, RADIATOR CLEANERS OR ANTIFREEZE BE
ESPECIALLY SURE TO FOLLOW THE MANUFACTURER’S RECOMMENDATIONS
CONCERNING TOXICITY.

WARNING

ETHYLENE GLYCOL MAY CATCH FIRE WHEN IT IS HOT OR EXPOSED TO AN


OPEN FLAME. DO NOT WELD, CUT OR USE AN OPEN FLAME NEAR LEAKING
COOLANT THAT CONTAINS ANTIFREEZE.

WARNING

DO NOT REMOVE FILLER CAP AFTER OPERATION UNTIL SYSTEM HAS COOLED
DOWN. FAILURE TO ALLOW ENGINE COOLANT TO COOL DOWN COULD RESULT
IN SECOND AND THIRD DEGREE BURNS. CAP MAY BE HALF-TURNED TO
RELIEVE PRESSURE AND THEN REMOVED TO INSPECT COOLANT LEVEL.

13-16
USAF TO 35C2-3-518-1
USA TM 9-6115-484-14
DRS RADIAN CTM 01646.1R0253/1R0254

WARNING

PERSONAL INJURY CAN RESULT FROM HOT COOLANT, STEAM AND ALKALI.

WARNING

AT OPERATING TEMPERATURE, ENGINE COOLANT IS HOT AND UNDER PRESSURE.


THE RADIATOR AND ALL LINES TO THE ENGINE CONTAIN HOT COOLANT OR STEAM.
ANY CONTACT CAN CAUSE SEVERE BURNS.

WARNING

REMOVE FILLER CAP SLOWLY TO RELIEVE PRESSURE ONLY WHEN THE ENGINE IS
STOPPED AND THE FILLER CAP IS COOL ENOUGH TO TOUCH WITH YOUR BARE HAND.

WARNING

COOLING SYSTEM CONDITIONER CONTAINS ALKALI. AVOID CONTACT WITH SKIN AND
EYES.

CAUTION

CARE MUST BE TAKEN TO ENSURE THAT FLUIDS ARE CONTAINED DURING


PERFORMANCE OF INSPECTION, MAINTENANCE, TESTING, ADJUSTING AND
REPAIR OF THE PU. BE PREPARED TO COLLECT THE FLUID WITH SUITABLE
CONTAINERS BEFORE OPENING ANY COMPARTMENT OR DISASSEMBLY ANY
COMPONENT CONTAINING FLUIDS. DISPOSE OF FLUIDS ACCORDING TO
LOCAL REGULATIONS AND MANDATES.

CAUTION

THE WATER TEMPERATURE REGULATORS (2 EA) ARE AN IMPORTANT PART OF


THE COOLING SYSTEM. THE WATER TEMPERATURE REGULATORS DIVIDE THE
COOLANT FLOW BETWEEN THE RADIATOR AND THE BYPASS ELBOW. THIS
WILL MAINTAIN THE CORRECT ENGINE TEMPERATURE. IF THE WATER
TEMPERATURE REGULATORS ARE NOT INSTALLED IN THE SYSTEM, THERE IS
NO MECHANICAL TEMPERATURE CONTROL. MOST OF THE COOLANT WILL GO
THROUGH THE BYPASS. THIS WILL CAUSE THE ENGINE TO OVERHEAT IN HOT
WEATHER. IF A HIGHER VOLUME OF COOLANT GOES THROUGH THE
RADIATOR, THE ENGINE WILL NOT REACH NORMAL OPERATING
TEMPERATURES. THIS OCCURS DURING COLD WEATHER.

To test the Water Temperature Regulator & Manifold, proceed as follows:

a. This maintenance requires that the PU MUST be shutdown, rendered unable to start, cool
enough for the maintenance to be performed, and Communication Cable (A) and (B)
rerouted to the next PU. This is accomplished by performing the following:

(1) Shutdown the PU in accordance with Section 5.1.6.1 Shutdown Generators.

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USA TM 9-6115-484-14
DRS RADIAN CTM 01646.1R0253/1R0254
(2) Isolate the PU from any power plant control system in accordance with Note 1.
(3) Pull to open the PU DC Power Control Breaker.
(4) Push to open both Emergency Stop Switches.
(5) Place both Engine Control Switches (ECS) in the OFF position.
(6) Place a DO NOT OPERATE tag on both generator control panels.
(7) Turn the Battery Bank Parallel Switch to the OFF position.
(8) De-energize both Battery Chargers.
(9) Disconnect the negative and positive cables from both Battery Banks.
(10) Place a DO NOT OPERATE tag on both Battery Banks.
(11) Place all Circuit Breakers in the LOCK OUT position.
(12) Disconnect both 7P1 and 7P2 Connectors located on the inside panel of the PDC.
(13) Close and Lock both generator set control panels.

NOTE 1: When the DC Control Power Circuit Breaker is in the (OFF) position (Pulled – Out), all control
power is turned off to the PU. This will cause the HUB to stop functioning. This causes the
network to not see the equipment shutdown and all PU’s after it. When pulling major
maintenance the (A) (B) Communication Cable must be routed to the next PU in order to
reestablish the communication network.

b. Remove the Water Temperature Regulator & Manifold. Refer to Section 13.4.1.3 for reference.

c. Heat water in a pan until the temperature is 98ºC (208ºF). Stir the water in the pan. This allows
the temperature to be consistent throughout the pan.

d. Hang one of the Water Temperature Regulators in the pan of water. The Water Temperature
Regulator must be below the surface of the water. The Water Temperature Regulator must be
away from the sides and the bottom of the pan.

e. Keep the water at the correct temperature for ten minutes.

f. After ten minutes, remove the Water Temperature Regulator. Immediately check the distance
that the Water Temperature Regulator has opened. Refer to Table 13.4.1.2-1 for reference.

TABLE 13.4.1.2-1 WATER TEMPERATURE REGULATOR


WATER TEMPERATURE REGULATOR 7C-3095
7C-3095 °F °C Regulator Dimension
REGULATOR START-TO-OPEN TEMP 190°F 88°C
REGULATOR FULL OPENING TEMPERATURE 208°F 98°C
MINIMUM OPENING DISTANCE 208°F 98°C 0.41 inch (10.4 mm)

g. The distance must be at least 0.41 inch (10.4 mm).

h. If the water temperature regulator does not meet specifications, replace it.

i. Repeat steps d through h for the other water temperature regulator.

13-18
USAF TO 35C2-3-518-1
USA TM 9-6115-484-14
DRS RADIAN CTM 01646.1R0253/1R0254

13.4.1.3 REMOVE WATER TEMPERATURE REGULATOR & MANIFOLD

To remove the Water Temperature Regulator & Manifold, proceed as follows:

a. This maintenance requires that the PU MUST be shutdown, rendered unable to start, cool
enough for the maintenance to be performed, and Communication Cable (A) and (B)
rerouted to the next PU. See procedures and warnings in paragraph 13.4.1.2.

COOLANT THERMOSTAT HOUSING

WATER PUMP HOUSING

OIL COOLER HOUSING

FIGURE 13.4.1.3-1 WATER TEMPERATURE REGULATOR

b. Drain the coolant from the engine into a suitable container for storage or disposal.

c. Disconnect the upper hose from the water manifold.

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USA TM 9-6115-484-14
DRS RADIAN CTM 01646.1R0253/1R0254

FIGURE 13.4.1.3-2 THERMOSTAT HOUSING

d. Loosen hose clamps (1). Remove five bolts (3). Use Figure 13.4.1.3-1 and Figure 13.4.1.3-2 for
reference.

e. Remove water temperature regulator housing (2) and manifold (4) for the water regulators as a
unit. Use Figure 13.3.4.1.3-2 for reference.

FIGURE 13.4.1.3-3 THERMOSTAT HOUSING

f. Remove gasket (5) from manifold (4) for the water temperature regulators. Use Figure 13.4.1.3-3
for reference.

FIGURE 13.4.1.3-4 THERMOSTAT HOUSING

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USA TM 9-6115-484-14
DRS RADIAN CTM 01646.1R0253/1R0254

g. Remove the four mounting bolts (6). Separate the Water Temperature Regulator Housing (2)
from the manifold for the Water Temperature Regulators. Use Figure 13.4.1.3-4 for reference.

FIGURE 13.4.1.3-5 DISASSEMBLY OF THERMOSTAT HOUSING

h. Remove the gasket (7) from the manifold (4) for the Water Temperature Regulators. Use Figure
13.4.1.3-5 for reference.

i. Remove two water temperature regulators (8) from Water Temperature Regulator Housing (2).
Use Figure 13.4.1.3-5 for reference.

FIGURE 13.4.1.3-6 DISASSEMBLED THERMOSTAT HOUSING

j. Remove two lip seals (9) from Water Temperature Regulator Housing (2). Use Figure 13.4.1.3-6
for reference.

13-21
USAF TO 35C2-3-518-1
USA TM 9-6115-484-14
DRS RADIAN CTM 01646.1R0253/1R0254
13.4.1.4 INSTALL WATER TEMPERATURE REGULATOR & MANIFOLD

To install the Water Temperature Regulator & Manifold, proceed as follows:

a. This maintenance requires that the PU MUST be shutdown, rendered unable to start, cool
enough for the maintenance to be performed, and Communication Cable (A) and (B)
rerouted to the next PU. See procedures and warnings in paragraph 13.4.1.2.

b. Reinstall two new lip seals (9) in the Water Temperature Regulator Housing (2). Use Figure
13.4.1.3-6 for reference.

c. Reinstall the two water temperature regulators (8) in Water Temperature Regulator Housing (2).
Use Figure 13.4.1.3-5 for reference.

d. Reinstall gasket (7) in the manifold (4) for the Water Temperature Regulator. Use Figure
13.4.1.3-5 for reference.

e. Assemble Water Temperature Regulator Housing (2) to the manifold for the Water Temperature
Regulators using Figure 13.4.1.3-4 for reference. Reinstall the four bolts (6).

f. Reinstall gasket with a new one (5) on the manifold (4) for the Water Temperature Regulators.
Use Figure 13.4.1.3-3 for reference.

g. Reinstall the Water Temperature Regulator Housing (2) and manifold (4) for the Water
Temperature Regulator as a unit using Figure 13.4.1.3-2 for reference.

h. Tighten the hose clamps (1). Reinstall the five bolts (3) using Figure 13.4.1.3-2 for reference.

i. Connect the upper hose to the water manifold.

j. Refill the coolant system using Section 13.4.5.5 and Annex G as reference.

13-22
USAF TO 35C2-3-518-1
USA TM 9-6115-484-14
DRS RADIAN CTM 01646.1R0253/1R0254

13.4.2 WATER PUMP

The following maintenance procedures are provided for the Water Pump:

Inspect
Test
Remove
Install

WATER PUMP

FIGURE 13.4.2-1 WATER PUMP

13.4.2.1 INSPECT WATER PUMP

Inspect the Water Pump for the following:

• Wear
• Cracks
• Pin holes

NOTE: A small amount of seepage at the weep hole on the water pump can be considered normal.

13-23
USAF TO 35C2-3-518-1
USA TM 9-6115-484-14
DRS RADIAN CTM 01646.1R0253/1R0254

13.4.2.2 TEST WATER PUMP

FIGURE 13.4.2.2-1 WATER PUMP

a. A failed water pump might cause severe engine overheating problems that could result in the
following conditions:

• Cracks in the cylinder head


• A piston seizure
• Other potential damage to the engine

b. To test the Water Pump Pressure, proceed as follows (Refer to Figure 13.4.2.2-1 callouts):

c. The water pump outlet pressure can be checked on the water manifold assembly (4). This check
will determine if the water pump is operating correctly.

d. Remove 1/2 “ square plug (1) from the water manifold assembly (2). Install the pressure gauge
9S-8138 Pressure Gauge in the port and measure the pump pressure. The pressure of the
water pump should be 16 + 2 PSI (112+ 12kPa).

e. A change of pressure can be measured between the plug (1) on the water manifold assembly (2)
and the plug (3) on the inlet side of the water pump (4).

13-24
USAF TO 35C2-3-518-1
USA TM 9-6115-484-14
DRS RADIAN CTM 01646.1R0253/1R0254

13.4.2.3 REMOVE WATER PUMP

WARNING

ALWAYS WEAR EYE PROTECTION WHEN YOU PERFORM ANY SERVICE WORK
ON A COOLING SYSTEM

WARNING

RELEASE THE PRESSURE IN THE COOLING SYSTEM BEFORE PERFORMING ANY


SERVICE WORK. IF THE PRESSURE IN THE COOLING SYSTEM IS NOT
RELEASED OR THE TEMPERATURE OF THE SYSTEM IS NOT PERMITTED TO
COOL, STEAM OR HOT WATER MAY BE RELEASED WHEN YOU REMOVE THE
FILLER CAP. THIS MAY CAUSE PERSONAL INJURY.

WARNING

TO RELEASE THE PRESSURE IN A COOLING SYSTEM, LET THE SYSTEM COOL,


PUT A HEAVY CLOTH OVER THE CAP AND LOOSEN IT SLOWLY.

WARNING

DO NOT ALLOW UNDILUTED CORROSION INHIBITORS OR DILUTED/UNDILUTED


RADIATOR CLEANERS TO COME IN CONTACT WITH THE SKIN OR EYES.

WARNING

ALWAYS FOLLOW THE MANUFACTURER’S INSTRUCTIONS WHEN HANDLING


CORROSION INHIBITORS, RADIATOR CLEANERS OR ANTIFREEZE BE
ESPECIALLY SURE TO FOLLOW THE MANUFACTURER’S RECOMMENDATIONS
CONCERNING TOXICITY.

WARNING

ETHYLENE GLYCOL MAY CATCH FIRE WHEN IT IS HOT OR EXPOSED TO AN


OPEN FLAME. DO NOT WELD, CUT OR USE AN OPEN FLAME NEAR LEAKING
COOLANT THAT CONTAINS ANTIFREEZE.

WARNING

DO NOT REMOVE FILLER CAP AFTER OPERATION UNTIL SYSTEM HAS COOLED
DOWN. FAILURE TO ALLOW ENGINE COOLANT TO COOL DOWN COULD RESULT
IN SECOND AND THIRD DEGREE BURNS. CAP MAY BE HALF-TURNED TO
RELIEVE PRESSURE AND THEN REMOVED TO INSPECT COOLANT LEVEL.

13-25
USAF TO 35C2-3-518-1
USA TM 9-6115-484-14
DRS RADIAN CTM 01646.1R0253/1R0254

WARNING

PERSONAL INJURY CAN RESULT FROM HOT COOLANT, STEAM AND ALKALI.

WARNING

AT OPERATING TEMPERATURE, ENGINE COOLANT IS HOT AND UNDER PRESSURE.


THE RADIATOR AND ALL LINES TO THE ENGINE CONTAIN HOT COOLANT OR STEAM.
ANY CONTACT CAN CAUSE SEVERE BURNS.

CAUTION

CARE MUST BE TAKEN TO ENSURE THAT FLUIDS ARE CONTAINED DURING


PERFORMANCE OF INSPECTION, MAINTENANCE, TESTING, ADJUSTING AND
REPAIR OF THE PU. BE PREPARED TO COLLECT THE FLUID WITH SUITABLE
CONTAINERS BEFORE OPENING ANY COMPARTMENT OR DISASSEMBLY ANY
COMPONENT CONTAINING FLUIDS. DISPOSE OF FLUIDS ACCORDING TO
LOCAL REGULATIONS AND MANDATES.

CAUTION

THE WATER TEMPERATURE REGULATORS (2 EA) ARE AN IMPORTANT PART OF


THE COOLING SYSTEM. THE WATER TEMPERATURE REGULATORS DIVIDE THE
COOLANT FLOW BETWEEN THE RADIATOR AND THE BYPASS ELBOW. THIS
WILL MAINTAIN THE CORRECT ENGINE TEMPERATURE. IF THE WATER
TEMPERATURE REGULATORS ARE NOT INSTALLED IN THE SYSTEM, THERE IS
NO MECHANICAL TEMPERATURE CONTROL. MOST OF THE COOLANT WILL GO
THROUGH THE BYPASS. THIS WILL CAUSE THE ENGINE TO OVERHEAT IN HOT
WEATHER. IF A HIGHER VOLUME OF COOLANT GOES THROUGH THE
RADIATOR, THE ENGINE WILL NOT REACH NORMAL OPERATING
TEMPERATURES. THIS OCCURS DURING COLD WEATHER.

To remove the Water Pump, proceed as follows:

a. This maintenance requires that the PU MUST be shutdown, rendered unable to start, cool
enough for the maintenance to be performed, and Communication Cable (A) and (B)
rerouted to the next PU. This is accomplished by performing the following:

13-26
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USA TM 9-6115-484-14
DRS RADIAN CTM 01646.1R0253/1R0254
(1) Shutdown the PU in accordance with Section 5.1.6.1 Shutdown Generators.
(2) Isolate the PU from any power plant control system in accordance with Note 1.
(3) Pull to open the PU DC Power Control Breaker.
(4) Push to open both Emergency Stop Switches.
(5) Place both Engine Control Switches (ECS) in the OFF position.
(6) Place a DO NOT OPERATE tag on both generator control panels.
(7) Turn the Battery Bank Parallel Switch to the OFF position.
(8) De-energize both Battery Chargers.
(9) Disconnect the negative and positive cables from both Battery Banks.
(10) Place a DO NOT OPERATE tag on both Battery Banks.
(11) Place all Circuit Breakers in the LOCK OUT position.
(12) Disconnect both 7P1 and 7P2 Connectors located on the inside panel of the PDC.
(13) Close and Lock both generator set control panels.

NOTE 1: When the DC Control Power Circuit Breaker is in the (OFF) position (Pulled – Out), all control
power is turned off to the PU. This will cause the HUB to stop functioning. This causes the
network to not see the equipment shutdown and all PU’s after it. When pulling major
maintenance the (A) (B) Communication Cable must be routed to the next PU in order to
reestablish the communication network.

b. Drain the coolant from the engine into a suitable container for storage or disposal.

c. Remove the Water Temperature Regulators and manifold.

d. Remove the Oil Cooler Front Bonnet. Be prepared to use Fluid Spillage Containment.

NOTE: Care must be taken to ensure that fluids are contained during performance of inspection,
maintenance, testing, adjusting and repair of the machine. Be prepared to collect the fluid
with suitable containers before opening any compartment or disassembling any component
containing fluids. Dispose of fluids according to local regulations and mandates.

e. Remove the coolant coupling from the line at the base of the Water Pump.

f. Remove mounting bolts from the timing gear cover and remove the Water Pump.

g. Check the condition of 0-ring seal. Use a new part for replacement if 0-ring seal is worn or
damaged.

13.4.2.4 INSTALL WATER PUMP

To install the Water Pump, proceed as follows:

a. This maintenance requires that the PU MUST be shutdown, rendered unable to start, cool
enough for the maintenance to be performed, and Communication Cable (A) and (B)
rerouted to the next PU. See procedures and warnings in paragraph 13.4.2.3.

b. Check the condition of 0-ring seal. Use a new part for replacement if 0-ring seal is worn or
damaged.

c. Reinstall the water pump and timing gear cover with the mounting bolts.

d. Reconnect the coolant coupling at the inlet of the water pump.

e. Reinstall the Oil Cooler and Oil Filter Base.

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DRS RADIAN CTM 01646.1R0253/1R0254
f. Reinstall the Water Temperature Regulator and manifold.

g. Refill the coolant system using Section 13.4.5.5 and Annex G as reference.

NOTE: Care must be taken to ensure that fluids are contained during performance of inspection,
maintenance, testing, adjusting and repair of the machine. Be prepared to collect the fluid
with suitable containers before opening any compartment or disassembling any component
containing fluids. Dispose of fluids according to local regulations and mandates.

13.4.3 FILLER CAP

The following maintenance procedures are provided for the Filler Cap:

Inspect
Test
Remove
Install

FILLER CAP

FIGURE 13.4.3-1 FILLER CAP

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USA TM 9-6115-484-14
DRS RADIAN CTM 01646.1R0253/1R0254
13.4.3.1 INSPECT FILLER CAP

WARNING

ALWAYS WEAR EYE PROTECTION WHEN YOU PERFORM ANY SERVICE WORK
ON A COOLING SYSTEM

WARNING

RELEASE THE PRESSURE IN THE COOLING SYSTEM BEFORE PERFORMING ANY


SERVICE WORK. IF THE PRESSURE IN THE COOLING SYSTEM IS NOT
RELEASED OR THE TEMPERATURE OF THE SYSTEM IS NOT PERMITTED TO
COOL, STEAM OR HOT WATER MAY BE RELEASED WHEN YOU REMOVE THE
FILLER CAP. THIS MAY CAUSE PERSONAL INJURY.

WARNING

TO RELEASE THE PRESSURE IN A COOLING SYSTEM, LET THE SYSTEM COOL,


PUT A HEAVY CLOTH OVER THE CAP AND LOOSEN IT SLOWLY.

WARNING

DO NOT ALLOW UNDILUTED CORROSION INHIBITORS OR DILUTED/UNDILUTED


RADIATOR CLEANERS TO COME IN CONTACT WITH THE SKIN OR EYES.

WARNING

ALWAYS FOLLOW THE MANUFACTURER’S INSTRUCTIONS WHEN HANDLING


CORROSION INHIBITORS, RADIATOR CLEANERS OR ANTIFREEZE BE
ESPECIALLY SURE TO FOLLOW THE MANUFACTURER’S RECOMMENDATIONS
CONCERNING TOXICITY.

WARNING

ETHYLENE GLYCOL MAY CATCH FIRE WHEN IT IS HOT OR EXPOSED TO AN


OPEN FLAME. DO NOT WELD, CUT OR USE AN OPEN FLAME NEAR LEAKING
COOLANT THAT CONTAINS ANTIFREEZE.

WARNING

DO NOT REMOVE FILLER CAP AFTER OPERATION UNTIL SYSTEM HAS COOLED
DOWN. FAILURE TO ALLOW ENGINE COOLANT TO COOL DOWN COULD RESULT
IN SECOND AND THIRD DEGREE BURNS. CAP MAY BE HALF-TURNED TO
RELIEVE PRESSURE AND THEN REMOVED TO INSPECT COOLANT LEVEL.

WARNING

PERSONAL INJURY CAN RESULT FROM HOT COOLANT, STEAM AND ALKALI.

13-29
USAF TO 35C2-3-518-1
USA TM 9-6115-484-14
DRS RADIAN CTM 01646.1R0253/1R0254

WARNING

AT OPERATING TEMPERATURE, ENGINE COOLANT IS HOT AND UNDER


PRESSURE. THE RADIATOR AND ALL LINES TO THE ENGINE CONTAIN HOT
COOLANT OR STEAM. ANY CONTACT CAN CAUSE SEVERE BURNS.

WARNING

REMOVE FILLER CAP SLOWLY TO RELIEVE PRESSURE ONLY WHEN THE


ENGINE IS STOPPED AND THE FILLER CAP IS COOL ENOUGH TO TOUCH WITH
YOUR BARE HAND.

WARNING

COOLING SYSTEM CONDITIONER CONTAINS ALKALI. AVOID CONTACT WITH


SKIN AND EYES.

CAUTION

CARE MUST BE TAKEN TO ENSURE THAT FLUIDS ARE CONTAINED DURING


PERFORMANCE OF INSPECTION, MAINTENANCE, TESTING, ADJUSTING AND
REPAIR OF THE PU. BE PREPARED TO COLLECT THE FLUID WITH SUITABLE
CONTAINERS BEFORE OPENING ANY COMPARTMENT OR DISASSEMBLY ANY
COMPONENT CONTAINING FLUIDS. DISPOSE OF FLUIDS ACCORDING TO
LOCAL REGULATIONS AND MANDATES.

CAUTION

THE WATER TEMPERATURE REGULATORS (2 EA) ARE AN IMPORTANT PART OF


THE COOLING SYSTEM. THE WATER TEMPERATURE REGULATORS DIVIDE THE
COOLANT FLOW BETWEEN THE RADIATOR AND THE BYPASS ELBOW. THIS
WILL MAINTAIN THE CORRECT ENGINE TEMPERATURE. IF THE WATER
TEMPERATURE REGULATORS ARE NOT INSTALLED IN THE SYSTEM, THERE IS
NO MECHANICAL TEMPERATURE CONTROL. MOST OF THE COOLANT WILL GO
THROUGH THE BYPASS. THIS WILL CAUSE THE ENGINE TO OVERHEAT IN HOT
WEATHER. IF A HIGHER VOLUME OF COOLANT GOES THROUGH THE
RADIATOR, THE ENGINE WILL NOT REACH NORMAL OPERATING
TEMPERATURES. THIS OCCURS DURING COLD WEATHER.

Inspect the Filler Cap for the following conditions:

a. This maintenance requires that the PU MUST be shutdown, rendered unable to start, cool
enough for the maintenance to be performed, and Communication Cable (A) and (B)
rerouted to the next PU. This is accomplished by performing the following:

(1) Shutdown the PU in accordance with Section 5.1.6.1 Shutdown Generators.


(2) Isolate the PU from any power plant control system in accordance with Note 1.
(3) Pull to open the PU DC Power Control Breaker.
(4) Push to open both Emergency Stop Switches.
(5) Place both Engine Control Switches (ECS) in the OFF position.
(6) Place a DO NOT OPERATE tag on both generator control panels.
(7) Turn the Battery Bank Parallel Switch to the OFF position.

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DRS RADIAN CTM 01646.1R0253/1R0254
(8) De-energize both Battery Chargers.
(9) Disconnect the negative and positive cables from both Battery Banks.
(10) Place a DO NOT OPERATE tag on both Battery Banks.
(11) Place all Circuit Breakers in the LOCK OUT position.
(12) Disconnect both 7P1 and 7P2 Connectors located on the inside panel of the PDC.
(13) Close and Lock both generator set control panels.

NOTE 1: When the DC Control Power Circuit Breaker is in the (OFF) position (Pulled – Out), all control
power is turned off to the PU. This will cause the HUB to stop functioning. This causes the
network to not see the equipment shutdown and all PU’s after it. When pulling major
maintenance the (A) (B) Communication Cable must be routed to the next PU in order to
reestablish the communication network.

b. After the engine cools, loosen the Filler Cap. Slowly release the pressure from the cooling
system. Then, remove the Filler Cap.

c. Carefully inspect the Filler Cap. Check for any damage to the seals and to the sealing surface.

d. Inspect the following components for any foreign substances:

• Filler Cap
• Seal
• Surface for seal

e. Remove any deposits or foreign materials that are found on these items.

13.4.3.2 TEST FILLER CAP

To test the Filler Cap for the amount of pressure that opens the Filler Cap, proceed as follows:

a. This maintenance requires that the PU MUST be shutdown, rendered unable to start, cool
enough for the maintenance to be performed, and Communication Cable (A) and (B)
rerouted to the next PU. See procedures and warnings in paragraph 13.4.3.1.

b. Carefully remove the Filler Cap from the coolant reservoir.

c. Place the Filler Cap on the Caterpillar 9S-8140 Pressuring Pump following instructions provided
with the Caterpillar 9S-8140 Pressuring Pump.

d. Look at the gauge for the exact pressure that opens the Filler Cap.

e. Compare the gauge’s reading with the correct pressure that should open the Filler Cap. The
pressure should be + 0.5lb of pressure printed on Filler Cap.

f. If the Filler Cap is defective, replace the Filler Cap.

13-31
USAF TO 35C2-3-518-1
USA TM 9-6115-484-14
DRS RADIAN CTM 01646.1R0253/1R0254
13.4.3.3 REMOVE AND INSTALL FILLER CAP

To remove the Filler Cap, proceed as follows:

a. This maintenance requires that the PU MUST be shutdown, rendered unable to start, cool
enough for the maintenance to be performed, and Communication Cable (A) and (B)
rerouted to the next PU. See procedures and warnings in paragraph 13.4.3.1.

b. After the engine cools, slowly loosen the Filler Cap.

c. Slowly release the pressure from the cooling system.

d. Remove the Filler Cap.

To install the Filler Cap, proceed as follows:

a. Place the Filler Cap into position.

b. Pushdown and twist to the right until the Filler Cap until the Filler Cap is properly sealed and in
the closed position.

13-32
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USA TM 9-6115-484-14
DRS RADIAN CTM 01646.1R0253/1R0254
13.4.4 ENGINE OIL COOLER

The following maintenance procedures are provided for the Engine Oil Cooler:

Inspect
Test
Remove
Install

ENGINE OIL COOLER

OIL FILTER BASE/ ADAPTER


FOR REMOTE OIL FILTER

FIGURE 13.4.4-1 ENGINE OIL COOLER

13.4.4.1 INSPECT ENGINE OIL COOLER

Inspect the Engine Oil Cooler for the following:

a. Inspect for evidence of damage or leakage.

b. Inspect for security of attachment.

c. Inspect for corrosion and signs of deterioration.

(See Caterpillar SENR1068, Section 1378-010 for reference)

13.4.4.2 TEST ENGINE OIL COOLER

To test the Engine Oil Cooler, proceed as follows:

There is no testing required for this device.

13-33
USAF TO 35C2-3-518-1
USA TM 9-6115-484-14
DRS RADIAN CTM 01646.1R0253/1R0254

13.4.4.3 REMOVE ENGINE OIL COOLER

WARNING

ALWAYS WEAR EYE PROTECTION WHEN YOU PERFORM ANY SERVICE WORK
ON A COOLING SYSTEM

WARNING

RELEASE THE PRESSURE IN THE COOLING SYSTEM BEFORE PERFORMING ANY


SERVICE WORK. IF THE PRESSURE IN THE COOLING SYSTEM IS NOT
RELEASED OR THE TEMPERATURE OF THE SYSTEM IS NOT PERMITTED TO
COOL, STEAM OR HOT WATER MAY BE RELEASED WHEN YOU REMOVE THE
FILLER CAP. THIS MAY CAUSE PERSONAL INJURY.

WARNING

TO RELEASE THE PRESSURE IN A COOLING SYSTEM, LET THE SYSTEM COOL,


PUT A HEAVY CLOTH OVER THE CAP AND LOOSEN IT SLOWLY.

WARNING

DO NOT ALLOW UNDILUTED CORROSION INHIBITORS OR DILUTED/UNDILUTED


RADIATOR CLEANERS TO COME IN CONTACT WITH THE SKIN OR EYES.

WARNING

ALWAYS FOLLOW THE MANUFACTURER’S INSTRUCTIONS WHEN HANDLING


CORROSION INHIBITORS, RADIATOR CLEANERS OR ANTIFREEZE BE
ESPECIALLY SURE TO FOLLOW THE MANUFACTURER’S RECOMMENDATIONS
CONCERNING TOXICITY.

WARNING

ETHYLENE GLYCOL MAY CATCH FIRE WHEN IT IS HOT OR EXPOSED TO AN


OPEN FLAME. DO NOT WELD, CUT OR USE AN OPEN FLAME NEAR LEAKING
COOLANT THAT CONTAINS ANTIFREEZE.

WARNING

DO NOT REMOVE FILLER CAP AFTER OPERATION UNTIL SYSTEM HAS COOLED
DOWN. FAILURE TO ALLOW ENGINE COOLANT TO COOL DOWN COULD RESULT
IN SECOND AND THIRD DEGREE BURNS. CAP MAY BE HALF-TURNED TO
RELIEVE PRESSURE AND THEN REMOVED TO INSPECT COOLANT LEVEL.

13-34
USAF TO 35C2-3-518-1
USA TM 9-6115-484-14
DRS RADIAN CTM 01646.1R0253/1R0254

WARNING

PERSONAL INJURY CAN RESULT FROM HOT COOLANT, STEAM AND ALKALI.

WARNING

AT OPERATING TEMPERATURE, ENGINE COOLANT IS HOT AND UNDER


PRESSURE. THE RADIATOR AND ALL LINES TO THE ENGINE CONTAIN HOT
COOLANT OR STEAM. ANY CONTACT CAN CAUSE SEVERE BURNS.

WARNING

COOLING SYSTEM CONDITIONER CONTAINS ALKALI. AVOID CONTACT WITH


SKIN AND EYES.

CAUTION

CARE MUST BE TAKEN TO ENSURE THAT FLUIDS ARE CONTAINED DURING


PERFORMANCE OF INSPECTION, MAINTENANCE, TESTING, ADJUSTING AND
REPAIR OF THE PU. BE PREPARED TO COLLECT THE FLUID WITH SUITABLE
CONTAINERS BEFORE OPENING ANY COMPARTMENT OR DISASSEMBLY ANY
COMPONENT CONTAINING FLUIDS. DISPOSE OF FLUIDS ACCORDING TO
LOCAL REGULATIONS AND MANDATES.

CAUTION

THE WATER TEMPERATURE REGULATORS (2 EA) ARE AN IMPORTANT PART OF


THE COOLING SYSTEM. THE WATER TEMPERATURE REGULATORS DIVIDE THE
COOLANT FLOW BETWEEN THE RADIATOR AND THE BYPASS ELBOW. THIS
WILL MAINTAIN THE CORRECT ENGINE TEMPERATURE. IF THE WATER
TEMPERATURE REGULATORS ARE NOT INSTALLED IN THE SYSTEM, THERE IS
NO MECHANICAL TEMPERATURE CONTROL. MOST OF THE COOLANT WILL GO
THROUGH THE BYPASS. THIS WILL CAUSE THE ENGINE TO OVERHEAT IN HOT
WEATHER. IF A HIGHER VOLUME OF COOLANT GOES THROUGH THE
RADIATOR, THE ENGINE WILL NOT REACH NORMAL OPERATING
TEMPERATURES. THIS OCCURS DURING COLD WEATHER.

To remove the Engine Oil Cooler, proceed as follows:

a. This maintenance requires that the PU MUST be shutdown, rendered unable to start, cool
enough for the maintenance to be performed, and Communication Cable (A) and (B)
rerouted to the next PU. This is accomplished by performing the following:

(1) Shutdown the PU in accordance with Section 5.1.6.1 Shutdown Generators.


(2) Isolate the PU from any power plant control system in accordance with Note 1.
(3) Pull to open the PU DC Power Control Breaker.
(4) Push to open both Emergency Stop Switches.
(5) Place both Engine Control Switches (ECS) in the OFF position.
(6) Place a DO NOT OPERATE tag on both generator control panels.
(7) Turn the Battery Bank Parallel Switch to the OFF position.
(8) De-energize both Battery Chargers.
(9) Disconnect the negative and positive cables from both Battery Banks.
(10) Place a DO NOT OPERATE tag on both Battery Banks.

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USAF TO 35C2-3-518-1
USA TM 9-6115-484-14
DRS RADIAN CTM 01646.1R0253/1R0254
(11) Place all Circuit Breakers in the LOCK OUT position.
(12) Disconnect both 7P1 and 7P2 Connectors located on the inside panel of the PDC.
(13) Close and Lock both generator set control panels.

NOTE 1: When the DC Control Power Circuit Breaker is in the (OFF) position (Pulled – Out), all control
power is turned off to the PU. This will cause the HUB to stop functioning. This causes the
network to not see the equipment shutdown and all PU’s after it. When pulling major
maintenance the (A) (B) Communication Cable must be routed to the next PU in order to
reestablish the communication network.

NOTE: Care must be taken to ensure that fluids are contained during performance of inspection,
maintenance, testing, adjusting and repair of the machine. Be prepared to collect the Fluid
with suitable containers before opening any compartment or disassembling any component
containing fluids. Dispose of fluids according to local regulations and mandates.

b. Drain the oil from the Engine Oil Cooler. Drain the coolant from the engine.

c. Remove the four mounting bolts that hold the Engine Oil Cooler to the Oil Filter Base.

d. Remove the four mounting bolts that hold the Engine Oil Cooler to the Cylinder Block. Remove
the Engine Oil Cooler.

e. Remove the coupling from the Oil Inlet Pipe.

f. Remove the O-ring seals from the coupling.

g. Put identification marks on the Elbow and Engine Oil Cooler for proper alignment during
assembly. Remove the elbow from the Engine Oil Cooler. Remove the O-ring seal from the
elbow.

h. Clean the Engine Oil Cooler Tubes with a .150 in (3.81mm) diameter rod.

NOTE: Check the condition of all O-ring seals on the engine oil cooler and oil filter base. If the
coupling and elbow are removed, replace O - rings with a new O - rings. Use new parts for
replacement if an O-ring seal appears to be worn or damaged. Put clean engine oil on the O-
ring seals before assembling the components.

13.4.4.4 INSTALL ENGINE OIL COOLER

To install the Engine Oil Cooler, proceed as follows:

a. This maintenance requires that the PU MUST be shutdown, rendered unable to start, cool
enough for the maintenance to be performed, and Communication Cable (A) and (B)
rerouted to the next PU. See procedures and warnings in paragraph 13.4.4.3.

b. Put the O-ring seal in position on Elbow. Put clean engine oil on the O-ring seal.

c. Align the Elbow with the Oil Cooler and reinstall the Elbow into the Oil Cooler.

d. Reinstall the O-rings seals on the Coupling. Put clean engine oil on the O-ring seals.

e. Reinstall the Coupling in the Water Inlet Pipe.

f. Put the Oil Cooler in position on the engine, and reinstall the four mounting bolts removed
earlier.

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DRS RADIAN CTM 01646.1R0253/1R0254

g. Reinstall the four mounting bolts removed earlier that hold the Oil Cooler to the Oil Filter Base.

h. Refill the coolant system using Section 13.4.5.5 and Annex G as reference.

13-37
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USA TM 9-6115-484-14
DRS RADIAN CTM 01646.1R0253/1R0254

13.4.5 RADIATOR AND AFTER COOLER ASSEMBLY

The following maintenance procedures are provided for the Radiator and After Cooler Assembly:

Inspect
Test
Remove
Install
Service

AIR TO AIR AFTERCOOLER


ENGINE COOLANT RADIATOR (ATAAC)

FIGURE 13.4.5-1 RADIATOR AND AFTERCOOLER ASSEMBLY

13-38
USAF TO 35C2-3-518-1
USA TM 9-6115-484-14
DRS RADIAN CTM 01646.1R0253/1R0254

13.4.5.1 INSPECT RADIATOR AND AFTER COOLER ASSEMBLY

Inspect the Radiator and After Cooler (ATAAC) Assembly for the following:

a. Inspect core assembly for evidence of damage or leakage.

b. Inspect for security of attachment.

c. Inspect for corrosion and signs of deterioration.

d. Inspect all Air and Coolant lines and hoses for damage and leaks.

e. Inspect the welded joints for any cracks.

f. Inspect the brackets for correct positioning and condition.

g. Inspect the after cooler and radiator cores fins for the following:

• Damage
• Debris
• Salt

NOTE: Use a stainless steel brush to remove any corrosion from the Radiator or After Cooler
Assembly. Make sure that you use soap and water. After the surface is thoroughly cleaned
and dry, prime and paint using a good quality paint.

13.4.5.2 TEST RADIATOR AND AFTER COOLER ASSEMBLY

WARNING

ALWAYS WEAR EYE PROTECTION WHEN YOU PERFORM ANY SERVICE WORK
ON A COOLING SYSTEM

WARNING

RELEASE THE PRESSURE IN THE COOLING SYSTEM BEFORE PERFORMING ANY


SERVICE WORK. IF THE PRESSURE IN THE COOLING SYSTEM IS NOT
RELEASED OR THE TEMPERATURE OF THE SYSTEM IS NOT PERMITTED TO
COOL, STEAM OR HOT WATER MAY BE RELEASED WHEN YOU REMOVE THE
FILLER CAP. THIS MAY CAUSE PERSONAL INJURY.

WARNING

TO RELEASE THE PRESSURE IN A COOLING SYSTEM, LET THE SYSTEM COOL,


PUT A HEAVY CLOTH OVER THE CAP AND LOOSEN IT SLOWLY.

WARNING

13-39
USAF TO 35C2-3-518-1
USA TM 9-6115-484-14
DRS RADIAN CTM 01646.1R0253/1R0254
DO NOT ALLOW UNDILUTED CORROSION INHIBITORS OR DILUTED/UNDILUTED
RADIATOR CLEANERS TO COME IN CONTACT WITH THE SKIN OR EYES.

WARNING

ALWAYS FOLLOW THE MANUFACTURER’S INSTRUCTIONS WHEN HANDLING


CORROSION INHIBITORS, RADIATOR CLEANERS OR ANTIFREEZE BE
ESPECIALLY SURE TO FOLLOW THE MANUFACTURER’S RECOMMENDATIONS
CONCERNING TOXICITY.

WARNING

ETHYLENE GLYCOL MAY CATCH FIRE WHEN IT IS HOT OR EXPOSED TO AN


OPEN FLAME. DO NOT WELD, CUT OR USE AN OPEN FLAME NEAR LEAKING
COOLANT THAT CONTAINS ANTIFREEZE.

WARNING

DO NOT REMOVE FILLER CAP AFTER OPERATION UNTIL SYSTEM HAS COOLED
DOWN. FAILURE TO ALLOW ENGINE COOLANT TO COOL DOWN COULD RESULT
IN SECOND AND THIRD DEGREE BURNS. CAP MAY BE HALF-TURNED TO
RELIEVE PRESSURE AND THEN REMOVED TO INSPECT COOLANT LEVEL.

WARNING

PERSONAL INJURY CAN RESULT FROM HOT COOLANT, STEAM AND ALKALI.

WARNING

AT OPERATING TEMPERATURE, ENGINE COOLANT IS HOT AND UNDER


PRESSURE. THE RADIATOR AND ALL LINES TO THE ENGINE CONTAIN HOT
COOLANT OR STEAM. ANY CONTACT CAN CAUSE SEVERE BURNS.

WARNING

REMOVE FILLER CAP SLOWLY TO RELIEVE PRESSURE ONLY WHEN THE


ENGINE IS STOPPED AND THE FILLER CAP IS COOL ENOUGH TO TOUCH WITH
YOUR BARE HAND.

WARNING

COOLING SYSTEM CONDITIONER CONTAINS ALKALI. AVOID CONTACT WITH


SKIN AND EYES.

13-40
USAF TO 35C2-3-518-1
USA TM 9-6115-484-14
DRS RADIAN CTM 01646.1R0253/1R0254

CAUTION

CARE MUST BE TAKEN TO ENSURE THAT FLUIDS ARE CONTAINED DURING


PERFORMANCE OF INSPECTION, MAINTENANCE, TESTING, ADJUSTING AND
REPAIR OF THE PU. BE PREPARED TO COLLECT THE FLUID WITH SUITABLE
CONTAINERS BEFORE OPENING ANY COMPARTMENT OR DISASSEMBLY ANY
COMPONENT CONTAINING FLUIDS. DISPOSE OF FLUIDS ACCORDING TO
LOCAL REGULATIONS AND MANDATES.

CAUTION

THE ENGINE WATER TEMPERATURE REGULATORS (2 EA) ARE AN IMPORTANT


PART OF THE COOLING SYSTEM. THE WATER TEMPERATURE REGULATORS
DIVIDE THE COOLANT FLOW BETWEEN THE RADIATOR AND THE BYPASS
ELBOW. THIS WILL MAINTAIN THE CORRECT ENGINE TEMPERATURE. IF THE
WATER TEMPERATURE REGULATORS ARE NOT INSTALLED IN THE SYSTEM,
THERE IS NO MECHANICAL TEMPERATURE CONTROL. MOST OF THE COOLANT
WILL GO THROUGH THE BYPASS. THIS WILL CAUSE THE ENGINE TO
OVERHEAT IN HOT WEATHER. IF A HIGHER VOLUME OF COOLANT GOES
THROUGH THE RADIATOR, THE ENGINE WILL NOT REACH NORMAL OPERATING
TEMPERATURES. THIS OCCURS DURING COLD WEATHER.

CAUTION

IF A TURBOCHARGER FAILURE OCCURS, REMOVE THE AIR TO AIR AFTER


COOLER CORE. FLUSH THE AIR TO AIR AFTER COOLER CORE INTERNALLY
WITH A SOLVENT THAT REMOVES OIL AND OTHER FORIEN SUBSTANCES.
SHAKE THE AFTER COOLER CORE ASSEMBLY IN ORDER TO REMOVE ANY
TRAPPED DEBRIS. WASH THE AFTER COOLER CORE ASSEMBLY WITH HOT
SOAPY WATER. THOROUGHLY RINCE THIS ASSEMBLY WITH CLEAN WATER,
AND THEN BLOW DRY THE ASSEMBLY IN THE REVERSE DIRECTION OF NORMAL
AIR FLOW. TO MAKE SURE THAT THE WHOLE SYSTEM IS CLEAN, CAREFULLY
INSPECT THE SYSTEM.

To test the Radiator and After Cooler Assembly, proceed as follows:

a. This maintenance requires that the PU MUST be shutdown, rendered unable to start, cool
enough for the maintenance to be performed, and Communication Cable (A) and (B)
rerouted to the next PU. This is accomplished by performing the following:

(1) Shutdown the PU in accordance with Section 5.1.6.1 Shutdown Generators.


(2) Isolate the PU from any power plant control system in accordance with Note 1.
(3) Pull to open the PU DC Power Control Breaker.
(4) Push to open both Emergency Stop Switches.
(5) Place both Engine Control Switches (ECS) in the OFF position.
(6) Place a DO NOT OPERATE tag on both generator control panels.
(7) Turn the Battery Bank Parallel Switch to the OFF position.
(8) De-energize both Battery Chargers.
(9) Disconnect the negative and positive cables from both Battery Banks.
(10) Place a DO NOT OPERATE tag on both Battery Banks.
(11) Place all Circuit Breakers in the LOCK OUT position.
(12) Disconnect both 7P1 and 7P2 Connectors located on the inside panel of the PDC.
(13) Close and Lock both generator set control panels.

13-41
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USA TM 9-6115-484-14
DRS RADIAN CTM 01646.1R0253/1R0254

NOTE 1: When the DC Control Power Circuit Breaker is in the (OFF) position (Pulled – Out), all control
power is turned off to the PU. This will cause the HUB to stop functioning. This causes the
network to not see the equipment shutdown and all PU’s after it. When pulling major
maintenance the (A) (B) Communication Cable must be routed to the next PU in order to
reestablish the communication network.

b. After the engine is cool, loosen the Filler Cap slowly and allow pressure out of the cooling
system. Then remove the Filler Cap from the Coolant Reservoir.

c. Ensure that the coolant level is within the coolant view glass.

d. Connect the 9S-8140 Pressuring Pump to the Coolant Reservoir.

e. Pump the 9S-8140 Pressuring Pump until a reading on the gauge on the 9S-8140 Pressuring
Pump reads 20 kPa (3 psi) more than the pressure on the Filler Cap.

f. Check the radiator for leakage on the outside.

g. Check all connection points for leakage, and check the hoses for leakage.

h. The cooling system does not have leakage only if the following conditions exist:

• You do not see any outside leakage.

• The reading on the gauge remains steady after five minutes.

i. The inside of the cooling system has leakage only if the following conditions exist:

• The reading on the gauge goes down.

• You do not observe any outside leakage.

NOTE: For testing procedures for the Air to Air After cooler, refer to Caterpillar manual SENR1067-
01 Systems Operation Testing and Adjusting or later version.

13.4.5.3 REMOVE RADIATOR AND AFTER COOLER ASSEMBLY

WARNING

ALWAYS WEAR EYE PROTECTION WHEN YOU PERFORM ANY SERVICE WORK
ON A COOLING SYSTEM

WARNING

RELEASE THE PRESSURE IN THE COOLING SYSTEM BEFORE PERFORMING ANY


SERVICE WORK. IF THE PRESSURE IN THE COOLING SYSTEM IS NOT
RELEASED OR THE TEMPERATURE OF THE SYSTEM IS NOT PERMITTED TO
COOL, STEAM OR HOT WATER MAY BE RELEASED WHEN YOU REMOVE THE
FILLER CAP. THIS MAY CAUSE PERSONAL INJURY.

13-42
USAF TO 35C2-3-518-1
USA TM 9-6115-484-14
DRS RADIAN CTM 01646.1R0253/1R0254

WARNING

TO RELEASE THE PRESSURE IN A COOLING SYSTEM, LET THE SYSTEM COOL,


PUT A HEAVY CLOTH OVER THE CAP AND LOOSEN IT SLOWLY.

WARNING

DO NOT ALLOW UNDILUTED CORROSION INHIBITORS OR DILUTED/UNDILUTED


RADIATOR CLEANERS TO COME IN CONTACT WITH THE SKIN OR EYES.

WARNING

ALWAYS FOLLOW THE MANUFACTURER’S INSTRUCTIONS WHEN HANDLING


CORROSION INHIBITORS, RADIATOR CLEANERS OR ANTIFREEZE BE
ESPECIALLY SURE TO FOLLOW THE MANUFACTURER’S RECOMMENDATIONS
CONCERNING TOXICITY.

WARNING

ETHYLENE GLYCOL MAY CATCH FIRE WHEN IT IS HOT OR EXPOSED TO AN


OPEN FLAME. DO NOT WELD, CUT OR USE AN OPEN FLAME NEAR LEAKING
COOLANT THAT CONTAINS ANTIFREEZE.

WARNING

DO NOT REMOVE FILLER CAP AFTER OPERATION UNTIL SYSTEM HAS COOLED
DOWN. FAILURE TO ALLOW ENGINE COOLANT TO COOL DOWN COULD RESULT
IN SECOND AND THIRD DEGREE BURNS. CAP MAY BE HALF-TURNED TO
RELIEVE PRESSURE AND THEN REMOVED TO INSPECT COOLANT LEVEL.

WARNING

PERSONAL INJURY CAN RESULT FROM HOT COOLANT, STEAM AND ALKALI.

WARNING

AT OPERATING TEMPERATURE, ENGINE COOLANT IS HOT AND UNDER


PRESSURE. THE RADIATOR AND ALL LINES TO THE ENGINE CONTAIN HOT
COOLANT OR STEAM. ANY CONTACT CAN CAUSE SEVERE BURNS.

WARNING

REMOVE FILLER CAP SLOWLY TO RELIEVE PRESSURE ONLY WHEN THE


ENGINE IS STOPPED AND THE FILLER CAP IS COOL ENOUGH TO TOUCH WITH
YOUR BARE HAND.

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WARNING

COOLING SYSTEM CONDITIONER CONTAINS ALKALI. AVOID CONTACT WITH


SKIN AND EYES.

CAUTION

CARE MUST BE TAKEN TO ENSURE THAT FLUIDS ARE CONTAINED DURING


PERFORMANCE OF INSPECTION, MAINTENANCE, TESTING, ADJUSTING AND
REPAIR OF THE PU. BE PREPARED TO COLLECT THE FLUID WITH SUITABLE
CONTAINERS BEFORE OPENING ANY COMPARTMENT OR DISASSEMBLY ANY
COMPONENT CONTAINING FLUIDS. DISPOSE OF FLUIDS ACCORDING TO
LOCAL REGULATIONS AND MANDATES.

CAUTION

THE WATER TEMPERATURE REGULATORS (2 EA) ARE AN IMPORTANT PART OF


THE COOLING SYSTEM. THE WATER TEMPERATURE REGULATORS DIVIDE THE
COOLANT FLOW BETWEEN THE RADIATOR AND THE BYPASS ELBOW. THIS
WILL MAINTAIN THE CORRECT ENGINE TEMPERATURE. IF THE WATER
TEMPERATURE REGULATORS ARE NOT INSTALLED IN THE SYSTEM, THERE IS
NO MECHANICAL TEMPERATURE CONTROL. MOST OF THE COOLANT WILL GO
THROUGH THE BYPASS. THIS WILL CAUSE THE ENGINE TO OVERHEAT IN HOT
WEATHER. IF A HIGHER VOLUME OF COOLANT GOES THROUGH THE
RADIATOR, THE ENGINE WILL NOT REACH NORMAL OPERATING
TEMPERATURES. THIS OCCURS DURING COLD WEATHER.

CAUTION

IF A TURBOCHARGER FAILURE OCCURS, REMOVE THE AIR TO AIR AFTER


COOLER CORE. FLUSH THE AIR TO AIR AFTER COOLER CORE INTERNALLY
WITH A SOLVENT THAT REMOVES OIL AND OTHER FORIEN SUBSTANCES.
SHAKE THE AFTER COOLER CORE ASSEMBLY IN ORDER TO REMOVE ANY
TRAPPED DEBRIS. WASH THE AFTER COOLER CORE ASSEMBLY WITH HOT
SOAPY WATER. THOROUGHLY RINCE THIS ASSEMBLY WITH CLEAN WATER,
AND THEN BLOW DRY THE ASSEMBLY IN THE REVERSE DIRECTION OF
NORMAL AIR FLOW. TO MAKE SURE THAT THE WHOLE SYSTEM IS CLEAN,
CAREFULLY INSPECT THE SYSTEM.

To remove the Radiator and After Cooler Assembly, proceed as follows:

a. This maintenance requires that the PU MUST be shutdown, isolated from any power plant
electrical bus or utility connection, isolated from any power plant control system, and rendered
unable to start. This is accomplished by performing the following:

(1) Shutdown the PU in accordance with Section 5.1.6.1 Shutdown Generators.


(2) Isolate the PU from any power plant or utility connection in accordance with Section
5.9.6.15, Unit Isolation Procedure with PSC. See Note 1 and 2.
(3) Isolate the PU from any power plant control system in accordance with Note 3.
(4) Pull to open the PU DC Power Control Breaker.
(5) Push to open both Emergency Stop Switches.
(6) Place both Engine Control Switches (ECS) in the OFF position.

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(7) Place a DO NOT OPERATE tag on both generator control panels.
(8) Turn the Battery Bank Parallel Switch to the OFF position.
(9) De-energize both Battery Chargers.
(10) Disconnect the negative and positive cables from both Battery Banks.
(11) Place a DO NOT OPERATE tag on both Battery Banks.
(12) Place all Circuit Breakers in the LOCK OUT position.
(13) Disconnect both 7P1 and 7P2 Connectors located on the inside panel of the PDC.
(14) Close and Lock both generator set control panels.

NOTE 1: Also the PU must be completely electrically isolated from the power distribution bus and
any other electrical source that can back feed into the PU. All medium voltage cables need to
be placed on the standoff insulators by use of hot sticks and other safety gear.

NOTE 2: Ensure cables are not energized by opening the circuit breaker of the Primary Switching
Center (PSC), then disconnect Load Cables (Using the proper safety gear) on the PU and
place them on the Parking Stands.

NOTE 3: When the DC Control Power Circuit Breaker is in the (OFF) position (Pulled – Out), all control
power is turned off to the PU. This will cause the HUB to stop functioning. This causes the
network to not see the equipment shutdown and all PU’s after it. When pulling major
maintenance the (A) (B) Communication Cable must be routed to the next PU in order to
reestablish the communication network.

b. Drain the coolant system. Use Section 13.4.5.5 for procedures.

c. Remove the twenty mounting bolts securing the Front Side Panel. Use Figure 8.4.1-1 for
reference.

d. Remove the Top Plenum Screen from above the Radiator and After Cooler Assembly about to be
removed. Use Figure 8.4.2-1 for reference.

e. Loosen the eight Air Tube Clamps at the four Rubber Couplings.

f. Remove the U-bolts and mounting nuts securing the Air Tubes to the support bracket.

g. Remove the Air Tubes.

h. Remove the Rubber Couplings and clamps.

i. Remove the four mounting bolts securing the Tube Support from Radiator and After Cooler
Assembly.

j. Loosen the two clamps securing the Radiator Expansion Tank Hoses from Radiator and After
Cooler Assembly and remove.

k. Loosen and Disconnect the lower radiator pipe clamp and slide off.

l. Loosen and Disconnect the upper radiator pipe clamp and slide off.

m. Remove the A-frame interior access panels by loosening bolts and removing panels.

n. Tag and Disconnect the Hydraulic Cooler Hoses. Cap ends to prevent dirt from entering. Pull
hoses through the inside panel of the A-frame.

o. Tag and Disconnect the Fuel Cooler Hoses. Cap ends to prevent dirt from entering. Pull hoses
through the inside panel of the A-frame.

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p. Tag and Disconnect the Hydraulic Fluid Hoses from the Radiator Cooling fan motor. Cap ends
to prevent dirt from entering. Pull hoses through the inside panel of the A-frame.

q. Tag and Disconnect the Hydraulic Fluid Hoses from the ATAAC fan motor. Cap ends to prevent
dirt from entering. Pull hoses through the inside panel of the A-frame.

r. Remove the Low Coolant Level Switch from Expansion Tank.

s. Remove the Radiator Drain Hose.

t. Remove the Bottom Plenum Screen from under the Radiator and After Cooler Assembly.

u. Remove the Radiator and After Cooler Assembly mounting hardware.

v. The Radiator and After Cooler Assembly weights approximately 850 pounds. Use a lift or crane
to carefully lift the Radiator and After Cooler Assembly out of PU.

NOTE: The Radiator and After Cooler Assembly must be removed through the top of the PU. The lift
or crane should have a minimum lift rating of 3 tons.

13.4.5.4 INSTALL RADIATOR AND AFTER COOLER ASSEMBLY

To install the Radiator and After Cooler Assembly, proceed as follows:

a. This maintenance requires that the PU MUST be shutdown, isolated from any power plant
electrical bus or utility connection, isolated from any power plant control system, and rendered
unable to start. See procedures and warnings in paragraph 13.4.5.3.

b. Using a lift or crane, carefully place the Radiator and After Cooler Assembly in the PU.

NOTE: Radiators must be installed through the roof. The lift or crane should have a minimum of 3
ton rating.

c. Reinstall mounting fasteners from the underside.

d. Reinstall the Hydraulic Cooler hoses. Remove marking tags.

e. Reinstall the Fuel Cooler hoses. Remove marking tags.

f. Reinstall the Radiator Fan Motor Hydraulic Hoses. Remove marking tags.

g. Reinstall the Aftercooler Assembly Fan Motor Hydraulic hoses. Remove marking tags.

h. Reinstall the Radiator Drain Hose.

i. Reinstall the Bottom Plenum Screen.

j. Reinstall both the Upper and Lower Coolant Pipes and secure with clamps.

k. Reinstall both Radiator Expansion Tank hoses and secure with hose clamps.

l. Reinstall the Low Coolant Level Switch on the Expansion Tank.

m. Reinstall the Air Tube Support Brackets to the Radiator.

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n. Slide the Air Tube Rubber Couplings over the Air Tubing and reinstall with clamps.

o. Reinstall the Air Tubes mounting U-bolts ensuring air tubes are properly aligned.

p. Fill coolant system until full. Refill the coolant system using Section 13.4.5.5 and Annex G as
reference.

q. Close the Cooling System Air Bleed Valve on the engine after coolant starts to run out.
Continue filling until the expansion tank has been filled to the proper level.

NOTE: After filling the cooling system, run the engine for several minutes with the Filler Cap off. Next,
reinstall the Filler Cap and run the engine until the coolant becomes warm. Check coolant level in
sight glass and fill as necessary.

r. Reinstall the Top Plenum Screen.

s. Reinstall the A-Frame Assembly interior side panels.

NOTE: After the engine has ran for several minutes, shutdown, and Remove A-Frame interior access
panels to check for Hydraulic and Fuel Leaks at the Fan Motors, Hydraulic Cooler and Fuel Cooler.
Repair as necessary and Reinstall Side Panels.

t. Reinstall the PU Front Side Panel.

13.4.5.5 SERVICE RADIATOR AND AFTER COOLER ASSEMBLY

WARNING

ALWAYS WEAR EYE PROTECTION WHEN YOU PERFORM ANY SERVICE WORK
ON A COOLING SYSTEM

WARNING

RELEASE THE PRESSURE IN THE COOLING SYSTEM BEFORE PERFORMING ANY


SERVICE WORK. IF THE PRESSURE IN THE COOLING SYSTEM IS NOT
RELEASED OR THE TEMPERATURE OF THE SYSTEM IS NOT PERMITTED TO
COOL, STEAM OR HOT WATER MAY BE RELEASED WHEN YOU REMOVE THE
FILLER CAP. THIS MAY CAUSE PERSONAL INJURY.

WARNING

TO RELEASE THE PRESSURE IN A COOLING SYSTEM, LET THE SYSTEM COOL,


PUT A HEAVY CLOTH OVER THE CAP AND LOOSEN IT SLOWLY.

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WARNING

DO NOT ALLOW UNDILUTED CORROSION INHIBITORS OR DILUTED/UNDILUTED


RADIATOR CLEANERS TO COME IN CONTACT WITH THE SKIN OR EYES.

WARNING

DO NOT USE CHROMATE CORROSION INHIBITORS IN A COOLING SYSTEM.

WARNING

ALWAYS FOLLOW THE MANUFACTURER’S INSTRUCTIONS WHEN HANDLING


CORROSION INHIBITORS, RADIATOR CLEANERS OR ANTIFREEZE BE
ESPECIALLY SURE TO FOLLOW THE MANUFACTURER’S RECOMMENDATIONS
CONCERNING TOXICITY.

WARNING

ETHYLENE GLYCOL MAY CATCH FIRE WHEN IT IS HOT OR EXPOSED TO AN


OPEN FLAME. DO NOT WELD, CUT OR USE AN OPEN FLAME NEAR LEAKING
COOLANT THAT CONTAINS ANTIFREEZE.

WARNING

DO NOT USE ALCOHOL IN PLACE OF ANTIFREEZE. ALCOHOL HAS A LOWER


BOILING TEMPERATURE AND FLASH POINT.

WARNING

DO NOT ATTEMPT TO TIGHTEN ANY HOSE CLAMPS WHILE THE COOLING


SYSTEM IS HOT OR UNDER PRESSURE. IF THERE IS A FAILURE OF THE HOSE
CLAMP WHEN IT IS TIGHTENED, A SUDDEN LOSS OF HOT COOLANT OR STEAM
COULD RESULT.

WARNING

DO NOT REMOVE FILLER CAP AFTER OPERATION UNTIL SYSTEM HAS COOLED
DOWN. FAILURE TO ALLOW ENGINE COOLANT TO COOL DOWN COULD RESULT
IN SECOND AND THIRD DEGREE BURNS. CAP MAY BE HALF-TURNED TO
RELIEVE PRESSURE AND THEN REMOVED TO INSPECT COOLANT LEVEL.

WARNING

PERSONAL INJURY CAN RESULT FROM HOT COOLANT, STEAM AND ALKALI.

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WARNING

AT OPERATING TEMPERATURE, ENGINE COOLANT IS HOT AND UNDER


PRESSURE. THE RADIATOR AND ALL LINES TO THE ENGINE CONTAIN HOT
COOLANT OR STEAM. ANY CONTACT CAN CAUSE SEVERE BURNS.

WARNING

REMOVE FILLER CAP SLOWLY TO RELIEVE PRESSURE ONLY WHEN THE


ENGINE IS STOPPED AND THE FILLER CAP IS COOL ENOUGH TO TOUCH WITH
YOUR BARE HAND.

WARNING

COOLING SYSTEM CONDITIONER CONTAINS ALKALI. AVOID CONTACT WITH


SKIN AND EYES.

CAUTION

CARE MUST BE TAKEN TO ENSURE THAT FLUIDS ARE CONTAINED DURING


PERFORMANCE OF INSPECTION, MAINTENANCE, TESTING, ADJUSTING AND
REPAIR OF THE PU. BE PREPARED TO COLLECT THE FLUID WITH SUITABLE
CONTAINERS BEFORE OPENING ANY COMPARTMENT OR DISASSEMBLY ANY
COMPONENT CONTAINING FLUIDS. DISPOSE OF FLUIDS ACCORDING TO
LOCAL REGULATIONS AND MANDATES.

CAUTION

THE WATER TEMPERATURE REGULATORS (2 EA) ARE AN IMPORTANT PART OF


THE COOLING SYSTEM. THE WATER TEMPERATURE REGULATORS DIVIDE THE
COOLANT FLOW BETWEEN THE RADIATOR AND THE BYPASS ELBOW. THIS
WILL MAINTAIN THE CORRECT ENGINE TEMPERATURE. IF THE WATER
TEMPERATURE REGULATORS ARE NOT INSTALLED IN THE SYSTEM, THERE IS
NO MECHANICAL TEMPERATURE CONTROL. MOST OF THE COOLANT WILL GO
THROUGH THE BYPASS. THIS WILL CAUSE THE ENGINE TO OVERHEAT IN HOT
WEATHER. IF A HIGHER VOLUME OF COOLANT GOES THROUGH THE
RADIATOR, THE ENGINE WILL NOT REACH NORMAL OPERATING
TEMPERATURES. THIS OCCURS DURING COLD WEATHER.

CAUTION

DO NOT USE A COMMERCIAL COOLANT/ANTIFREEZE THAT ONLY MEETS THE


ASTM D3306 OR D4656 SPECIFICATION. THIS TYPE OF COOLANT/ANTIFREEZE
IS MADE FOR LIGHT DUTY AUTOMOTIVE APPLICATIONS.

CAUTION

THE COOLANT SYSTEM MUST BE BLED OR DAMAGE WILL RESULT TO THE


ENGINE (FIGURE 13.4.5-5). OPEN THE VALVE AND FILL THE RADIATOR UNTIL
COOLANT FLOWS OUT OF THE VALVE, CLOSE THE VALVE.

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To service the Radiator and After Cooler Assembly, proceed as follows:

a. This maintenance requires that the PU MUST be shutdown, rendered unable to start, cool
enough for the maintenance to be performed, and Communication Cable (A) and (B)
rerouted to the next PU. This is accomplished by performing the following:

(1) Shutdown the PU in accordance with Section 5.1.6.1 Shutdown Generators.


(2) Isolate the PU from any power plant control system in accordance with Note 1.
(3) Pull to open the PU DC Power Control Breaker.
(4) Push to open both Emergency Stop Switches.
(5) Place both Engine Control Switches (ECS) in the OFF position.
(6) Place a DO NOT OPERATE tag on both generator control panels.
(7) Turn the Battery Bank Parallel Switch to the OFF position.
(8) De-energize both Battery Chargers.
(9) Disconnect the negative and positive cables from both Battery Banks.
(10) Place a DO NOT OPERATE tag on both Battery Banks.
(11) Place all Circuit Breakers in the LOCK OUT position.
(12) Disconnect both 7P1 and 7P2 Connectors located on the inside panel of the PDC.
(13) Close and Lock both generator set control panels.

NOTE 1: When the DC Control Power Circuit Breaker is in the (OFF) position (Pulled – Out), all control
power is turned off to the PU. This will cause the HUB to stop functioning. This causes the
network to not see the equipment shutdown and all PU’s after it. When pulling major
maintenance the (A) (B) Communication Cable must be routed to the next PU in order to
reestablish the communication network.

b. Before changing the coolant:

c. Clean and flush the coolant system before the recommended maintenance interval if the
following conditions exist:

• The engine overheats frequently.

• Foaming is observed.

• Oil or fuel has entered the coolant system and the coolant is contaminated.

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FIGURE 13.4.5.5-1 RADIATOR DRAIN

d. Drain the Radiator

• Drain the radiator using the following procedure using Figure 13.4.5.5-1 and Figure 13.4.5.5-
2 as a reference:

(1) Shutdown the Power Unit and allow it to cool below 100 °F, Check temperature with
a thermometer.

(2) Remove the Filler Cap on the Coolant Expansion Tank. Use Figure 13.4.5.5-3 for
reference.

(3) Remove the Drain Plug, then open the Drain Valve located under the front of the PU,
beneath the Radiator. Use Figure 13.4.5.5.1. for reference.

NOTE: Ensure Coolant is disposed of properly.

(4) Open the Cooling System Air Bleed Valve located on the engine Thermostat Housing
after coolant has stopped flowing from radiator drain valve. Use Figure 13.4.5.5-4 for
reference.

(5) Remove the Drain Plug, then open the Drain Valve located on the Lower Radiator
Pipe. Use Figure 13.4.5.5-2 for reference.

(6) Allow radiator and engine coolant to drain completely.

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FIGURE 13.4.5.5-2 RADIATOR HOSE DRAIN

NOTE: Dispose of the coolant properly.

(7) Flush the radiator in the following manner:

• Flush the radiator with clean water removing any and all debris.

• Close both engine and lower radiator drain valves.

• Refill the cooling system with a mixture of clean water and cooling system
cleaner. Ensure the coolant system bleed valve is open until coolant is present,
then close the valve.

• Start the engine and run for a minimum of 30 minutes.

• Shutdown the Power Unit and allow it to cool below 100 °F, Check temperature
with a thermometer.

• Remove the Filler Cap on the Coolant Expansion Tank. Use Figure 13.4.55-3
for reference.

• Remove the Drain Plug. Then open the Radiator Drain Valve located under the
front of the Power Unit, beneath the Radiator and After Cooler Assembly. Use
Figure 13.4.55-1 for reference.

• Remove the Drain Plug. Then open the Drain Valve located on the Lower
Radiator Pipe. Use Figure 13.4.55-2 for reference.

• Open the Cooling System Air Bleed Valve located on the engine Thermostat
Housing after coolant has stopped flowing from radiator drain. Use Figure
13.4.55-4 for reference.

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• Allow cleaner solution in the coolant system to drain completely. (Repeat if


required)

FIGURE 13.4.5.5-3 RADIATOR TANK

e. Refill the radiator using Figure 13.4.5.5-3 as a reference:

(1) Close all drain valves.

(2) Refill the cooling system with ELC. Ensure the Coolant System Air Bleed Valve is open until
coolant is present then close the valve. The Coolant system must be bled or damage will
result to the engine. Refer to Figure 13.4.5.5-4 for reference.

FIGURE 13.4.5.5-4 COOLANT SYSTEM AIR BLEED VALVE

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NOTE: Do not reinstall the Filler Cap.

(3) Start the engine for 1 minute.

(4) Stop engine.

(5) Check for proper coolant level and add coolant if necessary.

(6) Clean the Filler Cap and check Filler Cap gasket for damage. Reinstall Filler Cap.

(7) Start the engine. Inspect the cooling system for leaks and for proper operating temperature.

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CHAPTER 14
LUBRICATION SYSTEM REPAIR
TABLE OF CONTENTS

SECTION TITLE PAGE


14.0 REPAIR OF LUBRICATION SYSTEM 3

14.1 SAFETY INSTRUCTIONS 3

14.2 BRIEF DESCRIPTION 5

14.3 SERVICE REQUIREMENTS 6

14.3.1 CHANGING ENGINE OIL AND FILTER 8

14.3.1.1 PROCEDURE FOR CHANGING OIL IN THE 3456 EPG ENGINE 9

14.3.1.2 CATERPILLAR INC. PROCEDURE FOR INSPECTING USED OIL FILTER 13

14.3.1.3 CATERPILLAR OIL FILTER SERVICE FOR THE 3456 EPG ENGINE 15

14.3.2 INSPECT COMPONENTS OF THE LUBRICATION SYSTEM 16

14.3.2.1 INSPECT FILTER MONITORING PANEL 16

14.3.2.2 INSPECT LUBRICATION SYSTEM DRAIN VALVE AND HOSE 16

14.3.2.3 INSPECT OIL FILLER CAP 16

14.3.2.4 INSPECT LUBE OIL SYSTEM HOSES AND LINES 17

14.3.2.5 INSPECT FUMES DISPOSAL COLLECTOR 17

14.3.2.6 REMOVE FUMES DISPOSAL COLLECTOR 18

14.3.2.7 INSTALL FUMES DISPOSAL COLLECTOR 19

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LIST 0F FIGURES

FIGURE TITLE PAGE


FIGURE 14.3-1 OIL FILTER DIFFERENTIAL PRESSURE GAUGE 6

FIGURE 14.3-2 AUXILIARY ALARM PANEL 7

FIGURE 14.3.1-1 ENGINE OIL FILTER 8

FIGURE 14.3.1-2 OIL DRAIN VALVE 8

FIGURE 14.3.1.1-1 OIL LEVEL GAUGE 9

FIGURE 14.3.1.1-2 OIL LEVELS, STOPPED AND RUNNING 12

FIGURE 14.3.2.3-1 OIL FILTER CAP 16

FIGURE 14.3.2.5-1 FUMES DISPOSAL COLLECTOR 17

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14.0 REPAIR OF LUBRICATION SYSTEM

Maintenance procedures are provided for the following Cooling System components:

• Engine Oil Filter


• Engine Oil
• Filter Monitoring Panel
• Lubrication System Drain Valve and Hose
• Oil Filler Cap
• Lubrication System Hoses and Lines
• Fumes Disposal Collector

14.1 SAFETY INSTRUCTIONS

a. Safety precautions must be observed while any maintenance is being performed. Safety
precautions must be observed to ensure that the operator/technician cannot have contact with the
following:

• Hot engine parts


• Hot engine fluids
• Medium Voltage AC electricity
• Low Voltage AC electricity
• Low Voltage DC electricity
• Rotating Parts
• High noise levels

b. Minor troubleshooting can be performed while both engines are running as long as safety
precautions are taken.

c. Minor maintenance can be performed while one generator set is running and the other
generator set has been shutdown. Some examples of this maintenance are:

• Lubrication System – Oil and Filter Change.


• Hydraulic System – Oil and Filter Change.
• Fuel System – Primary and Secondary Filter Change.
• Coolant System – Coolant Change.
• Minor Troubleshooting.
• Check Fluid levels and add required fluids.

(1) The generator set that has been shut down must be rendered unable to start, and cool
enough for the maintenance to be performed. Procedures to render a generator set
unable to start are:

(a) Shutdown the PU in accordance with Section 5.1.6.1 Shutdown Generators.


(b) Push to OPEN the Emergency Stop Switch.
(c) Place the Engine Control Switch (ECS) in the OFF position.
(d) Place a DO NOT OPERATE tag on the generator control panel.
(e) Turn the Battery Bank Parallel Switch to the OFF position.

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(f) De-energize the Battery Charger.


(g) Disconnect the negative and positive cables from the Battery Bank for the engine
due maintenance.
(h) Place a DO NOT OPERATE tag on the Battery Bank.
(i) Place the generator Circuit Breaker in the LOCK OUT position.
(j) Disconnect the 7P1 and 7P2 Connectors located on the inside panel of the PDC.
(k) Close and Lock the generator set control panel.

NOTE: The fuel transfer pump electrical power is normally fed directly from the G1 generator set
battery bank. If you disconnect the G1 battery bank, the external fuel transfer pump will not
function. Place the Fuel Pump Source Switch (S2) into the (G1 or G2 position). Place the S2
in the (G1 or G2) position, for the generator set not receiving maintenance.

d. Major maintenance or service requires that the PU MUST be shutdown, isolated from any
power plant electrical bus or utility connection, isolated from any power plant control
system, and rendered unable to start. This is accomplished by performing the following:

(1) Shutdown the PU in accordance with Section 5.1.6.1 Shutdown Generators.


(2) Isolate the PU from any power plant or utility connection in accordance with Section
5.9.6.15, Unit Isolation Procedure with PSC. See Note 1 and 2.
(3) Isolate the PU from any power plant control system in accordance with Note 3.
(4) Pull to open the PU DC Power Control Breaker.
(5) Push to OPEN both Emergency Stop Switches.
(6) Place both Engine Control Switches (ECS) in the OFF position.
(7) Place a DO NOT OPERATE tag on both generator control panels.
(8) Turn the Battery Bank Parallel Switch to the OFF position.
(9) De-energize both Battery Chargers.
(10) Disconnect the negative and positive cables from both Battery Banks.
(11) Place a DO NOT OPERATE tag on both Battery Banks.
(12) Place all Circuit Breakers in the LOCK OUT position.
(13) Disconnect both 7P1 and 7P2 Connectors located on the inside panel of the PDC.
(14) Close and Lock both generator set control panels.

NOTE 1: Also the PU must be completely electrically isolated from the power distribution bus and
any other electrical source that can back feed into the PU. All medium voltage cables need to
be placed on the standoff insulators by use of hot sticks and other safety gear.

NOTE 2: Ensure cables are not energized by opening the circuit breaker of the Primary Switching
Center (PSC), then disconnect Load Cables (Using the proper safety gear) on the PU and
place them on the Parking Stands.

NOTE 3: When the DC Control Power Circuit Breaker is in the (OFF) position (Pulled – Out), all control
power is turned off to the PU. This will cause the HUB to stop functioning. This causes the
network to not see the equipment shutdown and all PU’s after it. When pulling major
maintenance the (A) (B) Communication Cable must be routed to the next PU in order to
reestablish the communication network.

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14.2 BRIEF DESCRIPTION

The engine lubrication system provides four primary functions:

• Lubricates - all interior engine components.

• Cools – carries heat away from the high heat areas in the engine to the oil sump.

• Seals – the oil forms seals on interior metal parts, for example piston rings.

• Cleans - the interior of the engine by carrying all oil through the oil filter.

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14.3 SERVICE REQUIREMENTS

OIL FILTER DIFFERENTIAL GAUGE

FIGURE 14.3-1 OIL FILTER DIFFERENTIAL PRESSURE GAUGE

a. Engine Oil and Filter Service requirements:

• Every 250 hours

• Annually

• When the Oil Filter Differential Pressure Gauge reads 30 PSID. The Oil Filter Bypass is set
to open at 37.5 PSID, allowing unfiltered oil to enter the engine use Figure 14.3-1 as
reference.

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FIGURE 14.3-2 AUXILIARY ALARM PANEL

• When the Auxiliary Alarm Panel, shows a yellow light for the Oil Filter High Differential
Pressure Alarm the Oil Filter needs to be replaced. Use Figure 14.3-2 as reference.

b. Inspect the following subcomponents of the Lubrication System:

(1) Inspect the Filter Monitoring Panel.

(2) Inspect the Lubrication System Drain Valve and Hose.

(3) Inspect the Oil Filler Cap.

(4) Inspect the Lube Oil System Hoses and Lines.

(5) Inspect the Fumes Disposal Collector.

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14.3.1 CHANGING ENGINE OIL AND FILTER

FIGURE 14.3.1-1 ENGINE OIL FILTER

• Figure 14.3.1-1 identifies the 3456 EPG Remote Engine Oil Filter Assembly.

FIGURE 14.3.1-2 OIL DRAIN VALVE

• Figure 14.3.1-2 identifies the Oil Drain Valve.

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14.3.1.1 PROCEDURE FOR CHANGING AND CHECKING OIL IN THE 3456 EPG ENGINE

OIL LEVEL GAUGE

FIGURE 14.3.1.1-1 OIL LEVEL GAUGE

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WARNING

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

WARNING

HIGH VOLTAGE MAY CAUSE SEVERE INJURY OR DEATH UPON CONTACT


DURING CHECKOUT OR MAINTENANCE OF THIS EQUIPMENT. USE CAUTION
AND AVOID CONTACT WITH ENERGIZED COMPONENTS. USE HOT STICK WHEN
LOAD CABLES ARE HANDLED.

WARNING

DO NOT PERFORM THE FOLLOWING TASK WHEN THE GENERATOR SET IS


OPERATING. DO NOT TOUCH EXPOSED ELECTRICAL CONNECTION WHEN A
SOURCE OF POWER SUCH AS UTILITY POWER OR ANOTHER GENERATOR SET
IS CONNECTED TO THE LOAD TERMINALS. DEATH OR INJURY MAY RESULT
FROM FAILURE TO OBSERVE THIS WARNING.

WARNING

REMOVE ALL RINGS, NECKLACES, JEWELERY AND LOOSE CLOTHING.


FAILURE TO DO SO COULD CAUSE SEVERE INJURY OR DEATH.

CAUTION

CARE MUST BE TAKEN TO ENSURE THAT FLUIDS ARE CONTAINED DURING


PERFORMANCE OF INSPECTION, MAINTENANCE, TESTING, ADJUSTING AND
REPAIR OF THE PU. BE PREPARED TO COLLECT THE FLUID WITH SUITABLE
CONTAINERS BEFORE OPENING ANY COMPARTMENT OR DISASSEMBLY ANY
COMPONENT CONTAINING FLUIDS. DISPOSE OF FLUIDS ACCORDING TO
LOCAL REGULATIONS AND MANDATES.

CAUTION

UNDER FILLING OR OVER FILLING THE CRANKCASE WITH OIL CAN CAUSE
ENGINE DAMAGE.

NOTE: Failure to follow this recommended procedure will cause the waste particles to be re-
circulated through the engine lubrication system with the new oil.

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NOTE: Caterpillar Oil Filters are built to Caterpillar specifications. Use of an oil filter not
recommended by Caterpillar could result in severe engine damage to the engine bearings,
crankshaft, etc., the result of the larger waste particles from unfiltered oil entering the engine
lubricating system. Only use oil filters recommended by Caterpillar.

a. This maintenance can be performed while one generator set is running and the other
generator set has been shutdown.

b. The generator set that requires the maintenance (G1 or G2) has been shut down, and must be
rendered unable to start, and be cool enough for the maintenance to be performed.
Procedures to render a generator set unable to start are:

(1) Shutdown the generator set (G1 or G2) in accordance with Section 5.1.6.1 Shutdown
Generators.
(2) Push to OPEN the Emergency Stop Switch.
(3) Place the Engine Control Switch (ECS) in the OFF position.
(4) Place a DO NOT OPERATE tag on the generator control panel.
(5) Turn the Battery Bank Parallel Switch to the OFF position.
(6) De-energize the Battery Charger.
(7) Disconnect the negative and positive cables from the Battery Bank for the engine due
maintenance.
(8) Place a DO NOT OPERATE tag on the Battery Bank.
(9) Place the generator Circuit Breaker in the LOCK OUT position.
(10) Disconnect the 7P1 and 7P2 Connectors located on the inside panel of the PDC.
(11) Close and Lock the generator set control panel.

NOTE: The fuel transfer pump electrical power is normally fed directly from the G1 generator set
battery bank. If you disconnect the G1 battery bank, the external fuel transfer pump will not
function. Place the Fuel Pump Source Switch (S2) into the (G1 or G2 position). Place the S2
in the (G1 or G2) position, for the generator set not receiving maintenance.

c. Drain the Engine Oil:

(1) Start the engine and run until normal operating temperature is achieved. Stop the engine.

(2) Remove the Oil Drain Cap located at the end of the Oil Drain Line. Use Figure 14.3.1-1 and
Figure 14.3.1-2 for reference.

(3) Open the drain valve. Use Figure 14.3.1-2 for reference.

(4) After the oil has drained, Close the drain valve.

(5) Reinstall the Oil Drain Cap located on the end of the Oil Drain Line.

(6) Install a new Oil Filter, part number 1R-0716; refer to Section 14.3.1.3 for procedures.

NOTE: The oil drain cap is located beneath the PU.

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d. Fill the Engine with Oil:

(1) Remove the Oil Filler Cap. Fill the crankcase with the proper type of Oil, based on
temperature and amount of oil. Refer to Annex G, for oil requirements.

(2) Start the engine and run the engine for two minutes. Perform this procedure in order to
ensure that the lubrication system has oil and that the Oil Filter is filled. Inspect the Oil Filter
for oil leaks.

(3) Stop the engine and allow the oil to drain back into the sump for a minimum of ten minutes.

(4) Check the Oil Level using the Oil Level Gauge. Fill as necessary.

e. Checking Engine Oil:


The oil level gauge (dipstick) has an “ENGINE RUNNING” and an “ENGINE STOPPED” side. See
Figure 14.3.1.1-2 for reference. Therefore, the oil level can be checked with the engine stopped or the
engine running. However, for the most accurate reading, you should always check the oil level with
the engine stopped.

When checking engine oil while the engine is running, make sure to read the “ENGINE RUNNING” side
of the gauge. .

When checking engine oil while the engine is stopped, make sure to read the “ENGINE STOPPED” side
of the gauge.

Always maintain the oil level between the “ADD” mark (X) and the “FULL” mark (Y) on the oil level gauge.
Do not fill the crankcase above the full mark (Y). See Figure 14.3.1.1-2.

NOTE: The oil level gauge has a Full Range level on each side as indicated by the crosshatched marks.
For optimum engine operations, maintain the oil level in the crosshatched area.

NOTE: Operating the engine when the oil is above the “FULL” mark could cause the crankshaft to dip
into the oil. The air bubbles created from the crankshaft dipping into the oil reduces the oil’s lubricating
characteristics and could result in the loss of power.

FIGURE 14.3.1.1-2 OIL LEVELS, STOPPED AND RUNNING

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14.3.1.2 CATERPILLAR INC. PROCEDURE FOR INSPECTING USED OIL FILTER

REQUIRED TOOLS
TOOL PART NUMBER PART DESCRIPTION QTY
A 2P-8250 Strap Wrench 1
B 4C-5084 Filter Cutter 1

NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened component life.

NOTICE
Care must be taken to ensure that fluids are contained during
performance of inspection, maintenance, testing, adjusting and repair of
the machine. Be prepared to collect the fluid with suitable containers
before opening any compartment or disassembling any component
containing fluids.
Refer to Special Publication NENG2500, "Caterpillar Tools and Shop
Products Guide", for tools and supplies suitable to collect and contain
fluids in Caterpillar machines.
Dispose of all fluids according to local regulations and mandates.

NOTICE
Caterpillar oil filters are built to Caterpillar specifications. Use of an oil
filter not recommended by Caterpillar could result in severe engine
damage to the engine bearings, crankshaft, etc., as a result of the larger
waste particles from unfiltered oil entering the engine lubricating system.
Only use oil filters recommended by Caterpillar.

1. Remove the used Oil Filter with a 2P8250 Strap Wrench.

2. Cut the Oil Filter open with a 4C-5084 Oil Filter Cutter. Break apart the pleats and inspect the
Oil Filter for metal debris. An excessive amount of metal debris in the Oil Filter may indicate early
wear or a pending failure.

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3. Use a magnet to differentiate between the ferrous metals and the nonferrous metals that are
found in the oil filter element. Ferrous metals may indicate wear on the steel and cast iron parts
of the engine. Nonferrous metals may indicate wear on the aluminum parts, brass parts or
bronze parts of the engine. Parts that may be affected include the following items: main bearings,
rod bearings, turbocharger bearings and cylinder heads. Due to normal wear and friction, it is not
uncommon to find small amounts of debris in the oil filter. Consult your Caterpillar dealer in order
to arrange for a further analysis if an excessive amount of debris is found in the oil filter.

4. Clean the sealing surface of the filter-mounting base. Ensure that the entire old oil filter gasket is
removed.

5. Apply clean engine oil to the new oil filter gasket.

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14.3.1.3 CATERPILLAR OIL FILTER SERVICE FOR THE 3456 EPG ENGINE

NOTICE
Do not fill the oil filters with oil before installing them. This oil would not
be filtered and could be contaminated. Contaminated oil can cause
accelerated wear to engine components.

1. Install new Oil Filter. Coat Seal with clean oil before installing.

2. Tighten the Oil Filter until the Oil Filter Gasket contacts the base.

3. Tighten the Oil Filter by hand according to the instructions that are shown on the Oil Filter. Do
not over-tighten the Oil Filter.

Installation of oil filter Example: Remote mounted oil filter

2P8250 Filter Strap Wrench

* Provides quick, efficient service when


removing all spin-on type fuel and oil filters

* Capable of applying the higher torque


required on larger filters, without denting the
filter can

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14.3.2 INSPECT COMPONENTS OF THE LUBRICATION SYSTEM

14.3.2.1 INSPECT FILTER MONITORING PANEL

Inspect the Oil Filter Monitoring Panel for the following conditions using Figure 14.3-1, as reference:

a. Inspect gauge range. The Oil Filter must be replaced if in 30 PSID range.

b. Inspect operation.

c. Inspect for dents, cracks, breaks, leaks, or other physical damage.

d. Inspect security of attachment.

14.3.2.2 INSPECT LUBRICATION SYSTEM DRAIN VALVE AND HOSE

Inspect the Oil Drain Valve and hoses for the following conditions: (See Figure 14.3.1-2 as reference)

a. Inspect hose couplings and adapters for leakage and security of attachment.

b. Inspect for signs of leakage and overheating.

c. Inspect hoses for swelling, wear, cracks, and signs of deterioration.

14.3.2.3 INSPECT OIL FILLER CAP

FIGURE 14.3.2.3-1 OIL FILLER CAP

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Inspect the Oil Filler Cap for the following conditions using Figure 14.3.2.3-1 for reference:

a. Inspect for signs of deterioration.

b. Inspect for bends, dents, and cracks.

c. Inspect for missing or damaged hardware.

14.3.2.4 INSPECT LUBE OIL SYSTEM HOSES AND LINES

Inspect the Lube Oil Hoses and Lines for the following conditions:

a. Inspect hoses and lines for swelling, wear, cracks, and signs of the deterioration.

b. Inspect adapters, nipples and bushings, for leakage.

14.3.2.5 INSPECT FUMES DISPOSAL COLLECTOR

CRANKCASE BREATHER HOSE CRANKCASE BREATHER HOSE

FUMES DISPOSAL FUMES DISPOSAL COLLECTOR


COLLECTOR DRAIN HOSE

FIGURE 14.3.2.5-1 FUMES DISPOSAL COLLECTOR

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Inspect the Crankcase Breathers and Fumes Disposal Collector for the following conditions using Figure
14.3.2.5-1 as a reference:

a. Inspect security of attachment.

b. Inspect hoses for wear, cracks, clogs, and signs of deterioration.

c. Inspect for loose or damage fittings.

d. Empty the Fumes Disposal Collector daily. The waste can be drained into an appropriate
container by use of the Drain Valve and Hose through the bottom of the PU.

14.3.2.6 REMOVE FUMES DISPOSAL COLLECTOR

WARNING

DO NOT PERFORM THE FOLLOWING TASK WHEN THE GENERATOR SET IS


OPERATING. DO NOT TOUCH EXPOSED ELECTRICAL CONNECTION WHEN A
SOURCE OF POWER SUCH AS UTILITY POWER OR ANOTHER GENERATOR SET
IS CONNECTED TO THE LOAD TERMINALS. DEATH OR INJURY MAY RESULT
FROM FAILURE TO OBSERVE THIS WARNING.

WARNING

REMOVE ALL RINGS, NECKLACES, JEWELERY AND LOOSE CLOTHING.


FAILURE TO DO SO COULD CAUSE SEVERE INJURY OR DEATH.

To remove the Fumes Disposal Collector , proceed as follows:

a. This maintenance can be performed while one generator set is running and the other
generator set has been shutdown.

b. The generator set that requires the maintenance (G1 or G2) has been shut down, and must be
rendered unable to start, and be cool enough for the maintenance to be performed.
Procedures to render a generator set unable to start are:

(1) Shutdown the generator set (G1 or G2) in accordance with Section 5.1.6.1 Shutdown
Generators.
(2) Push to OPEN the Emergency Stop Switch.
(3) Place the Engine Control Switch (ECS) in the OFF position.
(4) Place a DO NOT OPERATE tag on the generator control panel.
(5) Turn the Battery Bank Parallel Switch to the OFF position.
(6) De-energize the Battery Charger.
(7) Disconnect the negative and positive cables from the Battery Bank for the engine due
maintenance.
(8) Place a DO NOT OPERATE tag on the Battery Bank.
(9) Place the generator Circuit Breaker in the LOCK OUT position.
(10) Disconnect the 7P1 and 7P2 Connectors located on the inside panel of the PDC.
(11) Close and Lock the generator set control panel.

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NOTE: The fuel transfer pump electrical power is normally fed directly from the G1 generator set
battery bank. If you disconnect the G1 battery bank, the external fuel transfer pump will not
function. Place the Fuel Pump Source Switch (S2) into the (G1 or G2 position). Place the S2
in the (G1 or G2) position, for the generator set not receiving maintenance.

c. Using Figure 14.3.2.5-1 as a reference, disconnect the two Crankcase Breather Hoses from the
Fumes Disposal Collector.

d. Disconnect all mounting hardware from the Fumes Disposal Collector.

e. Disconnect the Fumes Disposal Collector Drain Hose from the Fume Disposal Collector.

f. Remove the Fumes Disposal Collector.

14.3.2.7 INSTALL FUMES DISPOSAL COLLECTOR

To install the Fumes Disposal Collector, proceed as follows:

a. This maintenance can be performed while one generator set is running and the other
generator set has been shutdown.

b. The generator set that requires the maintenance (G1 or G2) has been shut down, and must be
rendered unable to start, and be cool enough for the maintenance to be performed. See
procedures and warnings in paragraph 14.3.2.6.

c. Using Figure 14.3.2.5-1 as a reference, Reinstall the Fumes Disposal Collector Drain Hose to
the Fume Disposal Collector.

d. Reinstall the Fumes Disposal Collector and ensure that all of the necessary hardware is secured.

e. Reinstall the two Crankcase Breather Hoses to the Fumes Disposal Collector.

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THIS PAGE INTENTIONALLY BLANK

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CHAPTER 15
ENGINE ASSEMBLY REPAIR
TABLE OF CONTENTS

SECTION TITLE PAGE


15.0 ENGINE ASSEMBLY REPAIR 5
15.1 SAFETY INSTRUCTIONS 5
15.2 BRIEF DESCRIPTION 7
15.3 SERVICE REQUIREMENTS 11
15.4 COMPONENT REPAIR PROCEDURES 12
15.4.1 VALVE COVERS 12
15.4.1.1 INSPECT VALVE COVERS 13
15.4.1.2 REMOVE VALVE COVERS 13
15.4.1.3 INSTALL VALVE COVERS 14
15.4.1.4 CLEANING VALVE COVERS 14
15.4.2 TURBOCHARGER 15
15.4.2.1 INSPECT TURBOCHARGER 15
15.4.2.2 REMOVE TURBOCHARGER 17
15.4.2.3 INSTALL TURBOCHARGER 19
15.4.3 AIR INTAKE MANIFOLD 20
15.4.3.1 INSPECT AIR INTAKE MANIFOLD 20
15.4.3.2 REMOVE AIR INTAKE MANIFOLD 21
15.4.3.3 INSTALL AIR INTAKE MANIFOLD 22
15.4.4 EXHAUST MANIFOLD 23
15.4.4.1 INSPECT EXHAUST MANIFOLD 23
15.4.4.2 REMOVE EXHAUST MANIFOLD 24
15.4.4.3 INSTALL EXHAUST MANIFOLD 25
15.4.5 AIR TRANSFER TUBES 26

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TABLE OF CONTENTS

SECTION TITLE PAGE


15.4.5.1 INSPECT AIR TRANSFER TUBES 27
15.4.5.2 REMOVE AIR TRANSFER TUBES 27
15.4.5.3 INSTALL AIR TRANSFER TUBES 28
15.4.6 COOLANT TRANSFER TUBES 29
15.4.6.1 INSPECT COOLANT TRANSFER TUBES 30
15.4.6.2 REMOVE COOLANT TRANSFER TUBES 31
15.4.6.3 INSTALL COOLANT TRANSFER TUBES 33
15.4.7 HYDRAULIC FLUID TRANSFER HOSES 34
15.4.7.1 INSPECT HYDRAULIC FLUID TRANSFER HOSES 35
15.4.7.2 REMOVE HYDRAULIC FLUID TRANSFER HOSES 35
15.4.7.3 INSTALL HYDRAULIC FLUID TRANSFER HOSES 36
15.4.8 CATERPILLAR INC. PROCEDURE FOR VALVE LASH SETTING 38
15.4.9 CATERPILLAR INC. PROCEDURE FOR UNIT INJECTOR TIMING
ADJUSTMENT 42
15.4.10 CATERPILLAR INC. PROCEDURE FOR FINDING TOP CENTER
COMPRESSION POSITION FOR NO. 1 PISTON 44
15.4.11 CATERPILLAR INC. PROCEDURE FOR 3456 ENGINE INJECTOR AND
VALVE ADJUSTMENT SEQUENCE FOR DPGDS APPLICATION 49
15.4.12 POST MAINTENANCE ENGINE TEST 51

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LIST OF FIGURES

FIGURE TITLE PAGE


FIGURE 15.2-1 ENGINE ASSEMBLY RIGHT SIDE VIEW 7
FIGURE 15.2-2 ENGINE ASSEMBLY LEFT SIDE VIEW 9
FIGURE 15.4.1-1 VALVE COVER 12
FIGURE 15.4.1-2 VALVE COVER (INSIDE) 12
FIGURE 15.4.2-1 TURBOCHARGER 15
FIGURE 15.4.2-2 LUBE OIL TUBE ASSEMBLIES 18
FIGURE 15.4.3-1 AIR INTAKE MANIFOLD 20
FIGURE 15.4.4-1 EXHAUST MANIFOLD 23
FIGURE 15.4.5-1 AIR TRANSFER TUBES 26
FIGURE 15.4.6-1 UPPER COOLANT TRANSFER TUBE 29
FIGURE 15.4.6-2 UPPER COOLANT TRANSFER TUBE 30
FIGURE 15.4.7-1 HYDRAULIC TRANSFER HOSES 34
FIGURE 15.4.7-2 HYDRAULIC TANK SHUTOFF VALVES 34
FIGURE 15.4.8-1 VALVE LASH CHECK 39
FIGURE 15.4.8-2 CYLINDER BORE AND VALVE LOCATION 41
FIGURE 15.4.9-1 INJECTOR MECHANISM 42
FIGURE 15.4.10-1 LOCATING TOP CENTER (LEFT SIDE OF ENGINE) 45
FIGURE 15.4.10-2 LOCATING TOP CENTER (RIGHT SIDE OF ENGINE) 45
FIGURE 15.4.10-3 USING 9S9082 ENGINE TURNING TOOL (LEFT SIDE OF ENGINE) 46
FIGURE 15.4.10-4 VALVE COVER 47
FIGURE 15.4.10-5 VALVE COVER GASKET 47
FIGURE 15.4.10-6 ROCKER ARMS OF NO. 1 CYLINDER 47
FIGURE 15.4.10-7 BARRING ENGINE 48

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LIST OF TABLES

TABLE TITLE PAGE


TABLE 15.4.4.3-1 EXHAUST MANIFOLD BOLT TIGHTENING SEQUENCE 25
TABLE 15.4.7.3-1 TORQUE VALUES 37
TABLE 15.4.8-1 VALVE LASH SETTING REQUIRED TOOLS 38
TABLE 15.4.8-2 VALVE LASH CHECK 38
TABLE 15.4.8-3 VALVE LASH SPECIFICATION 39
TABLE 15.4.9-1 UNIT INJECTOR TIMING ADJUSTMENT REQUIRED TOOLS 42
TABLE 15.4.10-1 TOP CENTER COMPRESSION POSITION REQUIRED TOOLS 44
TABLE 15.4.11-1 TDC COMPRESSION/TDC EXHAUST 49
TABLE 15.4.11-2 VALVE LASH CHECK 49
TABLE 15.4.11-3 VALVE LASH SPECIFICATION 50

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15.0 ENGINE ASSEMBLY REPAIR

Maintenance procedures are provided for the following Engine Assembly Components:

• Valve Covers
• Turbocharger
• Air Intake Manifold
• Exhaust Manifold
• Air Transfer Tubes
• Coolant Transfer Tubes
• Hydraulic Fluid Transfer Hoses
• Valve Lash Setting
• Injector Timing Adjustment
• Top Center Compression Position for No. 1 Piston
• 3456 Engine Injector and Valve Adjustment Sequence for DPGDS Application
• Post Maintenance Engine Test

15.1 SAFETY INSTRUCTIONS

a. Safety precautions must be observed while any maintenance is being performed. Safety
precautions must be observed to ensure that the operator/technician cannot have contact with the
following:

• Hot engine parts


• Hot engine fluids
• Medium Voltage AC electricity
• Low Voltage AC electricity
• Low Voltage DC electricity
• Rotating Parts
• High noise levels

b. Minor troubleshooting can be performed while both engines are running as long as safety
precautions are taken.

c. Minor maintenance can be performed while one generator set is running and the other
generator set has been shutdown. Some examples of this maintenance are:

• Lubrication System – Oil and Filter Change.


• Hydraulic System – Oil and Filter Change.
• Fuel System – Primary and Secondary Filter Change.
• Coolant System – Coolant Change.
• Minor Troubleshooting.
• Check Fluid levels and add required fluids.

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(1) The generator set that has been shut down must be rendered unable to start, and cool
enough for the maintenance to be performed. Procedures to render a generator set
unable to start are:

(a) Shutdown the PU in accordance with Section 5.1.6.1 Shutdown Generators.


(b) Push to OPEN the Emergency Stop Switch.
(c) Place the Engine Control Switch (ECS) in the OFF position.
(d) Place a DO NOT OPERATE tag on the generator control panel.
(e) Turn the Battery Bank Parallel Switch to the OFF position.
(f) De-energize the Battery Charger.
(g) Disconnect the negative and positive cables from the Battery Bank for the engine
due maintenance.
(h) Place a DO NOT OPERATE tag on the Battery Bank.
(i) Place the generator Circuit Breaker in the LOCK OUT position.
(j) Disconnect the 7P1 and 7P2 Connectors located on the inside panel of the PDC.
(k) Close and Lock the generator set control panel.

NOTE: The fuel transfer pump electrical power is normally fed directly from the G1 generator set
battery bank. If you disconnect the G1 battery bank, the external fuel transfer pump will not
function. Place the Fuel Pump Source Switch (S2) into the (G1 or G2 position). Place the S2
in the (G1 or G2) position, for the generator set not receiving maintenance.

d. Major maintenance or service requires that the PU MUST be shutdown, isolated from any
power plant electrical bus or utility connection, isolated from any power plant control
system, and rendered unable to start. This is accomplished by performing the following:

(1) Shutdown the PU in accordance with Section 5.1.6.1 Shutdown Generators.


(2) Isolate the PU from any power plant or utility connection in accordance with Section
5.9.6.15, Unit Isolation Procedure with PSC. See Note 1 and 2.
(3) Isolate the PU from any power plant control system in accordance with Note 3.
(4) Pull to open the PU DC Power Control Breaker.
(5) Push to OPEN both Emergency Stop Switches.
(6) Place both Engine Control Switches (ECS) in the OFF position.
(7) Place a DO NOT OPERATE tag on both generator control panels.
(8) Turn the Battery Bank Parallel Switch to the OFF position.
(9) De-energize both Battery Chargers.
(10) Disconnect the negative and positive cables from both Battery Banks.
(11) Place a DO NOT OPERATE tag on both Battery Banks.
(12) Place all Circuit Breakers in the LOCK OUT position.
(13) Disconnect both 7P1 and 7P2 Connectors located on the inside panel of the PDC.
(14) Close and Lock both generator set control panels.

NOTE 1: Also the PU must be completely electrically isolated from the power distribution bus and
any other electrical source that can back feed into the PU. All medium voltage cables need to
be placed on the standoff insulators by use of hot sticks and other safety gear.

NOTE 2: Ensure cables are not energized by opening the circuit breaker of the Primary Switching
Center (PSC), then disconnect Load Cables (Using the proper safety gear) on the PU and
place them on the Parking Stands.

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DRS RADIAN CTM 01646.1R0253/1R0254

NOTE 3: When the DC Control Power Circuit Breaker is in the (OFF) position (Pulled – Out), all control
power is turned off to the PU. This will cause the HUB to stop functioning. This causes the
network to not see the equipment shutdown and all PU’s after it. When pulling major
maintenance the (A) (B) Communication Cable must be routed to the next PU in order to
reestablish the communication network.

15.2 BRIEF DESCRIPTION

TURBOCHARGER TEMPERATURE REGULATOR HOUSING

WATER PUMP
EXHAUST MANIFOLD

OIL COOLER

FIGURE 15.2-1 ENGINE ASSEMBLY RIGHT SIDE VIEW

a. Use Figure 15.2-1 while reviewing the “Right Side View” of the engine where the following
components are mounted:

• Turbocharger: Is driven from engine exhaust gas, and used to compress incoming filtered
air for combustion. This allows more air to be packed into each cylinder, more fuel to be
burned and creates higher engine horsepower output.

• Exhaust Manifold: Takes exhaust gasses from the cylinders and delivers it to the
turbocharger.

• Oil Cooler: The Oil Cooler is a tube and shell heat exchanger. The Oil Cooler takes hot
lubrication oil flowing into it and lowers the temperature of the oil. This is done as hot oil
travels through the tubes, and having coolant flowing around the tubes as it travels through
the shell. (Oil in the tube, Coolant in the shell).

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• Water Pump: Takes coolant from the Radiator and pumps it through the Oil Cooler. From
the Oil Cooler, the coolant travels into the engine block, around the hot cylinder liners picking
up heat and cooling engine parts. The coolant then continues to travel through the cylinder
heads picking up heat and cooling around the critical valve areas. From the cylinder head(s),
the coolant flows to the Water Temperature Regulator Housing, by the Water temperature
Regulator(s).

• Water temperature Regulator (2): If the coolant is cold, the water temperature regulator(s)
will remain closed and will force the coolant to re-circulate through the engine bypassing the
radiator.

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ENGINE CONTROL MODULE (ECM)

FUEL DISTRIBUTION BLOCK

FUEL PRIMING PUMP

ENGINE MOUNTED FUEL


TRANSFER PUMP

PRIMARY FUEL FILTER


SECONDARY FUEL FILTER

FIGURE 15.2-2 ENGINE ASSEMBLY LEFT SIDE VIEW

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DRS RADIAN CTM 01646.1R0253/1R0254

b. The “Left Side View” of the engine is where the following components are mounted:

• Fuel Priming Pump: The Fuel Priming Pump is used to prime the fuel system after the fuel
system has lost its prime. Its base is where the Secondary Fuel Filter is mounted.

• Engine Mounted Fuel Transfer Pump: The Engine Mounted Fuel Transfer Pump pulls fuel
from the Day Tank and pushes it to the engine.

• Primary Fuel Filter: The Primary Fuel Filter is the first component that the fuel from the day
tank enters. It acts as a filter and sediment/water trap.

• Fuel Distribution Block: Contains a Fuel Temperature Sensor, Air Bleeding Port, and
System Pressure Regulator Valve. The Fuel Tank, return hose connects here as does the
pressurized fuel connections from the Engine Mounted Fuel Transfer Pump and Secondary
Fuel Filter.

• Secondary Fuel Filter: Filters the fuel a second time, its filter medium is 2 micron. Clean
fuel is essential for the high-pressure Fuel Injectors to function properly and prevent
premature wear.

• Electronic Control Module (ECM): The ADEM II (ECM) sets certain limits on the amount of
fuel that can be injected into each cylinder and monitors many engine functions.

c. Caterpillar 3456 EPG Engine:

(1) See Figure 15.2-1 and Figure 15.2-2 for reference. The two 3456 EPG engines are
electronically controlled, mechanically actuated unit injector (EUI), diesel engines. The 3456
EPG engine is an in-line, six-cylinder engine with a bore of 5.5 inch (140 mm), and with a
stroke of 6.7 inch (171 mm). The 3456 EPG engine has a total displacement of 964.18 cubic
inches (15.8 L). The engine is configured for turbocharged air-to-air after cooling with
electronic unit injection.

(2) The electronic control system was designed to provide electronic governing, automatic fuel
ratio control, torque rise shaping, injection timing control, and system diagnostics.

(3) The Electronic unit injector system eliminates many of the mechanical components of an in-
line pump system. This system also provides increased control of the timing control and of
the fuel air ratio control. The timing advance is achieved by the precise control of the injector
timing. Adjusting the duration of the injection controls the engine rpm. A special pulse wheel
provides information to the ECM for the detection of the cylinder position and of the engine
rpm.

(4) The engine has built-in diagnostics in order to ensure that all of the components are
operating properly. In the event of a system component failure, the operator will be alerted to
the condition by the fault alarm lights on the GSC+. The GSC+ will display some diagnostic
codes and the Caterpillar ET tool can be used to read the numerical code of the faulty
component or its condition. Intermittent faults are logged and the information is stored in the
memory of the ECM.

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DRS RADIAN CTM 01646.1R0253/1R0254

d. Engine Starting:

The Electronic Control Module (ECM) will automatically provide the correct amount of fuel that is
necessary to start the engine. The engine ECM automates starting Aid operation. At engine coolant
temperatures below 32°F (0°C), the ECM will control ether injection. The EMCP+ controls the crank
cycles and duration of the starter motor. If the engine fails to start, the EMCP+ will cycle cranking to allow
the starter motor to be cooled for the programmed cycle time.

e. Cold Mode Operation:

The engine control system performs a Cold Start Strategy for the correct warm-up time after a cold engine
start. The temperature for a cold engine start is less than 64°F (18°C). This Cold Start Strategy is called
Cold Mode. After being activated, this Cold Mode will remain active until the coolant temperature rises
above 64°F (18°C) or until the engine has been running for 12 minutes. Cold Mode will also vary the fuel
injection amount, the timing for the maximum start-up, and the timing for the control of white smoke. The
time that is necessary for the engine to achieve the normal mode of operation is usually less than the time
that is required for a walk-around inspection of the engine.

15.3 SERVICE REQUIREMENTS

Service requirements on specific PU subsystems can be found in the following:

• Fuel System - Refer to Section 11.3

• Coolant System - Refer to Section 13.3

• Lubrication System - Refer to Section 14.3

• Air Intake and Exhaust System - Refer to Section 16.3

• Hydraulic System - Refer to Section 19.3

• Post Maintenance Engine Test – Refer to Section 15.4.12.

Each device covered in this chapter that requires service, has that service requirement described in that
section.

15-11
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DRS RADIAN CTM 01646.1R0253/1R0254

15.4 COMPONENT REPAIR PROCEDURES

15.4.1 VALVE COVERS

The following maintenance procedures are provided for the Valve Covers.

Inspect
Remove
Install
Clean

FIGURE 15.4.1-1 VALVE COVER

FIGURE 15.4.1-2 VALVE COVER (INSIDE)

The rocker housing cover prevents dirt from entering and oil from leaving the rocker lever housing.
Repair is limited to removal, inspection, cleaning, and replacement of component parts in accordance
with the following Sections.

15-12
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DRS RADIAN CTM 01646.1R0253/1R0254

15.4.1.1 INSPECT VALVE COVERS

Inspect the Valve Covers for the following:

a. Inspect for leaks

b. Inspect for loose and missing mounting hardware

15.4.1.2 REMOVE VALVE COVERS

WARNING

REMOVE ALL RINGS, NECKLACES, JEWELERY AND LOOSE CLOTHING.


FAILURE TO DO SO COULD CAUSE SEVERE INJURY OR DEATH.

WARNING

DO NOT ALLOW GASKET MATERIAL TO FALL INSIDE ROCKER LEVER HOUSING.


FAILURE TO COMPLY MAY RESULT IN DAMAGE TO ENGINE.

CAUTION

CARE MUST BE TAKEN TO ENSURE THAT FLUIDS ARE CONTAINED DURING


PERFORMANCE OF INSPECTION, MAINTENANCE, TESTING, ADJUSTING AND
REPAIR OF THE PU. BE PREPARED TO COLLECT THE FLUID WITH SUITABLE
CONTAINERS BEFORE OPENING ANY COMPARTMENT OR DISASSEMBLY ANY
COMPONENT CONTAINING FLUIDS. DISPOSE OF FLUIDS ACCORDING TO
LOCAL REGULATIONS AND MANDATES.

To remove the Valve Covers, proceed as follows:

a. This maintenance requires that the PU MUST be shutdown, rendered unable to start, cool
enough for the maintenance to be performed, and Communication Cable (A) and (B)
rerouted to the next PU. This is accomplished by performing the following:

(1) Shutdown the PU in accordance with Section 5.1.6.1 Shutdown Generators.


(2) Isolate the PU from any power plant or utility connection in accordance with Section
5.9.6.15, Unit Isolation Procedure with PSC.
(3) Isolate the PU from any power plant control system in accordance with Note 3.
(4) Pull to open the PU DC Power Control Breaker.
(5) Push to OPEN both Emergency Stop Switches.
(6) Place both Engine Control Switches (ECS) in the OFF position.
(7) Place a DO NOT OPERATE tag on both generator control panels.
(8) Turn the Battery Bank Parallel Switch to the OFF position.
(9) De-energize both Battery Chargers.
(10) Disconnect the negative and positive cables from both Battery Banks.
(11) Place a DO NOT OPERATE tag on both Battery Banks.
(12) Place all Circuit Breakers in the LOCK OUT position.
(13) Disconnect both 7P1 and 7P2 Connectors located on the inside panel of the PDC.
(14) Close and Lock both generator set control panels.

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DRS RADIAN CTM 01646.1R0253/1R0254

NOTE 1: When the DC Control Power Circuit Breaker is in the (OFF) position (Pulled – Out), all control
power is turned off to the PU. This will cause the HUB to stop functioning. This causes the
network to not see the equipment shutdown and all PU’s after it. When pulling major
maintenance the (A) (B) Communication Cable must be routed to the next PU in order to
reestablish the communication network.

b. Remove bolts (1) that hold valve cover (2) to valve cover base use Figure 15.4.1-1 as reference.

c. Remove valve cover (2).

d. Check the condition of the valve cover seal (3). If the valve cover seal appears to be worn or
damaged, use a new part for replacement use Figure 15.4.1-2 for reference.

NOTE: Do not place small parts and objects in the PU near the open engine that may accidentally
fall down inside the engine while the valve covers are removed.

NOTE: Protect the engine from flying sand and debris while the engine is exposed with the covers
removed.

NOTE: Before removing the two outside valve covers, loosen the clamps on breather cap and
remove it from the hose and valve cover.

15.4.1.3 INSTALL VALVE COVERS

To install the Valve Covers, proceed as follows:

a. This maintenance requires that the PU MUST be shutdown, rendered unable to start, cool
enough for the maintenance to be performed, and Communication Cable (A) and (B)
rerouted to the next PU. See procedures and warnings in paragraph 15.4.1.2.

b. Place the Valve Covers (2) in position on the valve cover base use Figure 15.4.1-1 as reference.

c. Reinstall the mounting bolts that hold the Valve Cover in place. Tighten the mounting bolts to a
torque of 18 ± 2 Ft-Lbs (25 ± 3 Nm).

d. Reinstall Breather Caps into the Breather Tube and Valve Cover.

e. Tighten the two clamps.

f. Connect the hoses to the Breather Caps.

g. Tighten the two clamps.

15.4.1.4 CLEANING VALVE COVERS

To clean the Valve Covers, proceed as follows:

a. Scrape all traces of old gasket from the valve cover and the Valve Cover Base Housing.

b. Clean Valve Cover housing with a safe, biodegradable and locally approved solvent that is safe
for the surfaces to be cleaned and that removes oil and other foreign substances. Use this
solvent in conjunction with a soft bristle brush.

15-14
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DRS RADIAN CTM 01646.1R0253/1R0254

15.4.2 TURBOCHARGER

The following maintenance procedures are provided for the Turbocharger.

Inspect
Remove
Install
TURBOCHARGER TURBINE WHEEL
TURBOCHARGER COMPRESSOR WHEEL HOUSING
HOUSING

TURBOCHARGER FILTERED AIR INLET

TURBOCHARGER EXHAUST OUTLET ELBOW

FIGURE 15.4.2-1 TURBOCHARGER

15.4.2.1 INSPECT TURBOCHARGER

WARNING

REMOVE ALL RINGS, NECKLACES, JEWELERY AND LOOSE CLOTHING.


FAILURE TO DO SO COULD CAUSE SEVERE INJURY OR DEATH.

CAUTION

TURBOCHARGER BEARING FAILURES CAN CAUSE LARGE QUANTITIES OF OIL


TO ENTER THE AIR INLET AND EXHAUST SYSTEMS AND AIR TO AIR AFTER
COOLER. LOSS OF ENGINE LUBRICANT CAN RESULT IN SERIOUS ENGINE
DAMAGE. TURBOCHARGER COMPONENTS REQUIRE PRECISION CLEARANCES.
THE TURBOCHARGER CARTRIDGE MUST BE BALANCED DUE TO HIGH RPM.
SEVERE SERVICE APPLICATIONS CAN ACCELERATE COMPONENT WEAR.
SEVERE SERVICE APPLICATIONS REQUIRE MORE FREQUENT INSPECTIONS OF
THE CARTRIDGE.

15-15
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DRS RADIAN CTM 01646.1R0253/1R0254

CAUTION

IF A TURBOCHARGER FAILURE OCCURS, REMOVE THE AIR TO AIR AFTER


COOLER CORE. FLUSH THE AIR TO AIR AFTER COOLER CORE INTERNALLY
WITH A SAFE, BIODEGRADABLE AND LOCALLY APPROVED SOLVENT THAT IS
SAFE FOR THE SURFACES TO BE CLEANED AND THAT REMOVES OIL AND
OTHER FORIEGN SUBSTANCES. SHAKE THE AFTER COOLER CORE ASSEMBLY
IN ORDER TO REMOVE ANY TRAPPED DEBRIS. WASH THE AFTER COOLER
CORE ASSEMBLY WITH HOT SOAPY WATER. THOROUGHLY RINCE THIS
ASSEMBLY WITH CLEAN WATER, AND THEN BLOW DRY THE ASSEMBLY IN THE
REVERSE DIRECTION OF NORMAL AIR FLOW. TO MAKE SURE THAT THE
WHOLE SYSTEM IS CLEAN, CAREFULLY INSPECT THE SYSTEM.

CAUTION

CARE MUST BE TAKEN TO ENSURE THAT FLUIDS ARE CONTAINED DURING


PERFORMANCE OF INSPECTION, MAINTENANCE, TESTING, ADJUSTING AND
REPAIR OF THE PU. BE PREPARED TO COLLECT THE FLUID WITH SUITABLE
CONTAINERS BEFORE OPENING ANY COMPARTMENT OR DISASSEMBLY ANY
COMPONENT CONTAINING FLUIDS. DISPOSE OF FLUIDS ACCORDING TO
LOCAL REGULATIONS AND MANDATES.

To Inspect the Turbocharger perform the following:

a. This maintenance requires that the PU MUST be shutdown, rendered unable to start, cool
enough for the maintenance to be performed, and Communication Cable (A) and (B)
rerouted to the next PU. This is accomplished by performing the following:

(1) Shutdown the PU in accordance with Section 5.1.6.1 Shutdown Generators.


(2) Isolate the PU from any power plant control system in accordance with Note 1.
(3) Pull to open the PU DC Power Control Breaker.
(4) Push to open both Emergency Stop Switches.
(5) Place both Engine Control Switches (ECS) in the OFF position.
(6) Place a DO NOT OPERATE tag on both generator control panels.
(7) Turn the Battery Bank Parallel Switch to the OFF position.
(8) De-energize both Battery Chargers.
(9) Disconnect the negative and positive cables from both Battery Banks.
(10) Place a DO NOT OPERATE tag on both Battery Banks.
(11) Place all Circuit Breakers in the LOCK OUT position.
(12) Disconnect both 7P1 and 7P2 Connectors located on the inside panel of the PDC.
(13) Close and Lock both generator set control panels.

NOTE 1: When the DC Control Power Circuit Breaker is in the (OFF) position (Pulled – Out), all control
power is turned off to the PU. This will cause the HUB to stop functioning. This causes the
network to not see the equipment shutdown and all PU’s after it. When pulling major
maintenance the (A) (B) Communication Cable must be routed to the next PU in order to
reestablish the communication network.

b. Remove the Exhaust Outlet Piping and remove the Air Inlet Piping from the Turbocharger.
Visually inspect the piping for the presence of oil. Use Figure 15.4.2-1 for reference.

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c. Turn the Compressor Wheel and the Turbine Wheel by hand. The assembly should turn freely
Inspect the Compressor Wheel for any contact with the rotating Turbine Wheel or with the
Turbocharger Housing. There should not be any visible signs of contact between the Turbine
Wheel or Compressor Wheel and the Turbocharger Housing. If there is any indication of contact
between the rotating Turbine Wheel or the Compressor Wheel and the Turbocharger Housing,
the Turbocharger should be reconditioned or replaced.

d. Check the Compressor Wheel for cleanliness. If only the blade side of the wheel is dirty, dirt
and/or moisture are passing through the air filtering system. If oil is found only on the backside of
the wheel, there is a possibility of a failed turbocharger oil seal.

e. Check for the presence of oil resulting from extended engine operation at low idle. The presence
of oil may also be the result of a restriction of the line for the inlet air (plugged air filters), which
causes the turbocharger to slobber.

f. Use a dial indicator to check the endplay on the shaft. Attach the Dial Indicator contact point
onto the end of the turbocharger shaft and zero the dial indicator. The other end of the shaft the
shaft should be pushed and pulled. Note the total dial indicator reading. If the measured
endplay clearance is greater than 0.003 to 0.0010 inches (0.08 to 0.25 mm), the turbocharger
should be repaired or replaced. If the endplay clearance is less than the minimum, that could
indicate a buildup of carbon on the turbine wheel and the turbocharger should be repaired.

g. Inspect the bore of the Turbine Housing for corrosion.

h. Clean the Turbocharger Housing with a safe, biodegradable and locally approved solvent that is
safe for the surfaces to be cleaned and that removes oil and other foreign substances. Use this
solvent in conjunction with a soft bristle brush.

i. Reinstall the Air Inlet Piping and the Exhaust Outlet Piping to the Turbocharger Housing.

15.4.2.2 REMOVE TURBOCHARGER

WARNING
CAUTION

BE EXTREMELY CAREFUL - WEIGHT HAZARD - THE TURBOCHARGER WEIGHS


75 LBS.

To remove the Turbocharger, proceed as follows:

a. This maintenance requires that the PU MUST be shutdown, rendered unable to start, cool
enough for the maintenance to be performed, and Communication Cable (A) and (B)
rerouted to the next PU. See procedures and warnings in paragraph 15.4.2.1.

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FIGURE 15.4.2-2 LUBE OIL TUBE ASSEMBLIES

b. Remove PU Side Panel for the engine requiring service use Section 8.4.1 for reference.

c. Remove the Turbocharger Oil Feed Line mounting hardware use Figure 15.4.2-2 for reference.

d. Remove the Turbocharger drain lines mounting hardware use Figure 15.4.2-2 for reference.

e. Check the condition of the O-ring Seals on the Oil Feed and Drain Line assemblies.

f. Loosen the Turbocharger Air Intake Hose Clamp and the Air Filter Assembly Outlet Hose Clamp.
Remove the Turbocharger Intake Hose.

g. Remove the Turbocharger to Muffler Flex Connection use Figure 8.4.7-1 as reference.

h. Remove the Air - to - Air Aftercooler Pipe, on intake side of the radiator.

i. Attach a strap and hoist to the Turbocharger.

j. Remove the four, Turbocharger Exhaust Manifold mounting bolts.

k. Visually inspect the Turbocharger before it is removed.

l. Carefully, remove the Turbocharger from the engine.

m. Clean all old gasket material from all mating surfaces.

15-18
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DRS RADIAN CTM 01646.1R0253/1R0254

15.4.2.3 INSTALL TURBOCHARGER

WARNING
CAUTION

BE EXTREMELY CAREFUL - WEIGHT HAZARD - THE TURBOCHARGER WEIGHS


75 LBS.

To install the Turbocharger, perform the following:

a. This maintenance requires that the PU MUST be shutdown, rendered unable to start, cool
enough for the maintenance to be performed, and Communication Cable (A) and (B)
rerouted to the next PU. See procedures and warnings in paragraph 15.4.2.1.

b. Clean all gasket-mating surfaces.

c. Place the turbocharger in position on a new manifold exhaust gasket on the exhaust manifold.

d. Put Caterpillar 5P-3931 Anti-Seize Compound on new mounting bolts.

e. Install the new mounting bolts and torque to 40 ± 4 Ft-Lbs.

f. Reinstall Turbocharger Lube Oil Feed Tubes. Insure that new O-rings are used.

g. Reinstall Turbocharger Lube Oil Drain Line Tubes. Insure that new O-rings are used.

h. Reinstall the Air - to - Air Aftercooler Pipe, on intake side of the radiator.

i. Reinstall the Turbocharger Intake Hose from the Air Filter Housing and tighten both hose
clamps.

j. Reinstall the Muffler Flex Connection to the exhaust side of the Turbocharger.

k. Visually inspect all connections before starting the PU.

l. Reinstall the Side Panel from the PU use Section 8.4.1 for reference.

m. Start the PU according to Section 5.1.

n. Inspect the Turbocharger for any leaks. After the PU has reached Normal Operating
temperature, shutdown the PU and inspect the Turbocharger for leaks.

15-19
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DRS RADIAN CTM 01646.1R0253/1R0254

15.4.3 AIR INTAKE MANIFOLD

The following maintenance procedures are provided for the Air Intake Manifold.

Inspect
Remove
Install

CONSTANT TORQUE HOSE CLAMP

AIR INTAKE HOSE

AIR INTAKE MANIFOLD

MOUNTING BOLTS

COLD START ETHER INJECTION PORT

FIGURE 15.4.3-1 AIR INTAKE MANIFOLD

Intake and exhaust manifolds provide a means of allowing the fuel/air mixture to enter and exhaust gases
to exit the engine assembly.

15.4.3.1 INSPECT AIR INTAKE MANIFOLD

Inspect the Air Intake Manifold for the following conditions:

a. Inspect for cracks or other physical damage that could cause leaks.

b. Inspect for blown gaskets.

c. Inspect for cracks or other physical damage that could cause leaks in the exhaust manifold.

15-20
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15.4.3.2 REMOVE AIR INTAKE MANIFOLD

WARNING

REMOVE ALL RINGS, NECKLACES, JEWELERY AND LOOSE CLOTHING.


FAILURE TO DO SO COULD CAUSE SEVERE INJURY OR DEATH.

To remove the Air Intake Manifold, proceed as follows:

a. This maintenance requires that the PU MUST be shutdown, rendered unable to start, cool
enough for the maintenance to be performed, and Communication Cable (A) and (B)
rerouted to the next PU. This is accomplished by performing the following:

(1) Shutdown the PU in accordance with Section 5.1.6.1 Shutdown Generators.


(2) Isolate the PU from any power plant control system in accordance with Note 1.
(3) Pull to open the PU DC Power Control Breaker.
(4) Push to open both Emergency Stop Switches.
(5) Place both Engine Control Switches (ECS) in the OFF position.
(6) Place a DO NOT OPERATE tag on both generator control panels.
(7) Turn the Battery Bank Parallel Switch to the OFF position.
(8) De-energize both Battery Chargers.
(9) Disconnect the negative and positive cables from both Battery Banks.
(10) Place a DO NOT OPERATE tag on both Battery Banks.
(11) Place all Circuit Breakers in the LOCK OUT position.
(12) Disconnect both 7P1 and 7P2 Connectors located on the inside panel of the PDC.
(13) Close and Lock both generator set control panels.

NOTE 1: When the DC Control Power Circuit Breaker is in the (OFF) position (Pulled – Out), all control
power is turned off to the PU. This will cause the HUB to stop functioning. This causes the
network to not see the equipment shutdown and all PU’s after it. When pulling major
maintenance the (A) (B) Communication Cable must be routed to the next PU in order to
reestablish the communication network.

b. Remove the Cold Start Ether Injector Port Hose use Figure 15.4.3-1 as reference.

c. Remove the two spring clamps from the Air Intake Tube .

d. Remove the Air Intake Hose.

e. Remove the four Air Intake Manifold mounting bolts, remove the Air Intake Manifold.

f. Clean all mating surfaces of old gasket material, dirt and grease.

15-21
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15.4.3.3 INSTALL AIR INTAKE MANIFOLD

WARNING

REMOVE ALL RINGS, NECKLACES, JEWELERY AND LOOSE CLOTHING.


FAILURE TO DO SO COULD CAUSE SEVERE INJURY OR DEATH.

To install the Air Intake Manifold, perform the following:

a. This maintenance requires that the PU MUST be shutdown, rendered unable to start, cool
enough for the maintenance to be performed, and Communication Cable (A) and (B)
rerouted to the next PU. See procedures in paragraph 15.4.3.2.

b. Reinstall the Air Intake Manifold with a new gasket and secure with the mounting bolts removed
earlier.

c. Reinstall the Air Intake Tube to the Air Intake Manifold. Do not forget to put the spring clamp on
before the Air Intake Manifold is attached to the Air Intake Hose. Tighten the constant torque
hose clamps to a torque of 98 + 9 In-Lbs (11+ 1 Nm). Use Figure 15.4.3-1 for reference.

d. Reinstall the Cold Start Ether Injection Port Hose.

15-22
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15.4.4 EXHAUST MANIFOLD

The following maintenance procedures are provided for the Exhaust Manifold.

Inspect
Remove
Install

EXHAUST MANIFOLD

MOUNTING NUTS AND WASHERS

FIGURE 15.4.4-1 EXHAUST MANIFOLD

15.4.4.1 INSPECT EXHAUST MANIFOLD

Inspect the Exhaust Manifold for the following conditions:

a. Inspect for cracks or other physical damage that could cause leaks.

b. Inspect for blown gaskets.

15-23
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15.4.4.2 REMOVE EXHAUST MANIFOLD

WARNING

REMOVE ALL RINGS, NECKLACES, JEWELERY AND LOOSE CLOTHING.


FAILURE TO DO SO COULD CAUSE SEVERE INJURY OR DEATH.

To remove the Exhaust Manifold, perform the following:

a. This maintenance requires that the PU MUST be shutdown, rendered unable to start, cool
enough for the maintenance to be performed, and Communication Cable (A) and (B)
rerouted to the next PU. This is accomplished by performing the following:

(1) Shutdown the PU in accordance with Section 5.1.6.1 Shutdown Generators.


(2) Isolate the PU from any power plant control system in accordance with Note 1.
(3) Pull to open the PU DC Power Control Breaker.
(4) Push to open both Emergency Stop Switches.
(5) Place both Engine Control Switches (ECS) in the OFF position.
(6) Place a DO NOT OPERATE tag on both generator control panels.
(7) Turn the Battery Bank Parallel Switch to the OFF position.
(8) De-energize both Battery Chargers.
(9) Disconnect the negative and positive cables from both Battery Banks.
(10) Place a DO NOT OPERATE tag on both Battery Banks.
(11) Place all Circuit Breakers in the LOCK OUT position.
(12) Disconnect both 7P1 and 7P2 Connectors located on the inside panel of the PDC.
(13) Close and Lock both generator set control panels.

NOTE 1: When the DC Control Power Circuit Breaker is in the (OFF) position (Pulled – Out), all control
power is turned off to the PU. This will cause the HUB to stop functioning. This causes the
network to not see the equipment shutdown and all PU’s after it. When pulling major
maintenance the (A) (B) Communication Cable must be routed to the next PU in order to
reestablish the communication network.

b. Remove the Turbocharger see Section 15.4.2.2 for reference.

c. Remove the Water Regulator Housing use Section 13.4.1 for reference.

d. Remove the twelve nuts, washers and spacers use Figure 15.4.4-1 for reference.

e. Remove the Exhaust Manifold.

f. Remove the six metal liners that hold the exhaust manifold gaskets in place. (For further
references, See Caterpillar Manual SENR 1068-01, section 1059-010, or later version)

g. Remove the six gaskets from the cylinder head.

NOTE: Check the condition of all gaskets, liners, studs and nuts. If any component is worn or
damaged, use a new part for replacement.

h. Clean all mating surfaces of old gasket material, dirt and grease.

15-24
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DRS RADIAN CTM 01646.1R0253/1R0254

15.4.4.3 INSTALL EXHAUST MANIFOLD

WARNING

REMOVE ALL RINGS, NECKLACES, JEWELERY AND LOOSE CLOTHING.


FAILURE TO DO SO COULD CAUSE SEVERE INJURY OR DEATH.

To install the Exhaust Manifold, perform the following:

a. This maintenance requires that the PU MUST be shutdown, rendered unable to start, cool
enough for the maintenance to be performed, and Communication Cable (A) and (B)
rerouted to the next PU. See procedures in paragraph 15.4.4.2.

b. Put Caterpillar 5P-3931 Anti-Seize Compound on the cylinder head studs.

c. Place six new exhaust manifold gaskets on the mounting studs.

d. Place the six liners into the head over the exhaust manifold gaskets.

e. Carefully place the Exhaust Manifold into position over the mounting studs and set the Exhaust
Manifold into place.

f. Reinstall the 12 spacers, washers and nuts.

g. Tighten the nuts in the number sequence shown in Table 15.4.4.3-1, to a torque 38 + 5 Ft-Lbs
(52 + 7 Nm).

TABLE 15.4.4.3-1 EXHAUST MANIFOLD BOLT TIGHTENING SEQUENCE


BOLT TIGHTENING SEQUENCE
CYLINDER 1 CYLINDER 2 CYLINDER 3 CYLINDER 4 CYLINDER 5 CYLINDER 6
1 3 5 7 9 11
4 2 8 6 12 10

h. Reinstall the Water Temperature Regulator see Section 13.4.1 for reference.

i. Reinstall the Turbocharger see Section 15.4.2.3 for reference.

15-25
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15.4.5 AIR TRANSFER TUBES

The following maintenance procedures are provided for the Air Transfer Tubes.

Inspect
Remove
Install

AIR TRANSFER TUBE

RUBBER HOSE COUPLING

CONSTANT TORQUE HOSE CLAMP

U-CLAMP AND AIR TUBE


STIFFENER

FIGURE 15.4.5-1 AIR TRANSFER TUBES

Air Transfer Tubes provide passageways for engine intake air from the turbocharger, through the Air-to-
Air Aftercooler (ATAAC), and to the engine air intake manifold.

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USA TM 9-6115-484-14
DRS RADIAN CTM 01646.1R0253/1R0254

15.4.5.1 INSPECT AIR TRANSFER TUBES

To Inspect the Air Transfer Tubes, proceed as follows:

a. Inspect for air or water leakage around area of couplings and clamps.

b. Inspect tubes for damage that could cause leakage.

c. Inspect with engine running at normal operating temperature inspect each joint and coupling for
evidence of leakage.

d. Refer damaged transfer tubes to the dealer for repair or replacement.

15.4.5.2 REMOVE AIR TRANSFER TUBES

WARNING

REMOVE ALL RINGS, NECKLACES, JEWELERY AND LOOSE CLOTHING.


FAILURE TO DO SO COULD CAUSE SEVERE INJURY OR DEATH.

To remove Air Transfer Tubes, proceed as follows:

a. This maintenance requires that the PU MUST be shutdown, rendered unable to start, cool
enough for the maintenance to be performed, and Communication Cable (A) and (B)
rerouted to the next PU. This is accomplished by performing the following:

(1) Shutdown the PU in accordance with Section 5.1.6.1 Shutdown Generators.


(2) Isolate the PU from any power plant control system in accordance with Note 1.
(3) Pull to open the PU DC Power Control Breaker.
(4) Push to open both Emergency Stop Switches.
(5) Place both Engine Control Switches (ECS) in the OFF position.
(6) Place a DO NOT OPERATE tag on both generator control panels.
(7) Turn the Battery Bank Parallel Switch to the OFF position.
(8) De-energize both Battery Chargers.
(9) Disconnect the negative and positive cables from both Battery Banks.
(10) Place a DO NOT OPERATE tag on both Battery Banks.
(11) Place all Circuit Breakers in the LOCK OUT position.
(12) Disconnect both 7P1 and 7P2 Connectors located on the inside panel of the PDC.
(13) Close and Lock both generator set control panels.

NOTE 1: When the DC Control Power Circuit Breaker is in the (OFF) position (Pulled – Out), all control
power is turned off to the PU. This will cause the HUB to stop functioning. This causes the
network to not see the equipment shutdown and all PU’s after it. When pulling major
maintenance the (A) (B) Communication Cable must be routed to the next PU in order to
reestablish the communication network.

b. Remove the U-clamps and Air Tube Stiffener below the Air Transfer Tube needing to be
removed, use Figure 15.4.5-1for reference.

c. Loosen the constant torque hose clamps from both ends of the Air Transfer Tube needing to be
removed use Figure 15.4.5-1for reference.

d. Pull one end of the air transfer tube from the Rubber Coupling it is seated in.

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e. If the Air Transfer Tube is within the Radiator Compartment, remove the appropriate Front Side
Panel, and perform steps b, and c.

15.4.5.3 INSTALL AIR TRANSFER TUBES

To install Air Transfer Tubes, proceed as follows:

a. This maintenance requires that the PU MUST be shutdown, rendered unable to start, cool
enough for the maintenance to be performed, and Communication Cable (A) and (B)
rerouted to the next PU. See procedures in paragraph 15.4.5.2.

b. Ensure that the Air Transfer Tube is positioned correctly, Place one end of the Air Transfer Tube
into the Rubber Coupling.

c. Ensure that both constant torque hose clamps are in position then put the other end of the Air
Transfer Tube into the final Rubber Coupling. Tighten the constant torque hose clamps to a
torque of 98 + 9 In-Lbs (11+ 1 Nm).

d. Reinstall the Air Tube Stiffener, U-clamps, and any panels that where removed in prior steps.

NOTE: Do not reinstall bent or damaged lines, tubes or hoses. Repair any loose or damaged lines,
tubes and hoses. Leaks can cause fires. Inspect all lines, tubes and hoses carefully.
Tighten all connections to the recommended torque (Refer to Caterpillar Manual SENR3130-
06).

NOTE: A constant torque hose clamp can be used in place of any standard hose clamp. Insure that
the constant torque hose clamp is the same size as the standard clamp. Due to extreme
temperature changes, the hose will heat set. Heat setting causes hose clamps to loosen.
This can result in leaks. A constant torque hose clamp will help to prevent loose hose
clamps.

15-28
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USA TM 9-6115-484-14
DRS RADIAN CTM 01646.1R0253/1R0254

15.4.6 COOLANT TRANSFER TUBES

The following maintenance procedures are provided for the Coolant Transfer Tubes.

Inspect
Remove
Install

UPPER RADIATOR TUBE

UPPER RADIATOR TUBE CONNECTOR

FIGURE 15.4.6-1 UPPER COOLANT TRANSFER TUBE

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UPPER RADIATOR TUBE AND TUBE CONNECTOR

LOWER RADIATOR TUBE AND CONNECTOR

FIGURE 15.4.6-2 UPPER COOLANT TRANSFER TUBE

Each Radiator is connected with a Coolant Transfer Tube.

15.4.6.1 INSPECT COOLANT TRANSFER TUBES

To inspect the Coolant Transfer Tubes, proceed as follows:

a. Inspect for coolant leakage around area of gaskets and seals.

b. Inspect the tubes for damage that could cause leakage.

c. Inspect with the engine running at normal operating temperature, each joint for evidence of
leakage.

15-30
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USA TM 9-6115-484-14
DRS RADIAN CTM 01646.1R0253/1R0254

15.4.6.2 REMOVE COOLANT TRANSFER TUBES

WARNING

REMOVE ALL RINGS, NECKLACES, JEWELERY AND LOOSE CLOTHING.


FAILURE TO DO SO COULD CAUSE SEVERE INJURY OR DEATH.

WARNING

ALWAYS WEAR EYE PROTECTION WHEN YOU PERFORM ANY SERVICE WORK
ON A COOLING SYSTEM

WARNING

RELEASE THE PRESSURE IN THE COOLING SYSTEM BEFORE PERFORMING ANY


SERVICE WORK. IF THE PRESSURE IN THE COOLING SYSTEM IS NOT
RELEASED OR THE TEMPERATURE OF THE SYSTEM IS NOT PERMITTED TO
COOL, STEAM OR HOT WATER MAY BE RELEASED WHEN YOU REMOVE THE
FILLER CAP. THIS MAY CAUSE PERSONAL INJURY.

WARNING

ETHYLENE GLYCOL MAY CATCH FIRE WHEN IT IS HOT OR EXPOSED TO AN


OPEN FLAME. DO NOT WELD, CUT OR USE AN OPEN FLAME NEAR LEAKING
COOLANT THAT CONTAINS ANTIFREEZE.

WARNING

DO NOT REMOVE FILLER CAP AFTER OPERATION UNTIL SYSTEM HAS COOLED
DOWN. FAILURE TO ALLOW ENGINE COOLANT TO COOL DOWN COULD RESULT
IN SECOND AND THIRD DEGREE BURNS. CAP MAY BE HALF-TURNED TO
RELIEVE PRESSURE AND THEN REMOVED TO INSPECT COOLANT LEVEL.

WARNING

PERSONAL INJURY CAN RESULT FROM HOT COOLANT, STEAM AND ALKALI.

WARNING

AT OPERATING TEMPERATURE, ENGINE COOLANT IS HOT AND UNDER PRESSURE.


THE RADIATOR AND ALL LINES TO THE ENGINE CONTAIN HOT COOLANT OR STEAM.
ANY CONTACT CAN CAUSE SEVERE BURNS.

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DRS RADIAN CTM 01646.1R0253/1R0254

WARNING

REMOVE FILLER CAP SLOWLY TO RELIEVE PRESSURE ONLY WHEN THE ENGINE IS
STOPPED AND THE FILLER CAP IS COOL ENOUGH TO TOUCH WITH YOUR BARE HAND.

WARNING

COOLING SYSTEM CONDITIONER CONTAINS ALKALI. AVOID CONTACT WITH SKIN AND
EYES.

CAUTION

CARE MUST BE TAKEN TO ENSURE THAT FLUIDS ARE CONTAINED DURING


PERFORMANCE OF INSPECTION, MAINTENANCE, TESTING, ADJUSTING AND
REPAIR OF THE PU. BE PREPARED TO COLLECT THE FLUID WITH SUITABLE
CONTAINERS BEFORE OPENING ANY COMPARTMENT OR DISASSEMBLY ANY
COMPONENT CONTAINING FLUIDS. DISPOSE OF FLUIDS ACCORDING TO
LOCAL REGULATIONS AND MANDATES.

To Remove the Coolant Transfer Tubes, proceed as follows:

a. This maintenance requires that the PU MUST be shutdown, rendered unable to start, cool
enough for the maintenance to be performed, and Communication Cable (A) and (B)
rerouted to the next PU. This is accomplished by performing the following:

(1) Shutdown the PU in accordance with Section 5.1.6.1 Shutdown Generators.


(2) Isolate the PU from any power plant control system in accordance with Note 1.
(3) Pull to open the PU DC Power Control Breaker.
(4) Push to open both Emergency Stop Switches.
(5) Place both Engine Control Switches (ECS) in the OFF position.
(6) Place a DO NOT OPERATE tag on both generator control panels.
(7) Turn the Battery Bank Parallel Switch to the OFF position.
(8) De-energize both Battery Chargers.
(9) Disconnect the negative and positive cables from both Battery Banks.
(10) Place a DO NOT OPERATE tag on both Battery Banks.
(11) Place all Circuit Breakers in the LOCK OUT position.
(12) Disconnect both 7P1 and 7P2 Connectors located on the inside panel of the PDC.
(13) Close and Lock both generator set control panels.

NOTE 1: When the DC Control Power Circuit Breaker is in the (OFF) position (Pulled – Out), all control
power is turned off to the PU. This will cause the HUB to stop functioning. This causes the
network to not see the equipment shutdown and all PU’s after it. When pulling major
maintenance the (A) (B) Communication Cable must be routed to the next PU in order to
reestablish the communication network.

b. Drain the coolant from the cooling system use Section 13.4.5.5 for reference.

c. Remove the tube connector clamps.

d. Disconnect the Coolant Transfer Tube in question, and remove it from the PU.

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DRS RADIAN CTM 01646.1R0253/1R0254

15.4.6.3 INSTALL COOLANT TRANSFER TUBES

To Install the Coolant Transfer Tubes, proceed as follows:

a. This maintenance requires that the PU MUST be shutdown, rendered unable to start, cool
enough for the maintenance to be performed, and Communication Cable (A) and (B)
rerouted to the next PU. See procedures and warnings in paragraph 15.4.6.2.

b. Reinstall the Coolant Transfer Tubes.

c. Reinstall the Coolant Transfer Tube clamps and tighten bolts.

d. Refill the cooling system see Section 13.4.5.5 for reference.

e. Start the engine. Inspect the cooling system for leaks.

f. Retighten any leaking Coolant Transfer Tube clamps after the PU has cooled to ambient
temperature and start the engine to retest.

NOTE: Do not reinstall bent or damaged lines, tubes or hoses. Repair any loose or damaged lines,
tubes and hoses. Leaks can cause fires. Inspect all lines, tubes and hoses carefully.
Tighten all connections to the recommended torque.

15-33
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USA TM 9-6115-484-14
DRS RADIAN CTM 01646.1R0253/1R0254

15.4.7 HYDRAULIC FLUID TRANSFER HOSES

The following maintenance procedures are provided for the Hydraulic Fluid Transfer Hoses.

Inspect
Remove
Install

HYDRAULIC TRANSFER HOSES

FIGURE 15.4.7-1 HYDRAULIC TRANSFER HOSES

HYDRAULIC TANK SHUTOFF VALVE

FIGURE 15.4.7-2 HYDRAULIC TANK SHUTOFF VALVES

Figure 15.4.7-1 and Figure 15.4.7-2 illustrates the hydraulic fluid transfer tubes that transfer hydraulic fluid
from the engine mounted hydraulic pumps, to the radiator and engine compartment fans.

15-34
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DRS RADIAN CTM 01646.1R0253/1R0254

15.4.7.1 INSPECT HYDRAULIC FLUID TRANSFER HOSES

Inspect the Hydraulic Fluid Transfer Hoses for the following:

a. Inspect for end fittings that are damaged or leaking.

b. Inspect for outer coverings that are chafed or cut.

c. Inspect for exposed wire that is used for reinforcement.

d. Inspect for outer coverings that are ballooning locally.

e. Inspect for flexible parts of the hose that is kinked or crushed.

f. Inspect armoring that is embedded in the outer covering.

NOTE: Do not bend or strike high-pressure lines. Do not reinstall bent or damaged lines, tubes and
hoses. Repair any loose or damaged lines, tubes and hoses. Leaks can cause fires.
Inspect all lines, tubes and hoses carefully. Tighten all connections to the recommended
torque. (Refer to Caterpillar Manual SENR3130-06).

15.4.7.2 REMOVE HYDRAULIC FLUID TRANSFER HOSES

WARNING

REMOVE ALL RINGS, NECKLACES, JEWELERY AND LOOSE CLOTHING.


FAILURE TO DO SO COULD CAUSE SEVERE INJURY OR DEATH.

WARNING

HYDRAULIC FLUID IS HOT AND UNDER HIGH PRESSURE. DO NOT PLACE ANY
PART OF YOUR BODY OVER ANY LEAK. SEVERE INJURY CAN OCCUR IF THIS
HAPPENS.

CAUTION

CARE MUST BE TAKEN TO ENSURE THAT FLUIDS ARE CONTAINED DURING


PERFORMANCE OF INSPECTION, MAINTENANCE, TESTING, ADJUSTING AND
REPAIR OF THE PU. BE PREPARED TO COLLECT THE FLUID WITH SUITABLE
CONTAINERS BEFORE OPENING ANY COMPARTMENT OR DISASSEMBLY ANY
COMPONENT CONTAINING FLUIDS. DISPOSE OF FLUIDS ACCORDING TO
LOCAL REGULATIONS AND MANDATES.

To remove the Hydraulic Fluid Transfer Hoses, proceed as follows:

a. This maintenance requires that the PU MUST be shutdown, rendered unable to start, cool
enough for the maintenance to be performed, and Communication Cable (A) and (B)
rerouted to the next PU. This is accomplished by performing the following:

15-35
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DRS RADIAN CTM 01646.1R0253/1R0254

(1) Shutdown the PU in accordance with Section 5.1.6.1 Shutdown Generators.


(2) Isolate the PU from any power plant control system in accordance with Note 1.
(3) Pull to open the PU DC Power Control Breaker.
(4) Push to open both Emergency Stop Switches.
(5) Place both Engine Control Switches (ECS) in the OFF position.
(6) Place a DO NOT OPERATE tag on both generator control panels.
(7) Turn the Battery Bank Parallel Switch to the OFF position.
(8) De-energize both Battery Chargers.
(9) Disconnect the negative and positive cables from both Battery Banks.
(10) Place a DO NOT OPERATE tag on both Battery Banks.
(11) Place all Circuit Breakers in the LOCK OUT position.
(12) Disconnect both 7P1 and 7P2 Connectors located on the inside panel of the PDC.
(13) Close and Lock both generator set control panels.

NOTE 1: When the DC Control Power Circuit Breaker is in the (OFF) position (Pulled – Out), all control
power is turned off to the PU. This will cause the HUB to stop functioning. This causes the
network to not see the equipment shutdown and all PU’s after it. When pulling major
maintenance the (A) (B) Communication Cable must be routed to the next PU in order to
reestablish the communication network.

b. Cut the wire ties on the Hydraulic Tank Shutoff Valves, and turn the to the shutoff position. See
Figure 15.4.7-2 for reference.

c. Loosen the fittings at the lowest end of the hose you are removing. Collect the fluid in the hose
into an approved container.

d. Loosen and remove both ends of the hydraulic hose you are removing.

e. Remove the hose.

15.4.7.3 INSTALL HYDRAULIC FLUID TRANSFER HOSES

To install the Hydraulic Fluid Transfer Hoses, proceed as follows:

a. This maintenance requires that the PU MUST be shutdown, rendered unable to start, cool
enough for the maintenance to be performed, and Communication Cable (A) and (B)
rerouted to the next PU. See procedures and warnings in paragraph 15.4.7.2.

b. Reinstall the new hydraulic hose into position.

c. Hand-tighten the new hydraulic hose fittings.

15-36
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USA TM 9-6115-484-14
DRS RADIAN CTM 01646.1R0253/1R0254

TABLE 15.4.7.3-1 TORQUE VALUES


NUTS FOR 37 DEGREE FLARED FITTINGS
OUTER DIAMETER OF THE
THREAD SIZE INCH STANDARD TORQUE
NOMINAL TUBE
0.125 inch (3.18 mm) 5/16 4 + 1 Ft-Lbs (5.0 + 1.5 Nm)
0.188 inch (4.76 mm) 3/8 8 + 1 Ft-Lbs (11 + 2 Nm)
0.250 inch (6.35 mm) 7/16 12 + 3 Ft-Lbs (16 + 4 Nm)
0.312 inch (7.94 mm) 1/2 15 + 4 Ft-Lbs (20 + 5 Nm)
0.375 inch (9.52 mm) 9/16 18 + 4 Ft-Lbs (25 + 5 Nm)
0.375 inch (9.52 mm) 5/8 26 + 4 Ft-Lbs (35 + 5 Nm)
0.500 inch (12.70 mm) 3/4 37 + 5 Ft-Lbs (50 + 7 Nm)
0.625 inch (15.88 mm) 7/8 48 + 5 Ft-Lbs (65 + Nm)
0.750 inch (19.05 mm) 1 1/16 75 + 7 Ft-Lbs (100 + 10 Nm)
0.875 inch (22.22 mm) 1 3/16 90 + 7 Ft-Lbs (120 + 10 Nm)
1.00 inch (25.40 mm) 1 5/16 100 + 11 Ft-Lbs (135 + 15 Nm)
1.250 inch (31.75 mm) 1 5/8 135 + 11 Ft-Lbs (180 + 15 Nm)
1.50 inch (38.10 mm) 1 7/8 165 + 11 Ft-Lbs (225 + 15 Nm)
2.00 inch (50.80 mm) 2 1/2 240 + 22 Ft-Lbs (320 + 30 Nm)

d. Torque the 37 degree flared fittings according to their thread size use Table 15.4.7.3-1 for correct
values.

NOTE: Use two wrenches to ensure that the stationary fitting does not move while tightening the
fitting.

e. Turn the Hydraulic Tank Shutoff Valves to the ON position. Reinstall the wire ties on the
Hydraulic Tank Shutoff Valves.

f. Refill the Hydraulic Reservoir to the proper level.

g. Start the engine and inspect for leaks. Re-torque any leaking fittings.

15-37
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USA TM 9-6115-484-14
DRS RADIAN CTM 01646.1R0253/1R0254

15.4.8 CATERPILLAR INC. PROCEDURE FOR VALVE LASH SETTING

TABLE 15.4.8-1 VALVE LASH SETTING REQUIRED TOOLS


REQUIRED TOOLS
TOOL PART NUMBER PART DESCRIPTION QTY
A 9S-9082 Turning Tool 1
B Angle Feeler Gauge .015” Valve Feeler Gauge 1
C Angle Feeler Gauge .030” Valve Feeler Gauge 1
D Torque Wrench (22 Ft-Lbs capacity) 1

NOTE: The No. 1 piston at top center (TC) on the compression stroke is the starting point of all under
valve cover timing procedures. Reference Finding Top Center for instructions.

• Injector Timing Check or Adjustment


• Valve Lash Check or Adjustment

To prevent possible injury, do not use the starter motor to turn the flywheel.
Hot engine components can cause burns. Allow additional time for the
engine to cool before measuring valve lash.
The 3456 uses high voltage to the unit injectors. Do not come in contact with

NOTE: Valve lash is measured between the rocker arm and the valve bridge. All measurements and
adjustments must be made with the engine stopped and the valves fully closed.

TABLE 15.4.8-2 VALVE LASH CHECK


VALVE LASH CHECK
VALVES ACCEPTABLE RANGE FOR VALVE LASH
INLET 0.015 ± 0.003 inch (0.38 ± 0.08 mm)
EXHAUST 0.030 ± 0.003 inch (0.76 ± .08 mm)

An adjustment is not necessary if the measurement of the valve lash is in the acceptable range. Check
the valve lash while the engine is stopped. The range is specified in Table 15.4.8-2. When adjusting
valves use specifications listed in Table 15.4.8-3.

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TABLE 15.4.8-3 VALVE LASH SPECIFICATION


VALVE LASH SPECIFICATION
VALVES GAUGE DIMENSION
INLET 0.015 inch (0.38 mm)
EXHAUST 0.030 inch (0.76 mm)

(1) Valve adjustment locknut


(2) Exhaust adjustment screw
(3) Valve adjustment locknut
(4) Inlet adjustment screw
(5) Feeler gauge

FIGURE 15.4.8-1 VALVE LASH CHECK


To make an adjustment to the valve lash, adjust the valve lash while the engine is stopped. Use the
following procedure:

1. Put the No. 1 piston at the top center position.

NOTE: See Testing and Adjusting, "Finding Top Center Position for the No. 1 Piston" for further
details.

2. With No. 1 piston at the top center position of the compression stroke, an adjustment can be
made to the valves. Before any adjustments are made, lightly tap each rocker arm at the top of
the adjustment screw. Use a soft mallet to ensure that the lifter roller seats against the
camshaft's base circle.

3. Make an adjustment to the valve lash on the inlet valves for cylinders 1, 2, and 4.

a. Loosen valve adjustment locknut (3) refer to Figure 15.4.8-1 and Figure 15.4.8-2.

b. Place the appropriate feeler gauge (5) between the inlet rocker arm and the inlet valve
bridge. Turn the inlet adjustment screw (4) while valve adjustment locknut (3) is being held
from turning. Adjust the valve lash until the correct specification is achieved. Refer to Figure
15.4.8-1 and Figure 15.4.8-2 and Table 15.4.8-3.

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c. After each adjustment, tighten the valve adjustment locknut (3) while the valve adjustment
screw (4) is being held from turning. Tighten to a torque of 22 ± 5 Ft-Lbs (30 ± 7 Nm).
Recheck each adjustment use Figure 15.4.8-1 for reference.

4. Make an adjustment to the valve lash on the exhaust valves for cylinders 1, 3, and 5.

a. Loosen valve adjustment locknut (1) use Figure 15.4.8-1 for reference.

b. Place the appropriate feeler gauge (5) between the exhaust rocker arm and the exhaust
valve bridge. Turn the exhaust adjustment screw (2) while valve adjustment locknut (1) is
being held from turning. Adjust the valve lash until the correct specification is achieved refer
to Figure 15.4.8-1 and Figure 15.4.8-2 and refer to Table 15.4.8-3.

c. After each adjustment, tighten the valve adjustment locknut (1) while the valve adjustment
screw (2) is being held from turning. Tighten to a torque of 22 ± 5 Ft-Lbs (30 ± 7 Nm).
Recheck after each adjustment. Refer to Figure 15.4.8-1 and Figure 15.4.8-2 and Table
15.4.8-3.

5. Remove the timing bolt, and turn the flywheel by 360 degrees in the direction of engine rotation.
This will position the No. 6 piston at the top center on the compression stroke. Reinstall the
timing bolt in the flywheel.

6. Make an adjustment to the valve lash on the inlet valves 3, 5, and 6.

a. Loosen the valve adjustment locknut (3) use Figure 15.4.8-1 for reference.

b. Place the appropriate feeler gauge (5) between the inlet rocker arm and the inlet valve
bridge. Turn inlet adjustment screw (4) while valve adjustment locknut (3) is being held from
turning. Adjust the valve lash until the correct specification is achieved refer to Figure 15.4.8-
1 and Figure 15.4.8-2 and refer to Table 15.4.8-3.

c. After each adjustment, tighten the valve adjustment locknut (3) while valve adjustment screw
(4) is being held from turning. Tighten to a torque of 22 ± 5 Ft-Lbs (30 ± 7 Nm). Recheck
after each adjustment. Refer to Figure 15.4.8-1 and Figure 15.4.8-2 and Table 15.4.8-3.

7. Make an adjustment to the valve lash on the exhaust valves 2, 4, and 6.

a. Loosen the valve adjustment locknut (1).

b. Place the appropriate feeler gauge (5) between the exhaust rocker arm and the exhaust
valve bridge. Turn the exhaust adjustment screw (2) while valve adjustment locknut (1) is
being held from turning. Adjust the valve lash until the correct specification is achieved refer
to Figure 15.4.8-1 and Figure 15.4.8-2 and refer to Table 15.4.8-3.

c. After each adjustment, tighten the valve adjustment locknut (1) while valve adjustment screw
(2) is being held from turning. Tighten to a torque of 30 ± 7 Nm (22 ± 5 Ft-Lbs). Recheck
after each adjustment. Refer to Figure 15.4.8-1 and Figure 15.4.8-2 and Table 15.4.8-3.

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8. Remove the timing bolt from the flywheel after all valve lash adjustments have been made.
NOTE: The timing must also be adjusted on the electronic unit injector. Refer to Section, "Electronic
Unit Injector - Adjust" for more information.

(A) Inlet valves (B) Exhaust valves


(C) Left side of the engine (D) Cylinder number
(E) Front of the engine (F) Right side of the engine
(G) Flywheel end of the engine

FIGURE 15.4.8-2 CYLINDER BORE AND VALVE LOCATION

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15.4.9 CATERPILLAR INC. PROCEDURE FOR UNIT INJECTOR TIMING ADJUSTMENT

TABLE 15.4.9-1 UNIT INJECTOR TIMING ADJUSTMENT REQUIRED TOOLS


REQUIRED TOOLS
TOOL PART NUMBER PART DESCRIPTION QTY

A 9U-7227 Injector Height Gauge 1


B 9S9082 Turning Tool 1
C Torque Wrench lb. ft. (60 lb. ft. capacity) 1

To prevent possible injury, do not use the starter motor to turn the flywheel.
Hot engine components can cause burns. Allow additional time for the
engine to cool before measuring valve lash.
The 3456 uses high voltage to the unit injectors. Do not come in contact with
the injector terminals while the engine is running.

(1) Rocker arm


(2) Adjusting screw
(3) Locknut
(4) 9U-7227 Injector Height Gauge

FIGURE 15.4.9-1 INJECTOR MECHANISM

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The tools required for this procedure are listed in Table 15.4.9-1. To make an adjustment to the
unit injectors on cylinders 3, 5, and 6 use the following procedure:

1. Put the No. 1 piston at the top center position on the compression stroke. Refer to "Finding Top
Center Position for No. 1 Piston" the following section.

2. Injector height gauge (4) is used in order to obtain a dimension of 3.07 ± 0.01 inch (78.0 ± 0.2
mm). The dimension is measured from the top of the unit injector to the machined ledge of the
fuel injector body refer to Figure 15.4.9-1.

3. Turn unit injector adjusting screw (2) clockwise until the correct height is obtained refer to Figure
15.4.9-1.

4. Hold the adjusting screw in this position and tighten locknut (3) to a torque of 60 ± 7 Ft-Lbs (81 ±
10 Nm) refer to Figure 15.4.9-1.

5. To make an adjustment to the unit injectors on cylinders 1, 2, and 4, remove the timing bolt.
Turn the flywheel by 360 degrees in the direction of engine rotation. The direction of engine
rotation is counterclockwise, as the engine is viewed from the flywheel end. This will put the
number 1 piston at the top center position on the exhaust stroke.

6. Repeat Steps 3 through 4.

7. Remove the timing bolt and turning tool from the flywheel after all the unit injector adjustments
have been made.

8. Reinstall the timing cover.

Typical warning label that is factory applied to valve cover area of 3456 engine. Wear,
repainting or pressure washing may have removed one or more of the warning films.
Contact your local Caterpillar dealer for replacement films.

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15.4.10 CATERPILLAR INC. PROCEDURE FOR FINDING TOP CENTER COMPRESSION


POSITION FOR NO. 1 PISTON

Rotating the engine by hand or with the starter without removing the timing
bolt and turning tool can result in personal injury or engine damage.

Caterpillar Inc. Procedure for Finding Top Center Compression


Position For No. 1 Piston
TABLE 15.4.10-1 TOP CENTER COMPRESSION POSITION REQUIRED TOOLS
REQUIRED TOOLS
TOOL PART NUMBER PART DESCRIPTION QTY

A 9S9082 Turning Tool 1

NOTE: The No. 1 piston at top center (TC) on the compression stroke is the starting point of all under
valve cover timing procedures.

• Injector Timing Check or Adjustment


• Valve Lash Check or Adjustment

NOTE: Engine rotation is determined by looking at the flywheel (generator) end of the engine. The
Caterpillar 3456 engine used with the DPGDS PU is of SAE Standard Rotation. SAE
standard rotation is counterclockwise as viewed from the flywheel (generator) end of the
engine. Do not rotate the engine without using the 9S9082-turning tool and do not rotate the
engine clockwise to make any adjustments. Always use the SAE standard rotation when
positioning the engine for any under valve cover adjustments.

NOTE: The 3456 EPG engines in the PU have two threaded holes in the flywheel. These holes are
in alignment with the holes with plugs in the left and right front of the flywheel housing. The
two holes in the flywheel are at a different distance from the center of the flywheel so the
timing bolt cannot be put in the wrong hole. There are also two turning tool locations on each
engine. For generator number 1, the left hand turning tool location and timing bolt hole of the
engine is assessable. On generator number 2, the right hand side turning tool location and
timing bolt hole is assessable.

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(1) Timing bolt. (2) Timing bolt location. (3) Cover.

FIGURE 15.4.10-1 LOCATING TOP CENTER (LEFT SIDE OF ENGINE)

(1) Turning Tool (4) Timing bolt location

FIGURE 15.4.10-2 LOCATING TOP CENTER (RIGHT SIDE OF ENGINE)

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1. See Figure 15.4.10-1 through Figure 15.4.10-7 for reference. The timing bolt (1) is a cover bolt
and can be installed in either the left side of the engine at location (2) or in the right side of the
engine at timing bolt location (4). Remove both bolts (1) and cover (3) from flywheel housing.
Remove the plug from the timing hole in the flywheel housing.

2. See Figure 15.4.10-1 through Figure 15.4.10-7 for reference. Place the timing bolt (1) [long bolt
that holds cover on the flywheel housing] through the timing hole in the flywheel housing. Use
the 9S9082 Engine Turning Tool and 1/2 inch drive ratchet wrench to turn the engine flywheel in
the direction of normal engine rotation (counterclockwise as viewed from the rear of the engine)
until the timing bolt engages with the threaded hole in the flywheel and can be threaded into the
3/8-16 threaded bolthole in the flywheel.

(1) Timing bolt. (5) 9S9082 Engine Turning Tool.


FIGURE 15.4.10-3 USING 9S9082 ENGINE TURNING TOOL (LEFT SIDE OF ENGINE)

NOTE: If the flywheel is turned beyond the point that the timing bolt engages in the threaded hole,
the flywheel must be turned opposite normal engine rotation approximately 45 degrees. Then
turn the flywheel in the direction of SAE Standard rotation until the timing bolt engages
with the threaded hole. The reason for this procedure is to make sure the play is removed
from the gears when the No. 1 piston is put on top center.

3. See Figure 15.4.10-1 through Figure 15.4.10-7 for reference. Remove the 6 bolts (1) and
remove front valve cover (2) from the engine. Check the seal (3) for damage. Seal is reusable if
no signs of damage to seal are found.

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FIGURE 15.4.10-4 VALVE COVER

FIGURE 15.4.10-5 VALVE COVER GASKET

FIGURE 15.4.10-6 ROCKER ARMS OF NO. 1 CYLINDER

NOTE: No. 1 cylinder is at the front end of the engine. (Opposite the generator end)

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4. The intake and exhaust valves for the No. 1 cylinder are fully closed if No. 1 piston is on the
"compression stroke" and the rocker arms can be moved by hand. If the rocker arms cannot be
moved and the valves are slightly open the No. 1 piston is on the "exhaust stroke".

NOTE: When the actual stroke position is identified, and the other stroke position is needed, it is
necessary to remove the timing bolt from the flywheel, turn the flywheel counterclockwise
(as viewed from the generator end) 360 degrees, and reinstall the timing bolt.

FIGURE 15.4.10-7 BARRING ENGINE

5. See Figure 15.4.10-1 through Figure 15.4.10-7 for reference. After Adjustments: Remove the
timing bolt (3) and turning tool (A). Install timing bolt location NPT pipe plug and turning tool
cover in flywheel housing.

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15.4.11 CATERPILLAR INC. PROCEDURE FOR 3456 ENGINE INJECTOR AND VALVE
ADJUSTMENT SEQUENCE FOR DPGDS APPLICATION

Rotating the engine by hand or with the starter without removing the timing
bolt and turning tool can result in personal injury or engine damage.

(SAE STANDARD ENGINE ROTATION, AS VIEWED FROM THE FLYWHEEL END)

NOTE: This chart supplements the instructions for “Valve Lash Setting” and “Injector Timing
Adjustment”. When simultaneous adjustments are being made to both the Valve Lash and
the Injector Timing, this chart can be used in conjunction with the instructions for Valve Lash
and Injector Timing Adjustment.

TABLE 15.4.11-1 TDC COMPRESSION/TDC EXHAUST


TDC COMPRESSION TDC EXHAUST
DPGDS 3456 EPG STROKE ON NUMBER 1 STROKE ON NUMBER 1
CYLINDER CYLINDER
INTAKE VALVES 1-2-4 3-5-6
EXHAUST VALVES 1-3-5 2-4-6
INJECTORS 3-5-6 1-2-4

3456 EPG Firing Order: 1-5-3-6-2-4

TABLE 15.4.11-2 VALVE LASH CHECK


VALVE LASH CHECK
VALVES ACCEPTABLE RANGE FOR VALVE LASH

INLET 0.015 ± 0.003 inch (0.38 ± 0.08 mm)


EXHAUST 0.030 ± 0.003 inch (0.76 ± .08 mm)

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TABLE 15.4.11-3 VALVE LASH SPECIFICATION


VALVE LASH SPECIFICATION
VALVES GAUGE DIMENSION

INLET 0.015 inch (0.38 mm)


EXHAUST 0.030 inch (0.76 mm)

NOTE: See Unit “Injector Timing Adjustment” and “Valve Lash Setting” instructions for details.

(Injector e-trim codes need to be programmed on the 3456 EPG engine when replacing an injector)

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15.4.12 POST MAINTENANCE ENGINE TEST

The following operational performance test of the engine may be conducted to ensure proper
operation:

a. Start and warm up engine in accordance with Section 5.1, Single PU, Prime Power, NO External
Switch, Manual Mode.

b. During engine warm-up, observe the following:

• If oil pressure falls below 25PSI (172 kPa), stop engine and troubleshoot lubrication system
in accordance with Table 7.3.1-1, Problem 14.

• Normal oil temperature should be between 180°F and 250°F (82°C and 121°C) at rated load.
If oil temperature is not within the normal range, troubleshoot in accordance with Table
7.3.1-1, Problem 17.

• After thermostat opening, the coolant temperature should remain in range of 160°F to 220° F
(71°C to 104°C) if coolant does not remain within normal range; troubleshoot in accordance
with Table 7.3.1-1, Problem 15 and Problem 16.

c. If engine does not run smoothly after normal operating temperature is reached or exhaust smoke
is excessive, troubleshoot in accordance with Table 7.3.1-1, Problem 4, Problem 5, and
Problem 6.

d. During operation and shutdown, observe engine for unusual noise or vibration. If unusual noise
or vibration occurs, shut down the engine and refer to the next higher level of maintenance.

e. Shut down the engine immediately if any of the following conditions are not met:

• Minimum oil pressure should be 40 PSI (276kPa) at rated load of 420 kW at 60 Hz and
350 kW at 50 Hz.

• Maximum coolant temperature should be 225°F (107°C).

• Any unusual noise or vibration.

f. If engine does not accelerate smoothly to rated load or exhaust smoke is excessive,
troubleshoot in accordance with Table 7.3.1-1 Problem 4, Problem 5, Problem 6, Problem 8,
Problem 9, and Problem 18.

g. If engine does not achieve or run smoothly at rated load or exhaust smoke is excessive,
troubleshoot in accordance with Table 7.3.1-1 Problem 4, Problem 5, Problem 6, Problem 8,
Problem 9, and Problem 18.

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CHAPTER 16
AIR INTAKE AND EXHAUST SYSTEM REPAIR
TABLE OF CONTENTS

SECTION TITLE PAGE


16.0 AIR INTAKE AND EXHAUST SYSTEM REPAIR 3

16.1 SAFETY INSTRUCTIONS 3

16.2 BRIEF SYSTEM DESCRIPTION 5

16.3 SERVICE REQUIREMENTS 7

16.3.1 AIR FILTER 7

16.3.1.1 AIR FILTER DIFFERENTIAL PRESSURE ALARM 7

16.3.1.2 FILTER DIFFERENTIAL PRESSURE GAUGE MONITORING PANEL 8

16.3.2 AIR FILTER 9

16.3.2.1 INSPECT AIR FILTER 9

16.3.2.2 REMOVE AIR FILTER 10

16.3.2.3 INSTALL AIR FILTER 11

16.3.3 INSPECTIONS 12

16.3.3.1 AIR FILTER ASSEMBLY PIPES, HOSES, AND CLAMPS 12

16.3.3.2 MUFFLER ASSEMBLY 12

16.3.3.2.1 RAIN CAPS 12

16.3.3.2.2 MUFFLER 13

16.3.3.2.3 EXHAUST PIPES, ELBOWS, AND GASKETS 13

16.3.3.3 AIR-TO-AIR AFTERCOOLER (ATAAC) 13

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LIST OF FIGURES

FIGURE TITLE PAGE


FIGURE 16.2-1 TYPICAL AIR INLET AND EXHAUST SYSTEM 5

FIGURE 16.2-2 EXTERNAL AIR FLOW 5

FIGURE 16.2-3 INTERNAL AIR FLOW 6

FIGURE 16.3.1.1-1 AIR FILTER DIFFERENTIAL PRESSURE ALARM 7

FIGURE 16.3.1.2-1 FILTER DIFFERENTIAL GAUGE MONITORING PANEL 8

FIGURE 16.3.2-1 AIR CLEANER 9

FIGURE 16.3.2.1-1 AIR CLEANER / PLENUM ASSEMBLY 10

FIGURE 16.3.3.2-1 MUFFLER ASSEMBLY 12

FIGURE 16.3.3.3-1 AIR-TO-AIR AFTERCOOLER (ATAAC) 13

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16.0 AIR INTAKE AND EXHAUST SYSTEM REPAIR

Service procedures are provided for the following Air Intake and Exhaust System Components:

• Air Filter Assembly


• Muffler Assembly
• Exhaust Pipes, Elbows, and Gaskets
• Air-to-Air Aftercooler (ATAAC)

16.1 SAFETY INSTRUCTIONS

a. Safety precautions must be observed while any maintenance is being performed. Safety
precautions must be observed to ensure that the operator/technician cannot have contact with the
following:

• Hot engine parts


• Hot engine fluids
• Medium Voltage AC electricity
• Low Voltage AC electricity
• Low Voltage DC electricity
• Rotating Parts
• High noise levels

b. Minor troubleshooting can be performed while both engines are running as long as safety
precautions are taken.

c. Minor maintenance can be performed while one generator set is running and the other
generator set has been shutdown. Some examples of this maintenance are:

• Lubrication System – Oil and Filter Change.


• Hydraulic System – Oil and Filter Change.
• Fuel System – Primary and Secondary Filter Change.
• Coolant System – Coolant Change.
• Minor Troubleshooting.
• Check Fluid levels and add required fluids.

(1) The generator set that has been shut down must be rendered unable to start, and cool
enough for the maintenance to be performed. Procedures to render a generator set
unable to start are:

(a) Shutdown the PU in accordance with Section 5.1.6.1 Shutdown Generators.


(b) Push to OPEN the Emergency Stop Switch.
(c) Place the Engine Control Switch (ECS) in the OFF position.
(d) Place a DO NOT OPERATE tag on the generator control panel.
(e) Turn the Battery Bank Parallel Switch to the OFF position.
(f) De-energize the Battery Charger.
(g) Disconnect the negative and positive cables from the Battery Bank for the engine
due maintenance.
(h) Place a DO NOT OPERATE tag on the Battery Bank.

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(i) Place the generator Circuit Breaker in the LOCK OUT position.
(j) Disconnect the 7P1 and 7P2 Connectors located on the inside panel of the PDC.
(k) Close and Lock the generator set control panel.

NOTE: The fuel transfer pump electrical power is normally fed directly from the G1 generator set
battery bank. If you disconnect the G1 battery bank, the external fuel transfer pump will not
function. Place the Fuel Pump Source Switch (S2) into the (G1 or G2 position). Place the S2
in the (G1 or G2) position, for the generator set not receiving maintenance.

d. Major maintenance or service requires that the PU MUST be shutdown, isolated from any
power plant electrical bus or utility connection, isolated from any power plant control
system, and rendered unable to start. This is accomplished by performing the following:

(1) Shutdown the PU in accordance with Section 5.1.6.1 Shutdown Generators.


(2) Isolate the PU from any power plant or utility connection in accordance with Section
5.9.6.15, Unit Isolation Procedure with PSC. See Note 1 and 2.
(3) Isolate the PU from any power plant control system in accordance with Note 3.
(4) Pull to open the PU DC Power Control Breaker.
(5) Push to OPEN both Emergency Stop Switches.
(6) Place both Engine Control Switches (ECS) in the OFF position.
(7) Place a DO NOT OPERATE tag on both generator control panels.
(8) Turn the Battery Bank Parallel Switch to the OFF position.
(9) De-energize both Battery Chargers.
(10) Disconnect the negative and positive cables from both Battery Banks.
(11) Place a DO NOT OPERATE tag on both Battery Banks.
(12) Place all Circuit Breakers in the LOCK OUT position.
(13) Disconnect both 7P1 and 7P2 Connectors located on the inside panel of the PDC.
(14) Close and Lock both generator set control panels.

NOTE 1: Also the PU must be completely electrically isolated from the power distribution bus and
any other electrical source that can back feed into the PU. All medium voltage cables need to
be placed on the standoff insulators by use of hot sticks and other safety gear.

NOTE 2: Ensure cables are not energized by opening the circuit breaker of the Primary Switching
Center (PSC), then disconnect Load Cables (Using the proper safety gear) on the PU and
place them on the Parking Stands.

NOTE 3: When the DC Control Power Circuit Breaker is in the (OFF) position (Pulled – Out), all control
power is turned off to the PU. This will cause the HUB to stop functioning. This causes the
network to not see the equipment shutdown and all PU’s after it. When pulling major
maintenance the (A) (B) Communication Cable must be routed to the next PU in order to
reestablish the communication network.

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16.2 BRIEF SYSTEM DESCRIPTION

a. The engine components of the Air Inlet and Exhaust System control the quality, and the amount
of air that is available for combustion.

b. Figure 16.2-1 shows the components of the Air Inlet and Exhaust System.

FIGURE 16.2-1 TYPICAL AIR INLET AND EXHAUST SYSTEM

c. Figure 16.2-2 shows the External Air Flow through the PU.

FIGURE 16.2-2 EXTERNAL AIR FLOW

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• Air enters from two locations from under the unit. Cool air for the Radiator and Aftercooler
enters from the underside, front part of the PU.

• The airflow to move ambient heat from the engine compartment enters from a grated area
between the Alternator and PDC.

d. Figure 16.2-3 shows the Internal Air Flow through the PU.

FIGURE 16.2-3 INTERNAL AIR FLOW

• The Turbocharger Compressor Wheel pulls air through the Air Cleaner Assembly and into the
air inlet.

• The air is then compressed which heats it to about 300°F before being forced to the
aftercooler.

• The air flows through the aftercooler core and the temperature of the compressed air is then
lowered to about 110°F before entering the engine.

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16.3 SERVICE REQUIREMENTS

16.3.1 AIR FILTER

There are 3 indicators of when to change the Air Filter, these are:

• Air Filter Differential Pressure Alarm, set at 25 inches of water

• Filter Differential Pressure Gauge Monitoring Panel

• 250 hours or Annually

16.3.1.1 AIR FILTER DIFFERENTIAL PRESSURE ALARM

FIGURE 16.3.1.1-1 AIR FILTER DIFFERENTIAL PRESSURE ALARM

a. Location: On each Generator Control Panel. It is shown as an alarm yellow light that is entitled
"Air Filter High Differential Pressure Alarm".

b. Purpose: The indicator monitors restrictions through the Air Filter. If it illuminates, the Air Filter
requires replacement.

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16.3.1.2 FILTER DIFFERENTIAL PRESSURE GAUGE MONITORING PANEL

AIR FILTER DIFFERENTIAL GAUGE

FIGURE 16.3.1.2-1 FILTER DIFFERENTIAL GAUGE MONITORING PANEL

• Check the Air Filter Differential Gauge range. The Air Filter must be replaced if 25 inches of
water if is reached.

• The Air Filters are changed after every 250 hours or annually which ever comes first.

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16.3.2 AIR FILTER

The following maintenance procedures are provided for the Air Filter:

Inspect
Remove
Install
Clean

FIGURE 16.3.2-1 AIR CLEANER

16.3.2.1 INSPECT AIR FILTER

Inspect the Air Filter for the following:

a. Inspect the element for dirt.

b. Do not strike the air filter in any way to examine dirt contamination level. This can damage the
Air Filter and allow dirty air to bypass the filter media and damage the engine if the Air Filter is
reinstalled.

c. Inspect all six latches and retaining springs for damage or missing parts.

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RETAINING SPRING

RETAINING LATCHES

RETAINING SPRING

FIGURE 16.3.2.1-1 AIR CLEANER / PLENUM ASSEMBLY

16.3.2.2 REMOVE AIR FILTER

WARNING

DO NOT PERFORM THE FOLLOWING TASK WHEN THE GENERATOR SET IS


OPERATING. DO NOT TOUCH EXPOSED ELECTRICAL CONNECTION WHEN A
SOURCE OF POWER SUCH AS UTILITY POWER OR ANOTHER GENERATOR SET
IS CONNECTED TO THE LOAD TERMINALS. DEATH OR INJURY MAY RESULT
FROM FAILURE TO OBSERVE THIS WARNING.

WARNING

REMOVE ALL RINGS, NECKLACES, JEWELERY AND LOOSE CLOTHING.


FAILURE TO DO SO COULD CAUSE SEVERE INJURY OR DEATH.

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To remove the Air Filter, proceed as follows:

a. This maintenance can be performed while the generator set not requiring maintenance is
running and the generator set requiring maintenance has been shutdown.

(1) Shutdown the generator set (G1 or G2) in accordance with Section 5.1.6.1 Shutdown
Generators.
(2) Push to OPEN the Emergency Stop Switch.
(3) Place the Engine Control Switch (ECS) in the OFF position.
(4) Place a DO NOT OPERATE tag on the generator control panel.
(5) Turn the Battery Bank Parallel Switch to the OFF position.
(6) De-energize the Battery Charger.
(7) Disconnect the negative and positive cables from the Battery Bank for the engine due
maintenance.
(8) Place a DO NOT OPERATE tag on the Battery Bank.
(9) Place the generator Circuit Breaker in the LOCK OUT position.
(10) Disconnect the 7P1 and 7P2 Connectors located on the inside panel of the PDC.
(11) Close and Lock the generator set control panel.

NOTE: The fuel transfer pump electrical power is normally fed directly from the G1 generator set
battery bank. If you disconnect the G1 battery bank, the external fuel transfer pump will not
function. Place the Fuel Pump Source Switch (S2) into the (G1 or G2 position). Place the S2
in the (G1 or G2) position, for the generator set not receiving maintenance.

b. Use Figure 16.3.2-1 and 16.3.2.1-1 for reference, disconnect the two retaining springs holding
the plenum assembly to the filter housing.

c. Push the Plenum Assembly away from the Air Filter Assembly.

d. Open the six retaining latches and remove the filter cover and the filter element.

e. Protect the filter housing to ensure that the engine is protected from debris entry through the
exposed filter housing.

16.3.2.3 INSTALL AIR FILTER

To install the Air Filter, proceed as follows:

a. This maintenance can be performed while the generator set not requiring maintenance is
running and the generator set requiring maintenance has been shutdown. See procedures
and warnings in paragraph 16.3.2.2. Use Figure 16.3.2-1 and Figure16.3.2.1-1 as reference,

b. Install Air Filter.

d. Reinstall filter cover and close the six retaining latches.

e. Push the plenum assembly to the filter assembly.

f. Reinstall the two retaining springs holding the plenum assembly to the filter housing.

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16.3.3 INSPECTIONS

16.3.3.1 AIR FILTER ASSEMBLY PIPES, HOSES, AND CLAMPS

Inspect the Air Filter Assembly, pipes, hoses, plenums and clamps for following conditions:

a. Inspect connections for security of attachment.

b. Inspect rubber elbows and adapters for cracks, breaks or deterioration.

c. Inspect support frame for security of attachment.

16.3.3.2 MUFFLER ASSEMBLY

FIGURE 16.3.3.2-1 MUFFLER ASSEMBLY

16.3.3.2.1 RAIN CAPS

Inspect the Rain Caps for the following conditions using Figure 16.3.3.2-1, as reference.

a. Inspect for security of attachment.

b. Inspect for proper operation.

c. Inspect for bends, dents, corrosion, and rust.

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16.3.3.2.2 MUFFLER

Inspect the Muffler for the following conditions using Figure 16.3.3.2-1, as reference:

a. Inspect for secure mounting.

b. Inspect for excessive rust or corrosion.

c. Inspect for deformities or ruptures.

d. Inspect for mounting hardware for excessive rust or corrosion.

16.3.3.2.3 EXHAUST PIPES, ELBOWS, AND GASKETS

Inspect the Exhaust Pipes, Elbows, and Gaskets for the following conditions using Figure 16.3.3.2-1, as
reference:

a. Inspect pipes and elbows for cracks, ruptures, corrosion, and security of attachment.

b. Inspect for evidence of exhaust leakage around connections and gaskets.

16.3.3.3 AIR-TO-AIR AFTERCOOLER (ATAAC)

FIGURE 16.3.3.3-1 AIR-TO-AIR AFTERCOOLER (ATAAC)

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Inspect the Air-to-Air-Aftercooler for the following, using Figure 16.3.3.3-1 as reference:

a. Inspect all lines for leaks or damage.

b. Inspect all hoses for dry rot, leaks or damage.

c. Inspect all gasket joints for leakage or damage.

d. Inspect the aftercooler core assembly’s fins for the following conditions:

• Damage
• Debris
• Salt Corrosion

NOTE: When Air-to-Air Aftercooler parts are replaced, a leak test should be completed. Refer to
Caterpillar Manual SENR1067-02, Dated November 2001 or later version, SMCS CODE
1063-081 for testing procedures.

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CHAPTER 17
OPERATOR REMOTE TERMINAL (ORT) REPAIR
TABLE OF CONTENTS

SECTION TITLE PAGE


17.0 OPERATOR REMOTE TERMINAL (ORT) REPAIR 3

17.1 SAFETY INSTRUCTIONS 3

17.2 BRIEF DESCRIPTION 7

17.3 ORT SERVICE PROCEDURES 7

17.3.1 ORT SETUP 7

17.3.2 ORT FUNCTIONS & LOG-ON PROCEDURES 8

17.3.3 ORT REBUILD PROCEDURES FOR ORT WITH SERIAL NUMBERS


009 - 237 9

17.3.4 ORT REBUILD PROCEDURES FOR ORT WITH SERIAL NUMBERS


238 AND UP 10

17.3.5 INSTALLATION OF SERVICE PACKS ON ANY ORT 14

17.3.5 ORT SYSTEM SOFTWARE REGISTRATION 17

17.3.6 ORT TROUBLESHOOTING PROCEDURES 18

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LIST OF FIGURES

CHAPTER TITLE PAGE


FIGURE 17.2-1 OPERATOR REMOTE TERMINAL (ORT) 7

FIGURE 17.3.4-1 DESK TOP SCREEN 12

FIGURE 17.3.4-2 ACTIVATION WINDOW 12

FIGURE 17.3.4-3 ACTIVATE WITHOUT REGISTERING SCREEN 13

FIGURE 17.3.4-4 PHONE ACTIVATION SCREEN 13

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17.0 OPERATOR REMOTE TERMINAL (ORT) REPAIR

The following Service procedures are provided for the Operator Remote Terminal (ORT):

• ORT Service Procedures


• ORT Setup
• ORT Functions & Log-On Procedures
• ORT Rebuild Procedures
• Installation of Service Packs
• ORT System Software Registration
• ORT Troubleshooting Procedures

17.1 SAFETY INSTRUCTIONS

WARNING

READ THIS SECTION, PRIOR TO PERFORMING ANY MAINTENANCE.

WARNING

IMPORTANT SAFETY WARNINGS APPROPRIATE FOR ALL MAINTENANCE


ACTIVITIES.

WARNING

THE EQUIPMENT COVERED IN THIS MANUAL MUST BE INSTALLED, OPERATED,


AND MAINTAINED BY QUALIFIED PERSONS WHO ARE KNOWLEDGEABLE IN THE
INSTALLATION, OPERATION, AND MAINTENANCE OF MEDIUM VOLTAGE
ELECTRICAL POWER GENERATION EQUIPMENT ALONG WITH ASSOCIATED
HAZARDS. A QUALIFIED PERSON IS ONE WHO IS TRAINED AND COMPETENT IN:

• THE SKILLS AND TECHNIQUES NECESSARY TO DISTINGUISH


ENERGIZED PARTS FROM NON-ENERGIZED PARTS OF ELECTRICAL
EQUIPMENT.

• THE SKILLS AND TECHNIQUES NECESSARY TO DETERMINE THE


PROPER APPROACH DISTANCES CORRESPONDING TO THE VOLTAGES
TO WHICH THE QUALIFIED PERSON WILL BE EXPOSED.

• THE PROPER USE OF SPECIAL PRECAUTIONARY TECHNIQUES,


PERSONAL PROTECTIVE EQUIPMENT, INSULATING AND SHIELDING
MATERIALS, AND INSULATED TOOLS FOR WORKING ON OR NEAR
ENERGIZED PARTS OF ELECTRICAL EQUIPMENT AND ROTATING
MACHINERY.

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• THE PROPER USE OF SPECIAL PRECAUTIONARY TECHNIQUES,


PERSONAL PROTECTIVE EQUIPMENT, INSULATING AND SHIELDING
MATERIALS, AND INSULATED TOOLS FOR WORKING ON OR NEAR
EXPOSED HOT SURFACES OF ENGINE AND EXHAUST SYSTEM
COMPONENTS.

THESE INSTRUCTIONS ARE INTENDED ONLY FOR SUCH QUALIFIED PERSONS.


THEY ARE NOT A SUBSTITUTE FOR ADEQUATE TRAINING AND EXPERIENCE IN
SAFETY PROCEDURES FOR THIS TYPE OF EQUIPMENT.

CAUTION

DO NOT ATTEMPT TO LOAD ANY COMPUTER PROGRAM INTO THE ORT WHILE IT
IS CONNECTED TO A POWER UNIT. DAMAGE TO EQUIPMENT MAY RESULT.

CAUTION

DO NOT ATTEMPT TO LOAD ANY COMPUTER PROGRAM INTO THE ORT NOT
SUPPLIED BY RADIAN INC. DAMAGE TO EQUIPMENT MAY RESULT.

CAUTION

DO NOT LOAD ANY SOFTWARE ON THE ORT NOT SUPPLIED BY DRS RADIAN.
ERRATIC OPERATIONS CAN RESULT.

CAUTION

NEVER ATTEMPT TO LOAD ANY SOFTWARE WHILE THE ORT IS MONITORING


POWER PLANT OPERATIONS. ERRATIC OPERATIONS CAN RESULT.

a. Safety precautions must be observed while any maintenance is being performed. Safety
precautions must be observed to ensure that the operator/technician cannot have contact with the
following:

• Hot engine parts


• Hot engine fluids
• Medium Voltage AC electricity
• Low Voltage AC electricity
• Low Voltage DC electricity
• Rotating Parts
• High noise levels

b. Minor troubleshooting can be performed while both engines are running as long as safety
precautions are taken.

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c. Minor maintenance can be performed while one generator set is running and the other
generator set has been shutdown. Some examples of this maintenance are:

• Lubrication System – Oil and Filter Change.


• Hydraulic System – Oil and Filter Change.
• Fuel System – Primary and Secondary Filter Change.
• Coolant System – Coolant Change.
• Minor Troubleshooting.
• Check Fluid levels and add required fluids.

(1) The generator set that has been shut down must be rendered unable to start, and cool
enough for the maintenance to be performed. Procedures to render a generator set
unable to start are:

(a) Shutdown the PU in accordance with Section 5.1.6.1 Shutdown Generators.


(b) Push to OPEN the Emergency Stop Switch.
(c) Place the Engine Control Switch (ECS) in the OFF position.
(d) Place a DO NOT OPERATE tag on the generator control panel.
(e) Turn the Battery Bank Parallel Switch to the OFF position.
(f) De-energize the Battery Charger.
(g) Disconnect the negative and positive cables from the Battery Bank for the engine
due maintenance.
(h) Place a DO NOT OPERATE tag on the Battery Bank.
(i) Place the generator Circuit Breaker in the LOCK OUT position.
(j) Disconnect the 7P1 and 7P2 Connectors located on the inside panel of the PDC.
(k) Close and Lock the generator set control panel.

NOTE: The fuel transfer pump electrical power is normally fed directly from the G1 generator set
battery bank. If you disconnect the G1 battery bank, the external fuel transfer pump will not
function. Place the Fuel Pump Source Switch (FPSS) into the (G1 or G2 position). Place the
FPSS in the (G1 or G2) position, for the generator set not receiving maintenance.

d. Major maintenance or service requires that the PU MUST be shutdown, isolated from any
power plant electrical bus or utility connection, isolated from any power plant control
system, and rendered unable to start. This is accomplished by performing the following:

(1) Shutdown the PU in accordance with Section 5.1.6.1 Shutdown Generators.


(2) Isolate the PU from any power plant or utility connection in accordance with Section
5.9.6.15, Unit Isolation Procedure with PSC. See Note 1 and 2.
(3) Isolate the PU from any power plant control system in accordance with Note 3.
(4) Pull to open the PU DC Power Control Breaker.
(5) Push to OPEN both Emergency Stop Switches.
(6) Place both Engine Control Switches (ECS) in the OFF position.
(7) Place a DO NOT OPERATE tag on both generator control panels.
(8) Turn the Battery Bank Parallel Switch to the OFF position.
(9) De-energize both Battery Chargers.
(10) Disconnect the negative and positive cables from both Battery Banks.
(11) Place a DO NOT OPERATE tag on both Battery Banks.
(12) Place all Circuit Breakers in the LOCK OUT position.
(13) Disconnect both 7P1 and 7P2 Connectors located on the inside panel of the PDC.
(14) Close and Lock both generator set control panels.

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NOTE 1: The PU must be completely electrically isolated from the power distribution bus and any
other electrical source that can back feed into the PU. All medium voltage cables need to be
placed on the standoff insulators by use of hot sticks and other safety gear.

NOTE 2: Ensure cables are not energized by opening the circuit breaker of the Primary Switching
Center (PSC), then disconnect Load Cables (Using the proper safety gear) on the PU and
place them on the Parking Stands.

NOTE 3: When the DC Control Power Circuit Breaker is in the (OFF) position (Pulled – Out), all control
power is turned off to the PU. This will cause the HUB to stop functioning. This causes the
network to not see the equipment shutdown and all PU’s after it. When pulling major
maintenance the (A) (B) Communication Cable must be routed to the next PU in order to
reestablish the communication network.

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17.2 BRIEF DESCRIPTION

FIGURE 17.2-1 OPERATOR REMOTE TERMINAL (ORT)

Figure 17.2-1 illustrates the “Production Model” ORT. The Production Model ORT is a Panasonic
Toughbook. The ORT provides DPGDS operators with a capability to conduct operations remotely, and
provides maintainers with a capacity to conduct detailed maintenance diagnostics through
communications with the Caterpillar Electronic Modular Control Panel (EMCP+), as well as the Caterpillar
Electronic Technician (ET) Tool (When installed). Refer to DRS Radian Inc. Supplement CTM
01646.1R0253/1R0254(S1) for installing the CAT ET Tool on the DPGDS ORT. This supplement is
included in the ET tool case.

17.3 ORT SERVICE PROCEDURES

17.3.1 ORT SETUP

a. Place the ORT on a desktop surface.

b. If AC power is available, plug in the AC power supply to an outlet and the back of the ORT. The
ORT can operate up to 3 hours on its batteries depending on the battery’s charge.

c. Connect the mouse to the mouse PS/2 port on the back of the ORT.

d. Connect one end of the Ethernet network cable to the RJ-45 connector on the ORT.

e. Route and Connect the other end of the cable to the RJ-45 connector on the PU.

f. Turn on the ORT.

g. Log on to the ORT as “Operator”. No password is required.

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h. Select the “EquipID” screen.

i. Enter the following data for each PU:

• Trailer ID

• Engine ID for engines 1 & 2

• Generator ID for generators 1 & 2

j. Select the “One-Line” screen.

k. Enter the descriptor for the load on each of the output breakers.

l. Return to the “Overview” screen.

17.3.2 ORT FUNCTIONS & LOG-ON PROCEDURES

a. ORT Functions:

(1) Operations

(a) Monitor individual generator operating parameters.


(b) Monitor individual engine operating parameters.
(c) Monitor total system parameters.
(d) Start and run individual generators with automatic synchronizing.
(e) Stop individual generators with cooldown.
(f) Immediate stop “Emergency Stop” individual generators without cooldown.
(g) Open individual breakers.
(h) Close individual breakers with auto synchronizing, when required.
(i) Enable/Disable the operation of the PU fuel transfer pump and solenoid.
(j) Enable/Disable engine economizing based on total system KW or KVA load.
(k) Adjust load levels on a PU level based on whether the PU is operating in a baseload
configuration.
(l) Provides listing of installed software versions.

b. Administrator LOG-ON procedure for ORTs:

(1) Turn on the ORT.

(2) Log on to the ORT as Administrator using the following login:

(3) Enter “Username”: “Administrator”

(4) Enter “Password”: “dpgds” (case sensitive)

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17.3.3 ORT REBUILD PROCEDURES FOR ORT NUMBERED 009 THROUGH 237

This procedure actually re-constructs the data on the computer’s internal hard drive by overwriting your
ORT’s hard drive with a completely new image that is on the CD and contains all of the latest software
versions and program updates. This Update is intended to bring all ORTs up to date and provide you
with the latest features. Once your ORT is updated, it can be used reliably on any DPGDS power plant in
the inventory.

The ORT Hard Drive Rebuild Procedure has been streamlined considerably and once started, the
computer does most of the work. Different computers operate at different speeds, therefore it is difficult
to estimate how much time that it will take to complete the procedure. In most cases it can take from 10
to 20 minutes for the computer to complete the upload.

Do not attempt to interrupt the rebuild process once it is placed in motion. Be patient and give the
computer time to work. Please remember, we are completely rebuilding the computer’s hard drive with a
vast amount of data.

Applicability:

This procedure applies to all ORTs numbered 009 through 237. Should you have an ORT numbered
238 or greater, please proceed to Section 17.3.4. The procedures outlined below will not work on your
ORT.

NOTE: This action erases all files (programs and data) on the ORT on all partitions.

a. Start the ORT. Be ready for step 2 almost immediately after starting the ORT.

b. Press the “ESC” when the start options appear in the lower right corner of the ORT screen.

c. Insert the “ORT SYSTEM CD” in the CD drive and the “PRODUCT DISK” in to the 3.5” floppy
drive.

d. From the boot menu select “CD DRIVE” using the down arrow key.

e. Press “ENTER”.

f. Ignore any error messages on the screen, they are normal and are expected during the rebuild.

g. When the message to continue or exit appears, press the “Spacebar” to continue with the
rebuild.

h. Observe that the “Ghost application” starts and the hard drive rebuild commences.

i. Observe the rebuild process as indicated by the progress bar. The rebuild should take 5-7
minutes.

j. When the “A:\Ghost” DOS prompt appears, press “CTRL+ALT+DEL” to reboot the ORT.

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k. Observe the ORT reboots to the Windows startup and goes through an automated setup.

l. When prompted reboot the ORT or allow the 15 seconds to expire allowing an automatic reboot.

m. When the logon appears log on to the ORT as “Operator” and press “ENTER” (no password is
required).

n. Remove the “ORT SYSTEM CD” from the CD drive and the “PRODUCT DISK” from the floppy
drive.

o. Allow the ORT to start the operator screens.

p. Do not turn off the ORT at this point because is where you will register the DPGDS System
Software by extracting information that will be provided to you by the computer itself. Go to
Section 17.3.6 and follow the steps to perform this task.

q. These ORTs use Iconics version 8, which will require contacting Iconics for reactivation of the
software any time the System CD is used to rebuild the hard drive.

17.3.4 ORT REBUILD PROCEDURES FOR ORT NUMBERS 238 AND UP

This procedure actually re-constructs the data on the computer’s internal hard drive by overwriting your
ORT’s hard drive with a completely new image that is on the CD and contains all of the latest software
versions and program updates. This Update is intended to bring all ORTs up to date and provide you with
the latest features. Once your ORT is updated, it can be used reliably on any DPGDS power plant in the
inventory.

The ORT Hard Drive Rebuild Procedure has been streamlined considerably and once started, the
computer does most of the work. Different computers operate at different speeds, therefore it is difficult
to estimate how much time that it will take to complete the procedure. In most cases it can take from 10 to
20 minutes for the computer to complete the upload.

Do not attempt to interrupt the rebuild process once it is placed in motion. Be patient and give the
computer time to work. Please remember, we are completely rebuilding the computer’s hard drive with a
vast amount of data.

Applicability:

This procedure applies to all ORTs numbered 238 and up. Should you have an ORT numbered 009
through 237, please return to Section 17.3.3. The procedures outlined below will not work on your
ORT.

NOTE: This action erases all files (programs and data) on the ORT on all partitions.

a. Replace, if necessary, the floppy drive with the CD drive.

b. Start the ORT. Be ready for step 2 almost immediately after starting the ORT.

c. Press the “ESC” when the start options appear in the lower right corner of the ORT screen.

d. Insert the “ORT SYSTEM CD” in the CD drive.

e. From the boot menu select “CD DRIVE” using the down arrow key.

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f. Press “ENTER”.

g. Ignore any error messages on the screen, they are normal and are expected during the rebuild.

h. When the message to continue or exit appears, press the “Spacebar” to continue with the
rebuild.

i. Observe that the “Ghost application” starts and the hard drive rebuild commences.

j. Observe the rebuild process as indicated by the progress bar. The rebuild should take 5-7
minutes.

k. When the “A:\Ghost” DOS prompt appears, remove the “ORT SYSTEM CD” from the CD drive.

l. Swap the CD drive fro the floppy drive.

m. Insert the “PRODUCT KEY” disk into the floppy drive.

n. Press “CTRL+ALT+DEL” to reboot the ORT.

o. Observe the ORT reboots to the Windows startup and goes through an automated setup.

p. When prompted, reboot the ORT or allow the 15 seconds to expire allowing an automatic reboot.

q. When the logon appears log on to the ORT as “Operator” and press “ENTER” (no password is
required).

r. Remove the “PRODUCT DISK” from the floppy drive.

s. Start the ORT in “Administrator mode and logon


(1) Enter “Username”: “Administrator”
(2) Enter “Password”: “dpgds” (case sensitive)

t. When the activation warning pops up in the lower right corner of the Desk Top Screen,
approximately 3 minutes after logging on, click on the activation icon (see Figure 17.3.4-1).

u. After clicking on the activation icon, the Activation Window appears; determine whether internet
access is available. If yes, continue (see Figure 17.3.4-2), if not skip to step w. to activate via
telephone (see Figure 17.3.4-4).

v. Using internet access, follow the screen instructions to activate Windows XP without registering
(see Figure 17.3.4-3).

w. Using a telephone, follow the screen instructions to activate Windows XP (see Figure 17.3.4-4).

x. Once activated reboot the ORT.

y. Allow the ORT to start the operator screens.

z. Do not turn off the ORT at this point because is where you will register the DPGDS System
Software by extracting information that will be provided to you by the computer itself. Go to
Section 17.3.6 and follow the steps to perform this task.

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FIGURE 17.3.4-1 DESK TOP SCREEN

FIGURE 17.3.4-2 ACTIVATION WINDOW

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FIGURE 17.3.4-3 ACTIVATE WITHOUT REGISTERING SCREEN

FIGURE 17.3.4-4 PHONE ACTIVATION SCREEN

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17.3.5 INSTALLATION OF SERVICE PACK FOLLOWING A SYSTEM RESTORATION

This procedure is for the installation of Service Packs onto an ORT following a system restoration. A
Service Pack is maintenance update to files onboard the ORT. It may contain updated Basler files, PLC
files, Operator screens or interfaces, or maintenance updates to the ORT. Depending on the included
updates in the Service Pack, associated hardware may also require being updated.

a. Start the ORT.


b. Log on to the ORT as Administrator using the following login:
(1) Enter “Username”: “Administrator”
(2) Enter “Password”: “dpgds” (case sensitive)
c. Insert the Service Pack CD into the CD drive.
d. From the START button on the taskbar select RUN.
e. Using the “Browse” button, navigate to “D:” drive (CD-ROM). It should have an “ORT_SPx”
(where “x” is the version of service pack) label.
f. Double click on the “Setup.cmd” file.
g. Click on “Ok” to start install.
h. If the “Windows Script 5.6” pop-up appears click <NO> and continue.
i. Click “OK” to acknowledge Service Pack installation.
j. Click “OK” to acknowledge currently installed service pack.
k. The install will proceed automatically providing updates as it starts and completes tasks. This will
include several ORT reboots that do not require any action.
l. If a Genesis32 pop-up appears about “Time-Limited Licenses”, just click OK and continue.
m. The installation portion of the Service Pack is completed when the ORT boots to the Genesis32
Temporary License Authorization.
n. Remove the Service Pack CD and return it to its case and the ORT case when complete.
o. Register ICONICS Software
There are 3 available methods of registering the Iconics software:
1) Register via the Internet using the ORT to logon to Iconics.
2) Register via the internet using another computer to logon to Iconics.
3) Register without the Internet using telephone.
NOTE: Use the phone method only when no access to the internet is
available. Iconics is available from 0800-1700 Eastern Monday- Friday.
The software gives you 30 days to activate, so it will function if immediate
contact with Iconics is not available.

1. Register via the Internet using the ORT to logon to Iconics.


a) Click on <Start> in the Taskbar.
b) Go to “Programs | Network Settings | Internet mode.cmd”.
c) Wait for the DOS window to close; this may take 10-15 seconds.
d) Connect an Ethernet cable that allows connection to the Internet. Allow the Ethernet
connection to acquire a network address, observed in the Taskbar.
e) On the Genesis32 Temporary License Authorization, click on <YES> “ I want to
activate my temporary authorization now.

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f) Click on <OK>.
g) The License Utility screen appears.
h) From the Menu select “Actions | Register for a License”.
i) Select the “Express Web Site Registration via internet”, click <OK>.
j) The ORT will access the ICONICS website.
k) Click on the “Register” button at the bottom center of the screen.
l) Enter the following data
-- Login: bteagarden
-- Password: scadalic
m) Select “NO” for the Autocomplete
n) Select “YES” for the Internet Explorer
o) Select “Authorize a new license”.
p) Click on <Same as Login>.
q) Scroll to the bottom of the page and click on <NEXT>.
r) Enter following:
-- Reg No 1: G837592721
-- Customer Key: CUS01703
s) Scroll to the bottom of the page and click on <NEXT>.
t) Select ONE of the check boxes.
u) Scroll to the bottom of the screen.
v) Click on the ICONICS – License Utility button on the taskbar.
w) Highlight the alpha-numeric number in the SITE CODE block. Copy the number to
memory <CTRL+C>.
x) Click on the ICONICS Online License Registration button on the taskbar.
y) Paste <CTRL+V> the copied Site Code into the block labeled “Please Enter Site Code
of PC:”.
z) Click <NEXT>.
aa) Click <Yes, Generate Site Key>.
bb) Highlight the red alpha-numeric number in the Site Key block. Copy the number to
memory <CTRL+C>.
cc) Click on the ICONICS Online License Registration button on the taskbar.
dd) Paste <CTRL+V> the copied Site Key into the block labeled “Site Key”.
ee) Click on <Update>.
ff) The update will take 15-20 seconds and is complete when the License View screen
appears.
gg) Click <OK>.
hh) Close all open screens.
ii) Click <OK> on the ORT Service Pack pop-up.
jj) Go to “Programs | Network Settings | ORT mode.cmd”.
kk) Wait for the DOS window to close; this may take 10-15 seconds.
ll) Verify the SP4 CD is removed from the CD drive.
mm) Shut down the ORT and replace the CD drive with the floppy drive.
nn) The ORT has been updated and is ready for ORT service.

2. Register via the internet using another computer to logon to Iconics.


a) On the ORT: Click on <Start> in the Taskbar.
b) On the ORT: On the Genesis32 Temporary License Authorization, click on <YES> “ I
want to activate my temporary authorization now.
c) On the ORT: Click on <OK>.
d) On the ORT: The License Utility screen appears.
e) On the ORT: From the Menu select “Actions | Register for a License”.
f) On the ORT: Select the “Express Web Site Registration via internet”, click <OK>.
g) On the ORT: When the “Internet Connection Wizard” appears, click <Cancel>.
h) On the ORT: The ICONICS License Authorization window will appear, displaying the
SITE CODE.
i) Using the computer with Internet access enter the following URL:

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http://www.iconics.com/support/licenseproduct.asp
j) Click on the “Register” button at the bottom center of the screen.
k) Enter the following data
-- Login: bteagarden
-- Password: scadalic
l) Select “NO” for the Autocomplete
m) Select “YES” for the Internet Explorer
n) Select “Authorize a new license”.
o) Click on <Same as Login>.
p) Scroll to the bottom of the page and click on <NEXT>.
q) Enter following:
-- Reg No 1: G837592721
-- Customer Key: CUS01703
r) Scroll to the bottom of the page, if necessary, and click on <NEXT>.
s) Scroll to the bottom of the page and select ONE of the check boxes.
t) Copy the SITE CODE block data displayed on the ORT into the box on the computer
logged onto the Iconics Online Registration. Be sure to enter data exactly as displayed.
u) Click <NEXT>.
v) Click <Yes, Generate Site Key>.
w) Copy the red alpha-numeric number in the Site Key block into the block labeled “Site
Key” on the ORT. Be sure to enter data exactly as displayed.
x) Click on <Update>.
y) The update will take 15-20 seconds and is complete when the License View screen
appears.
z) Click <OK>.
aa) Close all open screens.
bb) Click <OK> on the ORT Service Pack pop-up.
cc) Go to “Programs | Network Settings | ORT mode.cmd”.
dd) Wait for the DOS window to close; this may take 10-15 seconds.
ee) Verify the SP4 CD is removed from the CD drive.
ff) Shutdown the ORT and replace the CD drive with the floppy drive.
gg) The ORT has been updated and is ready for ORT service.

3. Register without the Internet using telephone.


a) Click on <Start> in the Taskbar.
b) On the Genesis32 Temporary License Authorization, click on <YES> “ I want to activate my
temporary authorization now.
c) Click on <OK>.
d) The License Utility screen appears.
e) From the Menu select “Actions | Register for a License”.
f) Select the “Express Web Site Registration via internet”, click <OK>.
g) When the “Internet Connection Wizard” appears, click <Cancel>.
h) The ICONICS License Authorization window will appear.
i) Call Iconics to get activation Site Key.
-- Phone Number: 800-946-9679, ext 246.
-- If no timely response call 309-699-0115. M-F 0730-2100 CST.
j) Paste Site Key into the block labeled “Site Key”.
k) Click on <Update>.
l) The update will take 15-20 seconds and is complete when the License View screen
appears.
m) Click <OK>.
n) Close all open screens.
o) Click <OK> on the ORT Service Pack pop-up.
p) Go to “Programs | Network Settings | ORT mode.cmd”.
q) Wait for the DOS window to close; this may take 10-15 seconds.
r) Verify the SP CD is removed from the CD drive.

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s) Shutdown the ORT and replace the CD drive with the floppy drive.
t) The ORT has been updated and is ready for ORT service.

17.3.6 ORT SYSTEM SOFTWARE REGISTRATION

Whereas this procedure is probably the easiest of the procedures in the package, it is probably one of the
more important because it confirms that the “Rebuild” of the hard drive was successful and the ORT is
ready for operation. This card should be received any time a Service Pack is released.

A pre-stamped return registration card was provided in your DPGDS System Software Update Package.
Please find this card and review. All of these registration cards are accountable and traceable to the
ORT. It is important that you complete this card completely and legibly for two very good reasons, 1) as
stated above it will “close the loop” by providing us with a confirmation that you were successful in
installing the updated software, 2) it fulfills a licensing agreement with Microsoft. Should you delay in
completing and returning this card, you will likely be contacted and inquired as to any difficulties that
might have precluded the timely return of the registration card.

1. Picking up from the end of Section 17.3.3 or 17.3.4, once the operator screens are running,
observe the “Versions” box in the lower right corner of the Overview screen.

NOTE: You may note that in the new Operator screen, the graphical depictions of the engine
generators are no longer shown. Not to worry, this is a new enhancement. Basically, the
graphics are still there but unless the ORT is actually connected to the network and the
power units are communicating with the ORT, they are not visible. On the older version, the
ORT screen would show four engine generators even if you only have two power units in
your plant.

2. Copy the appropriate data from the Versions box onto the pre-stamped Systems CD Registration
card.

3. Follow any specific instructions that came with the service pack before responding.

4. Press <END> to exit the monitoring software.

5. Select <SKIP ARCHIVE>.

6. Select the “Shutdown” button.

7. Select “Shutdown” from the shutdown scroll bar.

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17.3.7 ORT TROUBLESHOOTING PROCEDURES

a. If the computer does not start, freezes while in operation, or does not function properly. The
problem needs to be isolated. Isolating the problem first will drastically speed-up repairs.

b. First determine if the problems are ORT Hardware based. Refer to the Panasonic Personal
Computer Manual for the model ORT being used. The manual should be in the ORT case or on
the hard drive electronically.

(1) First try to reboot the computer. Refer to the Panasonic Manual. If it doesn’t correct the
problem go to the next step.
(2) Follow the troubleshooting section in the Panasonic Manual. If it is a hardware problem
contact Radian Inc. for further instructions.
(3) If the problem is determined to be a software problem, rebuild the ORT Hard drive, by
using the matching ORT System CD and Product Disk (3.5” floppy) supplied with the ORT.
Go to Section 17.3.3 for ORT Rebuild Procedures.

NOTE: The “ORT SYSTEM CD” and “PRODUCT DISK” are serial number matched to the ORT
serial number, do not use the “ORT SYSTEM CD” and “PRODUCT DISK” from another
ORT.

Rebuilding the ORT from the System CD should be a last resort, especially when doing so on
numbers 238 and up. These ORTs are built on Microsoft’s Windows XP and Iconics version
8. Both will require contacting their respective manufacturers, Microsoft and Iconics, for
reactivation of the software any time the System CD is used to rebuild the hard drive.

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CHAPTER 18
RUNNING GEAR AND TRAILER REPAIR
TABLE OF CONTENTS

SECTION TITLE PAGE


18.0 RUNNING GEAR AND TRAILER REPAIR 4
18.1 SAFETY INSTRUCTIONS 4
18.2 BRIEF DESCRIPTION 6
18.2.1 MEP-PU-810 BRAKE SYSTEM 6
18.2.1.1 MEP-PU-810A BRAKING SYSTEM 6
18.2.1.1.1 SURGE BRAKING SYSTEM 6
18.2.1.1.2 BREAKAWAY LEVER AND CHAIN 7
18.2.1.1.3 HYDRAULIC BRAKE OPERATION 8
18.2.1.1.3.1 SELF-ADJUSTING MECHANISM FOR HYDRAULIC BRAKES 9
18.2.1.1.4 PARKING BRAKE (REAR AXLE ONLY) 10
18.2.1.2 MEP-PU-810B 11
18.2.1.2.1 AIR BRAKE COMPONENTS 11
18.2.1.2.2 AIR CHAMBERS 12
18.2.1.2.3 SPRING BRAKES 13
18.2.1.2.4 SLACK ADJUSTERS 13
18.2.1.2.5 ANTI-LOCK BRAKE SYSTEM (ABS) 14
18.2.1.2.6 VAN LIGHTS 16
18.3 SERVICE REQUIREMENTS 17
18.3.1 MEP-PU-810A SERVICE REQUIREMENTS 17
18.3.1.1 INSPECTIONS 17
18.3.1.2 MEP-PU-810A TIRES 19
18.3.1.2.1 MEP-PU-810A TIRE CHANGING PROCEDURES 19
18.3.1.2.2 TORQUE REQUIREMENTS 20
18.3.1.2.3 TIRE TORQUE PROCEDURE 20
18.3.1.3 LUBRICATION FOR RUNNING GEAR ASSEMBLIES 22
18.3.1.3.1 MEP-PU-810A ZERK FITTINGS (GREASE POINTS) 22
18.3.1.3.2 MEP-PU-810A WHEEL HUB SITE GLASS 24
18.3.1.4 HYDRAULIC ACTUATOR SERVICE INSTRUCTIONS 25
18.3.1.5 MISCELLANEOUS OPERATION STORAGE PREPARATION 27

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TABLE OF CONTENTS

SECTION TITLE PAGE


18.3.1.5.1 AFTER PROLONGED STORAGE INSPECTION PROCEDURES 27
18.3.2 MEP-PU-810B SERVICE REQUIREMENTS 28
18.3.2.1 INSPECTIONS 28
18.3.2.2 AIR TANK SERVICE 29
18.3.2.3 MEP-PU-810B TIRES 30
18.3.2.3.1 MEP-PU-810B TIRE CHANGING PROCEDURES 30
18.3.2.3.2 TORQUE REQUIREMENTS 31
18.3.2.3.2.1 TIRE TORQUE PROCEDURE 31
18.3.2.4 BRAKE ADJUSTMENT PROCEDURES 32
18.3.2.5 MEP-PU-810B HUB ODOMETER 33
18.3.2.5.1 MEP-PU-810B HUB ODOMETER TORQUE REQUIREMENTS 33
18.3.2.6 BRAKE COMPONENT LUBRICATION 34
18.3.2.6.1 LUBRICATION GUIDELINES 34
18.3.2.6.2 HUB LUBRICATION 36
18.3.2.6.3 SERVICE BEARINGS 36
18.3.2.6.4 LANDING GEAR ASSEMBLY LUBRICATION 37

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LIST OF FIGURES

FIGURE TITLE PAGE


FIGURE 18.2.1.1.1-1 TRAILER BRAKES APPLIED 6
FIGURE 18.2.1.1.2-1 BREAKAWAY LEVER AND CHAIN POSITIONS 7
FIGURE 18.2.1.1.3-1 HYDRAULIC BRAKE DIAGRAM 8
FIGURE 18.2.1.1.3.1-1 FORWARD SELF-ADJUSTING HYDRAULIC BRAKE DIAGRAM 9
FIGURE 18.2.1.1.4-1 PARKING BRAKE 10
FIGURE 18.2.1.2.1-1 AIR BRAKE COMPONENTS 11
FIGURE 18.2.1.2.1-2 S-CAM BRAKE ASSEMBLY 12
FIGURE 18.2.1.2.4-1 BRAKE SYSTEM COMPONENTS 13
FIGURE 18.2.1.2.5-1 ABS WIRING LAYOUT 14
FIGURE 18.2.1.2.5-2 ECU AND ABS RELAY VALVE 15
FIGURE 18.2.1.2.5-3 ABS WARNING LIGHT 15
FIGURE 18.2.1.2.6-1 LIGHTING 16
FIGURE 18.3.1.2.1-1 JACK POINTS 19
FIGURE 18.3.1.2.3-1 TORQUING LUG NUTS 20
FIGURE 18.3.1.2.3-2 MEP-PU-810A BOLT TIGHTENING SEQUENCE 21
FIGURE 18.3.1.3.1-1 MODEL “A” ZERK FITTINGS (GREASE POINTS) 22
FIGURE 18.3.1.3.1-2 MODEL “A” ZERK FITTINGS (GREASE POINTS) 23
FIGURE 18.3.1.3.2-1 HUB LUBE OIL SITE GLASS 24
FIGURE 18.3.2.2-1 AIR TANK BLEED PETCOCK 29
FIGURE 18.3.2.3.1-1 JACK POINTS 30
FIGURE 18.3.2.3.2.1-1 MEP-PU-810B BOLT TIGHTENING SEQUENCE 31
FIGURE 18.3.2.5-1 MEP-PU-810B HUB ODOMETER 33
FIGURE 18.3.2.6.1-1 SLACK ADJUSTER LUBRICATION POINTS 34
FIGURE 18.3.2.6.1-2 SUPPORT AND SPIDER BUSHING LUBRICATION POINTS 35
FIGURE 18.3.2.6.4-1 ZERK FITTINGS (GREASE POINTS) 37

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18.0 RUNNING GEAR AND TRAILER REPAIR

18.1 SAFETY INSTRUCTIONS

a. Safety precautions must be observed while any maintenance is being performed. Safety
precautions must be observed to ensure that the operator/technician cannot have contact with the
following:

• Hot engine parts


• Hot engine fluids
• Medium Voltage AC electricity
• Low Voltage AC electricity
• Low Voltage DC electricity
• Rotating Parts
• High noise levels

b. Minor troubleshooting can be performed while both engines are running as long as safety
precautions are taken.

c. Minor maintenance can be performed while one generator set is running and the other
generator set has been shutdown. Some examples of this maintenance are:

• Lubrication System – Oil and Filter Change.


• Hydraulic System – Oil and Filter Change.
• Fuel System – Primary and Secondary Filter Change.
• Coolant System – Coolant Change.
• Minor Troubleshooting.
• Check Fluid levels and add required fluids.

(1) The generator set that has been shut down must be rendered unable to start, and cool
enough for the maintenance to be performed. Procedures to render a generator set
unable to start are:

(a) Shutdown the PU in accordance with Section 5.1.6.1 Shutdown Generators.


(b) Push to OPEN the Emergency Stop Switch.
(c) Place the Engine Control Switch (ECS) in the OFF position.
(d) Place a DO NOT OPERATE tag on the generator control panel.
(e) Turn the Battery Bank Parallel Switch to the OFF position.
(f) De-energize the Battery Charger.
(g) Disconnect the negative and positive cables from the Battery Bank for the engine
due maintenance.
(h) Place a DO NOT OPERATE tag on the Battery Bank.
(i) Place the generator Circuit Breaker in the LOCK OUT position.
(j) Disconnect the 7P1 and 7P2 Connectors located on the inside panel of the PDC.
(k) Close and Lock the generator set control panel.

NOTE: The fuel transfer pump electrical power is normally fed directly from the G1 generator set
battery bank. If you disconnect the G1 battery bank, the external fuel transfer pump will not
function. Place the Fuel Pump Source Switch (S2) into the (G1 or G2 position). Place the S2
in the (G1 or G2) position, for the generator set not receiving maintenance.

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d. Major maintenance or service requires that the PU MUST be shutdown, isolated from any
power plant electrical bus or utility connection, isolated from any power plant control
system, and rendered unable to start. This is accomplished by performing the following:

(1) Shutdown the PU in accordance with Section 5.1.6.1 Shutdown Generators.


(2) Isolate the PU from any power plant or utility connection in accordance with Section
5.9.6.15, Unit Isolation Procedure with PSC. See Note 1 and 2.
(3) Isolate the PU from any power plant control system in accordance with Note 3.
(4) Pull to open the PU DC Power Control Breaker.
(5) Push to OPEN both Emergency Stop Switches.
(6) Place both Engine Control Switches (ECS) in the OFF position.
(7) Place a DO NOT OPERATE tag on both generator control panels.
(8) Turn the Battery Bank Parallel Switch to the OFF position.
(9) De-energize both Battery Chargers.
(10) Disconnect the negative and positive cables from both Battery Banks.
(11) Place a DO NOT OPERATE tag on both Battery Banks.
(12) Place all Circuit Breakers in the LOCK OUT position.
(13) Disconnect both 7P1 and 7P2 Connectors located on the inside panel of the PDC.
(14) Close and Lock both generator set control panels.

NOTE 1: Also the PU must be completely electrically isolated from the power distribution bus and
any other electrical source that can back feed into the PU. All medium voltage cables need to
be placed on the standoff insulators by use of hot sticks and other safety gear.

NOTE 2: Ensure cables are not energized by opening the circuit breaker of the Primary Switching
Center (PSC), then disconnect Load Cables (Using the proper safety gear) on the PU and
place them on the Parking Stands.

NOTE 3: When the DC Control Power Circuit Breaker is in the (OFF) position (Pulled – Out), all control
power is turned off to the PU. This will cause the HUB to stop functioning. This causes the
network to not see the equipment shutdown and all PU’s after it. When pulling major
maintenance the (A) (B) Communication Cable must be routed to the next PU in order to
reestablish the communication network.

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18.2 BRIEF DESCRIPTION

The MEP-PU-801A and MEP-PU-810B have different braking systems. These braking systems will be
described in detail, throughout this Section.

18.2.1 MEP-PU-810 BRAKE SYSTEM

18.2.1.1 MEP-PU-810A BRAKING SYSTEM

18.2.1.1.1 SURGE BRAKING SYSTEM

FIGURE 18.2.1.1.1-1 TRAILER BRAKES APPLIED

a. The MEP-PU-810A has a hydraulic brake system. The hydraulic fluid from a master cylinder is
used to actuate the wheel cylinder, which, in turn, applies force against the brake shoes and
brake drums. The MEP-PU-810A brakes are actuation systems, which transfers the braking
signal from the tow vehicle to the brakes see Figure 18.2.1.1.1-1.

b. The Surge Braking System uses a specially designed trailer hitch coupler, which has a built in
hydraulic cylinder. When the tow vehicle applies its brakes, the tow vehicle decelerates causing
the trailer to apply a pushing force against the hitch. This force actuates the surge hitch hydraulic
cylinder, transferring high-pressure brake fluid to the wheel cylinder. See Figure 18.2.1.1.1-1.

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18.2.1.1.2 BREAKAWAY LEVER AND CHAIN

WARNING

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

FIGURE 18.2.1.1.2-1 BREAKAWAY LEVER AND CHAIN POSITIONS

a. The Surge Braking System incorporates a Safety Breakaway Lever and Chain that activates the
Surge Brake if the trailer separates from the tow vehicle. The actuator’s breakaway chain S-hook
should be securely attached to one of the tow vehicle safety chain connection points. Before
towing, check that the Breakaway Lever and Chain are properly positioned. See Figure
18.2.1.1.2-1. If the breakaway lever and chain are not located correctly, due to either the chain
being pulled during use or by accident, it must be reset prior to moving the trailer.

b. Resetting the Lever is accomplished by: first removing the two rearward bolts, located on each
side of the breakaway lever. These two bolts hold down the breakaway locks. Loosen, but do
not remove the remaining two bolts. This will allow the two locks to be swung aside and the lever
can be pushed back into its resting position. Reinstall the breakaway locks to their original
positions and retighten the four bolts using a torque wrench to 90-120 In-Lbs of torque.

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18.2.1.1.3 HYDRAULIC BRAKE OPERATION

FIGURE 18.2.1.1.3-1 HYDRAULIC BRAKE DIAGRAM

This Hydraulic Brake System utilizes a single acting Uni-Servo Cylinder. Upon actuation, the primary
shoe is pressed against the brake drum, which causes the shoe to move in the direction of rotation. This
movement in turn actuates the secondary shoe through the adjuster link assembly.

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18.2.1.1.3.1 SELF-ADJUSTING MECHANISM FOR HYDRAULIC BRAKES

FIGURE 18.2.1.1.3.1-1 FORWARD SELF-ADJUSTING HYDRAULIC BRAKE DIAGRAM

The brakes adjust on both forward and reverse stops. Components include an Adjuster Assembly,
adjuster lever arm, adjuster return springs, cable, cable anchor bracket, and an extension spring. The
new cable anchor bracket fits over the anchor post and has a slotted hole. The extension spring attaches
the cable anchor bracket to the primary brake shoe. The brake adjuster cable is routed from the cable
anchor bracket, over the cable guide, to the adjuster lever. The forward stop adjustment is accomplished
when the primary shoe lifts sufficiently far off the anchor post. The extension spring connecting the
primary shoe to the slotted cable anchor bracket pulls the bracket and the cable causing the adjuster
lever to rotate the adjuster screw star wheel. This will continue on each brake until the shoe clearance is
sufficiently small so that the primary shoe movement is insufficient to pull the cable to engage the next
tooth on the adjuster star wheel see Figure 18.2.1.1.3.1-1.

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18.2.1.1.4 PARKING BRAKE (REAR AXLE ONLY)

FIGURE 18.2.1.1.4-1 PARKING BRAKE

The Parking Break feature for the MEP-PU-810A is a positive mechanical device, that clamps against the
inside rear tires when applied.

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18.2.1.2 MEP-PU-810B

18.2.1.2.1 AIR BRAKE COMPONENTS

1 SLACK ADJUSTER 8 7 – WAY CONNECTOR


2 SPRING BRAKE 9 GLADHAND EMERGENCY SUPPLY
3 RESERVOIR 10 EXCITER RING
4 RT4 VALVE 70 PSI 11 SENSOR
5 DRAIN COCK 12 BRAKE BLOCK COMPOUND
6 MODULAR I ABS VALVE 13 HUB CAP
7 GLADHAND SERVICE / CONTROL 14 WHEEL OIL SEAL

FIGURE 18.2.1.2.1-1 AIR BRAKE COMPONENTS

Trailer Air Brake System is operated by the towing vehicles air supply through a series of relays and
check valves. When braking is desired, the air is supplied to the axle air chamber, which applies a torque
that is multiplied by the slack adjuster lever arm length. This force is transmitted rotationally through the
camshaft, which, through the geometry of the S-head, spreads the brake shoes to contact the brake drum
surface.

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FIGURE 18.2.1.2.1-2 S-CAM BRAKE ASSEMBLY

18.2.1.2.2 AIR CHAMBERS

See Figure 18.2.1.2.1-1 and Figure 18.2.1.2.1-2, the air chambers convert the compressed air into
mechanical force on the slack adjuster. The force on the slack adjuster operates on the end of the lever
and converts the chamber output force to a torque on the S-cam. Federal and state regulations state the
maximum pushrod stroke length as an indication of brake adjustment. The “maximum stroke indicator”,
located on the air chamber pushrod, shows this stroke length. Maximum allowable stroke is achieved
when the indicator is fully extended from the air chamber housing.

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18.2.1.2.3 SPRING BRAKES

WARNING

DO NOT DISASSEMBLE THE SPRING BRAKE. IT CONTAINS A COMPRESSED


SPRING THAT MAY CAUSE INJURY IF REMOVED. THE SPRING BRAKE MUST BE
CAGED BEFORE SERVICING AND SHOULD ONLY BE PERFORMED BY QUALIFIED
PERSONNEL.

18.2.1.2.4 SLACK ADJUSTERS

SPRING BRAKE ASSEMBLY

SLACK ADJUSTER

AIR CHAMBER

FIGURE 18.2.1.2.4-1 BRAKE SYSTEM COMPONENTS

See Figure 18.2.1.2.4-1, for parking and emergency braking, a spring brake chamber is used in
conjunction with the standard air chamber. The spring brake contains an additional air diaphragm and a
very strong spring. When air is applied to the spring brake, the spring is held in the off position by the air
diaphragm. When the air is exhausted, the spring provides the braking force to the air chamber pushrod,
thus activating the brakes.

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The air brake slack adjusters perform two functions:

(1) The slack adjuster acts as a lever arm to convert the linear pushrod force to rotational camshaft
torque. The length of the slack adjuster determines the amount of torque multiplication provided
from the pushrod.

(2) Allows a simple external adjustment of the lining to drum clearance to compensate for shoe lining
wear. The automatic slack adjuster maintains an optimum clearance between the brake lining
and the drum by automatically adjusting on the return stroke during break application. Various
brands of automatic slack adjusters may work differently. The initial set-up and adjustment of the
automatic slack adjuster is done at the factory.

18.2.1.2.5 ANTI-LOCK BRAKE SYSTEM (ABS)

8 6

1
2
7
8

1. Standard SAE J560 2. Power Cord 5 pin 3. Power Cord 5 pin


4. ECU Connector 19 Pin
Connector Connector Connector
7. Speed Sensor/Exciter 8. Sensors 1A and 1B
5. ABS Valve with ECU 6. Solenoid Connector
Ring Connectors

FIGURE 18.2.1.2.5-1 ABS WIRING LAYOUT

The ABS is made up of Wheel Speed Sensors (Figure 18.2.1.2.5-1), an ABS Relay Valve and integral
Electronic Control Unit (ECU) (Figure 18.2.1.2.5-2), mounted on the relay valve, and an ABS indicator
light as shown in Figure 18.2.1.2.5-3. The ECU monitors wheel speed through two-wheel speed sensors
mounted on the hubs of the axle (See Figure 18.2.1.2.5-1 Item 7). When the ECU detects that a wheel is
stopping too fast, during a brake application, the air pressure in the brake chambers of the wheels is
reduced via the ABS Relay Valve, allowing the wheels to recover. The ECU then commands the relay
valve to apply additional pressure until maximum braking potential is produced. This ABS cycle is
repeated roughly five times per second as needed, or until the vehicle is traveling at less than six miles
per hour. The ABS warning light will illuminate when there is a problem with the system that needs
attention.

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ECU

19 PIN CONNECTOR

ABS RELAY VALVE

FIGURE 18.2.1.2.5-2 ECU AND ABS RELAY VALVE

FIGURE 18.2.1.2.5-3 ABS WARNING LIGHT

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18.2.1.2.6 VAN LIGHTS

DOT LIGHTING

BLACK OUT LIGHTING COMBO

FIGURE 18.2.1.2.6-1 LIGHTING

The MEP-PU-810B has lights for Clearance, Reflectors, Turn Signals, and Tail/Stop-Lights in accordance
with Department Of Transportation (DOT) and Federal Motor Vehicle Safety Standard (FMVSS), 121,
571.124 standards for commercial operations using Figure 18.2.1.2.6-1 as a reference. For towing with a
commercial truck, the commercial lights are powered by the vehicle 12-volt circuit and are provided with a
7-way inter-vehicular cable. In addition, a set of blackout lights including clearance, reflectors, turn signal,
and tail/stop-lights powered by the vehicle 24-volt circuit using a 12-way inter-vehicular cable is provided
for towing with military vehicles. When in the blackout mode of operation, the commercial (DOT) lights
are non-operational.

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18.3 SERVICE REQUIREMENTS

A properly installed hydraulic system should not require any special attention with the exception of routine
maintenance such as shoe and lining replacement. If problems occur, a qualified mechanic, using a
methodical approach to determine the exact source of the problem, should trace the entire trailer braking
system. Typical problems in a hydraulic braking system are:

• Hydraulic system leaks

• Air in brake lines

• Water or other impurity in brake fluid

• Rusted or corroded master or wheel cylinders.

18.3.1 MEP-PU-810A SERVICE REQUIREMENTS

• Inspections

• MEP-PU-810A Tires

• Tire Changing Procedures

• Lubrication

• Hydraulic Actuator Service Instructions

18.3.1.1 INSPECTIONS

WARNING

ASBESTOS DUST HAZARD

SINCE SOME BRAKE SHOE FRICTION MATERIALS CONTAIN ASBESTOS.


CERTAIN PRECAUTIONS MUST BE TAKEN WHEN SERVICING BRAKES:

AVOID CREATING OR BREATHING DUST. AVOID MACHINING, FILING, OR


GRINDING THE BRAKE LININGS. DO NOT USE COMPRESSED AIR OR DRY
BRUSHING FOR CLEANING. DUST CAN BE REMOVED WITH A DAMP BRUSH.

a. Inspect the all hardware for the following condition using Figure 18.2.1.1.5-1 as a reference:

(1) Check shoe return-spring, hold down springs, and adjuster springs for stretch or wear.
Replace as required. Service kits are available.

(2) Check shoe-sliding freedom front and back. Proper hold down clearance is .010 - .015
inch.

b. Inspect the Wheel Cylinders for the following condition using Figure 18.2.1.1.5-1 as a reference:

(1) Check for leaks and smooth operation.

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(2) Clean with brake cleaner and flush with fresh brake fluid.

(3) Hone or replace as necessary.

c. Inspect the Brake Lines for the following condition:

(1) Check for cracks, kinks, or blockage.

(2) Check for leaks.

(3) Replace as necessary.

d. Inspect the Shoes and Linings for the following condition using Figure 18.2.1.1.3-1 as a
reference:

(1) Inspect visually.

(2) Replace if the lining is worn (to within1/16” or less), contaminated with grease or brake
fluid, or abnormally scored or gouged.

e. Inspect the surge brake for the following condition using Figure 18.2.1.1.1-1 as a reference:

(1) Check for Proper Operation.

• Move the trailer to flat, level ground.

• While attempting to back-up the trailer, the surge brake will apply a small amount of
pressure to the brakes.

• Lines and fittings for leakage.

(2) Master cylinder for security of attachment.

(3) Presence and security of safety chain.

f. Inspect the parking brakes for the following conditions using Figure 18.2.1.1.4-1 as a reference:

(1) Proper operation. Crank handle turns freely and bar tightens against the tires, as the
handle is turned clockwise.

(2) Linkage for rust or corrosion.

(3) Linkage for Bent or Loose Connections.

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18.3.1.2 MEP-PU-810A TIRES

The tires supplied with the MEP-PU810A are LT235/85R16. The load range is E. Tire air pressure is 80
PSI.

NOTE: The tires supplied with the MEP-PU-810A power units are:

• Over-The Road Truck Tires (Light Truck Tires)- Part No. - LT235/85R16

• The tires are rated at 2778 pounds at 65 MPH.

• The MEP-PU-810A has four (4) tires per axle, and is rated for a maximum speed of 20 MPH. The
maximum axle load (each) of the power unit is 13,000 pounds.

• Per GoodYear handbook, the percent increase in the load is 32 % at 16 to 25 MPH.

• Four (4) tires per axle X 2778 Lbs. X 1.32 = 14,668 Pounds (which meets the Power Unit tire
rating requirements).

• Replacement Tires must meet the minimum or higher load rating.

18.3.1.2.1 MEP-PU-810A TIRE CHANGING PROCEDURES

Jack points are stenciled on each side of both front and rear axles. If both tires on the same side are flat,
the minimum distance to the lift point is 6 ½ inches above grade. To achieve 1-inch clearance for tire
replacement, the lift point, which is the bottom of the axle, must be elevated to 15 inches above grade
(Figure 18.3.1.2.1-1).

FIGURE 18.3.1.2.1-1 JACK POINTS

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a. Block all wheels so that the unit will not roll or move during the tire changing process.

b. Loosen the lug nuts on the wheel you are going to change

c. Place the jack under the axle where the ‘jack’ stencil is located (low profile 12-15 ton).

d. Jack up the axle until 1-inch clearance is under the tire.

e. Remove the lug nuts and wheel.

f. Reinstall the wheel and reinstall the lug nuts.

g. Follow torque requirements and tire torque procedures in Section 18.3.1.2.2 and Section
18.3.1.2.3.

18.3.1.2.2 TORQUE REQUIREMENTS

CAUTION

WHEEL NUT OR BOLTS MUST BE APPLIED AND MAINTAINED AT THE PROPER


TORQUE LEVELS TO PREVENT LOOSE WHEELS, BROKEN STUDS, AND
POSSIBLE DANGEROUS SEPARATION OF WHEELS FROM YOUR AXLE.

It is extremely important to apply and maintain proper wheel mounting torque on your trailer axle. Torque
wrenches are the best method to assure the proper amount of torque is being applied to a fastener. The
torque requirement is 200-250 Ft-Lbs.

18.3.1.2.3 TIRE TORQUE PROCEDURE

FIGURE 18.3.1.2.3-1 TORQUING LUG NUTS

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1
8 6

3 4

5 7
2
8 BOLT

FIGURE 18.3.1.2.3-2 MEP-PU-810A BOLT TIGHTENING SEQUENCE

a. Be sure to use only the fasteners matched to the cone angle of your wheel (usually 60°or 90°.)
The proper procedure for attaching your wheels is as follows:

b. Start all bolts or nuts by hand to prevent cross threading.

c. Tighten bolts or nuts in the following sequence using Figure 18.3.1.2.3-1 as reference.

d. The tightening of the fasteners should be done in stages. Following the recommended
sequence, tighten fasteners to 200-250 Ft-Lbs per wheel torque requirements of Figure
18.3.1.2.3-2.

e. Wheel nuts/bolts should be re-torqued before first road use and after each wheel removal.

f. Check and re-torque after the first 50 miles and again at 100 miles. Check periodically
thereafter.

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18.3.1.3 LUBRICATION FOR RUNNING GEAR ASSEMBLIES

18.3.1.3.1 MEP-PU-810A ZERK FITTINGS (GREASE POINTS)

There are seven lubrication points on the Surge Braking Assembly and Towing Assembly that must be
lubricated every 90 days. Zerk fittings are installed to facilitate lubrication (Figure 18.3.1.3.1-1 and
18.3.1.3.1-2).

FIGURE 18.3.1.3.1-1 MODEL “A” ZERK FITTINGS (GREASE POINTS)

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FIGURE 18.3.1.3.1-2 MODEL “A” ZERK FITTINGS (GREASE POINTS)

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18.3.1.3.2 MEP-PU-810A WHEEL HUB SITE GLASS

FIGURE 18.3.1.3.2-1 HUB LUBE OIL SITE GLASS

a. Check the oil level in the Wheel Hub Site Glass. Ensure the oil level is at the full mark. Add oil
as required by removing the rubber oil cap and filling through the opening in the center of the
Site Glass. Refer to Annex G for type of oil and Figure 18.3.1.3.2-1 for reference.

b. Recommended Wheel Bearing Lubrication: See Annex G for lube oil specifications

c. Oil should be changed annually and whenever the seals or brakes are replaced. Oil level should
be inspected daily. Always allow a few minutes, after adding oil or after vehicle operation, for the
oil to settle when establishing the required oil level.

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18.3.1.4 HYDRAULIC ACTUATOR SERVICE INSTRUCTIONS

WARNING

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

CAUTION

THE ACTUATOR IS DESIGNED USING A BACK UP ISOLATING VALVE TO BLOCK


OUT THE ACTUATOR IN ORDER TO BACK UP THE PU WITH THE TOWING
VEHICLE. FAILURE TO REMOVE BLOCKING VALVE WILL ALSO PREVENT
FORWARD BRAKING. THE ACTUATOR BACK UP VALVE MUST BE OPENED
BEFORE NORMAL TOWING. THE MAXIMUM TOWING SPEED IS 20 MPH FOR THE
MEP-PU-810A.

a. Before Towing Check:

(1) Before Towing: Check that the Brake Fluid Reservoir is at least half full, if not, re-fill to 3/8
inch below the top of the reservoir with DOT-3 or DOT-4 brake fluid. Check for leaks and
repair as required.

(2) Before Towing: A film of grease on the coupler will extend coupler life while eliminating
squeaking. Wipe clean and renew film each time trailer is used.

(3) Periodic lubrication is required. You should grease the four (4) rollers every 90 days of use.

(4) Before Towing: Examine the actuator for bent parts or excessive wear. Straighten or
replace parts as necessary. Check to determine that mounting bolts are tight and welds not
cracked.

(5) There are no adjustments on the actuator.

(6) Excessive actuator travel (over one inch) when brakes are applied indicates a need to adjust
the brakes. Adjust per instructions found in brake installation manual. In general, back-off
adjusters two clicks from locked rotation. Adjust Free-Backing brakes by rotating in forward
direction only.

b. Service Instructions:

(1) Brake Fluid: DOT4 brake fluid is recommended. The fluid should be checked periodically for
the correct level, dirt, rust, or water contamination. Flush and replace the brake fluid if
contamination is present. To check fluid level, remove the rubber cylinder cover behind the
breakaway lever assembly. Unscrew the master cylinder filler cap. Brake fluid should fill the
cylinder to ¾ full.

(2) The ‘surge’ or ‘push’ of the trailer toward the tow vehicle automatically synchronizes the
trailer brakes with the tow vehicle brake. As the trailer pushes against the tow vehicle the
actuator telescopes together and applies the force to the master cylinder, supplying hydraulic
pressure to the brakes.

(3) Fill the system with DOT-3 or DOT-4 heavy-duty hydraulic brake fluid using a pressure type
brake bleeder.

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(4) To bleed the system manually, proceed as follows:

(a) Fill the master cylinder with fluid.

(b) Depress push rod by using the breakaway lever.

(c) Loosen the four (4) breakaway mounting bolts to keep breakaway locks from restricting
level motion.

(d) Use short strokes until bubbling stops inside master cylinder.

(5) Install bleeder hose on first wheel cylinder to be bled; bleed rear axle first. Have loose end of
hose submerged in a glass container of brake fluid to observe bubbling.

(6) By loosening the bleeder screw located in the wheel cylinder one turn, the system is open to
the atmosphere through the passage drilled in the screw. The bleeding operation is complete
when bubbling stops. Be sure to close bleeder screw securely.

(7) Repeat bleeding operation at each wheel cylinder. During the bleeding process, replenish
the brake fluid so the level does not fall below half full level in the master cylinder reservoir.

(8) After bleeding is completed, make sure master cylinder reservoir is filled to 3/8 inch below
the top of the reservoir and filler cap is securely in place. Tighten the four (4) breakaway
mounting bolts.

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18.3.1.5 MISCELLANEOUS OPERATION STORAGE PREPARATION

a. If the MEP-PU-810 is to be stored for an extended period of time or over the winter, it is important
that the PU be prepared properly.

b. Jack up the trailer and place jack stands under the trailer frame so that the weight will be off the
tires. Follow Section 4.4 for guidelines to lift and support the unit. Never jack up or place jack
stands on the axle tube or on the equalizers.

c. Lubricate mechanical moving parts such as the steering components that are exposed to the
weather.

NOTE: On oil lubricated hubs the upper part of the roller bearings are not immersed in oil and are
subject to potential corrosion. For maximum bearing wear it is recommended that you rotate
your wheels periodically during periods of prolonged storage.

18.3.1.5.1 AFTER PROLONGED STORAGE INSPECTION PROCEDURES

Before removing trailer from jack stands:

a. Remove all wheels and hubs or brake drums. Note which spindle and brake that the drum was
removed from so that it can be reinstalled in the same location.

b. Grease steering components.

c. Check tightness of the axle U-bolt nuts. (Torque values are minimum 130 Ft-Lbs & maximum 170
Ft-Lbs.

d. Check brake linings and brake drums for excessive wear or scoring.

e. Lubricate all brake moving parts using a high temperature brake lubricant. (LUBRIPLATE or
Equivalent).

WARNING

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


FUNCTION PROPERLY

f. Remove any rust from braking surface of drums with fine emery paper or crocus cloth. Protect
bearings from contamination while so doing.

g. Inspect oil or grease seals for wear or nicks. Replace if necessary.

h. Lubricate Hub Bearings. Refer to Section 18.3.2.6.3 for reference.

i. Reinstall Hubs and adjust Bearings see Section 18.3.2.6.3 for reference.

j. Mount and tighten wheels, see Section 18.3.1.2.2 for the MEP-PU-810A and Section 18.3.2.3.2
for the MEP-PU-810B for reference.

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18.3.2 MEP-PU-810B SERVICE REQUIREMENTS

• Inspections

• Air Tank Service

• MEP-PU-810B Tires

• MEP-PU-810B Tire Changing Procedures

• Torque Requirements

• Brake Adjustment Procedures

• Hub Odometer

• Brake Component Lubrication

18.3.2.1 INSPECTIONS

WARNING

ASBESTOS DUST HAZARD

SINCE SOME BRAKE SHOE FRICTION MATERIALS CONTAIN ASBESTOS.


CERTAIN PRECAUTIONS MUST BE TAKEN WHEN SERVICING BRAKES:

AVOID CREATING OR BREATHING DUST. AVOID MACHINING, FILING, OR


GRINDING THE BRAKE LININGS. DO NOT USE COMPRESSED AIR OR DRY
BRUSHING FOR CLEANING. DUST CAN BE REMOVED WITH A DAMP BRUSH.

a. Inspect the Air Brake Lines for the following condition:

(1) Check for cracks, kinks, or blockage.

(2) Check for leaks.

(3) Replace as necessary.

b. Inspect the Shoes and Linings for the following condition:

(1) Inspect visually.

(2) Replace if the lining is worn (to within1/16” or less), contaminated with grease or brake fluid,
or abnormally scored or gouged.

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18.3.2.2 AIR TANK SERVICE

FIGURE 18.3.2.2-1 AIR TANK BLEED PETCOCK

• Drain the Air Tank Daily using Figure 18.3.2.2-1 as reference.

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18.3.2.3 MEP-PU-810B TIRES

18.3.2.3.1 MEP-PU-810B TIRE CHANGING PROCEDURES

Jack points are stenciled on each side of the axle. If both tires on the same side are flat, the minimum
distance to the lift point is 9 inches above grade. To achieve 1-inch clearance for tire replacement, the lift
point, which is the bottom of the axle, must be elevated to 19 inches above grade. See Figure 18.3.2.3.1-
1 for reference.

FIGURE 18.3.2.3.1-1 JACK POINTS

a. Block all wheels and set parking brake so that the unit will not roll or move during the tire
changing process.

NOTE: Curbside wheel lug nuts are right-hand threads. Roadside wheel lug nuts are left-hand
threads. Therefore, to remove the roadside wheel lug nuts, turn the lug nuts in a
clockwise direction. To tighten the wheel lug nuts, turn the lug nut in the
counterclockwise direction.

b. Loosen the lug nuts on the wheel you are going to change.

c. Place the jack under the axle where the ‘jack’ stencil is located (12-15 ton).

d. Jack up the axle until 1-inch clearance is under the tire.

e. Remove the lug nuts and wheel.

f. Reinstall the wheel and Reinstall the lug nuts.

g. Follow TORQUE REQUIREMENTS and TIRE TORQUE PROCEDURES in Section 18.3.2.3.2


and Section 18.3.2.3.2.1.

NOTE: The tires supplied with the MEP-PU810B are 11R22.5. The load range is G. Tire air
pressure is 105 PSI.

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18.3.2.3.2 TORQUE REQUIREMENTS

CAUTION

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

It is extremely important to apply and maintain proper wheel mounting torque on your trailer axle. Torque
wrenches are the best method to assure the proper amount of torque is being applied to a fastener. The
torque requirement is 450 - 500 Ft-Lbs. Requires a special tool, see Annex H for required tool.

18.3.2.3.2.1 TIRE TORQUE PROCEDURE

1
10 7

4 5

6 3

8 9
2
10 BOLT

FIGURE 18.3.2.3.2.1-1 MEP-PU-810B BOLT TIGHTENING SEQUENCE

NOTE: Oil should be changed every 100,000 miles, or once a year and whenever the seals or
brakes are replaced. Oil level should be inspected every 1,000 miles. Always allow a few
minutes, after adding oil or after vehicle operation, for the oil to settle when establishing the
required oil level.

a. Be sure to use only the fasteners matched to the cone angle of your wheel (usually 60°or 90°.)
The proper procedure for attaching your wheels is as follows:

b. Start all bolts or nuts by hand to prevent cross threading.

c. Tighten bolts or nuts in the following sequence.

d. The tightening of the fasteners should be done in stages. Following the recommended
sequence, tighten fasteners to 450-500 Ft-Lbs, per wheel torque requirements using Figure
18.3.2.3.2.1-1 as reference.

NOTE: Curbside wheel lug nuts are right-hand threads. Roadside wheel lug nuts are left-hand
threads. Therefore, to remove the roadside wheel lug nuts, turn the lug nuts in a
clockwise direction. To tighten the wheel lug nuts, turn the lug nut in the
counterclockwise direction.

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e. Wheel nuts/bolts should be torqued before first road use and after each wheel removal.

f. Check and re-torque after the first 50 miles and again at 100 miles. Check periodically
thereafter.

18.3.2.4 BRAKE ADJUSTMENT PROCEDURES

a. Adjust the slack arm up to the point where the slack arm starts to engage into the clevis slot.

b. Take the ½” diameter pivot pin and place it into the clevis slot. Hold in place (at this point, the pin
is like a shim).

c. Continue adjusting the slack arm back into the pin. When the slack arm touches the pin, the
slack rotation will stop. The camshaft will start to rotate as you keep adjusting the slack with the
wrench.

d. Continue adjusting with the wrench, which is now bringing the shoes into closer contact with the
drum. As you continue to adjust, spin the drum by hand to get a feel for the brake drag.

d. Adjust until the drum stops.

e. Adjust an additional ¼ to ½ turn of the wrench.

f. Pull slack away by hand, from the pin.

g. Remove the pin from the slot.

h. Align ½” holes and insert the ½” pin.

i. Make sure the drum rotates one full revolution. If it did, proceed to step “j”. If it did not, start over
at step “a”. Do not tighten the adjuster hex nut as tight as previously done.

j. Insert the ¼” pin.

k. Reinstall and secure the cotter pins in the clevis and adjuster pins.

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18.3.2.5 MEP-PU-810B HUB ODOMETER

FIGURE 18.3.2.5-1 MEP-PU-810B HUB ODOMETER

CAUTION

DO NOT USE PAINTS, SOLVENTS OR THINNERS ON THE ODOMETER FACE,


GRILAMID HUB CAP OR ODOMETER HUB CAP WINDOW.

The MEP-PU-810B has one Hub Odometer mounted on the curbside tire Hub. This Hub Odometer has a
500,000-mile warranty and requires no service or maintenance, for the life of the Hub Odometer. If the
Hub Odometer is damaged, replace it see Figure 18.3.2.5-1.

18.3.2.5.1 MEP-PU-810B HUB ODOMETER TORQUE REQUIREMENTS

a. Tighten the locknuts to 15 Ft-Lbs, when replacing the Hub Odometer.

NOTE: DO NOT USE AIR IMPACT WRENCH.

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18.3.2.6 BRAKE COMPONENT LUBRICATION

See Section 6.3.2 for the Maintenance Schedule for periodic lubrication of brake components.

18.3.2.6.1 LUBRICATION GUIDELINES

WARNING

FAILURE TO CORRECTLY LUBRICATE BEARINGS AND MAINTAIN PROPER


LUBRICATION COULD CAUSE BEARING AND AXLE SPINDLE DAMAGE, WHICH
COULD RESULT IN THE WHEEL LOCKING UP OR COMING OFF DURING VEHICLE
OPERATION.

FIGURE 18.3.2.6.1-1 SLACK ADJUSTER LUBRICATION POINTS

Lubricate the slack adjusters with NLGI Grade 1 or 2 Lithium Grease Complex through the Zerk
fittings using Figure 18.3.2.6.1-1 as reference.

18-34