USA TM 9-6115-484-14
DRS RADIAN CTM 01646.1R0253/1R0254
Lubricate the Support and Spider Bushings (both sides) with NLGI Grade 2 grease through the Zerk
fittings using Figure 18.3.2.6.1-2 as reference.
For camshaft roller journals and anchor pins: Lubricate with high temperature anti-seize grease
18-35
USAF TO 35C2-3-518-1
USA TM 9-6115-484-14
DRS RADIAN CTM 01646.1R0253/1R0254
a. Check oil level in the Wheel Hub Site Glass. Ensure oil level is at the full mark. Add oil if
required by removing the rubber oil cap and filling through the opening in the site glass. Refer to
Annex G for type of oil.
WARNING
b. Prior to repacking bearings, all old grease should be removed from the wheel hub cavity and
bearings.
d. If a machine is unavailable, packing by hand method is acceptable, using the following method:
(2) Press a section of the widest end of bearing into the outer edge of the grease pile closest to
the thumb forcing grease into the interior of the bearing between two adjacent rollers.
(3) Repeat this while rotating the bearing from roller to roller.
(4) Continue this process until you have the entire bearing completely filled with grease.
(5) Before reinstalling, apply a light coat of grease onto the bearing cup mating surface.
18-36
USAF TO 35C2-3-518-1
USA TM 9-6115-484-14
DRS RADIAN CTM 01646.1R0253/1R0254
a. Two lubrication points are located on each landing leg. They must be lubricated every 90 days.
Zerk fittings are installed to facilitate lubrication use Figure 18.3.2.6.4-1 as reference.
b. The retractable landing legs require a medium coating of general-purpose grease, apply as
necessary.
18-37
USAF TO 35C2-3-518-1
USA TM 9-6115-484-14
DRS RADIAN CTM 01646.1R0253/1R0254
18-38
USAF TO 35C2-3-518-1
USA TM 9-6115-484-14
DRS RADIAN CTM 01646.1R0253/1R0254
CHAPTER 19
HYDRAULIC SYSTEM REPAIR
TABLE OF CONTENTS
19-1
USAF TO 35C2-3-518-1
USA TM 9-6115-484-14
DRS RADIAN CTM 01646.1R0253/1R0254
19-2
USAF TO 35C2-3-518-1
USA TM 9-6115-484-14
DRS RADIAN CTM 01646.1R0253/1R0254
LIST OF FIGURES
19-3
USAF TO 35C2-3-518-1
USA TM 9-6115-484-14
DRS RADIAN CTM 01646.1R0253/1R0254
FIGURE 19.4.9.1-1 RADIATOR FAN ASSEMBLY (TOP HALF REMOVED) 54
FIGURE 19.4.9.1-2 RADIATOR FAN ASSEMBLY (BOTTOM HALF WITH KEEPER INSTALLED) 54
FIGURE 19.4.9.2-1 FAN BLADE WITH FAN PITCH 56
FIGURE 19.4.9.2-2 RADIATOR FAN ASSEMBLY (TOP HALF MATED WITH BOTTOM HALF) 56
FIGURE 19.4.10-1 AFTERCOOLER FAN HUB DISASSEMBLY 58
FIGURE 19.4.10.1-1 AFTERCOOLER FAN ASSEMBLY (TOP HALF REMOVED) 59
FIGURE 19.4.10.1-2 AFTERCOOLER FAN ASSEMBLY (BOTTOM HALF W/ KEEPER INSTALLED)59
FIGURE 19.4.11-1 VENT FAN HUB DISASSEMBLY 60
FIGURE 19.4.11.1–1 VENT FAN ASSEMBLY (BOTTOM HALF WITH KEEPER INSTALLED) 60
FIGURE 19.4.11.1-2 FAN BLADE WITH FAN PITCH 61
FIGURE 19.4.12.2-1 TANK ACCESS COVER 63
FIGURE 19.4.12.2-2 TANK ACCESS COVER O-RING 63
FIGURE 19.4.12.2-3 HTLL SWITCH DEUTSCH CONNECTOR 64
19-4
USAF TO 35C2-3-518-1
USA TM 9-6115-484-14
DRS RADIAN CTM 01646.1R0253/1R0254
LIST OF TABLES
19-5
USAF TO 35C2-3-518-1
USA TM 9-6115-484-14
DRS RADIAN CTM 01646.1R0253/1R0254
Maintenance procedures are provided for the following Hydraulic System Components:
• Filter
• Strainer
• Fluid
• Control Block
• Hydraulic Pump
• Hydraulic Motors
• Fan Hub Assemblies
• Fan Blade Assemblies
• Hydraulic Tank Low Level Shutdown Switch (HTLL)
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:
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:
(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:
19-6
USAF TO 35C2-3-518-1
USA TM 9-6115-484-14
DRS RADIAN CTM 01646.1R0253/1R0254
(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.
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:
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.
NOTE 4: 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.
19-7
USAF TO 35C2-3-518-1
USA TM 9-6115-484-14
DRS RADIAN CTM 01646.1R0253/1R0254
Hazards Identification:
(1) EYE CONTACT: Flush thoroughly with cool water. If irritation occurs, call a physician.
(2) SKIN CONTACT: Wash contact areas with soap and water. High-pressure accidental
injection through the skin requires immediate attention for incision and/or debridgment.
(3) INHALATION: Not expected to be a problem.
(4) INGESTION: Not expected to be a problem. However, if greater than ½ liter (pint) is
ingested, immediately give 1 to 2 glasses of water and call a physician, hospital emergency
room or poison control center for assistance. Do not induce vomiting or give anything by
mouth to an unconscious person.
(5) EXPOSURE LIMITS: This product does not contain any components that have recognized
exposure limits. However, an exposure limit of 5.00 mg/m3 is suggested for oil mist.
(1) EXTINGUISHING MEDIA: Carbon dioxide, foam, dry chemical, and water fog.
(2) SPECIAL FIRE FIGHTING PROCEDURES: Water or foam may cause frothing. Use water to
keep fire exposed containers cool. Water spray may be used to flush spills away from
exposure. Prevent runoff from fire control or dilution from entering streams, sewers, or
drinking water supply.
(3) UNUSUAL FIRE AND EXPLOSION HAZARDS: None. Flash point 176ºC, 349ºF.
(4) ASTM D-92: Flammable limits-LEL-NA. UEL-NA.
(5) NFPA HAZARD ID: Health-0. Flammability-1. Reactivity-0.
(6) HAZARDOUS DECOMPOSITION PRODUCTS: Carbon Monoxide.
h. Disposal considerations:
(1) WASTE DISPOSAL: The product is suitable for burning in an enclosed, controlled burner for
fuel value or disposal by supervised incineration. Such burning may be limited to the
Recovery Conservation and Recovery Act (RCRA). In addition, the product is suitable for
processing by an approved recycling facility or can be disposed of at an appropriate
government waste disposal facility. Use of these methods is subject to user compliance with
applicable laws and regulations and consideration of product characteristics at time of
disposal.
(2) RCRA INFORMATION: The unused product, in our opinion, is not specifically listed by the
EPA as a hazard waste (40CFR, Part261D), nor is it formulated to contain materials which
are listed hazardous waste. It does not exhibit the hazardous characteristics of ignitability,
corrosivity, or reactivity and is not formulated with contaminants as determined by the Toxicity
Characteristic Leaching Procedures (TCLP). However used product may be regulated.
19-8
USAF TO 35C2-3-518-1
USA TM 9-6115-484-14
DRS RADIAN CTM 01646.1R0253/1R0254
Figure 19.2-1 illustrates the Hydraulic System Schematic. The hydraulic system used in Power Unit
provides the required power to cool the Power Unit. An engine mounted hydraulic gear pump takes low-
pressure hydraulic fluid from the reservoir, through one 100-mesh strainer (141 Micron) with a 3 PSI
bypass mounted inside the tank, and provides high-pressure fluid to the hydraulic fan motors that drive
the system. The high-pressure fluid from the hydraulic pumps is then forced through a Pressure
Relief/Control Block, which contains a 3,200 + 100-PSI pressure relief valve. From the control block the
high-pressure fluid is transferred through the hydraulic motors, which drive the cooling fans. After the
fluid passes through the hydraulic motors, the low-pressure fluid is then carried through a hydraulic fluid
heat exchanger. The cycle is completed when the fluid returns to the reservoir, through the tank top 3-
micron absolute filter. The case drain on the After Cooler Motor allows hydraulic fluid, from the seal cavity
in the motor, to drain back to the reservoir at atmospheric pressure.
a. Figure 19.2.1-1 and Figure 19.2.1-2 illustrate the Hydraulic Fluid Reservoir. The 18-gallon
reservoir has an internal strainer; a top mounted 3- micron absolute hydraulic filter, and vent cap.
The reservoir also has two top mounted fill ports, a 25 PSI bypass setting and Filter Differential
Gauge.
19-9
USAF TO 35C2-3-518-1
USA TM 9-6115-484-14
DRS RADIAN CTM 01646.1R0253/1R0254
NOTE: The reservoir is not pressurized. It is very important that the reservoir is filled through the top
of the Filter or through the 1” JIC Fill-Port, see Figure 19.2.1-2 for reference.
b. Adding Hydraulic Fluid from the top of the filter assembly or JIC Fill-Port will ensure that
contaminants are not introduced into the system. Keep the fluid level between the red and black
lines on the sight gauge (See Figure 19.2.1-3) and do not overfill. This will ensure that the Air
Vent Cap is kept open and the reservoir does not overflow. The reservoir also includes a
Hydraulic Tank Low Level (HTLL) shutdown switch installed in the back of the reservoir, which is
activated at 33% fluid remaining. This switch is wired to the GSC+ and the Hydraulic Tank Low
Level Light (HTLLL) (Red LED) on the Generator Control Panel. When activated, it will
automatically shut down the generator set and illuminate the HTLLL. Refer to fold out FO-12A
and FO-12B for the schematic wiring of the switch and light. The reservoir also has a fluid shutoff
valve, located in the rear of the Hydraulic Reservoir, where the fluid line is connected (See Figure
19.2.1-4). These valves are held open during normal operation.
NOTE: Prior to disconnecting any hose from a component of the system, the valves must be closed
to prevent draining the reservoir.
c. For hose connections, refer to Hose Connection Drawings FO-45, FO-46 and FO-47.
19-10
USAF TO 35C2-3-518-1
USA TM 9-6115-484-14
DRS RADIAN CTM 01646.1R0253/1R0254
FILTER FILL PORT
DIFFERENTIAL GAUGE
FULL LEVEL
19-11
USAF TO 35C2-3-518-1
USA TM 9-6115-484-14
DRS RADIAN CTM 01646.1R0253/1R0254
NOTE: Fluid Level should be centered within the sight gauge inspection window. Under normal
operating conditions, the hydraulic fluid (being measured by this site gauge) temperature
should not exceed 150 ºF. The temperature gauge is important to determine the ambient
temperature (prior to plant start up) in order to ensure that the correct type of hydraulic fluid is
being used. Refer to Annex G for the required hydraulic fluid in regards to seasonal ambient
temperature.
19-12
USAF TO 35C2-3-518-1
USA TM 9-6115-484-14
DRS RADIAN CTM 01646.1R0253/1R0254
Figure 19.2.2-1 illustrates the Hydraulic System Pump. The hydraulic pump is a positive displacement
pump. This means that the pump delivers a constant flow rate at a constant RPM. The engine’s front
accessory drive gears drive the pump. The pump rotates at 2,160 RPM, when the engine speed is 1,800
RPM. At this speed, the pump will deliver approximately 17.05 gallons per minute optimum flow. The
pump delivers high-pressure fluid, through the control block, to the radiator cooling fan motor, to the
engine air after-cooler fan motor, and the area ventilation motor. See Figure 19.2-1 for additional
information.
HYDRAULIC
PUMP
19-13
USAF TO 35C2-3-518-1
USA TM 9-6115-484-14
DRS RADIAN CTM 01646.1R0253/1R0254
Figure 19.2.3-1 illustrates the Pressure Relief/Control Block Diagram. Figure 19.2.3-2 illustrates the
actual Pressure Relief/Control Block. The Pressure Relief/Control Block includes one high-pressure input
(P1), two high-pressure outputs for the fan circuits (A1, A2), one low pressure return line (T), one relief
valve (RV), that is factory set to relieve the system pressure at 3,200 ± 100 PSI to ensure that the positive
displacement pump is not damaged, if there is a blockage in the system, and a low flow unloading valve
(UV) that bypasses the fan circuits when the pump flow rate is less than 4 GPM. This provides a soft
pump start feature before the engine reaches rated RPM during start up. The Pressure Relief/Control
Block also has two pressure gauge connections (G1, G2). G1 measures the pressure on the Air-Vent
Circuit and G2 measures the pressure on the Radiator Circuit.
Figure 19.2.3-3 illustrates the Hydraulic System Pressure Gauges. The pressure gauges are mounted on
the Engine Filter Differential Gauge Panel. The Radiator Circuit pressure gauge reads between 2,100
and 3,100 PSI, during normal operations. The Air-Vent pressure gauge reads between 2,300 and 3,100
PSI, during normal steady-state operations. The hydraulic gauges are 0 – 5000 PSI rated liquid filled
gauges for anti-vibration and long life.
19-14
USAF TO 35C2-3-518-1
USA TM 9-6115-484-14
DRS RADIAN CTM 01646.1R0253/1R0254
A2
A1
G2
UV
RV
P1
G1
19-15
USAF TO 35C2-3-518-1
USA TM 9-6115-484-14
DRS RADIAN CTM 01646.1R0253/1R0254
Figure 19.2.4-1 illustrates the Hydraulic System Fan Motors. The hydraulic gear motors are also fixed
displacement. This means that the motors will operate at a constant RPM under a constant flow rate. The
high-pressure fluid delivered by the pumps drives the motors. There are three motors per cooling
system: Radiator Coolant, After Cooler, and Ventilation Fan Motors. These motors are part of two
separate circuits. One circuit is for the Radiator Cooling Motor only. The other includes both the After
Cooler and Ventilation Fan Motors in series. All cooling motors operate between 1,750 and 2,400 RPM.
19-16
USAF TO 35C2-3-518-1
USA TM 9-6115-484-14
DRS RADIAN CTM 01646.1R0253/1R0254
Figure 19.2.5-1 illustrates the Hydraulic System Cooler. The Hydraulic System is equipped with a
hydraulic-oil heat exchanger, which cools the fluid prior to the fluid returning to the reservoir. It is located
in the engine coolant side of the radiator assembly. The air inlet side of the Air to Air After Cooler
(ATAAC) should be blown out at the same time the air filter is changed. Under particularly dusty
conditions, daily cleaning may be necessary.
19-17
USAF TO 35C2-3-518-1
USA TM 9-6115-484-14
DRS RADIAN CTM 01646.1R0253/1R0254
WARNING
WARNING
CAUTION
DO NOT OVERFILL THE HYDRAULIC SUMP. KEEP THE FLUID LEVEL BETWEEN
THE RED AND BLACK LINES ON THE SIGHT GAUGE. IF THE TANK IS TOO FULL,
IT COULD CAUSE AN OVER FLOW SITUATION.
CAUTION
CAUTION
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:
19-18
USAF TO 35C2-3-518-1
USA TM 9-6115-484-14
DRS RADIAN CTM 01646.1R0253/1R0254
(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. The Hydraulic System: incorporates an In-tank fluid strainer, (Figure 19.3.1.2-3), and an In-tank
return line filter (Figure 19.3.1.1-4). The In-tank Return Line Filter is located inside the hydraulic
filter assembly at the top of the reservoir. The In-tank Return Line Filter has a color-coded
pressure differential gauge, (Figure 19.2.1-2), on the side. This Differential Pressure Gauge is
used to determine In-tank Return Line Filter replacement time. The Return-Line Filter also has a
bypass built into the housing (Figure 19.3.1.1-3). This bypass is set to 25 PSI and will open when
the pressure drop across the element exceeds 25 PSI. The Return-Line Filter is designed to
have a very low pressure drop when new and at operating temperatures. As contaminants collect
on the element’s surface, the pressure drop across it increases.
c. When to Service: You should replace the filter when the indicating gauge reads 20 PSI
(top of green area) and the pressure should be checked at normal operating pressure.
Checking the filter during cold start up will result in substantially higher readings than at normal
operating temperatures. The reason for changing the filter at 20 PSI rather than 25 PSI (bypass
setting) is to make sure the filter does not go into bypass, allowing fluid to return unfiltered.
• Replace: the Return-Line Filter and O-ring after every 8,000 hours of use, during any
complete fluid change or every 12 months. This must be done even if the indicator gauge is
in the green (below 20 PSI).
• Inspect: the new Return-Line Filter element for any damage; prior to installation see Figure
19.3.1.1-4. The 100-mesh strainer (141 Micron) must be removed and cleaned annually.
Inspect the strainer for any damage, prior to installation. The reason for having a 100-mesh
(141 Micron) strainer and a 3-micron filter in the hydraulic system is to take out microscopic
contaminants. The size particles this filter element removes are smaller than the human eye
can see. Caution must be taken during the cleaning and replacement process not to
introduce any contaminates into the system. The strainer must be removed and cleaned
every time the hydraulic fluid is changed and the hydraulic fluid should be changed every
16,000 hours, or 3 years. Yearly hydraulic fluid samples should be taken and analyzed to
determine fluid contamination levels. Complete fluid change may increase based on analysis
findings.
19-19
USAF TO 35C2-3-518-1
USA TM 9-6115-484-14
DRS RADIAN CTM 01646.1R0253/1R0254
a. Clean the area around the In-tank Return Line Filter Assembly of contaminants that could fall into
the tank, during change out. You should also have a clean work area for components and
elements.
b. Unscrew the four mounting bolts holding the filter cap, rotate filter cap counter clockwise and
remove the cap (see Figures 19.3.1.1-1 and 19.3.1.1-2 for reference).
c. Inspect the filter cap for nicks or signs of damage. Reuse if acceptable, replace if necessary
(see Figure 19.3.1.1-3).
e. Remove the In-tank Return Line Filter from the housing (see Figure 19.3.1.1-4 for reference).
NOTE: The solid basket remains in the filter housing.
f. Lubricate the rubber gasket on each end of the new filter with hydraulic fluid and place the filter
into the basket and housing (see Figure 19.3.1.1-5).
g. Reinstall the filter cap and tighten the four bolts in an alternating fashion. Tighten each bolt in a
3-step progression. First hand tighten. Then torque each bolt to 11 ± 2 Ft-Lbs. Then torque
each bolt to 22 ± 2 Ft-Lbs.
FIGURE 19.3.1.1-1 FILTER CAP, FILL HOLE, AND JIC FILL PORT
19-20
USAF TO 35C2-3-518-1
USA TM 9-6115-484-14
DRS RADIAN CTM 01646.1R0253/1R0254
O-RING
BYPASS
19-21
USAF TO 35C2-3-518-1
USA TM 9-6115-484-14
DRS RADIAN CTM 01646.1R0253/1R0254
19-22
USAF TO 35C2-3-518-1
USA TM 9-6115-484-14
DRS RADIAN CTM 01646.1R0253/1R0254
Replace the Hydraulic Fluid and clean the internal strainers every 16,000 hours or three years,
sooner if yearly sampling indicates fluid contamination.
a. Start engine until the hydraulic fluid reaches normal operating temperature, then shutdown the
generator set. Do not allow fluid to cool.
b. Remove the Drain Plug in the bottom of the Hydraulic Reservoir; see Figure 19.2.1-1 for
reference.
e. Remove the eight ¼-20 bolts from the Hydraulic Reservoir Access Cover, attached to the vent
cap. See Figure 19.4.12.2-1 for reference. Remove the cover and O-ring
f. Unscrew the 100-mesh (141 Micron) strainer from inside the tank. Take care not to damage the
strainer during removal, see Figure 19.3.1.2-3 for reference.
g. Clean the strainer thoroughly and reinstall it the Hydraulic Reservoir. Hand tighten only, do
not use a wrench.
h. Discard the old O-ring and reinstall a new one. See Figure 19.3.1.2-2
i. Reinstall the Hydraulic Reservoir Access Cover and torque the eight 1/4" bolts to 10 ± 2 lb ft,
see Figure 19.4.12.2-1 for reference.
j. Unscrew the Vent Cap and install a new Vent Cap every time the hydraulic filter is changed, see
Figure 19.3.1.2-1 for reference.
k. Gravity-fill clean, filtered hydraulic fluid (approx. 18 gallons) into the reservoir through the In-tank
Return Line Filter Assembly Fill Port or through the 1” JIC Fill Port, see Figure 19.2.1-2 for
reference.
19-23
USAF TO 35C2-3-518-1
USA TM 9-6115-484-14
DRS RADIAN CTM 01646.1R0253/1R0254
19-24
USAF TO 35C2-3-518-1
USA TM 9-6115-484-14
DRS RADIAN CTM 01646.1R0253/1R0254
100-MESH STRAINER
19-25
USAF TO 35C2-3-518-1
USA TM 9-6115-484-14
DRS RADIAN CTM 01646.1R0253/1R0254
The following maintenance procedures are provided for the Pressure Relief/Control Block:
Inspect
Remove
Install
19-26
USAF TO 35C2-3-518-1
USA TM 9-6115-484-14
DRS RADIAN CTM 01646.1R0253/1R0254
To inspect the Pressure Relief/Control Block using Figure 19.4.1-1, proceed as follows:
a. This maintenance can be performed while the generator set not requiring maintenance is
running and the generator set requiring maintenance has been shutdown.
b. The generator set that requires the maintenance (G1 or G2) has been shut down, and must be
rendered unable to start, and be cool enough for the maintenance to be performed.
Procedures to render a generator set unable to start are:
(1) Shutdown the generator set (G1 or G2) in accordance with Section 5.1.6.1 Shutdown
Generators.
(2) Push to OPEN the Emergency Stop Switch.
(3) Place the Engine Control Switch (ECS) in the OFF position.
(4) Place a DO NOT OPERATE tag on the generator control panel.
(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. Prior to starting the Power Unit, inspect the engine compartment for any hydraulic fluid leaks.
Correct any leaks as necessary.
e. Start the Power Unit according to Chapter 5. Allow the Power Unit to reach operating
temperature and shutdown the Power Unit according to Chapter 5.
f. Check under the Power Unit for any hydraulic fluid leaks. Correct any leaks as necessary.
g. Check the Pressure Relief/Control Block for leaks, missing or loose hardware.
19-27
USAF TO 35C2-3-518-1
USA TM 9-6115-484-14
DRS RADIAN CTM 01646.1R0253/1R0254
To remove the Pressure Relief/Control Block using Figure 19.4.1-1, 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:
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. Close the Hydraulic Fluid Shutoff Valve. See Figure 19.2.1-4 for reference.
d. Disconnect the 6 input and output hoses. See Figure 19.4.1-1 for reference.
NOTE: Use proper procedures to collect any hydraulic fluid left in the hoses to prevent spills.
e. Remove the Pressure Relief/Control Block mounting bolts and lift the Pressure Relief/Control
Block from the engine.
19-28
USAF TO 35C2-3-518-1
USA TM 9-6115-484-14
DRS RADIAN CTM 01646.1R0253/1R0254
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 in paragraph 19.4.1.2.
b. Reinstall the Pressure Relief/Control Block and reinstall the Pressure Relief/Control Block
mounting bolts. Torque the mounting bolts to 30 + 5 Ft-Lbs.
c. Reinstall and torque the hydraulic hoses according to specifications found in Caterpillar Manual
SENR3130-6 or later version.
NOTE: Use proper procedures to collect any hydraulic fluid left in the hoses to prevent spills.
f. Open the Hydraulic Fluid Shut Off Valve. Secure the valve handle in the open position.
g. Prepare the PU to be started. All lockout and tag-out, tags must be removed.
h. Inspect the Hydraulic System starting at Section 19.4.1 and ending at Section 19.4.12.
j. Shut-down the Power Unit and inspect the hydraulic system starting at Section 19.4.1 and
ending at Section 19.4.12.
19-29
USAF TO 35C2-3-518-1
USA TM 9-6115-484-14
DRS RADIAN CTM 01646.1R0253/1R0254
19.4.2 HYDRAULIC PUMP
The following maintenance procedures are provided for the Hydraulic Pump:
Inspect
Remove
Install
HYDRAULIC
PUMP
To inspect the Hydraulic Pump use Figure 19.4.2-1 as reference, proceed as follows:
a. Prior to starting the Power Unit, inspect the engine compartment for any hydraulic fluid leaks.
Correct any leaks as necessary.
19-30
USAF TO 35C2-3-518-1
USA TM 9-6115-484-14
DRS RADIAN CTM 01646.1R0253/1R0254
c. Start the Power Unit according to Chapter 5. Allow the Power Unit to reach operating
temperature and shutdown the Power Unit according to Chapter 5.
d. Check under the PU for any hydraulic fluid leaks. Correct any leaks as necessary.
Note: See Figure 19.4.2-2. The hydraulic pump internal cavity between the adapter plate and pump
mounting surface gets hot and must breathe (vent to the outside). As a result, small bubbles can form
on the outer surface of the adapter plate or pump mounting surface. This is normal and is not an oil
seep or leak.
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:
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. Close the Hydraulic Fluid Shutoff Valve. See Figure 19.2.1-4 for reference.
19-31
USAF TO 35C2-3-518-1
USA TM 9-6115-484-14
DRS RADIAN CTM 01646.1R0253/1R0254
c. Tag the two input and output hoses for proper replacement.
d. Disconnect the two input and output hoses. See Figure 19.4.2-1 for reference.
NOTE: Use proper procedures to collect any hydraulic fluid left in the hoses to prevent spills.
e. Remove the two pump mounting bolts and lift the pump from the engine.
NOTE: The procedure is the same for either an inboard or outboard hydraulic pump.
f. Remove and discard old gasket material from the pump and engine surfaces.
g. Remove flange and O-ring, Inspect O-ring for damage and replace as necessary.
HYDRAULIC
ENGINE PUMP
HOUSING
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 in paragraph 19.4.2.2.
NOTE: Do Not use the old gasket use a new gasket. Coat both contact surfaces of the new gasket
with appropriate Gasket Sealant following manufacturer’s instructions.
c. Install flange and O-ring, Apply clean engine oil to the new O-ring and ensure seal is not
damaged or pinched during installation. See Figure 19.4.2-2 for reference.
NOTE: The adapter has a beveled edge. The beveled edge of the adapter must face towards the
pump.
19-32
USAF TO 35C2-3-518-1
USA TM 9-6115-484-14
DRS RADIAN CTM 01646.1R0253/1R0254
d. Reinstall the pump assembly and reinstall the two, pump mounting bolts. Torque the pump
mounting bolts mounting bolts to 75 + 5 Ft-Lbs.
e. Reinstall and torque the hydraulic hoses according to specifications found in Table 7, Torques
for flared and O-Ring fittings, Caterpillar Manual SENR3130.
NOTE: Use proper procedures to collect any hydraulic fluid left in the hoses to prevent spills.
i. Open the Hydraulic Fluid Shut Off Valve. Secure the valve handle in the open position.
j. Prepare the PU to be started. All lockout and tag-out, tags must be removed.
k. Inspect the Hydraulic System starting at Section 19.4.1 and ending at Section 19.4.12.
m. Shut-down the Power Unit and inspect the hydraulic system starting at Section 19.4.1 and
ending at Section 19.4.12.
19-33
USAF TO 35C2-3-518-1
USA TM 9-6115-484-14
DRS RADIAN CTM 01646.1R0253/1R0254
The following maintenance procedures are provided for the Radiator Hydraulic Motor:
Inspect
Remove
Install
To inspect the Radiator Hydraulic Motor see Figure 19.4.3-1 as reference, proceed as follows:
a. Prior to starting the Power Unit, inspect the engine compartment for any hydraulic fluid
leaks. Correct any leaks as necessary.
c. Start the Power Unit according to Chapter 5. Allow the Power Unit to reach operating
temperature and shutdown the Power Unit according to Chapter 5.
d. Check under the Power Unit for any hydraulic fluid leaks. Correct any leaks as necessary.
e. Check the Radiator Hydraulic Motor for leaks, missing or loose hardware.
19-34
USAF TO 35C2-3-518-1
USA TM 9-6115-484-14
DRS RADIAN CTM 01646.1R0253/1R0254
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:
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. Remove the Front Side Panel from the PU. See Figure 19.4.3.2-1 for reference.
19-35
USAF TO 35C2-3-518-1
USA TM 9-6115-484-14
DRS RADIAN CTM 01646.1R0253/1R0254
c. Close the Hydraulic Fluid Shutoff Valves. See Figure 19.2.1-4 for reference.
d. Tag the input and output hoses for proper replacement. See Figure 19.4.3-1 for reference.
NOTE: Use proper procedures to collect any hydraulic fluid left in the hoses to prevent spills.
f. Remove the Radiator-Hydraulic Motor Fan Assembly. See Section 19.4.6.2 for reference.
g. Remove the two motor mounting bolts and lift the motor off of its mounting bracket.
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 in paragraph 19.4.3.2.
b. Place the motor back on the mounting bracket and reinstall the mounting bolts. Torque the 3/8”
bolts to 35 + 7 Ft-Lbs per Caterpillar SENR3130, Torque Specifications.
c. Reinstall the Radiator-Hydraulic Motor Fan Assembly see Section 19.4.6.3 for reference.
19-36
USAF TO 35C2-3-518-1
USA TM 9-6115-484-14
DRS RADIAN CTM 01646.1R0253/1R0254
d. Reinstall the input and output hoses and torque the hydraulic fittings according to specifications
found in Table 7, (Torques for flared and O-Ring fittings), Caterpillar Manual SENR3130. Torque
the 3/4” input hose fitting to 37 + 5 ft. lbs, and 5/8” output fitting to 26 + 4 Ft-Lbs.
e. Reinstall the Radiator and ATAAC access covers. See Figure 19.4.3.2-1 for reference.
f. Reinstall the Front Side Panel from the Power Unit. See Figure 19.4.3.2-1 for reference.
h. Prepare the Power Unit to be started. All lockout and tag-out tags must be removed, the battery
bank reconnected.
i. Inspect the Hydraulic System starting at Section 19.4.1 and ending at Section 19.4.12.
j. Open the Hydraulic Fluid Shut Off Valves. Secure the valve handles in the open position.
l. Shut-down the Power Unit and inspect the hydraulic system starting at Section 19.4.1 and
ending at Section 19.4.12.
19-37
USAF TO 35C2-3-518-1
USA TM 9-6115-484-14
DRS RADIAN CTM 01646.1R0253/1R0254
The following maintenance procedures are provided for the ATAAC Hydraulic Motor:
Inspect
Remove
Install
a. Prior to starting the PU, check the engine compartment for any hydraulic fluid leaks.
Correct any leaks as necessary.
c. Start the Power Unit according to Chapter 5. Allow the Power Unit to reach operating
temperature and shutdown the Power Unit according to Chapter 5.
d. Check under the Power Unit for any hydraulic fluid leaks. Correct any leaks as necessary.
e. Check the Air to Air After Cooler-Hydraulic Motor for leaks, missing or loose hardware.
19-38
USAF TO 35C2-3-518-1
USA TM 9-6115-484-14
DRS RADIAN CTM 01646.1R0253/1R0254
To remove the Air to Air After Cooler-Hydraulic Motor, perform the following:
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:
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. Remove the Front Side Panel from the PU. See Figure 19.4.3.2-1 for reference.
c. Remove the Radiator and ATAAC Access Covers. See Figure 19.4.3.2-1 for reference.
d. Close the Hydraulic Fluid Shutoff Valves. See Figure 19.2.1-4 for reference.
CAUTION
19-39
USAF TO 35C2-3-518-1
USA TM 9-6115-484-14
DRS RADIAN CTM 01646.1R0253/1R0254
e. Tag the input/output and case drain hoses for proper replacement. See Figure 19.4.4-1 for
reference.
f. Disconnect the input/output and case drain hoses. See Figure 19.4.4-1 for reference.
NOTE: Use proper procedures to collect any hydraulic fluid left in the hoses to prevent spills.
g. Remove the Air to Air After Cooler-Hydraulic Motor Fan Assembly. See Section 19.4.7.2 for
reference.
h. Remove the two Air to Air After Cooler-Hydraulic Motor Fan Assembly mounting bolts and lift the
motor off of its mounting bracket.
To install the Air to Air After Cooler-Hydraulic Motor, perform the following:
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 in paragraph 19.4.4.2.
CAUTION
IF THE ATAAC HYDRAULIC FAN MOTOR IS INSTALLED INCORRECTLY THE FAN WILL
ROTATE IN THE WRONG DIRECTION. ENSURE THE FAN MOTOR IS INSTALLED IN THE
SAME DIRECTION AS THE ONE REMOVED (RELIEF PORT ORIENTATION).
b. Reinstall the motor back on the mounting bracket and reinstall mounting bolts. Torque the 3/8”
bolts to 35 + 7 Ft-Lbs per Caterpillar SENR3130, Torque Specifications.
c. Reinstall and torque the hydraulic hoses according to specifications found in Table 7, Torques
for flared and O-Ring fittings, Caterpillar Manual SENR3130. Torque the 5/8” fittings to 26 + 4
Ft-Lbs Torque the 3/8” fitting to 8 + 1 Ft-Lbs. Remove hose tags.
d. Reinstall the After Cooler- Motor Fan Assembly. See Section 19.4.7.3 for reference.
e. Reinstall the Radiator and ATAAC Access Covers. See Figure 19.4.3.2-1 for reference.
f. Reinstall the Front Side Panel from the Power Unit. See Figure 19.4.3.2-1 for reference.
g. Open the Hydraulic Fluid Shut Off Valves. Secure the valve handles in the open position.
h. Prepare the Power Unit to be started. All lockout and tag-out, tags must be removed, and the
battery bank reconnected.
i. Inspect the Hydraulic System starting at Section 19.4.1 and ending at Section 19.4.12.
l. Shut-down the Power Unit and inspect the hydraulic system starting at Section 19.4.1 and
ending at Section 19.4.12.
19-40
USAF TO 35C2-3-518-1
USA TM 9-6115-484-14
DRS RADIAN CTM 01646.1R0253/1R0254
m. The unit is now ready to operate.
The following maintenance procedures are provided for the Engine Compartment Vent-Hydraulic Motor:
Inspect
Remove
Install
a. Prior to starting the Power Unit, check the engine compartment for any hydraulic fluid leaks.
Correct any leaks as necessary.
c. Start the Power Unit according to Chapter 5. Allow the Power Unit to reach operating
temperature and shutdown the Power Unit according to Chapter 5.
d. Check under the Power Unit for any hydraulic fluid leaks. Correct any leaks as necessary.
e. Check the Engine Compartment Vent-Hydraulic Motor for leaks, missing or loose hardware.
19-41
USAF TO 35C2-3-518-1
USA TM 9-6115-484-14
DRS RADIAN CTM 01646.1R0253/1R0254
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:
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. Remove the bolts and keeper washers from the Top Plenum Screen on the top of the Power
Unit. Remove the Top Plenum Screen and Front Side Panel. See Section 8.4.1.2 and Section
8.4.2.2 for reference.
c. Close the Hydraulic Fluid Shutoff Valves. See Figure 19.2.1-4 for reference.
d. Remove the Fan Guard and Air Deflector assembly from around the motor and fan.
e. Tag and Disconnect the two input and output hoses for proper replacement. See Figure 19.4.5-
1 for reference.
NOTE: Use proper procedures to collect any hydraulic fluid left in the hoses to prevent spills.
g. Remove the Engine Compartment Vent-Motor Fan Assembly. See Section 19.4.8.2 for
reference.
h. Remove the two motor mounting bolts and then lift the motor off of its mounting bracket.
19-42
USAF TO 35C2-3-518-1
USA TM 9-6115-484-14
DRS RADIAN CTM 01646.1R0253/1R0254
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 in paragraph 19.4.5.2.
b. Reinstall the motor back on the mounting bracket and reinstall mounting bolts. Torque the 3/8”
bolts to 35 + 7 Ft-Lbs per Caterpillar SENR3130, Torque Specifications.
c. Reinstall the input and output hoses and torque the fittings according to specifications found in
Table 7, Torques for flared and O-Ring fittings, Caterpillar Manual SENR3130. Torque the 1”
fittings to 75 + 7 Ft-Lbs Torque the 5/8” fitting to 26 + 4 Ft-Lbs. Remove hose tags.
d. Reinstall the Engine Compartment Vent-Hydraulic Motor Fan Assembly. See Section 19.4.8.3
for reference.
e. Reinstall the Fan Guard and Air Deflector assembly from around the motor and fan.
f. Reinstall the Front Side Panel from the Power Unit. See Figure 19.4.3.2-1 for reference.
g. Open the hydraulic fluid shut off valves. Secure the valve handles in the open position.
i. Prepare the Power Unit to be started. All lockout and tag-out, tags must be removed, the battery
bank reconnected.
j. Inspect the Hydraulic System starting at Section 19.4.1 and ending at Section 19.4.12.
l. Shut-down the Power Unit and inspect the hydraulic system starting at Section 19.4.1 and
ending at Section 19.4.12.
19-43
USAF TO 35C2-3-518-1
USA TM 9-6115-484-14
DRS RADIAN CTM 01646.1R0253/1R0254
The following maintenance procedures are provided for the Radiator-Motor Fan Assembly:
Inspect
Remove
Install
19-44
USAF TO 35C2-3-518-1
USA TM 9-6115-484-14
DRS RADIAN CTM 01646.1R0253/1R0254
a. Prior to starting the Power Unit, check the engine compartment for any hydraulic fluid leaks.
Correct any leaks as necessary.
c. Start the Power Unit according to Chapter 5. Allow the Power Unit to reach operating
temperature and shutdown the Power Unit according to Chapter 5.
d. Check under the Power Unit for any hydraulic fluid leaks. Correct any leaks as necessary.
e. Check the Radiator-Motor Fan Assembly for leaks, missing or loose hardware.
f. Check the Radiator-Motor Fan Blades for broken fan blades, missing or loose hardware.
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:
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
19-45
USAF TO 35C2-3-518-1
USA TM 9-6115-484-14
DRS RADIAN CTM 01646.1R0253/1R0254
maintenance the (A) (B) Communication Cable must be routed to the next PU in order to
reestablish the communication network.
b. Remove the bolts and keeper washers from the Bottom Plenum Screen on the bottom of the
Power Unit. Remove the Bottom Plenum Screen and Front Side Panel. See Section 8.4.1.2 and
Section 8.4.2.2 for reference.
c. Close the Hydraulic Fluid Shutoff Valves. See Figure 19.2.1-4 for reference.
d. Remove the three pull-up bolts and screw them into the tapped holes in and insert them into the
three un-mounting holes and tighten each screw one 360º degree turn and then move to the next
screw and tighten 360º degree turn, continue until the fan assembly falls free from the shaft
mounting hub. See Figure 19.4.6-1 and Figure 19.4.6-2 for reference.
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 in paragraph 19.4.6.2.
b. Reinstall the fan assembly onto the shaft-mounting hub with the flat side of the fan blade
assembly facing down.
c. Reinstall the three mounting bolts into the unthreaded mounting holes in the fan blade hub, and
insert them into the threaded holes on the shaft-mounting hub. See Figure 19.4.6-1 for reference
and torque to 108 inch lbs.
e. Prepare the Power Unit to be started. All lockout and tag-out, tags must be removed, the battery
bank reconnected.
f. Inspect the Hydraulic System starting at Section 19.4.1 and ending at Section 19.4.12.
h. Shut-down the Power Unit and inspect the hydraulic system starting at Section 19.4.1 and
ending at Section 19.4.12.
19-46
USAF TO 35C2-3-518-1
USA TM 9-6115-484-14
DRS RADIAN CTM 01646.1R0253/1R0254
The following maintenance procedures are provided for the After Cooler Fan Assembly:
Inspect
Remove
Install
a. Prior to starting the Power Unit, inspect the engine compartment for any hydraulic fluid leaks.
Correct any leaks as necessary
c. Start the Power Unit according to Chapter 5. Allow the Power Unit to reach operating
temperature and shutdown the Power Unit according to Chapter 5.
d. Check under the Power Unit for any hydraulic fluid leaks. Correct any leaks as necessary.
e. Check the After Cooler-Motor Fan Assembly for leaks, missing or loose hardware.
f. Check the After Cooler-Motor Fan Blades for broken fan blades, missing or loose hardware.
19-47
USAF TO 35C2-3-518-1
USA TM 9-6115-484-14
DRS RADIAN CTM 01646.1R0253/1R0254
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:
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. Remove the bolts and keeper washers from the Bottom Plenum Screen on the bottom of the
Power Unit. Remove the Bottom Plenum Screen and Front Side Panel. See Section 8.4.1.2 and
Section 8.4.2.2 for reference.
d. Close the Hydraulic Fluid Shutoff Valves. See Figure 19.2.1-4 for reference.
e. Remove the three pull-up bolts and screw them into the tapped holes in and insert them into the
three un-mounting holes and tighten each screw one 360º degree turn and then move to the next
screw and tighten 360º degree turn, continue until the fan assembly falls free from the shaft
mounting hub. See Figure 19.4.7-1 for reference.
19-48
USAF TO 35C2-3-518-1
USA TM 9-6115-484-14
DRS RADIAN CTM 01646.1R0253/1R0254
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 in paragraph 19.4.7.2.
b. Reinstall the fan assembly onto the shaft-mounting hub with the flat side of the fan blade
assembly facing down.
c. Reinstall the three mounting bolts into the unthreaded mounting holes in the fan blade hub, and
insert them into the threaded holes on the shaft-mounting hub. See Figure 19.4.6-1 for reference
and torque to 108 inch lbs.
g. Prepare the Power Unit to be started. All lockout and tag-out, tags must be removed, the battery
bank reconnected.
h. Inspect the Hydraulic System starting at Section 19.4.1 and ending at Section 19.4.12.
j. Shut-down the Power Unit and inspect the hydraulic system starting at Section 19.4.1 and
ending at Section 19.4.12.
19-49
USAF TO 35C2-3-518-1
USA TM 9-6115-484-14
DRS RADIAN CTM 01646.1R0253/1R0254
The following maintenance procedures are provided for the Engine Compartment Vent-Motor Fan
Assembly:
Inspect
Remove
Install
19-50
USAF TO 35C2-3-518-1
USA TM 9-6115-484-14
DRS RADIAN CTM 01646.1R0253/1R0254
a. Prior to starting the Power Unit, check the engine compartment for any hydraulic fluid leaks.
Correct any leaks as necessary.
c. Start the Power Unit according to Chapter 5. Allow the Power Unit to reach operating
temperature and shutdown the Power Unit according to Chapter 5.
d. Check under the Power Unit for any hydraulic fluid leaks. Correct any leaks as necessary.
e. Check the Engine Compartment Vent-Motor Fan Assembly for leaks, missing or loose hardware.
f. Check the Engine Compartment Vent-Motor Fan blades for broken fan blades, missing or loose
hardware.
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:
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
19-51
USAF TO 35C2-3-518-1
USA TM 9-6115-484-14
DRS RADIAN CTM 01646.1R0253/1R0254
maintenance the (A) (B) Communication Cable must be routed to the next PU in order to
reestablish the communication network.
b. Remove the bolts and keeper washers from the Top Plenum Screen on the Top of the Power
Unit. Remove the Top Plenum Screen and Front Side Panel. See Section 8.4.1.2 and Section
8.4.2.2 for reference.
d. Remove the three mounting allen-head machine screws and insert them into the three un-
mounting holes and tighten each screw one 360º turn and then move to the next screw and
tighten 360º turn, continue until the fan assembly pulls free from the shaft mounting hub. See
Figure 19.4.8.2-1 and Figure 19.4.8.2-2 for reference.
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 in paragraph 19.4.8.2.
b. Reinstall the fan assembly onto the shaft-mounting hub with the flat side of the fan assembly
facing the Radiator Assembly.
c. Reinstall the three mounting bolts into the unthreaded mounting holes in the fan blade hub, and
insert them into the threaded holes on the shaft-mounting hub. See Figure 19.4.8-1 for reference
and torque to 60 inch lbs.
e. Prepare the Power Unit to be started. All lockout and tag-out, tags must be removed, the battery
bank reconnected.
f. Inspect the Hydraulic System starting at Section 19.4.1 and ending at Section 19.4.12.
h. Shut-down the Power Unit and inspect the hydraulic system starting at Section 19.4.1 and
ending at Section 19.4.12.
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The following maintenance procedures are provided for the Radiator-Motor Fan Blades:
Remove
Install
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NOTE: Care must be taken to keep track of the location of the flat washers removed during this
process and during assembly the washers must be returned to the same place. The washers
are used to balance the Fan Hub assembly.
PLASTIC KEEPER
FIGURE 19.4.9.1-2 RADIATOR FAN ASSEMBLY (BOTTOM HALF WITH KEEPER INSTALLED)
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 in paragraph 19.4.8.2.
b. Remove the Radiator-Motor Fan Assembly. See Section 19.4.6.2 for reference.
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d. Remove the 9 hub assembly bolts. See Figure 19.4.9-1 for reference.
e. Remove the top half of fan hub assembly. See Figure 19.4.9.1-1 for reference.
g. Ensure plastic keeper is still in place. See Figure 19.4.9.1-2 for reference.
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NOTE: Care must be taken to keep track of the location of the flat washers removed during this
process and during assembly the washers must be returned to the same place. The washers
are used to balance the Fan Hub assembly.
FIGURE 19.4.9.2-2 RADIATOR FAN ASSEMBLY (TOP HALF MATED WITH BOTTOM HALF)
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 in paragraph 19.4.8.2.
b. Ensure that the keeper is in the correct slot. See Figure 19.4.9.1-2 for reference.
c. Install the new blade at a 40° angle. This is accomplished by placing the blade so that the
keeper and the 40° angle indentation on the blade are mated together. See Figure 19.4.9.2-1
and Figure 19.4.9.2-2 for reference.
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d. Place the top half of the hub assembly on to the bottom half of the hub assembly. See Figure
19.4.9.2-2 for reference.
e. Ensure that the fan hub assembly fits together and all blades have the same pitch.
f. Reinstall all 9 of the fan hub assembly bolts. Torque to 108 inch lbs. See Figure 19.4.9-1 for
reference.
g. Reinstall the Radiator-Motor Fan Assembly. See Section 19.4.6.3 for reference.
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The following maintenance procedures are provided for the After Cooler-Motor Fan Blades:
Remove
Install
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NOTE: Care must be taken to keep track of the location of the flat washers removed during this
process and during assembly the washers must be returned to the same place. The washers
are used to balance the Fan Hub assembly.
PLASTIC KEEPER
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 in paragraph 19.4.8.2.
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b. After the Aftercooler-Motor Fan Assembly has been removed, Disassembly and Reassembly
procedures are the same as the Radiator Fan Motor. See Section 19.4.9.1 and 19.4.9.2 for
reference.
The following maintenance procedures are provided for the Engine Compartment Vent Motor Fan Blades:
Remove
Install
NOTE: Carefully observe the location of the flat washers removed during this process and during
assembly. The washers must be returned to the same place to balance the Fan Hub
assembly.
P L A S T IC K E E P E R
FIGURE 19.4.11.1–1 VENT FAN ASSEMBLY (BOTTOM HALF WITH KEEPER INSTALLED)
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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 in paragraph 19.4.8.2.
b. After the Engine Compartment Vent-Motor Fan Assembly has been removed, Disassembly and
Reassembly procedures are the same as the Radiator Fan Motor. See Section 19.4.9.1 and
19.4.9.2 for reference.
The following maintenance procedures are provided for the Hydraulic Tank Low Level Shutdown Switch
(HTLL):
Test
Remove
Install
There is one low fluid level shutdown switch mounted inside of each of the 18-gallon hydraulic tanks. The
“float type” switch is mounted on the back of the hydraulic tank. See Figure 19.2.1-1 and refer to Section
19.2.1 for an explanation on the operation of the switch.
To test the Hydraulic Tank Low Level Shutdown Switch (HTLL) Switch, proceed as follows:
a. Using a multimeter, set to OHMS (Ω) Rx1 scale. Test the HTLL switch wires for contact
continuity in the switch positions specified in Table 19.4.12.1-1. The multimeter should indicate
zero ohms when the hydraulic tank is empty. The switch is normally open.
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b. The multimeter should indicate infinite ohms when the hydraulic tank is full.
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HTLL DEUTSCH
CONNECTION
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To remove the Hydraulic Tank Low Level Shutdown Switch (HTLL) Switch, 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:
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. Remove the 9 mounting bolts from the Top Plenum Screen Assembly and remove the screen.
The screen can be slid over to the adjoining radiator screen. See Section 8.4.2 for reference.
c. Close the Hydraulic Fluid Shutoff Valve see Figure 19.2.1-4 for reference.
d. Drain the hydraulic tank of all fluid, into an appropriate container. Refer to Section 19.3.1.2 for
draining the reservoir.
e. Clean the area around the tank access cover of contaminants that could fall into the tank, during
change out. You should also have a clean work area for components and elements.
f. Remove the eight mounting bolts from the tank access cover, attached to the breather cap.
Discard the old O-ring and replace with new. See Figure 19.4.12.2-1 and 19.4.12.2-2 for
reference.
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g. Disconnect the switch from the wiring harness, at the DEUTSCH connector. Se Figure
19.4.12.2-3 for details.
h. Unscrew the lock nut on the backside of the switch and unscrew the switch from the unit.
To install the Hydraulic Tank Low Level Shutdown Switch (HTLL) Switch, 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 19.4.12.2.
b. Screw the switch into the mounting hole while insuring the switch does not bind on the bottom of
the tank. The switch’s moveable plastic float should be pointed at the top of the tank. Check the
switch for binding.
d. Reinstall the eight mounting bolts from the tank access cover, attached to the breather cap. See
previous instructions for access cover installation. See Figure 19.4.12.2-1 for reference.
f. Fill the hydraulic tank with the appropriate fluid as listed in Annex G.
i. Inspect the hydraulic system starting at Section 19.4.1 and ending at Section 19.4.12.
j. Start the engine and check for proper operation of fans and for fluid leaks.
k. Shut-down the Power Unit and Inspect the hydraulic system starting at Section 19.4.1 and
ending at Section 19.4.12.
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CHAPTER 20
PU STORAGE PROCEDURES
TABLE OF CONTENTS
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LIST OF TABLES
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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:
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:
(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:
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:
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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TABLE 20.2-1 STORAGE PROCEDURES FOR 3456 ENGINE AND SR-4B GENERATORS
POST-
PRE-STORAGE EQUIPMENT
SUBSYSTEM STORAGE
ACTIVITIES NEEDED
ACTIVITIES
Remove
▪ Clean exterior of engine of any dirt, rust, grease, and oil. protective covers.
▪ Paint areas that contain paint damage with good quality paint. Sprayer, Paint
▪ Remove any dirt from the air cleaners. Filters
▪ Apply lubricant to all points identified in this manual.
Drain and replace the crankcase oil, add VCI at the rate of 3- VCI Change oil and
4% by volume, and replace the oil filters. Oil filters filters
▪ Remove the air filter element.
▪ Turn the engine at cranking speed with the fuel off and spray VCI
a 50% VCI oil/50% engine oil mixture into the air inlet. Air filters
▪ Reinstall serviceable air filter
▪ Spray the same 50% VCI oil/50% engine oil mixture into the
exhaust openings. VCI
▪ Seal the exhaust pipe including any drain holes in the muffler.
▪ Clean the primary fuel filter.
▪ Fill with calibration fluid or kerosene.
▪ Install the primary fuel filter and operate the priming pump.
▪ Drain any water or dirt from inside the fuel tank.
3456 Engine EPG ▪ Apply a spray inside the tank to prevent rust and add a VCI Biocide
commercial biocide to the fuel.
▪ Apply a small amount of oil to the threads on the fuel tank
filler. Test the cooling
VCI Oil
▪ Seal all openings to the tank to prevent evaporation of the fuel system.
and preservative.
▪ Remove the fuel nozzles and apply a mixture of VCI oil Diesel Fuel Prime the engine
mixture in each cylinder. Turn the engine over slowly to put Biocide with diesel fuel.
the oil on each cylinder.
▪ Spray a thin amount of VCI oil mixture on the flywheel, ring
gear teeth, and start pinion. Install the covers to keep in the
VCI
VCI vapors.
▪ Install all covers and ensure that tape has been installed over
all openings.
▪ Apply a small amount of multipurpose grease to all moving
parts.
▪ If the stored engine will be subjected to below-freezing
temperatures, completely drain the system by removing the
drain plugs from the engine block, oil cooler, and radiator. Test the cooling
Clean the system and refill with a mixture of ELC antifreeze system
and distilled water.
See Section. 4.5.3
Sealing
▪ Seal all openings with tape. Tape/plastic wrap
SR-4B Generator ▪ Perform a resistance check of the windings and record the Megohmmeter
measurement. Ensure resistance is one megohm or greater.
▪ Dry generator windings if necessary.
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a. Prior to starting any preservation and or storage procedures for the Power Unit obtain and fill out
a Preservation Form.
b. Follow all Caterpillar instructions dealing with engine and alternator storage procedures. See
Section 20.2.2 for reference.
d. Disconnect and remove the batteries from the PU if, the PU will be stored for longer than three
months.
(See Caterpillar Manual SEHS9031-03, Storage Procedures For Caterpillar Products, Dated 4/97 or
later).
WARNING
The following procedures are required to prepare the MEP-PU-810 for storage and/or transport. Included
are instructions for preserving and packaging the engine fuel system, cooling system, lubrication system,
and housing as follows:
Caterpillar recommends the use of volatile corrosion inhibitors (VCI oil) in order to prevent internal engine
damage due to moisture during storage. These inhibitors act by evaporating inside the engine, then
condensing over the inside surfaces. This evaporation and condensing process offers full protection to
surfaces that cannot be reached with preservatives that require direct application. This process also
makes it easier to clean from the engine when removing the engine from storage. The volatile vapors are
removed by simply running the engine to operating temperature. A mineral oil base is left behind after the
volatile vapors are removed. The oil should then be drained and new oil and filters installed.
Cooling systems should be preserved with Caterpillar coolant or equivalent. Caterpillar coolant contains
the necessary inhibitors to prevent corrosion and pitting. When used in the proper mixture, the coolant will
prevent damage due to rust and freezing. It is common in warm climates to store the engine with water in
the cooling system. In such cases, distilled or de-ionized water is recommended for use in engine cooling
systems. DO NOT use hard tap water or salt softened tap water in engine cooling systems. If distilled or
de-ionized water is not available, use water that meets the minimum acceptable requirements listed in
Annex G.
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NOTE: The Caterpillar engines are equipped with air-to-air after-cooling (ATAAC), and require a minimum
of 30 percent glycol (60% maximum) to prevent water pump cavitation.
When approved water (distilled, de-ionized, or water that meets minimum acceptable Caterpillar
requirements) is used, the water MUST be treated with six to eight percent by volume Caterpillar
Supplemental Coolant Additive (SCA), also called Caterpillar Cooling System Conditioner, or equivalent.
Under NO circumstances should the engine be stored without the addition of the Caterpillar Supplemental
Coolant Additive or equivalent.
Always fill the radiator completely full to prevent rusting of the top tank. Do not leave any exposed air
space within the radiator. All exposed surface areas will rust.
Caterpillar Extended Life Coolant (ELC) is the preferred coolant to use in cooling systems. Caterpillar
ELC provides the best coolant service life, corrosion protection, water pump seal service life, and radiator
service life.
Use a six to eight percent concentration of Caterpillar Cooling System Conditioner on engines that will be
stored with only water in the cooling system. If the engine is stored with Caterpillar Antifreeze (ELC), there
is no need to add conditioner before storage. For Caterpillar Cooling System Conditioner part numbers
(See Annex G).
Caterpillar Cooling System Cleaner is designed to clean the cooling system of harmful scale and
corrosion. It is available in 1 gal (5 gal U.S.) containers. Directions for its use are included on the
container. For Caterpillar Cooling System Cleaner (Annex G)
Use all the necessary personal protective equipment needed to perform any of the following jobs:
a. Sprayer: A 1P-0540 Flow Checking Tool Group or an air compressor with a sprayer attachment
can be used to prepare the engine for storage. It should be possible to change the nozzle
adjustment to provide either a spray or a fog pattern. The fog adjustment pattern is better if
access to components is difficult. The spray pattern is better for parts on the outside of the
engine.
b. Paint: Outside parts of the engine can best be protected by thorough use of good quality paint.
Paint provides good protection for a storage period up to two years. Before painting, thoroughly
clean the engine.
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c. Plastic Bags: Use black or dark plastic bags. Clear plastic bags will deteriorate over long
periods of time.
d. Sealing Tape: Use a sealing tape with good adhesive properties. DO NOT use duct tape
because it will loosen over a short period of time. Two- inch wide rolls of sealing tape are
recommended.
e. Coolant Conditioner Test Kit: Use the 8T-5296 Conditioner Test Kit to check the concentration
of conditioner in the cooling system. Maintain the cooling system with a three to six percent
concentration of conditioner. Instructions are included with the kit.
f. Coolant And Battery Tester: The tester is used for checking coolant freezing point and battery
fluid condition. Instructions are provided with the tester. The 5P-0957 Coolant And Battery Tester
Group is available with the temperature scale in degrees Fahrenheit. The 5P-3514 Coolant And
Battery Tester Group is available with the temperature scale in degrees Celsius.
g. VCI Oil:
(1) Volatile Corrosion Inhibitor (VCI) oil can be used in all tanks, engine, fuel tank, hydraulic tank,
power steering tank, transmission, differential, etc. It is an oil stabilizer and rust preventative.
It can be used in combination with any petrochemical. Apply by using a spraying or fogging
pattern. Caterpillar recommends the use of VCI oil in order to prevent internal engine damage
due to moisture during storage. These inhibitors act by evaporating inside the engine then
condensing over the inside surfaces. This evaporation and condensing process offers full
protection to surfaces that cannot be reached with preservatives that require direct
application. This process also makes it easier to clean from the engine when removing the
engine from storage. The volatile vapors are removed by running the engine to operating
temperature. A mineral oil base is left behind after the volatile vapors are removed. The oil
should then be drained and new oil and filters installed. VCI oil should not be used full
strength on non-ferrous metals where it will have direct, prolonged contact.
(2) To be successful when treating an engine with VCI oil, the engine must be completely sealed
when stored. VCI oil is so volatile that any opening left unsealed will allow the vapors to
escape, causing the engine to lose its protection. Volatile corrosion inhibitor (VCI), NOX-
RUST VCI #10 oil or equivalent oil, provides both liquid and vapor protection to ferrous metal
surfaces against corrosion caused by moisture. In a closed compartment, protection is either
by direct contact with VCI oil or by contact with VCI vapors. Refer to Annex G for quantities
required. The VCI oil and regular oil are a 50/50 mix.
h. Diesel Fuel: Diesel fuel left in fuel tanks and fuel injection systems will sometimes cause
problems due to the growth of small organisms. This may result in plugged fuel filters, corrosion,
sticking fuel pumps, or malfunctioning fuel injection valves. Draining the fuel injection pump and
refilling it with Caterpillar Calibration Fluid can minimize this problem.
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i. Caterpillar Calibration Fluid: Is the preferred choice as a preservation fluid because it contains
Rust and Oxidation (R&O) inhibitors. If Caterpillar Calibration Fluid is not available, kerosene is a
second consideration. However, kerosene does not contain Rust and Oxidation inhibitors and, as
the result, is far from the best choice. Kerosene is preferred over diesel fuel (another alternative)
because kerosene is not as prone to oxidation as diesel fuel. Kerosene also will not thicken as
much as diesel fuel during long storage periods.
j. Fuel tanks should be protected internally with VCI oil and then sealed. The fuel tank must be
drained completely. All vents must sealed airtight. Spray VCI oil/regular oil at a 50/50 mix into
the fuel tank filler hole, then seal with the fuel tank filler cap.
k. Diesel Fuel Biocide: To prevent the growth of small organisms in the diesel fuel, use diesel fuel
biocide such as Biobor JF or equivalent.
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NOTE: If long-term storage for a period of time exceeding one year is necessary, contact your local
Caterpillar Dealer for the preferred procedure to use in your specific case.
NOTE: Upon completion of preservation, attach tag near engine start controls stating:
a. Clean the engine of any dirt, rust, grease, and oil. Inspect the exterior. Paint areas that contain
paint damage with good quality paint.
b. Remove any dirt from the air cleaner(s). Check all seals, gaskets, and the filter element for
damage.
c. Apply lubricant to all points shown in the chart “Lubrication & Maintenance” within the Operation
& Maintenance Manual for your equipment.
d. Drain and replace the crankcase oil and change the oil filter(s). For the proper procedure (See
Section 14.3.1)
e. Add VCI oil to the crankcase at the rate of three to four percent by volume.
NOTE: If the engine crankcase is full, drain enough engine oil so the mixture can be added.
f. Remove the air filter element(s). Turn the engine at cranking speed with the P91/J91 Electronic
Unit Injector Engine Harness Deutsch Connector disconnected at the engine valve cover base.
• Disconnecting the P91/J91 will keep the engine from starting during cranking. Reference:
P91/J91 connector, Radian Engine Schematic, drawing number FO-37)
• Reconnect the P91/J91 after this procedure. Use a sprayer to add a mixture of 50 percent
VCI oil and 50 percent engine oil into the air inlet or turbocharger inlet.
NOTE: VCI oil mixture can also be added to the inlet by removing the plug for checking turbocharger
boost pressure. The minimum application rate is 5.5 mL per L (3 oz per 1000 cu in) of engine
displacement. The minimum application rate is critical to prevent loss of protective vapors.
g. Install the air filter element(s) and completely enclose the element(s) with dark, plastic bags. Seal
them with tape. Replace the air filter covers. Place tape over all openings to seal VCI vapors in
the engine.
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h. Use a sprayer to apply a 50 percent VCI oil and 50 percent engine oil mixture into the exhaust
openings. The minimum application rate is 5.5 mL per L (3 oz per 1000 cu in) of engine
displacement. Seal the exhaust pipe, including any drain holes in the muffler.
i. Remove the fuel from the secondary fuel filter housing or empty and reinstall the spin-on fuel
filter element to remove any dirt and water. Drain the fuel injection pump (sleeve metering only).
Clean the primary fuel filter. Fill with calibration fluid or kerosene. Install the primary fuel filter
and operate the priming pump. This will send clean oil to the secondary filter and engine. Open
the fuel tank drain valve and allow any water or dirt to drain from inside the fuel tank. Apply a
spray of 30 mL per 30 L (1 oz per 7.50 gal U.S.) of fuel tank capacity to prevent rust in the fuel
tank. Add 0.15 mL per L (.02 oz per 1 gal U.S.) of commercial biocide (such as Biobor UF or
equivalent) to the fuel. Apply a small amount of oil to the threads on the fuel tank filler neck and
install the cap. Seal all openings to the tank to prevent evaporation of the fuel and preservative.
j. Remove the Electronic Unit Injectors and apply 30 mL (1 oz) of VCI oil mixture (50 percent VCI
oil and 50 percent engine oil) in each cylinder. Use a Caterpillar 9S9082 Engine Turning Tool to
turn the engine over slowly to put the oil on the cylinder walls. Re-install all Electronic Unit
Injectors with new O-ring seals. Using the correct procedure, tighten the EUI hold down clamp
with the correct torque. After re-installation of the rocker shaft assemblies, check/adjust the valve
lash and the injector timing using the correct procedures.
k. Spray a thin amount of VCI oil mixture (50 percent VCI oil and 50 percent engine oil) on the
flywheel, ring gear teeth, and starter pinion. Install the covers to keep in the VCI vapors.
l. Apply a heavy amount of multipurpose grease (MPGM) to all outside parts that move, such as
rod threads, ball joints, linkage, etc.
NOTE: Install all covers and ensure that tape has been installed over all openings, air inlet, exhaust
openings, flywheel housing, crankcase breather(s), dipstick tubes, etc.
m. Ensure that all covers are air tight and weatherproof. Use a waterproof, weather resistant type
tape (such as Kendall No. 231 or equivalent). Do not use duct tape. Duct tape will only seal for a
short period of time.
n. Under most conditions it is best to remove the batteries and use them in another application. As
an alternative, place them in storage where they can be periodically checked and electrically
charged again when needed. If the batteries are not removed, wash the tops of the batteries until
clean. Apply an electrical charge to the batteries to obtain a specific gravity of 1.225. Disconnect
the battery terminals. Place a plastic cover over the batteries.
o. Place a waterproof cover over the engine. Ensure the engine cover is secure, but loose enough
to allow air to circulate around the engine to prevent damage from condensation.
p. Attach a tag to the engine with a notation of the date that the unit was preserved.
q. Remove the waterproof cover every two or three months and check the engine for corrosion. If
the engine has signs of corrosion at the check period, repeat the protection procedure.
20-11
USAF TO 35C2-3-518-1
USA TM 9-6115-484-14
DRS RADIAN CTM 01646.1R0253/1R0254
When a generator is in storage, moisture condenses in the windings. To minimize condensation, always
place the generator in a dry storage area. Seal all openings with tape. Perform a resistance check of the
windings. Record this reading. The purpose of this check is to provide a base line to determine if moisture
or winding deterioration occurs during storage. (See Table 20.2-1)
NOTE: If long-term storage for a period of time exceeding one year is necessary, contact your local
Caterpillar Dealer for the preferred procedure to use in your specific case.
b. Before start-up of a generator, use a megohmmeter to check insulation resistance for moisture
and/or foreign material. Refer to (Section 10.4.5) for the procedure. A resistance reading of one
megohm or less is an indication that the winding has absorbed too much moisture.
a. Test the main stator windings with a megohmmeter in the following situations:
(3) If the generator has not been run under load for three months or more.
NOTE: This is a guideline only. It may be necessary to megger test more frequently if the
environment is extremely humid, salty, or if the last megger test was close to one megohm.
a. The quality of oil control components used in Caterpillar engines is such that, following engine
storage, only an operational check at initial start is necessary before operation. The purpose of
this operational check is to ensure that the correct pressures and temperatures are kept in the
lubrication, cooling, and fuel systems, and any leaks are corrected. To ensure a safe uniform
check at initial start, use the following procedure:
(2) Check frequently for leaks such as oil, coolant, and fuel during the first few hours of
operation. Repair any leaks as soon as detected.
20-12
USAF TO 35C2-3-518-1
USA TM 9-6115-484-14
DRS RADIAN CTM 01646.1R0253/1R0254
CHAPTER 21
ENGINE/ALTERNATOR REMOVAL AND INSTALLATION
PROCEDURES
TABLE OF CONTENTS
21-1
USAF TO 35C2-3-518-1
USA TM 9-6115-484-14
DRS RADIAN CTM 01646.1R0253/1R0254
LIST OF TABLES
21-2
USAF TO 35C2-3-518-1
USA TM 9-6115-484-14
DRS RADIAN CTM 01646.1R0253/1R0254
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:
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.
21-3
USAF TO 35C2-3-518-1
USA TM 9-6115-484-14
DRS RADIAN CTM 01646.1R0253/1R0254
WARNING
WARNING
WARNING
PRIOR TO TROUBLESHOOTING THE POWER UNIT (PU), ENSURE THE TIE AND
FEEDER CABLES ARE ALL INSTALLED ON PARKING STANDS, TO PREVENT THE
POSSIBILITY OF UTILITY POWER BEING FED BACK INTO GENERATOR SET.
ENSURE EQUIPMENT IS PROPERLY TAGGED AND NOT ENERGIZED. RESIDUAL
VOLTAGE IS PRESENT AT THE GENERATOR LEADS WITH THE REGULATOR
TURNED OFF, REACHING SEVERAL HUNDRED VOLTS ON THE GENERATOR SET.
PROPER INSULATION AND ISOLATION OF METERING EQUIPMENT MUST BE
OBSERVED WHEN TESTING GENERATOR. USE PROPER TEST EQUIPMENT TO
CHECK FOR VOLTAGE BEFORE PROCEEDING. FAILURE TO COMPLY MAY
RESULT IN DEATH BY ELECTROCUTION.
CAUTION
CAUTION
21-4
USAF TO 35C2-3-518-1
USA TM 9-6115-484-14
DRS RADIAN CTM 01646.1R0253/1R0254
21-5
USAF TO 35C2-3-518-1
USA TM 9-6115-484-14
DRS RADIAN CTM 01646.1R0253/1R0254
TABLE 21.2-1 MEP-PU-810A/B ENGINE/GENERATOR REMOVAL PROCEDURE (CONTINUED)
STEP PROCEDURE
Disconnect the 40P, 7P1 and 7P2 harnesses from the PDC and secure the free end to the
30
generator.
31 Disconnect the PU chassis ground wire from the generator mounting foot.
32 Remove the engine/generator skid from the PU chassis mounting hardware.
Carefully position the forks of a 10,000 lb minimum capacity forklift under the marked
33
provisions on the engine/generator skid.
34 Using the forklift, lift the engine/generator slightly until it is just clear of the PU mounts.
Remove the engine/generator from the PU by carefully backing the forklift away from the PU.
35
Be sure the engine/generator does not snag any PU components during the process.
36 Set the engine/generator down on blocks on the ground in a protected location.
21-6
USAF TO 35C2-3-518-1
USA TM 9-6115-484-14
DRS RADIAN CTM 01646.1R0253/1R0254
21.3 ENGINE/ALTERNATOR INSTALLATION
WARNING
WARNING
WARNING
PRIOR TO TROUBLESHOOTING THE POWER UNIT (PU), ENSURE THE TIE AND
FEEDER CABLES ARE ALL INSTALLED ON PARKING STANDS, TO PREVENT THE
POSSIBILITY OF UTILITY POWER BEING FED BACK INTO GENERATOR SET.
ENSURE EQUIPMENT IS PROPERLY TAGGED AND NOT ENERGIZED. RESIDUAL
VOLTAGE IS PRESENT AT THE GENERATOR LEADS WITH THE REGULATOR
TURNED OFF, REACHING SEVERAL HUNDRED VOLTS ON THE GENERATOR SET.
PROPER INSULATION AND ISOLATION OF METERING EQUIPMENT MUST BE
OBSERVED WHEN TESTING GENERATOR. USE PROPER TEST EQUIPMENT TO
CHECK FOR VOLTAGE BEFORE PROCEEDING. FAILURE TO COMPLY MAY
RESULT IN DEATH BY ELECTROCUTION.
CAUTION
CAUTION
21-7
USAF TO 35C2-3-518-1
USA TM 9-6115-484-14
DRS RADIAN CTM 01646.1R0253/1R0254
Carefully position the forks of a 10,000 lb minimum capacity forklift under the marked
1
provisions on the engine/generator skid.
2 Using the forklift, lift the engine/generator until it is just clear of the PU mounts.
Insert the engine/generator into the PU by carefully moving the forklift toward the PU. Be
3
sure the engine/generator does not snag any PU components during the process.
Position the engine/generator on the PU chassis mounting provisions, set in place, and
4
remove the forklift.
5 Reinstall the engine/generator skid to PU chassis mounting hardware.
6 Reinstall the PU chassis ground wire to the generator mounting foot.
7 Reinstall the 40P, 7P1 and 7P2 harnesses from the engine/generator to the PDC.
Reinstall the generator and ground wires through the conduit hole in the PDC and reinstall
8
the conduit end into the PDC.
9 Reinstall the ground wire to the ground bus inside the PDC.
10 Reinstall the four generator high voltage output wires to the buses inside the PDC.
11 Reinstall the PDC generator connection access cover.
12 Reinstall the crankcase oil drain hose.
13 Reinstall the electrical wires at the starter motor.
14 Reinstall the exhaust pipe to the muffler and the turbocharger.
15 Reinstall the coupling to the charge-air cold line at the intake manifold.
16 Reinstall the coupling to the charge air hot line at the turbocharger.
17 Reinstall the coupling to the engine coolant return line.
18 Reinstall the coupling to the engine coolant supply line.
19 Reinstall the engine coolant drain hose.
20 Close the engine coolant drain valve.
Refill the engine cooling system with coolant. Open the engine cooling system vent valve as
21
necessary to release entrapped air from the engine block.
22 Reinstall the radiator cap.
23 Reinstall the fuel inlet line to the Primary fuel filter.
24 Reinstall the fuel return line.
25 Open the fuel inlet supply valve.
26 Using the fuel system hand-priming pump, prime the engine fuel system.
27 Reinstall the engine gauge assembly onto the PU housing.
28 Reinstall the hydraulic pump assembly onto the engine.
29 Reinstall the hydraulic control block onto the engine.
21-8
USAF TO 35C2-3-518-1
USA TM 9-6115-484-14
DRS RADIAN CTM 01646.1R0253/1R0254
30 Reinstall the hydraulic pressure gauge lines to the hydraulic control block.
31 Reinstall the air inlet duct assembly.
32 Reinstall the PU housing side panel ("H" panel).
33 Reinstall both negative and positive cables on both Battery Banks and untag.
34 Un tag and reinstall both Battery Charger input power cables.
35 Check both Battery Chargers for proper operation.
21-9
USAF TO 35C2-3-518-1
USA TM 9-6115-484-14
DRS RADIAN CTM 01646.1R0253/1R0254
21-10
USAF TO 35C2-3-518-1
USA TM 9-6115-484-14
DRS RADIAN CTM 01646.1R0253/1R0254
CHAPTER 22
PDC REMOVAL AND INSTALLATION PROCEDURES
TABLE OF CONTENTS
22-1
USAF TO 35C2-3-518-1
USA TM 9-6115-484-14
DRS RADIAN CTM 01646.1R0253/1R0254
LIST OF FIGURES
22-2
USAF TO 35C2-3-518-1
USA TM 9-6115-484-14
DRS RADIAN CTM 01646.1R0253/1R0254
LIST OF TABLES
22-3
USAF TO 35C2-3-518-1
USA TM 9-6115-484-14
DRS RADIAN CTM 01646.1R0253/1R0254
NOTE: This is a DEALER Level Task. It is included in this manual for EMERGENCY USE ONLY.
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:
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.
22-4
USAF TO 35C2-3-518-1
USA TM 9-6115-484-14
DRS RADIAN CTM 01646.1R0253/1R0254
WARNING
WARNING
WARNING
PRIOR TO TROUBLESHOOTING THE POWER UNIT (PU), ENSURE THE TIE AND
FEEDER CABLES ARE ALL INSTALLED ON PARKING STANDS, TO PREVENT THE
POSSIBILITY OF UTILITY POWER BEING FED BACK INTO GENERATOR SET.
ENSURE EQUIPMENT IS PROPERLY TAGGED AND NOT ENERGIZED. RESIDUAL
VOLTAGE IS PRESENT AT THE GENERATOR LEADS WITH THE REGULATOR
TURNED OFF, REACHING SEVERAL HUNDRED VOLTS ON THE GENERATOR SET.
PROPER INSULATION AND ISOLATION OF METERING EQUIPMENT MUST BE
OBSERVED WHEN TESTING GENERATOR. USE PROPER TEST EQUIPMENT TO
CHECK FOR VOLTAGE BEFORE PROCEEDING. FAILURE TO COMPLY MAY
RESULT IN DEATH BY ELECTROCUTION.
WARNING
CAUTION
CAUTION
NOTE: This is a DEALER Level Task. It is included in this manual for EMERGENCY USE ONLY.
22-5
USAF TO 35C2-3-518-1
USA TM 9-6115-484-14
DRS RADIAN CTM 01646.1R0253/1R0254
PDC removal and installation procedures are presented in Table 22.2-1, Table 22.2-2, Table 22.3-1, and
Table 22.3-2. Figure 22.2-1 illustrates the removable parts on the PDC.
STEP PROCEDURE
1 De-energize and disconnect feeder output cables, tie output cables, and the ground cables.
2 Disconnect the battery cables from the batteries.
3 Remove Pin Plug 40P, with an Allen wrench, from the PDC, for both GEN 1 and GEN 2 units.
Remove Pin Plugs 7P1 and 7P2. Twist the plugs and pull out, for both GEN 1 and GEN 2
4
units.
Remove the access cover on the back of the control panel for GEN 1 and GEN 2. Tag and
5
Disconnect generator leads T1, T2, T3, neutral and ground from the bus bars.
Remove the curbside cover from the transformer. Tag and Disconnect H1, H2, H3, and
6
ground and disconnect the Seal - Tight connector.
7 Remove feeder protective covers.
Remove the Mounting Hardware from the PDC flashing on the right, left and top, and remove
8
the flashing see Figure 22.2-1 for reference.
22-6
USAF TO 35C2-3-518-1
USA TM 9-6115-484-14
DRS RADIAN CTM 01646.1R0253/1R0254
STEP PROCEDURE
Remove (2) 3/8” x 1” inch bolts from the front bottom of the PDC, from under the trailer frame
9
see Figure 22.2-1 for reference.
10 Remove (4) 3/8” x 2” inch bolts from the rear of the PDC, under the trailer frame.
With a 4000 lb forklift lift the PDC to clear the PU trailer frame, and remove the Korfund Pads
11
(Packing between the PDC and Frame). Lower the panel slightly and remove the PDC.
STEP PROCEDURE
22-7
USAF TO 35C2-3-518-1
USA TM 9-6115-484-14
DRS RADIAN CTM 01646.1R0253/1R0254
WARNING
WARNING
WARNING
PRIOR TO TROUBLESHOOTING THE POWER UNIT (PU), ENSURE THE TIE AND
FEEDER CABLES ARE ALL INSTALLED ON PARKING STANDS, TO PREVENT THE
POSSIBILITY OF UTILITY POWER BEING FED BACK INTO GENERATOR SET.
ENSURE EQUIPMENT IS PROPERLY TAGGED AND NOT ENERGIZED. RESIDUAL
VOLTAGE IS PRESENT AT THE GENERATOR LEADS WITH THE REGULATOR
TURNED OFF, REACHING SEVERAL HUNDRED VOLTS ON THE GENERATOR SET.
PROPER INSULATION AND ISOLATION OF METERING EQUIPMENT MUST BE
OBSERVED WHEN TESTING GENERATOR. USE PROPER TEST EQUIPMENT TO
CHECK FOR VOLTAGE BEFORE PROCEEDING. FAILURE TO COMPLY MAY
RESULT IN DEATH BY ELECTROCUTION.
CAUTION
CAUTION
22-8
USAF TO 35C2-3-518-1
USA TM 9-6115-484-14
DRS RADIAN CTM 01646.1R0253/1R0254
STEP PROCEDURE
With a 4000lb forklift lift the PDC into the PU trailer slightly above the frame and reinstall the
1 Korfund Pads (Packing between the PDC and Frame). Lower the panel and reinstall the
panel.
2 Reinstall (4) 3/8” x 2” inch bolts from the rear of the PDC, under the trailer frame.
3 Reinstall (2) 3/8” x 1” inch bolts from the front bottom of the PDC, from under the trailer frame.
Reinstall the flashing on the right, left and top of the control panel using Mounting Hardware.
4
Reinstall gasket as required.
Reinstall generator leads T1, T2, T3, neutral and ground to the bus bars. Reinstall the
5
access cover on back of the control panel for GEN 1 and GEN 2.
6 Reinstall Pin Plugs 7P1 and 7P2. Twist the plugs and push in, for both units.
Reinstall H1, H2, H3 and ground in the transformer and Reinstall the Seal-Tight connector
7
and Reinstall the transformer cover.
8 Reinstall feeder protective covers.
9 Reinstall Pin Plug 40P, to the PDC with an Allen wrench, for both units.
10 Reinstall battery cables to the batteries. See Foldout (FO 35)
STEP PROCEDURE
With a 4000lb forklift lift the PDC slightly above the frame and reinstall the Korfund Pads
1
(Packing between the PDC and Frame). Lower the panel and install the panel.
2 Reinstall (2) 3/8” x 2” inch bolts from the rear of the PDC, under the trailer frame.
3 Reinstall (2) 3/8” x 1” inch bolts from the front bottom of the PDC, from under the trailer frame.
4 Reinstall the flashing on the right, left and top of the control panel using Mounting Hardware.
Reinstall generator leads T1, T2, T3, neutral and ground to the bus bars. Reinstall the
5
access cover and filter on back of the control panel for GEN 1 and GEN 2.
6 Reinstall Pin Plugs 7P1 and 7P2. Twist the plugs and push in, for both units.
Reinstall H1, H2, H3 and ground in the transformer and reinstall the Seal-Tight connector and
7
reinstall the transformer cover.
8 Reinstall Pin Plug 40P, to the PDC with an Allen wrench, for both units.
9 Reinstall the tail light assemblies.
10 Reinstall battery cables to the batteries. See Foldout (FO 35)
22-9
USAF TO 35C2-3-518-1
USA TM 9-6115-484-14
DRS RADIAN CTM 01646.1R0253/1R0254
22-10
USAF TO 35C2-3-518-1
USA TM 9-6115-484-14
DRS RADIAN CTM 01646.1R0253/1R0254
*This manual supersedes USAF TO 35C2-3-518-1/ USA TM 9-6115-484-14, JUNE 9, 2006, including all changes
USAF TO 35C2-3-518-1
USA TM 9-6115-484-14
DRS RADIAN CTM 01646.1R0253/1R0254
ANNEX A
OTHER MANUAL REFERENCES FOR THE POWER UNIT
The following is a list of vender reference manuals and additional DRS Radian manuals for the Power
Unit:
CATERPILLAR
NUMBER TITLE
NOVEMBER 1998, or TROUBLESHOOTING (3456 DPGDS GENERATOR SET ENGINE-
later SUPPLEMENT)
NOVEMBER 1998, or SERVICE MANUAL 3456 DPGDS GENERATOR SET ENGINE-
later SUPPLEMENT (EMCP II+ FOR EUI ENGINES)
SPECIAL INSTRUCTION (PARTS LISTING OF THE DEUTSCH
REHS 0148-01, or later
CONNECTORS AND COMPONENTS)
SYSTEMS OPERATION TESTING AND ADJUSTING (EMCP II+ FOR EUI
RENR 1200-01, or later
ENGINES)
RENR 2227-02, or later TROUBLESHOOTING (3406E GENERATOR SET ENGINES)
SEBP 3201-01, or later PARTS MANUAL – 3456 DPGDS GENERATOR SET – MILITARY
OPERATION AND MAINTENANCE MANUAL (CUSTOMER
SEBU 6874-04, or later
COMMUNICATION MODULE FOR DIESEL ENGINES)
OPERATION AND MAINTENANCE MANUAL (SR4B GENERATORS AND
SEBU 6918-03, or later
CONTROL PANELS)
SEBU 6959-02, or later CAT O&M 3406E, 3456 INDUSTRIAL ENGINE
OPERATION AND MAINTENANCE MANUAL ELECTRIC SET
SEBU 7163-01, or later
GENERATORS
SYSTEMS OPERATION TESTING AND ADJUSTING (3406E AND 3456
SENR 1067-02, or later
INDUSTRIAL ENGINES)
SENR 1068-01, or later DISASSEMBLY AND ASSEMBLY (3406E & 3456 INDUSTRIAL ENGINE)
SENR 2995-04, or later PRODUCT SAFETY
SENR 3130-06, or later SPECIFICATIONS (TORQUE SPECIFICATIONS)
SENR 5359-01, or later SERVICE MANUAL-(SR4B GENERATOR)
SPECIFICATIONS SYSTEM OPERATION, TESTING AND ADJUSTING
SENR 5833-02, or later
(DIGITAL VOLTAGE REGULATOR)
SYSTEM OPERATION, TESTING, AND ADJUSTING (GENERATOR SET
SENR 6565-02, or later
LOAD SENSOR AND LOAD SHARING MODULE)
TOOL OPERATING MANUAL (SERVICING DEUTSCH HD & DT STYLE
SEHS 9615-02, or later
CONNECTORS)
SPECIAL INSTRUCTION-CLEANING AND DRYING OF GENERATORS
SEHS 9124-01, or later
AND CONTROL PANELS
SPECIAL INSTRUCTION (STORAGE PROCEDURE FOR CATERPILLAR
SEHS 9031-03, or later
PRODUCTS)
A-1
USAF TO 35C2-3-518-1
USA TM 9-6115-484-14
DRS RADIAN CTM 01646.1R0253/1R0254
A-2
USAF TO 35C2-3-518-1
USA TM 9-6115-484-14
DRS RADIAN CTM 01646.1R0253/1R0254
ANNEX B
DPGDS GSC+ PROGRAMMABLE SETPOINTS
OP5-0 SETPOINTS
SETPOINTS OP5-0 ENGINE/GENERATOR PROGRAMMING①
FACTORY DPGDS
SETPOINT-NAME-DESCRIPTIONS RANGE OF VALUES
DEFAULT SETPOINT
P001 - Fuel Solenoid Type: type of fuel system solenoid used 0- ETR fuel solenoid
0 0
on the genset. 1- ETS fuel solenoid
P002 - Units Shown: type of measurement units shown on the 0-for English units (PSI, ºF)
0 0
GSC+ display. 1-for metric units (kPa, ºC).
0-for engine shutdown
P003 - Shutdown Override For Engine Fault: GSC+ response
1-for alarm only (shutdown override, no engine 0 0
to a low engine oil pressure or high coolant temperature fault.
shutdown).
P004 - Shutdown Override For Sensor Fault: GSC+ response 0-for alarm only shutdown override, no engine
to a diagnostic fault with the engine oil pressure sensor, coolant shutdown). 0 0
temperature sensor, oil temperature sensor, sensor power supply
or coolant loss sensor. 1-for engine shutdown.
P005 - Coolant Loss Sensor Installed: tells whether or not the 0-for gensets without a coolant loss sensor
0 1
optional engine coolant loss sensor is installed on the genset. 1-for gensets with coolant loss sensor
B-1
USAF TO 35C2-3-518-1
USA TM 9-6115-484-14
DRS RADIAN CTM 01646.1R0253/1R0254
P020④ - AC Voltage: nominal AC voltage of the generator. The 700, 150, 300, 500, 600, 750, 3.0k, 4.5k,
700 5.20k
GSC+ measures the AC voltage and shows it on the display. 5.20k, 5.25k, 9.0k, 15.0k, 18.0k, 30.0k
P021 - AC Current Full Scale: nominal full scale AC current of 75, 100, 150, 200, 300, 400, 600, 800,
the generator. AC current full scale is equal to the ratio of the 1000, 1200, 1500, 2000, 2500, 3000, and 600A 100A
external current transformers in the generator housing. 4000A
B-2
USAF TO 35C2-3-518-1
USA TM 9-6115-484-14
DRS RADIAN CTM 01646.1R0253/1R0254
① The setpoints (stored or being programmed) must match the specified DPGDS setpoints.
② When oil pressure drops to within 5PSI (34kPa) of the P013 or P014 setpoint, a low oil pressure alarm is issued by the GSC+.
③ When coolant temperature rises to within 11ºF (6ºC) of the P015 setpoint, a high coolant temperature alarm is issued by the GSC+.
④ The values other than the default (700V) are for switchgear applications and require the use of external potential transformers and the
removal of the AC voltage range jumper located in the relay module. The DPGDS unit is factory configured for the 5.20 K value.
See the Caterpillar Electronic Modular Control Panel II+ manual topic AC Voltage Range Selection in the Testing and Adjusting
section.
⑤ After setpoint P022 is reprogrammed, the GSC+ must be power cycled (powered down and then powered up)
B-3
USAF TO 35C2-3-518-1
USA TM 9-6115-484-14
DRS RADIAN CTM 01646.1R0253/1R0254
OP5-1 SETPOINTS
SETPOINTS OP5-1 PROTECTIVE RELAYING PROGRAMMING①
FACTORY 60HZ 50HZ
SETPOINT-NAME-DESCRIPTION RANGE OF VALUES
DEFAULT SETPOINT SETPOINT
P101 - Generator Overvoltage Alarm Enable: 0 - disabled
the GSC+ enables or disables the generator 1 1 1
overvoltage alarm function. 1 - enabled
P102 - Generator Overvoltage Alarm
100 to 125% of nameplate voltage in
Threshold: voltage the GSC+ uses to issue an 105% 105% 105%
increments of 1%.
overvoltage alarm.
P103 - Generator Overvoltage Alarm Time
Delay: amount of time the GSC+ waits before 0 through 120 seconds② in increments of 1 10 seconds 10 seconds 10 seconds
issuing an overvoltage alarm.
P104 - Generator Overvoltage Shutdown 0 - disabled
Enable: the GSC+ enables or disables the 1 1 1
generator overvoltage shutdown function. 1 - enabled
P105 - Generator Overvoltage Shutdown
100 to 125% of nameplate voltage in
Threshold: voltage the GSC+ uses to issue an 110% 110% 110%
increments of 1%.
overvoltage shutdown.
P106 - Generator Overvoltage Shutdown Time
Delay: amount of time the GSC+ waits before 0 through 120 seconds② in increments of 1 10 seconds 10 seconds 10 seconds
issuing an overvoltage shutdown.
P107 - Generator Undervoltage Alarm Enable: 0 - disabled
the GSC+ enables or disables the generator 1 1 1
undervoltage alarm function. 1 - enabled
P108 - Generator Undervoltage Alarm
60 to 100% of nameplate voltage in
Threshold: voltage the GSC+ uses to issue an 90% 90% 90%
increments of 1%.
undervoltage alarm.
P109 - Generator Undervoltage Alarm Time
Delay: amount of time the GSC+ waits before 0 through 120 seconds② in increments of 1 10 seconds 10 seconds 10 seconds
issuing an undervoltage alarm.
P110 - Generator Undervoltage Shutdown 0 - disabled
Enable: the GSC+ enables or disables the 1 1 1
generator undervoltage shutdown function. 1 - enabled
P111 - Generator Undervoltage Shutdown
60 through 100% of rated voltage in
Threshold: voltage the GSC+ uses to issue an 85% 85% 85%
increments of 1%.
undervoltage shutdown.
P112 - Generator Undervoltage Shutdown Time
Delay: amount of time the GSC+ waits before 0 through 120 seconds② in increments of 1 15 seconds 03 seconds 03 seconds
issuing an undervoltage shutdown.
P113 - Generator Overfrequency Alarm Enable: 0 - disabled
the GSC+ enables or disables the generator 1 1 1
overfrequency alarm function. 1 - enabled
B-4
USAF TO 35C2-3-518-1
USA TM 9-6115-484-14
DRS RADIAN CTM 01646.1R0253/1R0254
OP5-1 SETPOINTS (CONTINUED)
SETPOINTS OP5-1 PROTECTIVE RELAYING PROGRAMMING①
FACTORY 60HZ 50HZ
SETPOINT-NAME-DESCRIPTION RANGE OF VALUES
DEFAULT SETPOINT SETPOINT
P118 - Generator Overfrequency Shutdown
Time Delay: amount of time the GSC+ waits 0 through 120 seconds② in increments of 1 10 seconds 10 seconds 10 seconds
before issuing an overfrequency shutdown.
P119 - Generator Underfrequency Alarm 0 - disabled
Enable: the GSC+ enables or disables the 1 1 1
generator underfrequency alarm function. 1 - enabled
B-5
USAF TO 35C2-3-518-1
USA TM 9-6115-484-14
DRS RADIAN CTM 01646.1R0253/1R0254
B-6
USAF TO 35C2-3-518-1
USA TM 9-6115-484-14
DRS RADIAN CTM 01646.1R0253/1R0254
OP6 SETPOINTS
SETPOINTS OP6 SPARE INPUT/OUTPUT PROGRAMMING
FACTORY DPGDS
SETPOINT-NAME-DESCRIPTIONS RANGE OF VALUES
DEFAULT SETPOINT
SP01 - Spare Input 1 Active State. Input state used by the GSC+ to 0-active low
0 0
declare a SP1 fault exists. 1-active high
0-shutdown
SP02 - Spare Input 1 Response: GSC+ response to a SP1 fault. 0 0
1-alarm
SP03 - Spare Input 1 Time Delay: Amount of time the GSC+ waits
0 - 250 seconds in increments of 1 0 seconds 1 second
before responding to a SP1 fault.
SP04 - Spare Input 2 Active State. Input state used by the GSC+ to 0-active low
0 1
declare a SP2 fault exists. 1-active high
0-shutdown
SP05 - Spare Input 2 Response: GSC+ response to a SP2 fault. 0 0
1-alarm
SP06 - Spare Input 2 Time Delay: Amount of time the GSC+ waits
0 - 250 seconds in increments of 1 0 seconds 0 seconds
before responding to a SP2 fault.
SP07 - Spare Input 3 Active State. Input state used by the GSC+ to 0-active low
0 0
declare a SP3 fault exists. 1-active high
0-shutdown
SP08 - Spare Input 3 Response: GSC+ response to a SP3 fault. 0 0
1-alarm
SP09 - Spare Input 3 Time Delay: Amount of time the GSC+ waits
0 - 250 seconds in increments of 1 0 seconds 0 seconds
before responding to a SP3 fault.
SP10 - Spare Input 4 Active State. Input state used by the GSC+ to 0-active low
0 0
declare a SP4 fault exists. 1-active high
0-shutdown
SP11 - Spare Input 4 Response: GSC+ response to a SP4 fault. 0 0
1-alarm
SP12 - Spare Input 4 Time Delay: Amount of time the GSC+ waits
0 - 250 seconds in increments of 1 0 seconds 0 seconds
before responding to a SP4 fault.
SP13 - Spare Output Response: GSC+ response to the spare output 0-active low
0 0
trigger condition. 1-active high
0-unused
B-7
USAF TO 35C2-3-518-1
USA TM 9-6115-484-14
DRS RADIAN CTM 01646.1R0253/1R0254
SP4 faults②
③ Battleshort and 50Hz Mode are unique features to DPGDS for spare indicators 2 and 3.
B-8
USAF TO 35C2-3-518-1
USA TM 9-6115-484-14
DRS RADIAN CTM 01646.1R0253/1R0254
ANNEX C
ENGINE/GENERATOR ALARM AND SHUTDOWN POINTS
ENGINE – GSC
C-1
USAF TO 35C2-3-518-1
USA TM 9-6115-484-14
DRS RADIAN CTM 01646.1R0253/1R0254
GENERATOR - GSC
9 • 50Hz - 48 Hz - 45 Hz
• 60Hz - 57 Hz - 54Hz
C-2
USAF TO 35C2-3-518-1
USA TM 9-6115-484-14
DRS RADIAN CTM: 01646.1R0253/1R0254
ANNEX D
BASLER OVERCURRENT RELAY SETPOINTS, ALARM AND
SHUTDOWN POINTS
CT RATIO SETTINGS
BREAKER RELAY CT RATIO “P” VALUE “N” VALUE
GENERATOR 100:5 20 20
FEEDER 200:5 40 40
TIE 200:5 40 40
D-1
USAF TO 35C2-3-518-1
USA TM 9-6115-484-14
DRS RADIAN CTM: 01646.1R0253/1R0254
D-2
USAF TO 35C2-3-518-1
TM 9-6115-484-14
DRS RADIAN CTM. 01646.1R0253/1RO254
ANNEX E
AUTOMATIC VOLTAGE REGULATOR (AVR) SETPOINTS
Step 1: Go to parameter 90 and set "DPGDS Setpoints" to 01. Setpoints can only be changed when
parameter 90 is any number besides 0009. 0009 locks changes out. After all changes have been made
to setpoints, return to parameter 90 and change back to 0009.
DPGDS
DPGDS AVR PARAMETERS
SETPOINTS
RANGE OF DEFAULT 60HZ 50HZ
PARAMETER TITLE TYPE UNITS
VALUES VALUE OPS OPS
01 Generator Output Voltage Program Volts 0080-9999 480① 4160 3800
33③ KVAR Reference Program Per Unit 00.00-01.00 0000 .10 .10
E-1
USAF TO 35C2-3-518-1
TM 9-6115-484-14
DRS RADIAN CTM. 01646.1R0253/1RO254
DPGDS
DPGDS AVR PARAMETERS
SETPOINTS
RANGE OF DEFAULT 60HZ 50HZ
PARAMETER TITLE TYPE UNITS
VALUES VALUE OPS OPS
58③,④ Three Phase kVAR (KE and later) View
① Default value for output voltage is different depending on regulator sensing voltage. If the regulator is
designed for l20 volts sensing, then the default output voltage is 4l60 volts. All other sensing types have the
default output voltage set to 480 volts.
② Digital Voltage Regulators with earlier software (KD and earlier) have I less digit to the right of the decimal
point.
③ Optional feature.
④ New parameter on serial number prefix KE and later Digital Voltage Regulators.
⑤ Previous range of 0001-099.9 and default value of 002.0
⑥ Previous range of 0001-099.9 and default value of 002.0
NOTE: Parameters 20, 21, 22, 36, 37, and 38 are displayed but not used.
E-2
USAF TO 35C2-3-518-1
USA TM 9-6115-484-14
DRS RADIAN CTM: 01646.1R0253/1RO254
ANNEX F
3456 EPG ADEM SETPOINTS
01/12/2000 2:36 PM
Parameter Value
Equipment ID
Engine Serial Number use data plate
9BZ00002
value
ECM Serial Number 08390151CG
Personality Module Part Number 1730820-00
Personality Module Release Date May99
Personality Module Description EPG 3456
F-1
USAF TO 35C2-3-518-1
USA TM 9-6115-484-14
DRS RADIAN CTM: 01646.1R0253/1RO254
Parameter Value
F-2
USAF TO 35C2-3-518-1
USA TM 9-6115-484-14
DRS RADIAN CTM: 01646.1R0253/1RO254
F-3
USAF TO 35C2-3-518-1
USA TM 9-6115-484-14
DRS RADIAN CTM: 01646.1R0253/1RO254
01/12/2000 2:43 PM
Parameter Value
F-4
USAF TO 35C2-3-518-1
USA TM 9-6115-484-14
DRS RADIAN CTM: 01646.1R0253/1RO254
01/12/2000 2:44 PM
Parameter Value
01/12/2000 2:43 PM
Injector Code
use data from each individual engine and the injector
Injector 1 engine specific value 8837
Injector 2 engine specific value 8922
Injector 3 engine specific value 4657
Injector 4 engine specific value 7827
Injector 5 engine specific value 5622
Injector 6 engine specific value 5867
F-5
USAF TO 35C2-3-518-1
USA TM 9-6115-484-14
DRS RADIAN CTM: 01646.1R0253/1RO254
01/12/2000 2:42 PM
Parameter Value
Code Description
No Active Codes
01/12/2000 2:42 PM
Parameter Value
F-6
USAF TO 35C2-3-518-1
USA TM 9-6115-484-14
DRS RADIAN CTM: 01646.1R0253/1RO254
01/12/2000 2:42 PM
Parameter Value
01/12/2000 2:39 PM
Parameter Value
F-7
USAF TO 35C2-3-518-1
USA TM 9-6115-484-14
DRS RADIAN CTM: 01646.1R0253/1RO254
01/12/2000 2:40 PM
Parameter Value
F-8
USAF TO 35C2-3-518-1
USA TM 9-6115-484-14
DRS RADIAN CTM: 01646.1R0253/1RO254
01/12/2000 2:41 PM
Parameter Value
F-9
USAF TO 35C2-3-518-1
USA TM 9-6115-484-14
DRS RADIAN CTM: 01646.1R0253/1RO254
01/12/2000 2:41 PM
Parameter Value
01/12/2000 2:41 PM
Parameter Value
F-10
USAF TO 35C2-3-518-1
USA TM 9-6115-484-14
DRS RADIAN CTM: 01646.1R0253/1RO254
01/12/2000 2:43 PM
Parameter Value
F-11
USAF TO 35C2-3-518-1
USA TM 9-6115-484-14
DRS RADIAN CTM: 01646.1R0253/1RO254
F-12
USAF TO 35C2-3-518-1
USA TM 9-6115-484-14
DRS RADIAN CTM: 01646.1R0253/1R0254
ANNEX G
CONSUMABLE OPERATING AND MAINTENANCE SUPPLIES
Table G-1 lists the consumable materials needed to operate, maintain, and store/preserve the MEP-PU-
810 A/B. The items are identified by Military Specification, National Stock Number (NSN) or Vendor Part
Number.
NOTE 1: Oil used in the Caterpillar 3456 engine must meet SAE viscosity ratings.
(SAE = Society of Automotive Engineers) Also Oil used in the Caterpillar 3456 EPG engine must meet
the following API standards. (API = American Petroleum Institute)
G-1
USAF TO 35C2-3-518-1
USA TM 9-6115-484-14
DRS RADIAN CTM: 01646.1R0253/1R0254
Mobile
Hydraulic
DTE 18M 36 Gallons
Fluid
Hydraulic (48˚F to 125˚F)
System
Mobil
M9150 01 461
DTE 11M
1142
(-25˚F to 75˚F)
Hydraulic
RE-409-10 2
Filter
G-2
USAF TO 35C2-3-518-1
USA TM 9-6115-484-14
DRS RADIAN CTM: 01646.1R0253/1R0254
MEP-PU-810 CONSUMABLE MATERIALS (CONTINUED)
QUANTITY
MEP-PU-810
NSN/ PART REQUIRED
MAJOR SUBSYSTEM ITEM DESCRIPTION
NUMBER FOR INITIAL
COMPONENT
START-UP
Mobil grease
Thickener Type: Lithium
HP.
complex
Ronex MP.
Dropping Point: 446°F
minimum
Kendall L-
427.
Consistency: NLGI No.
2
Grease: Valvoline
Val-plex EP
Additives:
Grease.
EP, Corrosion &
Oxidation Inhibitors
Pennzoil
Premium
Wheel Base Oil: Solvent
Wheel
Bearings/ Refined
Bearing
Slack Petroleum Oil
Grease 707L.
Adjusters/
Union MP
Spider and
Gear Lube –
Support
LS.
Bushings
TRAILER Exxon
Gear Oil
GX80W-90.
Oil Mobilube
SHC 75W-90.
Pennzoil
Multipurpose
Gear
Lubricant
4092 and
4096.
Surge Brake
DOT-3 or 1 Pint
(MEP-PU- Brake Fluid
DOT-4
810A only)
Towing
General
assembly
purpose axle
Landing Leg
Grease grease
assembly
(MEP-PU-
GAA
810B only)
4C-6794 VCI Oil 5 Gallons
3456 Storage/ Preserving
ENGINE Preservation Fluids
6V-6068 Calibration Fluid 5 Gallons
G-3
USAF TO 35C2-3-518-1
USA TM 9-6115-484-14
DRS RADIAN CTM: 01646.1R0253/1R0254
G-4
USAF TO 35C2-3-518-1
USA TM 9-6115-484-14
DRS RADIAN CTM: 01646.1R0253/1R0254
ANNEX H
SPECIAL TOOLS AND EQUIPMENT
The tools and equipment required for Organizational Level Maintenance of the MEP-PU-810 are listed in
the following Table:
H-1
USAF TO 35C2-3-518-1
USA TM 9-6115-484-14
DRS RADIAN CTM: 01646.1R0253/1R0254
H-2
USAF TO 35C2-3-518-1
USA TM 9-6115-484-14
DRS RADIAN CTM 01646.1R0253/1R0254
ANNEX I
I-1
Terminator
Decision
Predefined subprocess
Logic process
Data
Extract
Merge
Off-page connector
Connector
I-2
This Power Unit Logic Flowchart is provided with Government Purpose License Rights
Start - Power ON Entry point when system is powered up
1 to 2
I-3
This Power Unit Logic Flowchart is provided with Government Purpose License Rights
Page
I-3
1 to 2
Page
I-5
I-4
This Power Unit Logic Flowchart is provided with Government Purpose License Rights
Page
I-4
False
Operate Logic Specific for operating unit A Subroutine
PPU A (Page I-61)
1 to 3
1 to 2
Tie / Feeder
Control Controls tie & feeder breakers Subroutine
(Page I-95)
Page
I-3
I-5
This Power Unit Logic Flowchart is provided with Government Purpose License Rights
Start - Initialize Variables Entry point for initialize variables routine
1 to 2
I-6
This Power Unit Logic Flowchart is provided with Government Purpose License Rights
Start - Main Logic Entry point for main logic subprogram
SMS True
Not Auto System Mode Switch (SMS) not set to Auto RTU-IN1
False
False
Dual Genset Dual Genset Set Dual variable to "True" if both ready for Virtual
Auto operation, otherwise "False".
Single Genset Single Genset Set Single variable to "False" if both ready for Virtual
Auto operation, otherwise "True".
Page
I-8
I-7
This Power Unit Logic Flowchart is provided with Government Purpose License Rights
Page
I-7
False
Total KW True Is total system KW load for ORT > 50? Virtual
> 50
1 to 2
Set auxillary Sets the auxillary relay for tie breaker status Virtual
tie breaker to current tie breaker status.
Set auxillary Sets the auxillary relay for system bus status Virtual
system bus to current system bus status.
Page
I-9
I-8
This Power Unit Logic Flowchart is provided with Government Purpose License Rights
Page
I-8
False
B_Status_Word Set network value used by "A" unit to check for Virtual
=0 overcurrent on "B" unit to 0.
False
C_Status_Word Set network value used by "A" unit to check for Virtual
=0 overcurrent on "C" unit to 0.
False
D_Status_Word Set network value used by "A" unit to check for Virtual
=0 overcurrent on "D" unit to 0.
I-9
This Power Unit Logic Flowchart is provided with Government Purpose License Rights
Start - Station ID Start of Station ID subprogram.
True
MSPB Is the Master Start Enable Switch in either RTU-IN3
ENABLE position?
Page
I-11
I-10
This Power Unit Logic Flowchart is provided with Government Purpose License Rights
Page
I-10
False Is the PPU station ID not set and ready for Virtual
True
RTU_EN operation?
=F
False
False
False
Page Page
I-12 A I-12 B
I-11
This Power Unit Logic Flowchart is provided with Government Purpose License Rights
Page Page
I-11 A I-11 B
False MSPB_TOG Set the Master System Enable Toggle bit to T. Virtual
=T
False MSPB_TOG Set the Master System Enable Toggle bit to F. Virtual
=F
False
ip_reset = F ip_reset = T ip_reset = F Set variable flagging if the station's IP address Virtual
was reset, T or F.
Page
I-13
I-12
This Power Unit Logic Flowchart is provided with Government Purpose License Rights
Page
I-12
False
False
False
False
False
False
Page Page
I-14 A I-14 B
I-13
This Power Unit Logic Flowchart is provided with Government Purpose License Rights
Page Page
I-14 A I-14 B
False
False
I-14
This Power Unit Logic Flowchart is provided with Government Purpose License Rights
Start - Unpack Data Entry point for unpack data routine
False
False
Unpack GSC Takes 16-bit analog from GSC and unpacks Function
Alarm Data into 16 1-bit booleans.
False
Page
I-16
I-15
This Power Unit Logic Flowchart is provided with Government Purpose License Rights
Page
I-15
False
False
False
Page
I-17
I-16
This Power Unit Logic Flowchart is provided with Government Purpose License Rights
Page
I-16
False
Page
I-18
I-17
This Power Unit Logic Flowchart is provided with Government Purpose License Rights
Page
I-17
Unpack Gen. Takes 16-bit analog from GSC and unpacks Function
Shutdown Data into 16 1-bit booleans.
I-18
This Power Unit Logic Flowchart is provided with Government Purpose License Rights
Start - Calculate Baseload
False RTU Is the local PPU configured and ready for Virtual
True
Enabled operation?
False
Calculate Baseload Reference: take baseload Function,
Calculate setpoint (500 default), convert to KW, and limit virtual
BL_REF between 500 and 9830.
I-19
This Power Unit Logic Flowchart is provided with Government Purpose License Rights
Start - Engine Emg. Stops
False
False
False
False
I-20
This Power Unit Logic Flowchart is provided with Government Purpose License Rights
Start - Lockout
False
False
False
False
False
1 to 2
Page
I-22
I-21
This Power Unit Logic Flowchart is provided with Government Purpose License Rights
Page
I-21
False
False
Is tie lockout set to T? Virtual
True
Tie lockout
False
Low fuel True Is there a low fuel level in the PPU daytank? DIM2-IN13
in PPU day
tank
False
True
Low fuel Is there a low fuel fault? Virtual
Fault
False
Set low fuel Set flag to shutdown engine for low fuel. Virtual
engine shutdown
=T
Not low True Is there NOT a low fuel level in the PPU DIM2-IN13
fuel PPU day daytank?
tank
False
True
Low fuel Are the PPU engines flagged to shutdown due Virtual
shutdown to low fuel?
False
Set low fuel
engine shutdown Reset flag to shutdown engine for low fuel. Virtual
=F
Pack overcurrent Pack OCR1, OCR2 and OCR3 into virtual word DIM1-IN5,
signals into 16-bit "stat_word". DIM2-IN5, &
word "stat_word" DIM1-IN13
I-22
This Power Unit Logic Flowchart is provided with Government Purpose License Rights
Start - Frequency
False
PLC 50 Hz Set PLC output to 50 Hz. DOM1-OUT10
FSS
60 Hz True Switch set for 60 Hz operation. RTU-IN6
False
SMS Off True System mode switch is in the OFF position and Virtual
parameters have been cleared.
False
PLC True PLC output shows 50 Hz. DOM1-OUT10
50 Hz (ON)
False
PLC 60 Hz Set PLC output to 60 Hz. DOM1-OUT10
(OFF)
MSPB True Is the Master system enable toggle set to True? Virtual
=T
False
PLC True Does PLC output show 60 Hz? DOM1-OUT10
60 Hz (OFF)
False
KVA Setpoint Set KVA setpoint for loadsharing at 489. Virtual
=489
Page
I-24
I-23
This Power Unit Logic Flowchart is provided with Government Purpose License Rights
Page
I-23
MSPB True Is the Master system enable toggle set to True? Virtual
=T
False
PLC True Does PLC output show 50 Hz? DOM1-OUT10
50 Hz (ON)
False
KVA Setpoint Set KVA setpoint for loadsharing at 418. Virtual
=418
I-24
This Power Unit Logic Flowchart is provided with Government Purpose License Rights
Start - PDC Status
Page Page
I-26 A I-26 B
I-25
This Power Unit Logic Flowchart is provided with Government Purpose License Rights
Page Page
I-25 A I-25 B
False
False
False
False
False
False
False
Genset lockout False Genset lockout Set summary genset lockout boolean flag to Virtual
=F =T T or F.
I-26
This Power Unit Logic Flowchart is provided with Government Purpose License Rights
Start - Load Share
False
Page
I-28
I-27
This Power Unit Logic Flowchart is provided with Government Purpose License Rights
Page
I-27
False
False
False Gen. 2 Is the breaker for local PPU generator 2 open? DIM2-IN3
True
breaker not
closed
False
Set load sharing error alarm control = F. Virtual
Load sharing
error alarm=F
I-28
This Power Unit Logic Flowchart is provided with Government Purpose License Rights
Start - GenSet Load Share This program runs twice on each PPU: once for
generator 1 and once for generator 2.
False
False
False
Delay for 45 seconds Start timer to delay for 45 seconds. Function
Load sharing error Load sharing error Set load sharing alarm variable to T or F. Virtual
alarm = F alarm = T
Gen. X load share Gen. X load share Set current value of load share time delay for Virtual
delay = F delay = T generator x to T or F.
I-29
This Power Unit Logic Flowchart is provided with Government Purpose License Rights
Start - Alarms
False
True
Low coolant Is there a low coolant temperature alarm on GSC
temp generator 1 from the GSC?
False
True
Low oil Is there a low oil ressure alarm on generator 1 GSC
pressure from the GSC?
False
True
High oil Is there a high oil ressure alarm on generator 1 GSC
pressure from the GSC?
False
True
ADEM Is there a ADEM unit control alarm? GSC
unit alarm
False
True
E1 battery Is the battery low (<21V) for engine 1? Virtual
low
False
False False
Reset timer Start 2 second timer Start or reset a 2 second timer if the value is Function
changing from the previous cycle.
False
Page
I-31
I-30
This Power Unit Logic Flowchart is provided with Government Purpose License Rights
Page
I-30
True
ADEM fault Is there a ADEM unit fault shutdown from GSC
shutdown engine 1 GSC?
False
True
Emerg. stop Is there an emergency stop shutdown from GSC
eng. 1 engine 1 GSC?
False
True
Eng. 1 spare Is there a spare shutdown (ORT immediate GSC
shutdown stop) from engine 1 GSC?
False
True
High cool. Is there a high coolant temperature shutdown GSC
temp from engine 1 GSC?
False
True
Low oil Is there a low oil pressure shutdown from GSC
pressure engine 1 GSC?
False
True
Overcrank Is there an overcrank shutdown from engine 1 GSC
shutdown GSC?
False
True
Overspeed Is there an overspeed shutdown from engine 1 GSC
shutdown GSC?
False
True
Gen. 1 Is the summary failure for generator 1 true? Virtual
sum. fail
False
True
Eng. 1 Is the emergency stop activated for engine 1? Virtual
emg. stop
False
True
Eng. 1 Did the GSC send a fault signal on engine 1? DIM1-IN4
fault
False
Page Page
I-32A I-32B
I-31
This Power Unit Logic Flowchart is provided with Government Purpose License Rights
Page Page
I-31B I-31B
True
Eng. 1 Did the GSC send a fault signal on engine 1? DIM1-IN4
fault
False
False
True True
Changing Changing Is the low PPU daytank fuel level signal
T to F F to T changing?
False False
Reset timer Start 10 minute Start or reset a 10 minute timer if the value Function
timer is changing from the previous cycle.
False
Low fuel time Low fuel time Low fuel time Set variable to the low fuel level timer elapsed Virtual
expired = 0 expired = timer expired = 10 time.
Page
I-33
I-32
This Power Unit Logic Flowchart is provided with Government Purpose License Rights
Page
I-32
False
True
Low coolant Is there a low coolant temperature alarm on GSC
temp generator 2 from the GSC?
False
True
Low oil Is there a low oil ressure alarm on generator 2 GSC
pressure from the GSC?
False
True
High oil Is there a high oil ressure alarm on generator 2 GSC
pressure from the GSC?
False
True
ADEM Is there a ADEM unit control alarm? GSC
unit alarm
False
True
E2 battery Is the battery low (<21V) for engine 2? Virtual
low
False
False False
Reset timer Start 2 second timer Start or reset a 2 second timer if the value is Function
changing from the previous cycle.
False
Page
I-31
I-33
This Power Unit Logic Flowchart is provided with Government Purpose License Rights
Page
I-33
True
ADEM fault Is there a ADEM unit fault shutdown from GSC
shutdown engine 2 GSC?
False
True
Emerg. stop Is there an emergency stop shutdown from GSC
eng. 2 engine 2 GSC?
False
True
Eng. 2 spare Is there a spare shutdown (ORT immediate GSC
shutdown stop) from engine 2 GSC?
False
True
High cool. Is there a high coolant temperature shutdown GSC
temp from engine 2 GSC?
False
True
Low oil Is there a low oil pressure shutdown from GSC
pressure engine 2 GSC?
False
True
Overcrank Is there an overcrank shutdown from engine 2 GSC
shutdown GSC?
False
True
Overspeed Is there an overspeed shutdown from engine 2 GSC
shutdown GSC?
False
True
Gen. 2 Is the summary failure for generator 2 true? Virtual
sum. fail
False
True
Eng. 2 Is the emergency stop activated for engine 2? Virtual
emg. stop
False
True
Eng. 2 Did the GSC send a fault signal on engine 2? DIM2-IN4
fault
False
Page Page
I-35A I-35B
I-34
This Power Unit Logic Flowchart is provided with Government Purpose License Rights
Page Page
I-34B I-34B
True
Eng. 2 Did the GSC send a fault signal on engine 2? DIM2-IN4
fault
False
False
True True
Changing Changing Is the low PPU daytank fuel level signal
T to F F to T changing?
False False
Reset timer Start 10 minute Start or reset a 10 minute timer if the value Function
timer is changing from the previous cycle.
False
Low Fuel Fault Low Fuel Fault Set low fuel fault variable to T or F. Virtual
=F =T
Page
I-37
This section runs twice - once for each genset.
True
Underfreq. Is there an underfrequency alarm on generator x GSC
alarm from it's respective GSC?
False
True
Overfreq. Is there an overfrequency alarm on generator x GSC
alarm from it's respective GSC?
False
Page Page
I-36A I-36B
I-35
This Power Unit Logic Flowchart is provided with Government Purpose License Rights
Page Page
I-35A I-35B
True
Undervolt. Is there an undervoltage alarm on generator x GSC
alarm from it's respective GSC?
False
True
Overvolt. Is there an overvoltage alarm on generator x GSC
alarm from it's respective GSC?
False
True
Rev. power Is there a reverse power alarm on generator x GSC
alarm from it's respective GSC?
False
True
Freq. sense Is there an frequency sensing alarm on GSC
alarm generator x from it's respective GSC?
False
True
Overcurr. rel. Is there an overcurrent relay fault on DIM1-IN6 or
fault generator x? DIM2-IN6
False
True
GSC eng. Is there a GSC fault on generator x? DIM1-IN4 or
fault DIM2-IN4
False
True
NGR Is there a neutral ground resistor fault from DIM1-IN7 or
fault generator x? DIM2-IN7
False
Page
I-37
I-36
This Power Unit Logic Flowchart is provided with Government Purpose License Rights
Page
I-36
True
Batt. volt. Is the unscaled battery voltage for generator x Virtual
<= 42 <= 42?
False
True
ECS not Is the engine control switch not in the OFF - Virtual
OFF RESET position?
False
True
Timer Is the timer reset but not running?
not running
False
Start, reset or let run a 60 second timer. Function
Reset timer Start 60 second
timer
True
Timer Did the 60 second timer expire?
expired
False
Battery low Battery low Set the battery low flag for engine x to T or F. Virtual
flag = F flag = T
1 to 2
Divide current LF delay Divide the time remaining until PPU shutdown Function
time by 60,000 for low fuel alarm by 60,000 (convert from ms
to seconds).
I-37
This Power Unit Logic Flowchart is provided with Government Purpose License Rights
Start - Generator Count Beginning of generator count subprogram.
True
A RTU not Is there not an RTU designated "A", online Virtual
enabled and functioning?
False
Return Exit the subprogram.
Total KW Total KW load Set total KW & total KW load variables to the Virtual
= sum = sum sum.
Sum generator Take the KVA loads from generators 1 & 2 on Function
KVA loads PPU A, B, C and D and sum them.
Sum generators Take the number of generators that are online Function
online in PPU A, B, C & D and sum them.
Total gen. online Set total generators online variable to the sum. Virtual
= sum
True
Total KW Is the total KW load <= the KW setpoint × 1? Virtual
load <= sp
False
True
Total KVA Is the total KVA load <= the KVA setpoint × 1? Virtual
load <= sp
False
True
Does not Does the total plant load not require 2 Virtual
need 2 gen generators?
False
Page
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Page
I-38
True
Total KW Is the total KW load > the KW setpoint × 1? Virtual
load > sp
False
True
Total KW Is the total KW load <= the KW setpoint × 2? Virtual
load <= sp
False
True
Total KVA Is the total KVA load > the KVA setpoint × 1? Virtual
load > sp
False
True
Total KVA Is the total KVA load <= the KVA setpoint × 2? Virtual
load <= sp
False
True
Does not Does the total plant load not require 3 Virtual
need 3 gen generators?
False
True
Total KW Is the total KW load > the KW setpoint × 2? Virtual
load > sp
False
True
Total KW Is the total KW load <= the KW setpoint × 3? Virtual
load <= sp
False
True
Total KVA Is the total KVA load > the KVA setpoint × 2? Virtual
load > sp
False
True
Total KVA Is the total KVA load <= the KVA setpoint × 3? Virtual
load <= sp
False
True
Does not Does the total plant load not require 4 Virtual
need 4 gen generators?
False
Page
I-40
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I-39
True
Total KW Is the total KW load > the KW setpoint × 3? Virtual
load > sp
False
True
Total KW Is the total KW load <= the KW setpoint × 4? Virtual
load <= sp
False
True
Total KVA Is the total KVA load > the KVA setpoint × 3? Virtual
load > sp
False
True
Total KVA Is the total KVA load <= the KVA setpoint × 4? Virtual
load <= sp
False
True
Does not Does the total plant load not require 5 Virtual
need 5 gen generators?
False
True
Total KW Is the total KW load > the KW setpoint × 4? Virtual
load > sp
False
True
Total KW Is the total KW load <= the KW setpoint × 5? Virtual
load <= sp
False
True
Total KVA Is the total KVA load > the KVA setpoint × 4? Virtual
load > sp
False
True
Total KVA Is the total KVA load <= the KVA setpoint × 5? Virtual
load <= sp
False
True
Does not Does the total plant load not require 6 Virtual
need 6 gen generators?
False
Page
I-41
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Page
I-40
True
Total KW Is the total KW load > the KW setpoint × 5? Virtual
load > sp
False
True
Total KW Is the total KW load <= the KW setpoint × 6? Virtual
load <= sp
False
True
Total KVA Is the total KVA load > the KVA setpoint × 5? Virtual
load > sp
False
True
Total KVA Is the total KVA load <= the KVA setpoint × 6? Virtual
load <= sp
False
True
Does not Does the total plant load not require 7 Virtual
need 7 gen generators?
False
True
Total KW Is the total KW load > the KW setpoint × 6? Virtual
load > sp
False
True
Total KW Is the total KW load <= the KW setpoint × 7? Virtual
load <= sp
False
True
Total KVA Is the total KVA load > the KVA setpoint × 6? Virtual
load > sp
False
True
Total KVA Is the total KVA load <= the KVA setpoint × 7? Virtual
load <= sp
False
True
Does not Does the total plant load not require 8 Virtual
need 8 gen generators?
False
Page
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I-41
True
Total KW Is the total KW load > the KW setpoint × 7? Virtual
load > sp
False
True
Total KVA Is the total KVA load > the KVA setpoint × 7? Virtual
load > sp
False
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This Power Unit Logic Flowchart is provided with Government Purpose License Rights
Start - Economy Beginning of economy subprogram.
True
PPU not Is the local PPU not configured as the A unit? Virtual
A unit
False
True
SMS Is the SMS not in the AUTO position? RTU-IN1
not AUTO
False
True
GMS Is the Generator Mode Switch in the Utility RTU-IN5
baseload Parallel position?
False
Return Exit subprogram
True
Requires Does the plant load require 1 generator? Virtual
1 gen.
False
True
Gen. online Is the number of generators online < 1? Virtual
<1
False
True
Requires Does the plant load require 2 generator? Virtual
2 gen.
False
True
Gen. online Is the number of generators online < 2? Virtual
<2
False
True
Requires Does the plant load require 3 generator? Virtual
3 gen.
False
True
Gen. online Is the number of generators online < 3? Virtual
<3
False
True
Requires Does the plant load require 4 generator? Virtual
4 gen.
False
True
Gen. online Is the number of generators online < 4? Virtual
<4
False
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I-43A I-43B
True
Requires Does the plant load require 5 generator? Virtual
5 gen.
False
True
Gen. online Is the number of generators online < 5? Virtual
<5
False
True
Requires Does the plant load require 6 generator? Virtual
6 gen.
False
True
Gen. online Is the number of generators online < 6? Virtual
<6
False
True
Requires Does the plant load require 7 generator? Virtual
7 gen.
False
True
Gen. online Is the number of generators online < 7? Virtual
<7
False
True
Requires Does the plant load require 8 generator? Virtual
8 gen.
False
True
Gen. online Is the number of generators online < 8? Virtual
<8
False
True
No genset Is the no genset currently locked out? Virtual
lockout
False
True
Requires Does the plant load require 7 generator? Virtual
7 gen.
False
True
Gen. online Is the number of generators online > 7? Virtual
>7
False
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I-44A I-44B I-44C
True
Requires Does the plant load require 6 generator? Virtual
6 gen.
False
True
Gen. online Is the number of generators online > 6? Virtual
>6
False
True
Requires Does the plant load require 5 generator? Virtual
5 gen.
False
True
Gen. online Is the number of generators online > 5? Virtual
>5
False
True
Requires Does the plant load require 4 generator? Virtual
4 gen.
False
True
Gen. online Is the number of generators online > 4? Virtual
>4
False
True
Requires Does the plant load require 3 generator? Virtual
3 gen.
False
True
Gen. online Is the number of generators online > 3? Virtual
>3
False
True
Requires Does the plant load require 2 generator? Virtual
2 gen.
False
True
Gen. online Is the number of generators online > 2? Virtual
>2
False
True
Requires Does the plant load require 1 generator? Virtual
1 gen.
False
True
Gen. online Is the number of generators online > 1? Virtual
>1
False
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I-45A I-45C
Page
I-45B
True
No load Is automated load management enabled? Virtual
mgt. block
False
True
False A unit Does the A unit recognize the D unit? Virtual
sees D
False
True
D unit Does the D PPU have two gensets available? Virtual
dual on
False
True
A unit Does the A PPU have exactly one genset Virtual
single available?
False
True
A unit Does the A PPU have no gensets available? Virtual
none
False
True
B unit Does the B PPU have exactly one genset Virtual
single available?
False
True
B unit Does the B PPU have no gensets available? Virtual
none
False
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I-47A I-47B I-47C
True
C unit Does the C PPU have exactly one genset Virtual
single available?
True
False D unit
single Does the C PPU have no gensets available? Virtual
C unit True
none
False
True True
changing changing Is the logical value changing from F to T? Function
T to F F to T
False False
Reset timer 3 minute timer Start or reset a 3 minute timer. Function
True
timer Has the timer expired? Function
expired
False
Subtract D Gen. Subtract D Gen. Flag D PPU to shut off a genset, T or F. Virtual
=F =T
True
False A unit Does the A unit recognize the C unit? Virtual
sees C
False
True
C unit Does the D PPU have two gensets available? Virtual
dual on
False
True
D unit Does the D PPU have no gensets available? Virtual
none
False
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I-47A I-47B I-47C
True
A unit Does the A PPU have exactly one genset Virtual
single available?
False
True
A unit Does the A PPU have no gensets available? Virtual
none
False
True
B unit Does the B PPU have exactly one genset Virtual
single available?
False
True
B unit Does the B PPU have no gensets available? Virtual
none
False
True
C unit Does the C PPU have exactly one genset Virtual
single available?
False
True
D unit Does the D PPU have no gensets available? Virtual
none
False
True True
changing changing Is the logical value changing from F to T? Function
T to F F to T
False False
Reset timer Start 3 minute timer Start or reset a 3 minute timer. Function
True
timer Has the timer expired? Function
expired
False
Subtract C Gen. Subtract C Gen. Flag C PPU to shut off a genset, T or F. Virtual
=F =T
False
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I-49A I-49B
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True
A unit
sees B Does the A unit recognize the B unit? Virtual
False
True
B unit Does the B PPU have two gensets available? Virtual
dual on
False
True
C unit Does the C PPU have no gensets available? Virtual
none
False
D unit True Does the D PPU have exactly one genset Virtual
single available?
False
False
False
True
A unit Does the A PPU have no gensets available? Virtual
none
False
True
B unit Does the B PPU have exactly one genset Virtual
single available?
False
True
C unit Does the C PPU have no gensets available? Virtual
none
False
True
D unit Does the D PPU have no gensets available? Virtual
none
False
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I-50A I-50B
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This Power Unit Logic Flowchart is provided with Government Purpose License Rights
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True True
changing changing Is the logical value changing from F to T? Function
T to F F to T
False False
Reset timer Start 3 minute timer Start or reset a 3 minute timer. Function
True
timer Has the timer expired? Function
expired
False
Subtract B Gen. Subtract B Gen. Flag B PPU to shut off a genset, T or F. Virtual
=F =T
False True
A unit Does the A PPU have both gensets available? Virtual
dual
False
True
B unit Does the B PPU have exactly one genset Virtual
single available?
False
True
B unit Does the B PPU have no gensets available? Virtual
none
False
True
C unit Does the C PPU have exactly one genset Virtual
single available?
False
True
C unit Does the C PPU have no gensets available? Virtual
none
False
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I-51A I-51B
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D unit True Does the D PPU have exactly one genset Virtual
single available?
False
False
True True
changing changing Is the logical value changing from F to T? Function
T to F F to T
False False
Reset timer Start 3 minute timer Start or reset a 3 minute timer. Function
True
timer Has the timer expired? Function
expired
False
Subtract A Gen. Subtract A Gen. Flag A PPU to shut off a genset, T or F. Virtual
=F =T
True
Add-Gen Is flag set to turn on one genset? Virtual
False
True
A PPU Is the local PPU the A unit, and it is configured Virtual
local and online?
False
local unit True Does the local PPU have exactly one genset Virtual
single available?
False
local unit True Does the local PPU have no gensets available? Virtual
none
False
local unit True Does the local PPU not have both gensets Virtual
not dual online?
False
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I-51A I-51B I-51C
local unit True Does the local PPU not have either genset Virtual
not single online?
False
local unit True Does the local PPU have exactly one genset Virtual
single online?
False
B unit True Does the B PPU have exactly one genset Virtual
single available?
False
B unit True Does the B PPU have both gensets available? Virtual
dual
False
True
A unit not Does the A unit not recognize the B unit? Virtual
see B
False
C unit True Does the C PPU have exactly one genset Virtual
single available?
False
C unit True Does the C PPU have both gensets available? Virtual
dual
False
A unit not True Does the A unit not recognize the C unit? Virtual
see C
False
D unit True Does the D PPU have exactly one genset Virtual
single available?
False
D unit True Does the D PPU have both gensets available? Virtual
dual
False
True
A unit not Does the A unit not recognize the D unit? Virtual
see D
False
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I-53A I-53B
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This Power Unit Logic Flowchart is provided with Government Purpose License Rights
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I-52A I-52B
True True
changing changing Is the logical value changing from F to T? Function
T to F F to T
False False
Reset timer Start 1 minute timer Start or reset a 1 minute timer. Function
True
timer Has the timer expired? Function
expired
False
True
Add-Gen Is flag set to turn on one genset? Virtual
False
True
A unit Does the A unit recognize the B unit? Virtual
sees B
False
B unit True Does the B PPU have exactly one genset Virtual
single available?
False
B unit True Does the B PPU have both gensets available? Virtual
dual
False
B unit True Is the B PPU running neither genset? Virtual
none
False
local unit True Does the local PPU have exactly one genset Virtual
single available?
False
A unit True Does the A unit have neither genset online? Virtual
none
False
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I-53A I-53B I-53C I-53D
local unit True Does the local PPU not have both gensets Virtual
not dual available?
False
local unit True Does the local PPU not have exactly one genset Virtual
not single available?
False
local unit True Does the local PPU have both gensets Virtual
dual available?
False
local unit True Does the local PPU have exactly one genset Virtual
single available?
False
B unit True Does the B PPU have exactly one genset Virtual
single available?
False
False
C unit True Does the C PPU have exactly one genset Virtual
single available?
False
False
A unit not True Does the A unit not recognize the C unit? Virtual
see C
False
D unit True Does the C PPU have exactly one genset Virtual
single available?
False
False
A unit not True Does the A unit not recognize the C unit? Virtual
see D
False
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I-54A I-54B
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This Power Unit Logic Flowchart is provided with Government Purpose License Rights
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I-54A I-54B
True True
changing changing Is the logical value changing from F to T? Function
T to F F to T
False False
Reset timer Start 1 minute timer Start or reset a 1 minute timer. Function
True
timer Has the timer expired? Function
expired
False
True
Add-Gen Is flag set to turn on one genset? Virtual
False
True
A unit Does the A unit recognize the C unit? Virtual
sees C
False
C unit True Does the C PPU have exactly one genset Virtual
single available?
False
C unit True Does the C PPU have both gensets available? Virtual
dual
False
C unit True Is the C PPU running neither genset? Virtual
none
False
local unit True Does the local PPU have exactly one genset Virtual
single available?
False
local unit True Does the local PPU have both gensets Virtual
dual available?
False
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Page Page Page
I-55A I-55B I-55C
B unit True Does the B PPU have exactly one genset Virtual
single available?
False
False
local unit True Does the local PPU have exactly one genset Virtual
single available?
False
local unit True Does the local PPU have both gensets Virtual
dual available?
False
B unit True Does the B PPU have exactly one genset Virtual
single available?
False
False
C unit True Does the C PPU have exactly one genset Virtual
single available?
False
False
D unit True Does the D PPU have exactly one genset Virtual
single available?
False
False
A unit not True Does the A unit not recognize the D unit? Virtual
see D
False
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I-57A I-57B
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This Power Unit Logic Flowchart is provided with Government Purpose License Rights
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I-56A I-56B
True True
changing changing Is the logical value changing from F to T? Function
T to F F to T
False False
Reset timer Start 1 minute timer Start or reset a 1 minute timer. Function
True
timer Has the timer expired? Function
expired
False
True
Add-Gen Is flag set to turn on one genset? Virtual
False
True
A unit Does the A unit recognize the D unit? Virtual
sees D
False
D unit True Does the D PPU have exactly one genset Virtual
single available?
False
D unit True Does the D PPU have both gensets available? Virtual
dual
False
D unit True Is the D PPU running neither genset? Virtual
none
False
local unit True Does the local PPU have exactly one genset Virtual
single available?
False
local unit True Does the local PPU have both gensets Virtual
dual available?
False
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I-57A I-57B I-57C
B unit True Does the B PPU have exactly one genset Virtual
single available?
False
False
C unit True Does the C PPU have exactly one genset Virtual
single available?
False
False
local unit True Does the local PPU have exactly one genset Virtual
single available?
False
local unit True Does the local PPU have both gensets Virtual
dual available?
False
B unit True Does the B PPU have exactly one genset Virtual
single available?
False
False
C unit True Does the C PPU have exactly one genset Virtual
single available?
False
False
D unit True Does the D PPU have exactly one genset Virtual
single available?
False
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I-59A I-59B
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I-58A I-58B
True True
changing changing Is the logical value changing from F to T? Function
T to F F to T
False False
Reset timer Start 1 minute timer Start or reset a 1 minute timer. Function
True
timer Has the timer expired? Function
expired
False
local unit True Does the local PPU not have exactly one Virtual
not single genset available?
False
local unit True Does the local PPU not have both gensets Virtual
not dual available?
False
B unit True Does the B PPU not have exactly one genset Virtual
not single available?
False
B unit True Does the B PPU not have both gensets Virtual
not dual available?
False
A unit not True A unit True Does the A unit recognize the B unit? Virtual
see B sees B
False False
Page
I-58A
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I-58A
C unit True Does the C PPU not have exactly one genset Virtual
not single available?
False
C unit True Does the C PPU not have both gensets Virtual
not dual available?
False
A unit not True A unit True Does the A unit recognize the C unit? Virtual
see C sees C
False False
D unit True Does the D PPU not have exactly one genset Virtual
not single available?
False
D unit True Does the D PPU not have both gensets Virtual
not dual available?
False
A unit not True A unit True Does the A unit recognize the D unit? Virtual
see D sees D
False False
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This Power Unit Logic Flowchart is provided with Government Purpose License Rights
Start - Operate PPU A Start of subroutine of logic specific to PPU A.
Not True Is the Unit Select Switch not in the "A" DIM1-IN15
A PPU position?
False
Not True Is the PPU not configured as "A" for network? Virtual
A PPU
True
B PPU False Is the PPU configured as "B" for network? Virtual
False
True
C PPU Is the PPU configured as "C" for network? Virtual
False
True
D PPU Is the PPU configured as "D" for network? Virtual
False
local PPU True Is the local PPU configured and ready for Virtual
enabled operation?
False
station True Is the local PPU station ID set and ready for Virtual
ready operation?
False
B unit True Does the B PPU not have exactly one genset Virtual
not single online?
False
B unit True Does the B PPU not have both gensets online? Virtual
not dual
False
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I-62A I-62B
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B unit True Does the B PPU have exactly one genset Virtual
single online?
False
B unit True Does the B PPU have both genset online? Virtual
dual
False
C unit True Does the C PPU not have exactly one genset Virtual
not single online?
False
C unit True Does the C PPU not have both gensets online? Virtual
not dual
False
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I-63A I-63B
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I-62A I-62B
C unit True Does the C PPU have exactly one genset Virtual
single online?
False
C unit True Does the C PPU have both genset online? Virtual
dual
False
D unit True Does the D PPU not have exactly one genset Virtual
not single online?
False
D unit True Does the D PPU not have both gensets online? Virtual
not dual
False
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I-64A I-64B
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D unit True Does the D PPU have exactly one genset Virtual
single online?
False
D unit True Does the C PPU have both genset online? Virtual
dual
False
D_Qty_On Set D PPU generator quantity online to 2. Virtual
=2
Page
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I-64
I-65
This Power Unit Logic Flowchart is provided with Government Purpose License Rights
Start - Operate PPU Start of subroutine of logic to operate PPU B,
C, and D. This subroutine runs three times;
once for each.
USS True Is the Unit Select Switch not in the X position DIM1-IN16, o
not X (B, C or D, depending on iteration)? DIM2-IN15, o
DIM2-IN16
False
Unit True Is the PPU not configured as X? Virtual
not X
False
False
False
False
Return Exit subroutine.
Local PPU True Is the local PPU configured and ready for Virtual
ready operation?
False
PPU Set PPU variable to X (B if first iteration, C if Virtual
=X second, D if third).
False
Unit X True Is the network not telling PPU X that it has Virtual
DBC control of the dead bus permissive?
False
Gen. 1 True Is generator 1 dead bus close permissive set? Virtual
DBC
False
False
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I-66A I-66B
False Gen. 1 breaker Close generator 1's breaker for PPU X. Virtual
= close
False
False
False
SMS True Is the system mode switch in the AUTO RTU-IN1
AUTO position?
False
Gen. 1 B True Is generator 1's breaker for PPU X closed? Virtual
closed
False Gen. 1 breaker Open generator 1's breaker for PPU X. Virtual
= open
False
Unit X True Is the network not telling PPU X that it has Virtual
DBC control of the dead bus permissive?
False
Gen. 2 True Is generator 2 dead bus close permissive set? Virtual
DBC
False
False
Gen. 2 RB True Is generator 2 remote breaker open? Virtual
open
False Gen. 2 breaker Close generator 2's breaker for PPU X. Virtual
= close
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I-67
False
False
False
SMS True Is the system mode switch in the AUTO RTU-IN1
AUTO position?
False
Gen. 2 B True Is generator 2's breaker for PPU X closed? Virtual
closed
False Gen. 2 breaker Open generator 2's breaker for PPU X. Virtual
= open
Page
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I-68
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This Power Unit Logic Flowchart is provided with Government Purpose License Rights
Start - Status Start of subroutine to control status LEDs.
False
False
False
False
False
Amber SSL Amber SSL Amber SSL Turn the amber system status light on/off. DOM2-OUT14
= Off = On = On/Off
False
False
False
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False
Blink Blink output on/off, 1 second per state. Function
Red SSL Red SSL Red SSL Turn the red system status light on/off. DOM1-OUT14
= Off = On = On/Off
False
Gen. 1 Br. True Is the generator 1 breaker switch not in the Virtual
not PTL Pull-to-Lock position?
False
No eng. 1 True Is there no engine 1 alarm? Virtual
alarm
False
No gen. 1 True Is there no generator 1 alarm? Virtual
alarm
False
False
False
False
False
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I-72A I-72B I-72C
Gen. 1 SSL Gen. 1 SSL Gen. 1 SSL Turn the generator 1 status light on/off. DOM1-OUT13
= Off = On/Off = On
False
Gen. 2 Br. True Is the generator 2 breaker switch not in the
not PTL Pull-to-Lock position? Virtual
False
No eng. 2 True Is there no engine 2 alarm?
alarm Virtual
False
No gen. 2 True Is there no generator 2 alarm?
alarm Virtual
False
False
False
False
False
Blink Blink output on/off, 500 millisecond per state. Function
Gen. 1 SSL Gen. 1 SSL Gen. 1 SSL Turn the generator 2 status light on/off. DOM2-OUT13
= Off = On/Off = On
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Start - DBC Control Subroutine to control DBC.
Tie output True Is the tie output bus not energized? DIM2-IN11
not energ.
False
B bus True Is the B PPU system bus not energized? Virtual
not energ.
False
C bus True Is the C PPU system bus not energized? Virtual
not energ.
False
D bus True Is the D PPU system bus not energized? Virtual
not energ.
False
DBP pulse True Is the dead bus close permissive transfer pulse Virtual
Off to On changing from Off to On?
False
False
Reset counter Reset the counter to 0. Function
DBC current Set dbc current value variable to the counter. Virtual
value = counter
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I-73
False
B bus True Is the B PPU system bus energized? Virtual
energ.
False
C bus True Is the C PPU system bus energized? Virtual
energ.
False
D bus True Is the D PPU system bus energized? Virtual
energ.
False
False
False
False
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I-74
False
I-75
This Power Unit Logic Flowchart is provided with Government Purpose License Rights
Start - Engine Control Subroutine to control engines. This subroutine
runs twice, once for each engine (X = 1, 2).
False
Gen. X True Is generator X not available for auto operation? Virtual
not ready
False
SMS True Is the system mode switch not in the AUTO RTU-IN1
not AUTO position?
False
False
Eng. X block Block engine X from starting on initial power Virtual
from start = T plant startup.
False
Eng. X block True Is engine X blocked from starting on initial Virtual
not start power plant startup?
False
X= True Does X = 1 (first iteration of this program)?
genset 1
False
Eng. 1 True Is engine 1 running? Virtual
running
False
False
False
Gen. X start Gen. X start Flag generator X to start on initial power plant Virtual
=F =T startup, T or F.
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I-76
Eng. X ECS True Is the engine control switch for engine X in the Virtual
AUTO AUTO position?
False
SMS True Is the system mode switch in the AUTO RTU-IN1
AUTO position?
False
No gen. X True Is there not a summary failuer on generator X? Virtual
sum. fail.
False
No gen. X True Is there not an overcurrent alarm on generator Virtual
overcurrent X?
False
False
Gen. X True Does the generator X breaker have the red DIM1-IN1 or
breaker red target visible (not green)? DIM2-IN1
False
Genset True Is the summary genset lockout set to F? Virtual
lockout = F
False
Gen. X ready Gen. X ready Generator X is available for auto operation, Virtual
=F =T T or F.
SMS True Is the system mode switch in the MAN position? RTU-IN2
MAN
False
Eng. X True Is the engine control switch for engine X in the Virtual
MAN manual position?
False
Eng. X True Is engine X running? Virtual
running
False
Changing True Is the output changing from F to T?
F to T
False
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I-77A I-77B I-77C
False
Reset Reset the timer.
Timer
False
Gen. X SMS Gen. X SMS System mode switch transfer between MAN and Virtual
transfer = F transfer = T AUTO on generator X without affecting
operation, T or F.
Eng. X True Is the engine control switch for engine X in the Virtual
ECS auto auto position?
False
Gen. X True Is the breaker closed on generator X (on = DIM1-IN3 or
breaker cl. closed)? DIM2-IN3
False
USS True Is the unit select switch in the A position? RTU-OUT1
A
False
A sub. gen. True Is the A PPU flag to shut down one genset Virtual
F to T changing from F to T?
False
False
B sub. gen. True Is the B PPU flag to shut down one genset Virtual
F to T changing from F to T?
False
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I-78A I-78B I-78C
False
C sub. gen. True Is the C PPU flag to shut down one genset Virtual
F to T changing from F to T?
False
False
D sub. gen. True Is the D PPU flag to shut down one genset Virtual
F to T changing from F to T?
False
False
X=1 True Is this the first iteration (run for genset 1)?
False
En. 1 hm True Is the hourmeter for engine 1 > hourmeter for Virtual
> eng. 2 hm engine 2?
False
En. 2 hm True Is the hourmeter for engine 2 > hourmeter for Virtual
> eng. 1 hm engine 1?
False
Eng. X ECS True Is the engine control switch for engine X in the Virtual
OFF OFF / RESET position?
False
PDC True Is the system mode switch in the OFF position Virtual
OFF and parameters have cleared?
False
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I-79A I-79B
False
Gen. X True Does the generator X breaker not have the red DIM1-IN1 or
breaker grn. target visible (is green)? DIM2-IN1
False
False
Gen. X Aux. Gen. X Aux. Set auxillary stop relay #2 for generator X to Virtual
Stop 2 = F Stop 2 = T T or F.
False
Gen. X True Is auxillary stop relay #1 for generator X Virtual
aux. stop 1 from F to T?
False
False
Eng. X ECS True Is the engine control switch for engine X in the Virtual
AUTO AUTO position?
False
Gen. X True Is the remote start/stop for generator X Virtual
RSS changing from T to F?
False
Gen. X SS Set start/stop permissive for generator X to T. Virtual
Permissive = T
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I-80
Eng. X ECS True Is the engine control switch for engine X in the Virtual
AUTO AUTO position?
False
MSPB_TOG True Is the master system enable toggle = T? Virtual
=T
False
Eng. X True Is engine X not running? Virtual
not running
False
False
Gen. X True Is the summary failure set to F for generator X? Virtual
no failure
False
False
MSES True Is the master start eneable switch is changing RTU-IN3
F to T to either of the two enable positions?
False
False
SMS trans. True Is the system mode switch transfering between Virtual
=T AUTO and MAN?
False
False
Gen. X Aux. Gen. X Aux. Set auxillary stop relay #2 for generator X to Virtual
Start 2 = F Start 2 = T T or F.
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I-81
Eng. X ECS True Is the engine control switch for engine X in the Virtual
AUTO AUTO position?
False
Gen. X brk. True Is the breaker not closed for generator X? DIM1-IN3 or
not closed DIM2-IN3
False
Gen. Y brk. True Is the breaker not closed for generator Y (the DIM2-IN3 or
not closed generator this iteration is not run for)? DIM1-IN3
False
X=1 True Is this the first iteration (run for genset 1)?
False
En. 1 hm True Is the hourmeter for engine 1 >= hourmeter for Virtual
< eng. 2 hm engine 2?
False
En. 2 hm True Is the hourmeter for engine 2 < hourmeter for Virtual
< eng. 1 hm engine 1?
False
False
Gen. X True Is generator X available for auto operation? Virtual
ready
False
False
False
A add gen. True Is the flag for the A PPU to add a genset Virtual
F to T changing from F to T?
False
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I-82A I-82B I-82C
False
B add gen. True Is the flag for the B PPU to add a genset Virtual
F to T changing from F to T?
False
False
C add gen. True Is the flag for the C PPU to add a genset Virtual
F to T changing from F to T?
False
False
D add gen. True Is the flag for the D PPU to add a genset Virtual
F to T changing from F to T?
False
Gen. X Aux. Gen. X Aux. Set auxillary stop relay #1 for generator X to Virtual
Start 1 = F Start 1 = T T or F.
False
Gen. X aux. True Is the auxillary stop relay #1 for generator X Virtual
start 1 = T = T?
False
Gen. X aux. True Is the auxillary stop relay #2 for generator X Virtual
start 2 F/T changing from F to T?
False
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I-83A I-83B I-83C
Eng. X ECS True Is the engine control switch for engine X in the Virtual
AUTO AUTO position?
False
Gen. X RSS True Is the remote start/stop flag for generator X Virtual
F to T changing from F to T?
False
Gen. X Set start/stop permissive for generator X to F. Virtual
start/stop = F
False
Gen. X True Is generator X available for auto operation? Virtual
ready =T
False
Gen. X SS True Is the start/stop permissive for generator X =F? Virtual
=F
False
SMS trans. True Is the system mode switch transfering between Virtual
=T AUTO and MAN?
False
PDC not True Is the system mode switch not in the OFF Virtual
OFF position and parameters cleared?
False
Changing True Is the input changing from F to T?
F to T
False
Start 250ms Start a 250 ms timer. Function
timer
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I-84A I-84B
False
Reset timer Reset the timer. Function
False
False
Eng. X ECS True Is the engine control switch for engine X in the Virtual
MAN MAN position?
False
Eng. X True Is engine X running? Virtual
running
False
50 Hz True Is the PPU set for 50 Hz? Virtual
mode
False
VRMS avg. True Is the average VRMS for generator X greater Virtual
> 3610 than 3610?
False
VRMS avg. True Is the average VRMS for generator X less Virtual
< 3990 than 3990?
False
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I-85A I-85B I-85C
False
VRMS avg. True Is the average VRMS for generator X greater Virtual
> 3952 than 3952?
False
VRMS avg. True Is the average VRMS for generator X less Virtual
< 4368 than 4368?
False
False
Start 3 second Start a 3 second timer. Function
timer
False
Reset timer Reset the timer. Function
False
Gen. X ready for Gen. X ready for Generator X is running and ready for load, T or Virtual
load = F load = T F.
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I-86
False
SMS True Is the system mode switch in the AUTO RTU-IN1
AUTO position?
False
Gen. X br. True Is the breaker switch for generator X not in the DIM3-IN1 or
not PTL Pull-To-Lock position? DIM3-IN2
False
Tie output True Is the tie output bus not energized? DIM2-IN11
not energ.
False
False
Gen. 1 True Is the dead bus close permissive relay for Virtual
no DBC generator 1 set to F?
False
Blink at Function
2.5 second cycle
False
PPU True Is the PPU configured as "A"? RTU-OUT1
A
False
A DBC True Is the A PPU dead bus permissive close relay Virtual
=T set to T?
False
False
B DBC True Is the B PPU dead bus permissive close relay Virtual
=T set to T?
False
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I-87A I-87B I-87C
False
C DBC True Is the C PPU dead bus permissive close relay Virtual
=T set to T?
False
False
D DBC True Is the D PPU dead bus permissive close relay Virtual
=T set to T?
False
Gen. X DBC Gen. X DBC Generator X dead bus close permissive = T or Virtual
=F =T F.
False
Eng. Y no True Is the PLC output to autostart genset Y set to DOM1-OUT2 or
autostart F? DOM1-OUT2 or
False
False
False
False
Eng. X not True Is engine X not running? Virtual
running
False
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I-88A I-88B
False
SMS True Is the system mode switch in the AUTO RTU-IN1
AUTO position?
False
Gen. X br. True Is the breaker switch for generator X not in the DIM3-IN1 or
not PTL Pull-To-Lock position? DIM3-IN2
False
Tie output True Is the tie output bus energized? DIM2-IN11
energized
False
Gen. X br. True Is the breaker for generator X not closed? DIM1-IN3 or
not closed DIM2-IN3
False
False
Gen. X rem. True Is the rempte breaker control for generator X Virtual
br. open open?
False
Gen. X True Is generator X available for auto operation? Virtual
ready
False
Gen. X autosync Gen. X autosync PLC output to enable autosync for generator X DOM1-OUT3 or
output = F output = T is T or F. DOM2-OUT3
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I-89
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I-89
Gen. X rem. True Is the rempte breaker control for generator X Virtual
br. open open?
False
Gen. X no True Is generator X not set to autstart? DOM1-OUT2 or
autostart DOM2-OUT2
False
Gen. X True Is the breaker open for generator X? DIM1-IN3 or
br. open DIM2-IN3
False Reset gen. X Reset the generator X remote breaker control Virtual
remote br. to F to F (breaker open).
Gen. X rem. True Is the rempte breaker control for generator X Virtual
br. open open?
False
Local PPU True Is the local PPU configured and ready for Virtual
ready operation?
False
False
SMS True Is the system mode switch in the AUTO RTU-IN1
AUTO position?
False
False
False
False
False
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I-90A I-90B I-90C
False
Enable gen. X br. Enable gen. X br. Enable generator X's breaker to open, T or F. DOM1-OUT6 or
to open = F to open = T DOM2-OUT6
Gen. X rem. True Is the rempte breaker control for generator X Virtual
br. closed closed?
False
Gen. X True Is the PLC output to enable autosync for DOM1-OUT3 or
autosync generator X turned on? DOM2-OUT3
False
False
Gen. X br. True Is the PLC output to enable generator X's DOM1-OUT6 or
open = F breaker to open set to F? DOM2-OUT6
False
Gen. X True Does the generator X breaker have the red DIM1-IN1 or
breaker red target visible (not green)? DIM2-IN1
False
False
Enable gen. X br. Enable gen. X br. Enable generator X's breaker to close, T or F. DOM1-OUT5 or
to close = F to close = T DOM2-OUT5
False
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I-91A I-91B
False
Eng. X True Is engine X running? Virtual
running
False
Eng. X True Is the engine control switch for engine X in the Virtual
ECS STOP STOP position?
False
False
Gen. X True Is generator X's breaker closed? DIM1-IN3
br. closed DIM2-IN3
False
False
Eng. X rpm True Is engine X's rpm >= 800? Virtual
>=800
False
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False
Eng. X not True Is engine X not running? Virtual
running
False
Changing True Is the input changing from F to T?
F to T
False
Start 2 minute Start a 2 minute timer.
timer
Changing True
T to F
False
Stop and reset Stop and reset the 2 minute timer.
timer
False
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I-94C
False
False
Gen. X br. True Is the breaker for generator X not closed? DIM1-IN3 or
not closed DIM2-IN3
False
Changing True
F to T
False
Start 1 minute Start a 2 minute timer.
timer
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I-93A I-93B I-93C
Changing True
T to F
False
Stop and reset Stop and reset the 1 minute timer.
timer
False
False
False
MSES True Is the master start enable switch in either RTU-IN3
ENABLE enable position?
False
Gen. X summary Gen. X summary Set the summary failure flag for generator X, Virtual
failure = F failure = T T or F.
I-94
This Power Unit Logic Flowchart is provided with Government Purpose License Rights
Start - Tie / Feeder Control Controls tie & feeder breakers.
False
Not last True Is the LS-NET casble plugged into the "B" RTU-IN8
PPU connector?
False
Remote tie True Is the remote tie open/close toggle set for Virtual
open open?
False
False
Main bus True Is the main system bus not energized? DIM2-IN12
not ener.
False
Tie bus True Is the tie output bus not energized? DIM2-IN11
not ener.
False
Main bus True Is the main system bus energized? DIM2-IN12
energized
False
False
False
Enable tie close Enable tie close Enable tie breaker to close, T or F. Virtual
=F =T
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False
Tie not True Is the tie breaker not closed? DIM1-IN12
closed
False
No tie True Is the PLC output to enable the tie breaker to DOM2-OUT11
open en. open set to F?
False
Tie not True Is the tie breaker switch not in the Pull-To-Lock DIM3-IN3
PTL position?
False
False
Enable tie close Enable tie close Enable tie breaker to close, T or F. DOM2-OUT10
=F =T
Last True Is the LS-NET cable not plugged into the "B" RTU-IN8
PPU connector?
False
GMS True Is the generator mode switch not in the utility RTU-IN5
prime pow. parallel position (is in the prime power position)?
False
Tie remote True Is the tie breaker remote open/close toggle set Virtual
closed to close?
False
SMS True Is the system mode switch in the AUTO RTU-IN1
AUTO position?
False
False
Battleshort True Is the battleshort switch in the NORMAL RTU-IN4
NORMAL position?
False
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I-96A I-96B
False
False
Enable tie open Enable tie open Enable tie breaker to open, T or F. DOM2-OUT11
=F =T
Tie remote True Is the tie breaker remote open/close toggle set Virtual
closed to close?
False
SMS AUTO True Is the system mode switch changing from the RTU-IN1
T to F AUTO position to a different position?
False Tie remote close Reset tie breaker remote open/close to F Virtual
=F (open).
False
Tie bus True Is the tie output bus energized? DIM2-IN11
energized
False
Feeder 1 True Is the feeder 1 breaker remote open/close Virtual
rem. close toggle set to T (closed)?
False
PPU True Is the local PPU configured and ready for Vitual
ready operation?
False
False
No feeder 1 True Is there no overcurrent trip on feeder 1? DIM1-IN9
OC trip
False
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I-97A I-97B I-97C
False
Tie bus True Is the tie output bus not energized? DIM2-IN11
not energ.
False
False
False
Feeder 1 True Is feeder 1 not closed (open)? DIM1-IN8
open
False
Changing True Is the input changing from F to T?
F to T
False
Start 1 second Start a 1 second timer.
timer
Changing True
T to F
False
Stop and reset Stop and reset the 1 second timer.
timer
False
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I-99A I-99B
I-98
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I-98A I-98B
Feeder 1 True Is the remote open/close toggle for feeder 1 set Virtual
rem. close to close?
False
Feeder 1 remote Set feeder 1 remote open/close toggle to F Virtual
open/close = F (open).
False
Feeder 1 True Does the feeder 1 breaker switch have the red DIM3-IN6
br. red target visible?
False
Feeder 1 True Is feeder 1 not closed? DIM1-IN8
not closed
False
Feeder 1 not True Is the PLC output to enable feeder 1 breaker DOM1-OUT8
open en. to open set to F?
False
Feeder 1 close Feeder 1 close PLC output to enable feeder 1 to close = T or F. DOM1-OUT7
enable = F enable = T
False
Battleshort True Is the battleshort switch in the NORMAL RTU-IN4
NORMAL position?
False
False
Feeder 1 True Is the breaker switch for feeder 1 in the Pull-To- DIM3-IN4
PTL Lock position?
False
Feeder 1 open Feeder 1 open PLC output to enable feeder 1 to open = T or F. DOM1-OUT8
enable = F enable = T
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I-99
False
Tie bus True Is the tie output bus energized? DIM2-IN11
energized
False
Feeder 2 True Is the feeder 2 breaker remote open/close Virtual
rem. close toggle set to T (closed)?
False
PPU True Is the local PPU configured and ready for Vitual
ready operation?
False
False
No feeder 2 True Is there no overcurrent trip on feeder 2? DIM2-IN9
OC trip
False
False
Tie bus True Is the tie output bus not energized? DIM2-IN11
not energ.
False
False
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I-99A I-99B
False
Feeder 2 True Is feeder 2 not closed (open)? DIM2-IN8
open
False
Changing True Is the input changing from F to T?
F to T
False
Start 1 second Start a 1 second timer.
timer
Changing True
T to F
False
Stop and reset Stop and reset the 1 second timer.
timer
False
Feeder 2 True Is the remote open/close toggle for feeder 2 set Virtual
rem. close to close?
False
Feeder 2 remote Set feeder 2 remote open/close toggle to F Virtual
open/close = F (open).
False
Feeder 2 True Does the feeder 2 breaker switch have the red DIM3-IN7
br. red target visible?
False
Feeder 2 True Is feeder 2 not closed? DIM2-IN8
not closed
False
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I-100A I-100B
Feeder 2 not True Is the PLC output to enable feeder 2 breaker DOM2-OUT8
open en. to open set to F?
False
Feeder 2 close Feeder 2 close PLC output to enable feeder 2 to close = T or F. DOM2-OUT7
enable = F enable = T
False
Battleshort True Is the battleshort switch in the NORMAL RTU-IN4
NORMAL position?
False
False
Feeder 2 True Is the breaker switch for feeder 2 in the Pull-To- DIM3-IN5
PTL Lock position?
False
Feeder 2 open Feeder 2 open PLC output to enable feeder 1 to open = T or F. DOM2-OUT8
enable = F enable = T
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Start - Announce Controls the PPU buzzer.
False
Eng. 1 HCT True Is the high coolant temperature alarm for engine GSC
F to T 1 changing from F to T?
False
Eng. 1 LCT True Is the low coolant temperature alarm for engine GSC
F to T 1 changing from F to T?
False
Eng. 1 LOP True Is the low oil pressure alarm for engine 1 GSC
F to T changing from F to T?
False
Eng. 1 HOT True Is the high oil temperature alarm for engine 1 GSC
F to T changing from F to T?
False
Eng. 1 ADEM True Is the ADEM unit alarm for engine 1 changing GSC
F to T from F to T?
False
False
False
Gen. 1 OF True Is the generator 1 overfrequency alarm GSC
F to T changing from F to T?
False
False
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False
False
False
Eng. 1 ECS True Is the engine control switch for engine 1 not in Virtual
not OFF the OFF position?
False
Eng. 1 BL True Is the engine 1 battery low (<21 VDC) changing Virtual
F to T from F to T?
False
Add 1 to Add 1 to the Alarm_Count variable. Virtual
Alarm_Count
False
False
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I-103
False
Eng. 2 HCT True Is the high coolant temperature alarm for engine GSC
F to T 2 changing from F to T?
False
Eng. 2 LCT True Is the low coolant temperature alarm for engine GSC
F to T 2 changing from F to T?
False
Eng. 2 LOP True Is the low oil pressure alarm for engine 2 GSC
F to T changing from F to T?
False
Eng. 2 HOT True Is the high oil temperature alarm for engine 2 GSC
F to T changing from F to T?
False
Eng. 2 ADEM True Is the ADEM unit alarm for engine 2 changing GSC
F to T from F to T?
False
False
False
Gen. 2 OF True Is the generator 2 overfrequency alarm GSC
F to T changing from F to T?
False
False
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I-104A I-104B I-104C
False
False
False
Eng. 2 ECS True Is the engine control switch for engine 2 not in Virtual
not OFF the OFF position?
False
Eng. 2 BL True Is the engine 2 battery low (<21 VDC) changing Virtual
F to T from F to T?
False
Add 1 to Add 1 to the Alarm_Count variable. Virtual
Alarm_Count
False
False
LFL True Is the low fuel level in the PPU daytank DIM2-IN13
F to T changing from F to T?
False
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I-106
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Page Page
I-105A I-105B
Tie OC trip True Is the overcurrent trip signal for the tie contactor DIM1-IN13
F to T changing from F to T?
False
LSE alm. True Is the load sharing error alarm changing from Virtual
F to T F to T?
False
Add 1 to Add 1 to the Alarm_Count variable. Virtual
Alarm_Count
Gen. 1 estop True Is the emergency stop shutdown flag for GSC
F to T generator 1 changing from F to T?
False
False
Gen. 1 HCT True Is the generator 1 shutdown for high coolant GSC
F to T temperature changing from F to T?
False
Gen. 1 LOP True Is the generator 1 shutdown for low oil pressure GSC
F to T changing from F to T?
False
False
False
False
Page Page
I-107A I-107B
I-107
This Power Unit Logic Flowchart is provided with Government Purpose License Rights
Page Page
I-106A I-106B
False
Add 1 to Add 1 to the Alarm_Count variable. Virtual
Alarm_Count
False
False
False
False
Gen. 1 NGR True Is the generator 1 neutral ground resistor fault DIM1-IN7
F to T changing from F to T?
False
False
False
Eng. 1 estop True Is the engine 1 emergency stop flag changing Virtual
F to T from F to T?
False
Page Page
I-108A I-108B
I-108
This Power Unit Logic Flowchart is provided with Government Purpose License Rights
Page Page
I-107A I-107B
False
False
Gen. 2 estop True Is the emergency stop shutdown flag for GSC
F to T generator 2 changing from F to T?
False
False
Gen. 2 HCT True Is the generator 2 shutdown for high coolant GSC
F to T temperature changing from F to T?
False
Gen. 2 LOP True Is the generator 2 shutdown for low oil pressure GSC
F to T changing from F to T?
False
False
False
Page Page
I-109A I-109B
I-109
This Power Unit Logic Flowchart is provided with Government Purpose License Rights
Page Page
I-108A I-108B
False
False
Add 1 to Add 1 to the Alarm_Count variable. Virtual
Alarm_Count
False
False
False
False
Gen. 2 NGR True Is the generator 2 neutral ground resistor fault DIM1-IN7
F to T changing from F to T?
False
False
False
Page Page
I-110A I-110B
I-110
This Power Unit Logic Flowchart is provided with Government Purpose License Rights
Page Page
I-109A I-109B
Eng. 2 estop True Is the engine 2 emergency stop flag changing Virtual
F to T from F to T?
False
Add 1 to Add 1 to the Alarm_Count variable. Virtual
Alarm_Count
False
False
LF ORT True Is the PPU daytank low fuel fault for ORT Virtual
F to T changing from F to T?
False
Tie OC trip True Is the tie overcurrent trip signal changing from DIM1-IN13
F to T F to T?
False
False
Page
I-111
I-111
This Power Unit Logic Flowchart is provided with Government Purpose License Rights
Page
I-110
False
False
False
False
False
False
False
Subtract 1 from Subtract 1 from the Alarm_Count variable. Virtual
Alarm_Count
Aux. Silence Aux. Silence Set the auxillary buzzer silence relay to T or F. Virtual
=F =T
ORT silence True Is the remote buzzer silence command from Virtual
F to T ORT changing from F to T?
False
Page Page
I-112A I-112B
I-112
This Power Unit Logic Flowchart is provided with Government Purpose License Rights
Page Page
I-111A I-111B
False
Alarm count True Is the current alarm count <= 0? Virtual
<= 0
False
Alarm_Count Set the alarm_count variable to 0. Virtual
=0
False
ORT silence True Is the remote buzzer silence command from Virtual
=T ORT set to T?
False ORT silence Reset the remote buzzer silence command from Virtual
=F ORT to F.
Page Page
I-113A I-113B
I-113
This Power Unit Logic Flowchart is provided with Government Purpose License Rights
Page Page
I-112A I-112B
I-114
This Power Unit Logic Flowchart is provided with Government Purpose License Rights
USAF TO 35C2-3-518-1
USA TM 9-6115-484-14&P
DRS RADIAN CTM: 01646.1R0253/1R0254
ANNEX J
FOLDOUTS
TABLE OF CONTENTS
TITLE PAGE
DPGDS ABBREVIATIONS FOLDOUT 1
DPGDS ABBREVIATIONS, DEVICES AND NOTES FOLDOUT 2
PU - ONE-LINE ELECTRICAL DIAGRAM, (WITH PROTECTIVE DEVICES) FOLDOUT 3
DPGDS AC SCHEMATIC, SHEET 1 OF 4 FOLDOUT 4A
DPGDS AC SCHEMATIC, SHEET 2 OF 4 FOLDOUT 4B
DPGDS AC SCHEMATIC, SHEET 3 OF 4 FOLDOUT 5
DPGDS AC SCHEMATIC, SHEET 4 OF 4 FOLDOUT 6
DPGDS DC SCHEMATIC, PDC DC CONTROL SCHEMATIC, SHEET 1 OF 7 FOLDOUT 7
DPGDS DC SCHEMATIC, PDC DC RTU AND I/O SCHEMATIC, SHEET 2 OF 7 FOLDOUT 8
DPGDS DC SCHEMATIC, PDC DC DISCRETE INPUT SCHEMATIC, SHEET 3 OF 7 FOLDOUT 9
DPGDS DC SCHEMATIC, PDC DC DISCRETE INPUT SCHEMATIC, SHEET 4 OF 7 FOLDOUT 10
DPGDS DC SCHEMATIC, PDC DC DISCRETE OUTPUT SCHEMATIC, SHEET 5 OF 7 FOLDOUT 11
DPGDS DC SCHEMATIC, PDC DC PANEL SCHEMATIC, SHEET 6 OF 7 FOLDOUT 12A
DPGDS DC SCHEMATIC, PDC DC PANEL SCHEMATIC, SHEET 7 OF 7 FOLDOUT 12B
WIRING DIAGRAMS POWER SUPPLIES FOR PCM AND HUB, SHEET 1 OF 30 FOLDOUT 13
WIRING DIAGRAMS GENERATOR 1/FEEDER 1 DOOR SUBPAN, SHEET 2 OF 30 FOLDOUT 14
WIRING DIAGRAMS GENERATOR 1/FEEDER 1 DOOR, SHEET 3 OF 30 FOLDOUT 15
WIRING DIAGRAMS GENERATOR 1/FEEDER 1 DOOR, SHEET 4 OF 30 FOLDOUT 16
WIRING DIAGRAMS GENERATOR 1/CONTACTOR & POTENTIAL TRANSFORMER,
SHEET 5 OF 30 FOLDOUT 17
WIRING DIAGRAMS GENERATOR 1 TERMINAL BOARD, SHEET 6 OF 30 FOLDOUT 18
WIRING DIAGRAMS LOAD TIE DOOR, SHEET 7 OF 30 FOLDOUT 19
WIRING DIAGRAM MASTER CONTROL PANEL DOOR, CONTACTOR AND POTENTIAL
TRANSFORMER, SHEET 8 OF 30 FOLDOUT 20
WIRING DIAGRAM MASTER CONTROL PANEL “SWING DOOR”, SHEET 9 OF 30 FOLDOUT 21
WIRING DIAGRAM MASTER CONTROL PANEL “SWING DOOR”, SHEET 10 OF 30 FOLDOUT 22
WIRING DIAGRAM MASTER CONTROL PANEL “SWING DOOR”, SHEET 11 OF 30 FOLDOUT 23
WIRING DIAGRAM MASTER CONTROL PANEL TERMINAL BOARD, SHEET 12 OF 30 FOLDOUT 24
WIRING DIAGRAM MASTER CONTROL PANEL TERMINAL BOARD, SHEET 13 OF 30 FOLDOUT 25
WIRING DIAGRAM GENERATOR 2/FEEDER 2 DOOR, SHEET 14 OF 30 FOLDOUT 26
J-1
USAF TO 35C2-3-518-1
USA TM 9-6115-484-14&P
DRS RADIAN CTM: 01646.1R0253/1R0254
TABLE OF CONTENTS
TITLE PAGE
WIRING DIAGRAM GENERATOR 2/FEEDER 2 DOOR, SHEET 15 OF 30 FOLDOUT 27
WIRING DIAGRAM GENERATOR 2/FEEDER 2 DOOR, SHEET 16 OF 30 FOLDOUT 28
WIRING DIAGRAM GENERATOR 2/FEEDER 2 CONTACTOR - POTENTIAL
TRANSFORMERS, SHEET 17 OF 30 FOLDOUT 29
WIRING DIAGRAM GENERATOR 2 TERMINAL BOARD, SHEET 18 OF 30 FOLDOUT 30
WIRING DIAGRAM PDC ENGINE/GENERATOR CONTROL PLUGS, SHEET 19 OF 30 FOLDOUT 31
WIRING DIAGRAM A-B COMMUNICATION CABLE, SHEET 20 OF 30 FOLDOUT 32
WIRING DIAGRAM ENGINE FLUID LEVEL SWITCHES, SHEET 21 OF 30 FOLDOUT 33
WIRING DIAGRAM POWER UNIT HARNESS, SHEET 22 OF 30 FOLDOUT 34
WIRING DIAGRAM POWER UNIT HARNESS - GENERATOR TO BUS, SHEET 23 OF 30 FOLDOUT 35A
WIRING DIAGRAM POWER UNIT HARNESS - GENERATOR TO BUS, SHEET 24 OF 30 FOLDOUT 35B
WIRING DIAGRAM SYSTEM POWER DISTRIBUTION TO LOAD BREAK ELBOWS,
SHEET 25 OF 30 FOLDOUT 35C
SCHEMATIC DIAGRAM POWER DISTRIBUTION 4160/2400 VAC 3 TO 208/120 VAC 3
PHASE, SHEET 26 OF 30 FOLDOUT 36A
WIRING DIAGRAM POWER DISTRIBUTION 4160/2400 VAC 3 TO 208/120 VAC 3
PHASE, SHEET 27 OF 30 FOLDOUT 36B
WIRING DIAGRAM POWER DISTRIBUTION 4160/2400 VAC 3 TO 208/120 VAC 3
PHASE, SHEET 28 OF 30 FOLDOUT 36C
WIRING DIAGRAM, POWER DISTRIBUTION DEVICES, SHEET 29 OF 30 FOLDOUT 36D
WIRING DIAGRAM BATTERY LEAD INSTALLATION AND INTERCONNECT,
SHEET 30 OF 30 FOLDOUT 37
ENGINE WIRING DIAGRAM, SHEET 1 OF 5 FOLDOUT 38
ENGINE WIRING DIAGRAM, SHEET 2 OF 5 FOLDOUT 39
ENGINE WIRING DIAGRAM, SHEET 3 OF 5 FOLDOUT 40
ENGINE WIRING DIAGRAM, SHEET 4 OF 5 FOLDOUT 41
ENGINE WIRING DIAGRAM, SHEET 5 OF 5 FOLDOUT 42
SCHEMATIC, FUEL TRANSFER CONTROL BOX ASSEMBLY, SHEET 1 OF 5 FOLDOUT 43A
WIRING DIAGRAM, FUEL TRANSFER CONTROL BOX ASSEMBLY, SHEET 2 OF 5 FOLDOUT 43B
WIRING DIAGRAM, FUEL TRANSFER CONTROL BOX ASSEMBLY, SHEET 3 OF 5 FOLDOUT 44A
WIRING DIAGRAM, FUEL TRANSFER CONTROL BOX ASSEMBLY, SHEET 4 OF 5 FOLDOUT 44B
WIRING DIAGRAM, FUEL TRANSFER CONTROL BOX ASSEMBLY, SHEET 5 OF 5 FOLDOUT 44C
COMPONENTS/FLUID FLOW HYDRAULIC SYSTEM, SHEET 1 OF 3 FOLDOUT 45
COMPONENTS/FLUID FLOW HYDRAULIC SYSTEM, SHEET 2 OF 3 FOLDOUT 46
COMPONENTS/FLUID FLOW HYDRAULIC SYSTEM, SHEET 3 OF 3 FOLDOUT 47
J-2
USAF TO 35C2-3-518-1
USA TM 9-6115-484-14&P
DRS RADIAN CTM: 01646.1R0253/1R0254
TABLE OF CONTENTS
TITLE PAGE
SCHEMATIC DIAGRAM INTERNAL FUEL SYSTEM, SHEET 1 OF 2 FOLDOUT 48
SCHEMATIC DIAGRAM EXTERNAL FUEL SYSTEM, SHEET 2 OF 2 FOLDOUT 49
SCHEMATIC DIAGRAM MEP-PU-810B, 12VDC, 7 PIN CONNECTOR, SHEET 1 OF 4 FOLDOUT 50
ABS SYSTEM SCHEMATIC DIAGRAM, SCHEMATIC DIAGRAM MEP-PU-810B,
12VDC, 7 PIN CONNECTOR, SHEET 2 OF 4 FOLDOUT 51
SCHEMATIC DIAGRAM MEP-PU-810B, 12VDC, 7 PIN CONNECTOR, SHEET 3 OF 4 FOLDOUT 52A
WIRING DIAGRAM MEP-PU-810B, 12VDC, 7 PIN CONNECTOR, SHEET 4 OF 4 FOLDOUT 52B
SCHEMATIC DIAGRAM MEP-PU-810B, 24VDC, 12 PIN CONNECTOR, SHEET 1 OF 2 FOLDOUT 53
SCHEMATIC DIAGRAM MEP-PU-810B, 24VDC, 12 PIN CONNECTOR, SHEET 2 OF 2 FOLDOUT 54
SCHEMATIC DIAGRAM MEP-PU-810B, ABS BRAKE SYSTEM FOLDOUT 55
J-3
USAF TO 35C2-3-518-1
USA TM 9-6115-484-14&P
DRS RADIAN CTM: 01646.1R0253/1R0254
J-4
By Order of the Secretary of the Army:
PETER J. SCHOOMAKER
General, United States Army
Official: Chief of Staff
JOYCE E. MORROW
Administrative Assistant to the
Secretary of the Army
0828808