TM 9-6115-484-14 Mep-Pu-810a/b Part 6

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USA TM 9-6115-484-14
DRS RADIAN CTM 01646.1R0253/1R0254
FIGURE 18.3.2.6.1-2 SUPPORT AND SPIDER BUSHING LUBRICATION POINTS
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
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18.3.2.6.2 HUB LUBRICATION
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.
b. Recommended Lubrication: See Annex G for Specifications.
18.3.2.6.3 SERVICE BEARINGS
WARNING
DO NOT MIX LITHIUM, CALCIUM, SODIUM OR BARIUM COMPLEX GREASES DUE

TO POSSIBLE COMPATIBILITY PROBLEMS. WHEN CHANGING FROM ONE TYPE
OF GREASE TO ANOTHER, IT IS NECESSARY TO ENSURE ALL THE OLD GREASE
HAS BEEN REMOVED.
The following schedule is appropriate:
a. Replace grease annually.
b. Prior to repacking bearings, all old grease should be removed from the wheel hub cavity and
bearings.
c. Bearings should be packed by machine if possible.
d. If a machine is unavailable, packing by hand method is acceptable, using the following method:
(1) Place a quantity of grease onto the palm of your hand.
(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.
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18.3.2.6.4 LANDING GEAR ASSEMBLY LUBRICATION
FIGURE 18.3.2.6.4-1 ZERK FITTINGS (GREASE POINTS)
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.
c. Recommended Grease: See Appendix G for Specifications.
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CHAPTER 19
HYDRAULIC SYSTEM REPAIR
TABLE OF CONTENTS
SECTION TITLE PAGE

19.0 HYDRAULIC SYSTEM REPAIR 6
19.1 SAFETY INSTRUCTIONS 6
19.2 HYDRAULIC SYSTEM DESCRIPTION 9
19.2.1 HYDRAULIC FLUID RESERVOIR 9
19.2.2 HYDRAULIC SYSTEM PUMP 13
19.2.3 PRESSURE RELIEF/CONTROL BLOCK AND PRESSURE GAUGES 14
19.2.4 HYDRAULIC SYSTEM FAN MOTORS 16
19.2.5 HYDRAULIC SYSTEM COOLER 17
19.3 SERVICE REQUIREMENTS FOR HYDRAULIC SYSTEM 18
19.3.1 SERVICE THE RETURN-LINE FILTER, STRAINER, AND HYDRAULIC FLUID 18
19.3.1.1 REPLACING THE FILTER ELEMENT 20
19.3.1.2 CHANGING HYDRAULIC FLUID, VENT CAP, CLEANING THE STRAINERS 23
19.4 COMPONENT REPAIR PROCEDURES 26
19.4.1 PRESSURE RELIEF/CONTROL BLOCK 26
19.4.1.1 INSPECTING PRESSURE RELIEF/CONTROL BLOCK 27
19.4.1.2 REMOVE PRESSURE RELIEF/CONTROL BLOCK 28
19.4.1.3 INSTALL PRESSURE RELIEF/CONTROL BLOCK 29
19.4.2 HYDRAULIC PUMP 30
19.4.2.1 INSPECT HYDRAULIC PUMP 30
19.4.2.2 REMOVE HYDRAULIC PUMP 31
19.4.2.3 INSTALL HYDRAULIC PUMP 32
19.4.3 RADIATOR HYDRAULIC MOTOR 34
19.4.3.1 INSPECT RADIATOR HYDRAULIC MOTOR 34
19.4.3.2 REMOVE RADIATOR HYDRAULIC MOTOR 35
19.4.3.3 INSTALL RADIATOR-HYDRAULIC MOTOR 36
19.4.4 AIR TO AIR AFTER COOLER (ATAAC) HYDRAULIC MOTOR 38
19.4.4.1 INSPECT AIR TO AIR AFTER COOLER (ATAAC) MOTOR 38
19.4.4.2 REMOVE AIR TO AIR AFTER COOLER (ATAAC) HYDRAULIC MOTOR 39
19.4.4.3 INSTALL AIR TO AIR AFTER COOLER (ATAAC) MOTOR 40
19.4.5 ENGINE COMPARTMENT VENT-HYDRAULIC MOTOR 41
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19.4.5.1 INSPECT ENGINE COMPARTMENT VENT-HYDRAULIC MOTOR 41

19.4.5.2 REMOVE ENGINE COMPARTMENT VENT-HYDRAULIC MOTOR 42
19.4.5.3 INSTALL ENGINE COMPARTMENT VENT-HYDRAULIC MOTOR 43
19.4.6 RADIATOR-MOTOR FAN ASSEMBLY 44
19.4.6.1 INSPECT RADIATOR-MOTOR FAN ASSEMBLY 45
19.4.6.2 REMOVE RADIATOR-MOTOR FAN ASSEMBLY 45
19.4.6.3 INSTALL RADIATOR-MOTOR FAN ASSEMBLY 46
19.4.7 AFTER COOLER-MOTOR FAN ASSEMBLY 47
19.4.7.1 INSPECT AFTER COOLER-MOTOR FAN ASSEMBLY 47
19.4.7.2 REMOVE AFTER COOLER-MOTOR FAN ASSEMBLY 48
19.4.7.3 INSTALL AFTER COOLER-MOTOR FAN ASSEMBLY 49
19.4.8 ENGINE COMPARTMENT VENT-MOTOR FAN ASSEMBLY 50
19.4.8.1 INSPECT ENGINE COMPARTMENT VENT-MOTOR FAN ASSEMBLY 51
19.4.8.2 REMOVE ENGINE COMPARTMENT VENT-MOTOR FAN ASSEMBLY 51
19.4.8.3 INSTALL ENGINE COMPARTMENT VENT-MOTOR FAN ASSEMBLY 52
19.4.9 RADIATOR-MOTOR FAN BLADES 53
19.4.9.1 REMOVE RADIATOR-MOTOR FAN BLADES 54
19.4.9.2 INSTALL RADIATOR-MOTOR FAN BLADES 56
19.4.10 AFTER COOLER-MOTOR FAN BLADES 58
19.4.10.1 REMOVE AND INSTALL AFTER COOLER-MOTOR FAN BLADES 59
19.4.11 ENGINE COMPARTMENT VENT-MOTOR FAN BLADES 60
19.4.11.1 REMOVE AND INSTALL ENGINE COMPARTMENT VENT-MOTOR FAN BLADES 60
19.4.12 HYDRAULIC TANK LOW LEVEL SHUTDOWN SWITCH (HTLL) 61
19.4.12.1 TEST HYDRAULIC TANK LOW LEVEL SHUTDOWN SWITCH (HTLL) 61
19.4.12.2 REMOVE HYDRAULIC TANK LOW LEVEL SHUTDOWN SWITCH (HTLL) 63
19.4.12.3 INSTALL HYDRAULIC TANK LOW LEVEL SHUTDOWN SWITCH (HTLL) 66
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LIST OF FIGURES
FIGURE TITLE PAGE

FIGURE 19.2-1 HYDRAULIC SYSTEM SCHEMATIC 9
FIGURE 19.2.1-1 HYDRAULIC FLUID RESERVOIR 10
FIGURE 19.2.1-2 HYDRAULIC TANK 11
FIGURE 19.2.1-3 FLUID LEVEL/TEMPERATURE SIGHT GAUGE 11
FIGURE 19.2.1-4 HYDRAULIC TANK SHUTOFF VALVE 12
FIGURE 19.2.2-1 HYDRAULIC SYSTEM PUMP 13
FIGURE 19.2.3-1 PRESSURE RELIEF/CONTROL BLOCK DIAGRAM 14
FIGURE 19.2.3-2 PRESSURE RELIEF/CONTROL BLOCK 15
FIGURE 19.2.3-3 HYDRAULIC SYSTEM PRESSURE GAUGES 15
FIGURE 19.2.4-1 HYDRAULIC SYSTEM FAN MOTORS 16
FIGURE 19.2.5-1 HYDRAULIC SYSTEM COOLER 17
FIGURE 19.3.1.1-1 FILTER CAP, FILL HOLE, AND JIC FILL PORT 20
FIGURE 19.3.1.1-2 FILTER CAP AND BYPASS ASSEMBLY 21
FIGURE 19.3.1.1-3 FILTER CAP ASSEMBLY WITH O-RING AND BYPASS 21
FIGURE 19.3.1.1-4 3-MICRON ABSOLUTE HYDRAULIC FILTER 22
FIGURE 19.3.1.1-5 HYDRAULIC FILTER GASKET 22
FIGURE 19.3.1.2-1 TANK ACCESS COVER AND VENT CAP 24
FIGURE 19.3.1.2-2 TANK ACCESS COVER O-RING 24
FIGURE 19.3.1.2-3 100-MESH STRAINER (141 MICRON) 25
FIGURE 19.3.1.2-4 JIC FILL PORT 25
FIGURE 19.4.1-1 PRESSURE RELIEF/CONTROL BLOCK 26
FIGURE 19.4.2-1 HYDRAULIC PUMP 30
FIGURE 19.4.2-2 HYDRAULIC PUMP, O-RING, FLANGE, AND GASKET 32
FIGURE 19.4.3-1 RADIATOR HYDRAULIC MOTOR 34
FIGURE 19.4.3.2-1 RADIATOR / AIR TO AIR AFTER COOLER (ATAAC) COMPARTMENT 36
FIGURE 19.4.4-1 AFTER COOLER HYDRAULIC MOTOR 38
FIGURE 19.4.5-1 ENGINE COMPARTMENT VENT-HYDRAULIC MOTOR 41
FIGURE 19.4.6-1 MOUNTING AND UN-MOUNTING HOLES 44
FIGURE 19.4.6-2 SHAFT MOUNTING HUB 44
FIGURE 19.4.8-2 SHAFT MOUNTING HUB 50
FIGURE 19.4.9-1 RADIATOR FAN HUB DISASSEMBLY 53
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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
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LIST OF TABLES
TABLE TITLE PAGE

TABLE 19.4.12.1-1 HTLL SWITCH CONTACT POSITIONS 62
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19.0 HYDRAULIC SYSTEM REPAIR
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)
19.1 SAFETY INSTRUCTIONS
a. Safety precautions must be observed while any maintenance is being performed. Safety
precautions must be observed to ensure that the operator/technician cannot have contact with the
following:
• Hot engine parts

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

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

(b) Push to OPEN the Emergency Stop Switch.
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(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:
(1) Shutdown the PU in accordance with Section 5.1.6.1 Shutdown Generators.

(2) Isolate the PU from any power plant or utility connection in accordance with Section
5.9.6.15, Unit Isolation Procedure with PSC. See Note 1 and 2.
(3) Isolate the PU from any power plant control system in accordance with Note 3.
(4) Pull to open the PU DC Power Control Breaker.
(5) Push to OPEN both Emergency Stop Switches.
(6) Place both Engine Control Switches (ECS) in the OFF position.
(7) Place a DO NOT OPERATE tag on both generator control panels.
(8) Turn the Battery Bank Parallel Switch to the OFF position.
(9) De-energize both Battery Chargers.
(10) Disconnect the negative and positive cables from both Battery Banks.
(11) Place a DO NOT OPERATE tag on both Battery Banks.
(12) Place all Circuit Breakers in the LOCK OUT position.
(13) Disconnect both 7P1 and 7P2 Connectors located on the inside panel of the PDC.
(14) Close and Lock both generator set control panels.
NOTE 1: Also the PU must be completely electrically isolated from the power distribution bus and
any other electrical source that can back feed into the PU. All medium voltage cables need to
be placed on the standoff insulators by use of hot sticks and other safety gear.
NOTE 2: Ensure cables are not energized by opening the circuit breaker of the Primary Switching
Center (PSC), then disconnect Load Cables (Using the proper safety gear) on the PU and
place them on the Parking Stands.
NOTE 3: When the DC Control Power Circuit Breaker is in the (OFF) position (Pulled – Out), all control
power is turned off to the PU. This will cause the HUB to stop functioning. This causes the
network to not see the equipment shutdown and all PU’s after it. When pulling major
maintenance the (A) (B) Communication Cable must be routed to the next PU in order to
reestablish the communication network.
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.
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e. Material safety information:
Composition and Information on Ingredients: This information is not formulated to contain

ingredients, which have exposure limits established by U.S. agencies. It is not hazardous to health
as defined by the European Union Dangerous Substance/Preparation Directives.
Hazards Identification:
(1) US OSHA HAZARDS COMMUNICATION STANDARDS: Product assessed in accordance

with OSHA 29 CFR 1910.1200 and determined not to be hazardous.
(2) EFFECT OF OVEREXPOSURE: No significant effect expected.
(3) EMERGENCY RESPONSE DATA: Amber liquid. DOT REG No.-NA.
f. First aid measures:
(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.
g. Fire fighting measures:
(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.
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19.2 HYDRAULIC SYSTEM DESCRIPTION
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.
FIGURE 19.2-1 HYDRAULIC SYSTEM SCHEMATIC
19.2.1 HYDRAULIC FLUID RESERVOIR
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.
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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.
FIGURE 19.2.1-1 HYDRAULIC FLUID RESERVOIR
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FILTER FILL PORT
JIC FILL PORT
DIFFERENTIAL GAUGE
TANK BREATHER SIGHT GLASS
FIGURE 19.2.1-2 HYDRAULIC TANK
FULL LEVEL
FIGURE 19.2.1-3 FLUID LEVEL/TEMPERATURE SIGHT GAUGE
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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.
FIGURE 19.2.1-4 HYDRAULIC TANK SHUTOFF VALVE
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19.2.2 HYDRAULIC SYSTEM PUMP
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
FIGURE 19.2.2-1 HYDRAULIC SYSTEM PUMP
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19.2.3 PRESSURE RELIEF/CONTROL BLOCK AND PRESSURE GAUGES
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.
FIGURE 19.2.3-1 PRESSURE RELIEF/CONTROL BLOCK DIAGRAM
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A2
A1
G2
UV
RV
P1
G1
FIGURE 19.2.3-2 PRESSURE RELIEF/CONTROL BLOCK
FIGURE 19.2.3-3 HYDRAULIC SYSTEM PRESSURE GAUGES
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19.2.4 HYDRAULIC SYSTEM FAN MOTORS
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.
ENGINE COMPARTMENT VENT MOTOR
RADIATOR HYDRAULIC MOTOR
ATAAC HYDRAULIC MOTOR
FIGURE 19.2.4-1 HYDRAULIC SYSTEM FAN MOTORS
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19.2.5 HYDRAULIC SYSTEM COOLER
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.
HYDRAULIC SYSTEM COOLER
FIGURE 19.2.5-1 HYDRAULIC SYSTEM COOLER
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19.3 SERVICE REQUIREMENTS FOR HYDRAULIC SYSTEM
19.3.1 SERVICE THE RETURN-LINE FILTER, STRAINER, AND HYDRAULIC FLUID
WARNING
REMOVE ALL RINGS, NECKLACES, JEWELERY AND LOOSE CLOTHING.

FAILURE TO DO SO COULD CAUSE SEVERE INJURY OR DEATH.
WARNING
HYDRAULIC FLUID PRESSURES CAN REACH 3,000 PSI WHILE THE PU IS

OPERATING. DO NOT TOUCH ANY SUSPECTED LEAKS OF THE HYDRAULIC
SYSTEM. SERIOUS INJURIES COULD OCCUR TO UNPROTECTED SKIN OR EYES.
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
CARE MUST BE TAKEN TO ENSURE THAT FLUIDS ARE CONTAINED DURING

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

(5) Push to open both Emergency Stop Switches.
19-18
USAF TO 35C2-3-518-1
USA TM 9-6115-484-14
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
19.3.1.1 REPLACING THE FILTER ELEMENT
Replace Filter every 8,000 hours of use or annually.
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).
d. Discard the old O-ring and replace with new
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
FIGURE 19.3.1.1-2 FILTER CAP AND BYPASS ASSEMBLY
O-RING
BYPASS
FIGURE 19.3.1.1-3 FILTER CAP ASSEMBLY WITH O-RING AND BYPASS
19-21
USAF TO 35C2-3-518-1
USA TM 9-6115-484-14
FIGURE 19.3.1.1-4 3-MICRON ABSOLUTE HYDRAULIC FILTER
FIGURE 19.3.1.1-5 HYDRAULIC FILTER GASKET
19-22
USAF TO 35C2-3-518-1
USA TM 9-6115-484-14
19.3.1.2 CHANGING HYDRAULIC FLUID, VENT CAP, CLEANING THE STRAINERS
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.
c. Drain fluid into an appropriate container (20 gal).
d. Clean and reinstall the Hydraulic Reservoir Drain Plug.
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
FIGURE 19.3.1.2-1 TANK ACCESS COVER AND VENT CAP
FIGURE 19.3.1.2-2 TANK ACCESS COVER O-RING
19-24
USAF TO 35C2-3-518-1
USA TM 9-6115-484-14
100-MESH STRAINER
FIGURE 19.3.1.2-3 100-MESH STRAINER (141 MICRON)
JIC FILL PORT
FIGURE 19.3.1.2-4 JIC FILL PORT
19-25
USAF TO 35C2-3-518-1
USA TM 9-6115-484-14
19.4 COMPONENT REPAIR PROCEDURES
19.4.1 PRESSURE RELIEF/CONTROL BLOCK
The following maintenance procedures are provided for the Pressure Relief/Control Block:
Inspect
Remove
Install
FIGURE 19.4.1-1 PRESSURE RELIEF/CONTROL BLOCK
19-26
USAF TO 35C2-3-518-1
USA TM 9-6115-484-14
19.4.1.1 INSPECTING PRESSURE RELIEF/CONTROL BLOCK
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.
(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
c. Prior to starting the Power Unit, inspect the engine compartment for any hydraulic fluid leaks.
Correct any leaks as necessary.
d. Check the Hydraulic Fluid level and add fluid 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
19.4.1.2 REMOVE PRESSURE RELIEF/CONTROL BLOCK
To remove the Pressure Relief/Control Block using Figure 19.4.1-1, proceed as follows:

b. Close the Hydraulic Fluid Shutoff Valve. See Figure 19.2.1-4 for reference.
c. Tag the 6 input and output hoses for proper reinstallation.
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
19.4.1.3 INSTALL PRESSURE RELIEF/CONTROL BLOCK
To install the Pressure Relief/Control Block perform the following:
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.
d. Remove hydraulic hose tags.
e. Refill the hydraulic system according to procedures found in Section 19.3.1.2.
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.
i. Start the Power Unit and allow it to reach operating temperature.
j. Shut-down the Power Unit and inspect the hydraulic system starting at Section 19.4.1 and
ending at Section 19.4.12.
k. The unit is now ready to operate.
19-29
USAF TO 35C2-3-518-1
USA TM 9-6115-484-14
19.4.2 HYDRAULIC PUMP
The following maintenance procedures are provided for the Hydraulic Pump:
Inspect
Remove
Install
HYDRAULIC
PUMP
FIGURE 19.4.2-1 HYDRAULIC PUMP
19.4.2.1 INSPECT 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.
19-30
USAF TO 35C2-3-518-1
USA TM 9-6115-484-14
b. Check the hydraulic fluid level and add fluid as necessary.
c. Start the Power Unit according to Chapter 5. Allow the Power Unit to reach operating
d. Check under the PU for any hydraulic fluid leaks. Correct any leaks as necessary.
e. Check the Hydraulic Pump for leaks, missing or loose hardware.
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.
19.4.2.2 REMOVE HYDRAULIC PUMP
To remove the Hydraulic Pumps, perform the following:

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
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.
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.
GASKET FLANGE O-RING
HYDRAULIC
ENGINE PUMP
HOUSING
FIGURE 19.4.2-2 HYDRAULIC PUMP, O-RING, FLANGE, AND GASKET
19.4.2.3 INSTALL HYDRAULIC PUMP
To install the Hydraulic Pump perform the following:
b. Install a new gasket for the pump.
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
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.
f. Tighten the spring clamps to 16 ± 2 in. lbs
g. Remove the hose tags.
h. Refill the hydraulic system according to procedures found in Section 19.3.1.2.
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.
l. Start the Power Unit and allow it to reach operating temperature.
m. Shut-down the Power Unit and inspect the hydraulic system starting at Section 19.4.1 and
n. The unit is now ready to operate.
19-33
USAF TO 35C2-3-518-1
USA TM 9-6115-484-14
19.4.3 RADIATOR HYDRAULIC MOTOR
The following maintenance procedures are provided for the Radiator Hydraulic Motor:
Inspect
Remove
Install
FIGURE 19.4.3-1 RADIATOR HYDRAULIC MOTOR
19.4.3.1 INSPECT RADIATOR HYDRAULIC MOTOR
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.
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
19.4.3.2 REMOVE RADIATOR HYDRAULIC MOTOR
To remove the Radiator-Hydraulic Motor, perform the following:

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
FIGURE 19.4.3.2-1 RADIATOR / AIR TO AIR AFTER COOLER (ATAAC) COMPARTMENT
c. Remove the Radiator Fan Motor Access panel.
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.
e. Disconnect the input and output hoses.
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.
19.4.3.3 INSTALL RADIATOR-HYDRAULIC MOTOR
To install the Radiator-Hydraulic Motor, perform the following:
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
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.
g. Refill the Hydraulic System. See Section 19.3.1.2 for procedures.
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.
k. Start the Power Unit and allow it to reach operating temperature.
l. Shut-down the Power Unit and inspect the hydraulic system starting at Section 19.4.1 and
m. The unit is now ready to operate.
19-37
USAF TO 35C2-3-518-1
USA TM 9-6115-484-14
19.4.4 AIR TO AIR AFTER COOLER (ATAAC) HYDRAULIC MOTOR
The following maintenance procedures are provided for the ATAAC Hydraulic Motor:
Inspect
Remove
Install
FIGURE 19.4.4-1 AFTER COOLER HYDRAULIC MOTOR
19.4.4.1 INSPECT AIR TO AIR AFTER COOLER (ATAAC) MOTOR
To inspect the Air to Air After Cooler-Hydraulic Motor, proceed as follows:
a. Prior to starting the PU, check the engine compartment for any hydraulic fluid leaks.
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
19.4.4.2 REMOVE AIR TO AIR AFTER COOLER (ATAAC) HYDRAULIC MOTOR
To remove the Air to Air After Cooler-Hydraulic Motor, perform the following:

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
THE HYDRAULIC MOTORS FOR G1 AND G2 ATAAC ARE INSTALLED DIFFERENTLY TO

ENSURE THAT THE FAN ROTATES IN THE CORRECT DIRECTION. NOTE WHICH WAY
THE RELIEF PORT ON TOP OF THE MOTOR IS FACING, (FRONT OR REAR OF MOTOR AS
INSTALLED). ENSURE THE NEW HYDRAULIC MOTOR IS INSTALLED IN THE SAME
DIRECTION AS REMOVED. FAILURE TO OBSERVE THIS CAUTION MAY CAUSE THE FAN
TO ROTATE IN THE WRONG DIRECTION.
19-39
USAF TO 35C2-3-518-1
USA TM 9-6115-484-14
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.
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.
19.4.4.3 INSTALL AIR TO AIR AFTER COOLER (ATAAC) MOTOR
To install the Air to Air After Cooler-Hydraulic Motor, perform the following:
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”
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.
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.
j. Start the Power Unit and allow it to reach operating temperature.
k. Ensure the fan blades are rotating correctly (
19-40
USAF TO 35C2-3-518-1
USA TM 9-6115-484-14
19.4.5 ENGINE COMPARTMENT VENT-HYDRAULIC MOTOR
The following maintenance procedures are provided for the Engine Compartment Vent-Hydraulic Motor:
Inspect
Remove
Install
FIGURE 19.4.5-1 ENGINE COMPARTMENT VENT-HYDRAULIC MOTOR
19.4.5.1 INSPECT ENGINE COMPARTMENT VENT-HYDRAULIC MOTOR
To inspect the Engine Compartment Vent-Hydraulic Motor, proceed as follows:
a. Prior to starting the Power Unit, check the engine compartment for any hydraulic fluid leaks.
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
19.4.5.2 REMOVE ENGINE COMPARTMENT VENT-HYDRAULIC MOTOR
To remove the Engine Compartment Vent-Hydraulic Motor, proceed as follows:

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 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.
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
19.4.5.3 INSTALL ENGINE COMPARTMENT VENT-HYDRAULIC MOTOR
To install the Engine Compartment Vent-Hydraulic Motor, proceed as follows:
b. Reinstall the motor back on the mounting bracket and reinstall mounting bolts. Torque the 3/8”
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.
g. Open the hydraulic fluid shut off valves. Secure the valve handles in the open position.
h. Reinstall the PU Top Plenum Screen.
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.
k. Start the Power Unit and allow it to reach operating temperature.
19-43
USAF TO 35C2-3-518-1
USA TM 9-6115-484-14
19.4.6 RADIATOR-MOTOR FAN ASSEMBLY
The following maintenance procedures are provided for the Radiator-Motor Fan Assembly:
Inspect
Remove
Install
FIGURE 19.4.6-1 MOUNTING AND UN-MOUNTING HOLES
FIGURE 19.4.6-2 SHAFT MOUNTING HUB
19-44
USAF TO 35C2-3-518-1
USA TM 9-6115-484-14
19.4.6.1 INSPECT RADIATOR-MOTOR FAN ASSEMBLY
To inspect the Radiator-Motor Fan Assembly, proceed as follows:
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.
19.4.6.2 REMOVE RADIATOR-MOTOR FAN ASSEMBLY
To remove the Radiator-Motor Fan Assembly, proceed as follows:

5.9.6.15, Unit Isolation Procedure with PSC.
19-45
USAF TO 35C2-3-518-1
USA TM 9-6115-484-14
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. 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.
19.4.6.3 INSTALL RADIATOR-MOTOR FAN ASSEMBLY
To install the Radiator-Motor Fan Assembly, proceed as follows:
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.
d. Reinstall the Bottom Plenum Screen.
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.
g. Start the Power Unit and allow it to reach operating temperature.
h. Shut-down the Power Unit and inspect the hydraulic system starting at Section 19.4.1 and
i. The unit is now ready to operate.
19-46
USAF TO 35C2-3-518-1
USA TM 9-6115-484-14
19.4.7 AFTER COOLER-MOTOR FAN ASSEMBLY
The following maintenance procedures are provided for the After Cooler Fan Assembly:
Inspect
Remove
Install
19.4.7.1 INSPECT AFTER COOLER-MOTOR FAN ASSEMBLY
To inspect the After Cooler-Motor Fan Assembly, proceed as follows:
a. Prior to starting the Power Unit, inspect the engine compartment 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.
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19.4.7.2 REMOVE AFTER COOLER-MOTOR FAN ASSEMBLY
To remove the After Cooler-Motor Fan Assembly, proceed as follows:

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. Remove the PU Top Plenum Screen.
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.
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19.4.7.3 INSTALL AFTER COOLER-MOTOR FAN ASSEMBLY
To install the After Cooler-Motor Fan Assembly, proceed as follows:
b. Reinstall the fan assembly onto the shaft-mounting hub with the flat side of the fan blade
assembly facing down.
d. Reinstall the Bottom Plenum Screen.
e. Open the hydraulic fluid shut-off valves and Secure handles.
f. Reinstall the PU Top Plenum Screen.
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.
i. Start the Power Unit and allow it to reach operating temperature.
j. Shut-down the Power Unit and inspect the hydraulic system starting at Section 19.4.1 and
k. The unit is now ready to operate.
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19.4.8 ENGINE COMPARTMENT VENT-MOTOR FAN ASSEMBLY
The following maintenance procedures are provided for the Engine Compartment Vent-Motor Fan
Assembly:
Inspect
Remove
Install
MOUNTING UNTHREADED HOLE
UN-MOUNTING THREADED HOLE
FIGURE 19.4.8-2 SHAFT MOUNTING HUB
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19.4.8.1 INSPECT ENGINE COMPARTMENT VENT-MOTOR FAN ASSEMBLY
To inspect the Engine Compartment Vent-Motor Fan Assembly, proceed as follows:
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.
19.4.8.2 REMOVE ENGINE COMPARTMENT VENT-MOTOR FAN ASSEMBLY
To remove the Engine Compartment Vent-Motor Fan Assembly, proceed as follows:

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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
c. Remove the Air Deflector Assembly.
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.
19.4.8.3 INSTALL ENGINE COMPARTMENT VENT-MOTOR FAN ASSEMBLY
To install the Engine Compartment Vent-Motor Fan Assembly, proceed as follows:
b. Reinstall the fan assembly onto the shaft-mounting hub with the flat side of the fan assembly
facing the Radiator Assembly.
d. Reinstall the Air Deflector Assembly.
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.
g. Start the Power Unit and allow it to reach operating temperature.
h. Shut-down the Power Unit and inspect the hydraulic system starting at Section 19.4.1 and
i. The unit is now ready to operate.
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19.4.9 RADIATOR-MOTOR FAN BLADES
The following maintenance procedures are provided for the Radiator-Motor Fan Blades:
Remove
Install
FIGURE 19.4.9-1 RADIATOR FAN HUB DISASSEMBLY
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19.4.9.1 REMOVE RADIATOR-MOTOR FAN BLADES
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 19.4.9.1-1 RADIATOR FAN ASSEMBLY (TOP HALF REMOVED)
PLASTIC KEEPER
FIGURE 19.4.9.1-2 RADIATOR FAN ASSEMBLY (BOTTOM HALF WITH KEEPER INSTALLED)
To remove the Radiator-Motor Fan Blades, proceed as follows:
b. Remove the Radiator-Motor Fan Assembly. See Section 19.4.6.2 for reference.
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c. Place the fan hub assembly on a flat surface.
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.
f. Remove the broken or damaged fan blade.
g. Ensure plastic keeper is still in place. See Figure 19.4.9.1-2 for reference.
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19.4.9.2 INSTALL RADIATOR-MOTOR FAN BLADES
FIGURE 19.4.9.2-1 FAN BLADE WITH FAN PITCH
FIGURE 19.4.9.2-2 RADIATOR FAN ASSEMBLY (TOP HALF MATED WITH BOTTOM HALF)
To install the Radiator-Motor Fan Blades, proceed as follows:
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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19.4.10 AFTER COOLER-MOTOR FAN BLADES
The following maintenance procedures are provided for the After Cooler-Motor Fan Blades:
Remove
Install
FIGURE 19.4.10-1 AFTERCOOLER FAN HUB DISASSEMBLY
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19.4.10.1 REMOVE AND INSTALL AFTER COOLER-MOTOR FAN BLADES
FIGURE 19.4.10.1-1 AFTERCOOLER FAN ASSEMBLY (TOP HALF REMOVED)
PLASTIC KEEPER
FIGURE 19.4.10.1-2 AFTERCOOLER FAN ASSEMBLY (BOTTOM HALF W/ KEEPER INSTALLED)
To remove the Aftercooler-Motor Fan Blades, proceed as follows:
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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.
19.4.11 ENGINE COMPARTMENT VENT-MOTOR FAN BLADES
The following maintenance procedures are provided for the Engine Compartment Vent Motor Fan Blades:
Remove
Install
FIGURE 19.4.11-1 VENT FAN HUB DISASSEMBLY
19.4.11.1 REMOVE AND INSTALL ENGINE COMPARTMENT VENT-MOTOR FAN BLADES
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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FIGURE 19.4.11.1-2 FAN BLADE WITH FAN PITCH
To remove the Engine Compartment Vent-Motor Fan Blades, proceed as follows:
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
19.4.12 HYDRAULIC TANK LOW LEVEL SHUTDOWN SWITCH (HTLL)
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.
19.4.12.1 TEST HYDRAULIC TANK LOW LEVEL SHUTDOWN SWITCH (HTLL)
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.
c. Replace the switch if it fails any of the above requirements.
TABLE 19.4.12.1-1 HTLL SWITCH CONTACT POSITIONS

HYDRAULIC TANK LOW LEVEL SHUTDOWN SWITCH (HTLL) SWITCH
SWITCH POSITION SWITCH CONTACTS
HYDRAULIC TANK FULL Infinite OHMS

HYDRAULIC TANK BELOW 33% Ø OHMS
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19.4.12.2 REMOVE HYDRAULIC TANK LOW LEVEL SHUTDOWN SWITCH (HTLL)
FIGURE 19.4.12.2-1 TANK ACCESS COVER
FIGURE 19.4.12.2-2 TANK ACCESS COVER O-RING
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HTLL DEUTSCH
CONNECTION
FIGURE 19.4.12.2-3 HTLL SWITCH DEUTSCH CONNECTOR
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To remove the Hydraulic Tank Low Level Shutdown Switch (HTLL) Switch, proceed as follows

5.9.6.15, Unit Isolation Procedure with PSC.
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.
19.4.12.3 INSTALL HYDRAULIC TANK LOW LEVEL SHUTDOWN SWITCH (HTLL)
To install the Hydraulic Tank Low Level Shutdown Switch (HTLL) Switch, proceed as follows
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.
c. Connect the switch to the Power Unit wiring harness.
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.
e. Open the hydraulic fluid shutoff valve.
f. Fill the hydraulic tank with the appropriate fluid as listed in Annex G.
g. Check for leaks.
h. Reinstall the Top Plenum Screen Assembly and 9 mounting bolts.
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
l. Place the DC Control Power Circuit Breaker (CBCP) to ON.
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CHAPTER 20
PU STORAGE PROCEDURES
TABLE OF CONTENTS
SECTION TITLE PAGE

20.0 PU STORAGE PROCEDURES 3
20.1 SAFETY PROCEDURES 3
20.2 PRESERVATION/STORAGE PROCEDURES FOR THE PU 5
20.2.1 PU AND TRAILER ASSEMBLY 6
20.2.2 GENERAL REQUIREMENTS: 3456 EPG ENGINE 6
20.2.2.1 COOLING SYSTEMS 6
20.2.2.1.1 CATERPILLAR COOLANT AND ANTIFREEZE 7
20.2.2.1.2 SUPPLEMENTAL COOLANT ADDITIVE 7
20.2.2.1.3 COOLING SYSTEM CLEANER 7
20.2.2.2 NECESSARY EQUIPMENT AND CONSUMABLES 7
20.3 LONG TERM STORAGE 10
20.3.1 ENGINE STORAGE - UP TO ONE YEAR 10
20.3.2 ALTERNATOR STORAGE - UP TO ONE YEAR 12
20.3.2.1 REMOVAL FROM STORAGE 12
20.3.2.2 INSULATION RESISTANCE CHECKS: (MEGGER) 12
20.3.2.3 INITIAL OPERATION AFTER STORAGE 12
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LIST OF TABLES
TABLE TITLE PAGE

TABLE 20.2-1 STORAGE PROCEDURES FOR 3456 ENGINE AND SR-4B
GENERATORS 5
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20.0 PU STORAGE PROCEDURES
20.1 SAFETY PROCEDURES
a. Safety precautions must be observed while any maintenance is being performed. Safety
precautions must be observed to ensure that the operator/technician cannot have contact with the
following:
• Hot engine parts

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

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

(b) Push to OPEN the Emergency Stop Switch.
(c) Place the Engine Control Switch (ECS) in the OFF position.
(d) Place a DO NOT OPERATE tag on the generator control panel.
(e) Turn the Battery Bank Parallel Switch to the OFF position.
(f) De-energize the Battery Charger.
(g) Disconnect the negative and positive cables from the Battery Bank for the engine
due maintenance.
(h) Place a DO NOT OPERATE tag on the Battery Bank.
(i) Place the generator Circuit Breaker in the LOCK OUT position.
(j) Disconnect the 7P1 and 7P2 Connectors located on the inside panel of the PDC.
(k) Close and Lock the generator set control panel.
NOTE: The fuel transfer pump electrical power is normally fed directly from the G1 generator set
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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:

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20.2 PRESERVATION/STORAGE PROCEDURES FOR THE PU
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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20.2.1 PU AND TRAILER ASSEMBLY
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.
c. Cover all exterior vents and screens with tarps or plastic.
d. Disconnect and remove the batteries from the PU if, the PU will be stored for longer than three
months.
20.2.2 GENERAL REQUIREMENTS: 3456 EPG ENGINE
(See Caterpillar Manual SEHS9031-03, Storage Procedures For Caterpillar Products, Dated 4/97 or
later).
WARNING
TO AVOID PERSONAL INJURY, READ AND UNDERSTAND ALL DIRECTIONS AND

HAZARDS DESCRIBED ON THE LABELS OF ANY PRODUCT USED TO PRESERVE
YOUR EQUIPMENT.
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.
20.2.2.1 COOLING SYSTEMS
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.
20.2.2.1.1 CATERPILLAR COOLANT AND ANTIFREEZE
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.
20.2.2.1.2 SUPPLEMENTAL COOLANT ADDITIVE
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).
20.2.2.1.3 COOLING SYSTEM CLEANER
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)
20.2.2.2 NECESSARY EQUIPMENT AND CONSUMABLES
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.
NOTE: Refer to Annex G for quantities available.
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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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20.3 LONG TERM STORAGE
20.3.1 ENGINE STORAGE - UP TO ONE YEAR
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:
“ENGINE PRESERVED. DO NOT CRANK UNTIL ISSUED TO USER”.
NOTE: Affix a red warning tag stating:
“DEPROCESS THIS ENGINE IN ACCORDANCE WITH INSTRUCTIONS CONTAINED ON DA FORM

2258 OR AFTO FORM 20 (ATTACHED TO THIS EQUIPMENT). IN ADDITION, AIR CLEANERS, FILL
CAPS, EXHAUST STACKS, BREATHER TUBES, DIPSTICK TUBES, AND ACCESSORIES HAVE
BEEN SEALED. REMOVE ALL SEALS PRIOR TO CRANKING ENGINE”.
NOTE: Attach tag near engine start controls.
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.
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20.3.2 ALTERNATOR STORAGE - UP TO ONE YEAR
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.
20.3.2.1 REMOVAL FROM STORAGE
a. Remove all protective covers.
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.
20.3.2.2 INSULATION RESISTANCE CHECKS: (MEGGER)
a. Test the main stator windings with a megohmmeter in the following situations:
(1) Before initial startup of the generator set.
(2) Every three months if the generator is operating in a humid environment.
(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.
20.3.2.3 INITIAL OPERATION AFTER STORAGE
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:
(1) Operate the engine for 30 minutes at rated speed.
(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.
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CHAPTER 21
ENGINE/ALTERNATOR REMOVAL AND INSTALLATION
PROCEDURES
TABLE OF CONTENTS
SECTION TITLE PAGE

21.0 ENGINE/ALTERNATOR REMOVAL AND INSTALLATION PROCEDURES 3
21.2 ENGINE/ALTERNATOR REMOVAL PROCEDURES 4
21.3 ENGINE/ALTERNATOR INSTALLATION 7
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LIST OF TABLES
TABLE TITLE PAGE

TABLE 21.2-1 MEP-PU-810A/B ENGINE/GENERATOR REMOVAL PROCEDURE 5
TABLE 21.2-1 MEP-PU-810A/B ENGINE/GENERATOR REMOVAL

PROCEDURE (CONTINUED) 6
TABLE 21.3-1 MEP-PU-810A/B ENGINE/GENERATOR INSTALLATION

PROCEDURE TABLE 8
TABLE 21.3-1 MEP-PU-810A/B ENGINE/GENERATOR INSTALLATION

PROCEDURE TABLE (CONTINUED) 9
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21.0 ENGINE/ALTERNATOR REMOVAL AND INSTALLATION PROCEDURES

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21.2 ENGINE/ALTERNATOR REMOVAL PROCEDURES
WARNING

WARNING
HIGH VOLTAGE MAY CAUSE SEVERE INJURY OR DEATH UPON CONTACT

DURING CHECKOUT OR MAINTENANCE OF THIS EQUIPMENT. USE CAUTION
AND AVOID CONTACT WITH ENERGIZED COMPONENTS. USE HOT STICK WHEN
LOAD CABLES ARE HANDLED.
WARNING
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
SIGNIFICANT DIFFERENCES BETWEEN THE MEP-PU-810A AND MEP-PU-810B

REQUIRE SPECIFIC INSTRUCTIONS FOR EACH VERSION.
CAUTION

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TABLE 21.2-1 MEP-PU-810A/B ENGINE/GENERATOR REMOVAL PROCEDURE

STEP PROCEDURE
1 Lock-out and tag-out the PU per Section 21.1.

2 Remove the PU housing side panel ("H" panel).
3 Remove the air inlet duct assembly.
4 Tag the hydraulic pressure gauge lines and fittings at the hydraulic control block.
5 Disconnect the hydraulic pressure gauge lines from the hydraulic control block.
Leaving the hoses connected, unbolt the hydraulic control block from the engine and secure
6
it to the PU housing in a location, which permits engine/generator removal.
Leaving the hoses connected, unbolt the hydraulic pump assembly from the engine and
7
position in a location, which permits engine/generator removal.
Leaving the lines connected, unbolt the engine gauge assembly from the PU housing and
8
secure the assembly and lines to the engine.
Disconnect the fuel return line from the engine and secure the free end to the top of the
9
engine compartment cooling fan guard.
10 Close the fuel inlet supply valve.
11 Disconnect the fuel inlet line at the Primary Fuel Filter and drain.
12 Open and remove the radiator cap.
13 Open the engine coolant drain valve and drain the coolant from the engine.
14 Remove the engine coolant drain hose from the engine.
15 Remove the coupling from the engine coolant supply line.
16 Remove the coupling from the engine coolant return line.
17 Remove the coupling from the charge-air hot line at the turbocharger.
18 Remove the coupling from the charge-air cold line at the intake manifold.
19 Disconnect and remove the exhaust pipe completely from the PU.
20 Tag the electrical wires and connections at the starter motor.
21 Disconnect the electrical wires at the starter motor.
22 Ensure that the crankcase oil drain valve is closed.
23 Disconnect, drain, and remove the crankcase oil drain hose.
24 Open the PDC generator connection access panel.
25 Tag the four generator high voltage output wires and the bus connections inside the PDC..
26 Disconnect the four generator high voltage output wires from the buses inside the PDC.
27 Tag the ground wire and ground bus connection inside the PDC.
28 Disconnect the ground wire from the ground bus inside the PDC.
Disconnect the generator wire conduit from the PDC, feed the generator and ground wires
29
through the conduit hole, and secure the free ends to the generator.
21-5
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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
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21.3 ENGINE/ALTERNATOR INSTALLATION
WARNING

WARNING

WARNING
CAUTION

CAUTION

21-7
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TABLE 21.3-1 MEP-PU-810A/B ENGINE/GENERATOR INSTALLATION PROCEDURE TABLE

STEP PROCEDURE
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.
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TABLE 21.3-1 MEP-PU-810A/B ENGINE/GENERATOR INSTALLATION PROCEDURE TABLE

(CONTINUED)
STEP PROCEDURE
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
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21-10
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CHAPTER 22
PDC REMOVAL AND INSTALLATION PROCEDURES
TABLE OF CONTENTS
SECTION TITLE PAGE

22.0 PDC REMOVAL AND INSTALLATION PROCEDURES 4
22.2 PRIMARY DISTRIBUTION PANEL (PDC) REMOVAL 5
22.3 PRIMARY DISTRIBUTION PANEL (PDC) INSTALLATION 8
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LIST OF FIGURES
FIGURE TITLE PAGE

FIGURE 22.2-1 PDC REMOVAL PROCEDURES 6
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LIST OF TABLES
TABLE TITLE PAGE

TABLE 22.2-1 MEP-PU-810A PDC REMOVAL PROCEDURE 6
TABLE 22.2-1 MEP-PU-810A PDC REMOVAL PROCEDURE (CONTINUED) 7
TABLE 22.2-2 MEP-PU-810B PDC REMOVAL PROCEDURE 7
TABLE 22.3-1 MEP-PU-810A PDC INSTALLATION PROCEDURE 9
TABLE 22.3-2 MEP-PU-810B PDC INSTALLATION PROCEDURE 9
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22.0 PDC REMOVAL AND INSTALLATION PROCEDURES
NOTE: This is a DEALER Level Task. It is included in this manual for EMERGENCY USE ONLY.

22-4
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22.2 PRIMARY DISTRIBUTION PANEL (PDC) REMOVAL
WARNING

WARNING

WARNING
WARNING
DAMAGE TO PDC WILL OCCUR IF 7P1 AND 7P2 ARE TRANSPOSED.
CAUTION

CAUTION

NOTE: This is a DEALER Level Task. It is included in this manual for EMERGENCY USE ONLY.
22-5
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FIGURE 22.2-1 PDC REMOVAL PROCEDURES
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.
TABLE 22.2-1 MEP-PU-810A PDC REMOVAL PROCEDURE
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
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TABLE 22.2-1 MEP-PU-810A PDC REMOVAL PROCEDURE (CONTINUED)
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.
TABLE 22.2-2 MEP-PU-810B PDC REMOVAL PROCEDURE
STEP PROCEDURE
1 Disconnect battery cables from batteries.

2 Remove Pin Plug 40P, with an Allen wrench, from the PDC, for both units.
3 Remove Pin Plugs 7P1 and 7P2. Twist the plugs and pull out, for both units.
Remove access cover and filter on back of the control panel for GEN 1 and GEN 2.
4
Disconnect generator leads T1, T2, T3, neutral and ground from the bus bars.
Remove cover from the transformer. Disconnect H1, H2, H3, and ground and disconnect the
5
Seal-Tight connector.
Remove the Mounting Hardware from the flashing on the right, left and top of the control
6
panel and remove the flashing.
7 Remove (2) 3/8” x 1” inch bolts from the front bottom of the PDC, from under the trailer frame.
8 Remove (2) 3/8” x 2” inch bolts from the rear of the PDC, under the trailer frame.
9 Remove the tail light assemblies.
With a 4000lb forklift lift the PDC to clear the PU trailer frame, and remove the Korfund Pads
10
(Packing between the PDC and Frame). Lower the panel slightly and remove the PDC.
NOTE: To remove or install the PDC a minimum of a 4000 lb forklift is required.
22-7
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22.3 PRIMARY DISTRIBUTION PANEL (PDC) INSTALLATION
WARNING

WARNING

WARNING
CAUTION

CAUTION

22-8
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TABLE 22.3-1 MEP-PU-810A PDC INSTALLATION PROCEDURE
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)
TABLE 22.3-2 MEP-PU-810B PDC INSTALLATION PROCEDURE
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)
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22-10
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COMMERCIAL TECHNICAL MANUAL

BOOK 2 OF 2
GENERATOR – 840 KW MEP-PU-810A/B
Radian Part Numbers: 1R0253-3/1R0254-3
OPERATION AND MAINTENANCE

ANNEXES A THROUGH J
© 2007 DRS RADIAN

ALL RIGHTS RESERVED
5845 RICHMOND HWY. SUITE 725 ALEXANDRIA, VIRGINIA 22303-1865
FEBRUARY 23, 2007 (REVISION 5) *
DISTRIBUTION STATEMENT: Approved for public release; distribution is unlimited. Questions pertaining to technical
content shall be referred to 542 SEVSG/GBZFM, Robins AFB, GA 31098. Other requests for this document shall be
referred to 542 MSUG/GBMUDE, Robins AFB, GA 31098.
*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

USAF TO 35C2-3-518-1
USA TM 9-6115-484-14
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
CONTROL PANELS)
SEBU 6959-02, or later CAT O&M 3406E, 3456 INDUSTRIAL ENGINE
OPERATION AND MAINTENANCE MANUAL ELECTRIC SET
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
(DIGITAL VOLTAGE REGULATOR)
SYSTEM OPERATION, TESTING, AND ADJUSTING (GENERATOR SET
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
AND CONTROL PANELS
SPECIAL INSTRUCTION (STORAGE PROCEDURE FOR CATERPILLAR
PRODUCTS)
A-1
USAF TO 35C2-3-518-1
USA TM 9-6115-484-14
OTHER VENDOR MANUALS

VENDOR MANUAL NUMBER TITLE
SPM-A SYNCHRONIZER (INSTALLATION,
82384R
OPERATION, AND CALIBRATION MANUAL)
WOODWARD
LOAD SHARING MODULE (INSTALLATION,
02036
OPERATION, AND CALIBRATION MANUAL)
INSTRUCTION MANUAL, FOR THE INSTALLATION,
OPERATION, AND MAINTENANCE OF TRITON, SL
CUTLER-HAMMER I.B. 48018N
160/200/360/400, MEDIUM VOLTAGE VACUUM
CONTACTORS
BE1 – 851 OVER CURRENT RELAY INSTRUCTION
BASLER 9 2899 00 990 REV: D
MANUAL
BL1600 C-PROGRAMMABLE CONTROLLER, USERS
Z-WORLD REVISION E
MANUAL
VERSATRAK AND MINI-VERSATRAK USER
MANUAL (REMOTE TERMINAL UNITS
SIXNET INSTALLATION AND MAINTENANCE)
SIXNET USER MANUAL (MODULAR DIN RAIL I/O,
INSTALLATION AND MAINTENANCE)
MASTER
INSTRUCTION MANUAL, BATTERY CHARGER,
CONTROL
MODEL MBC6X-24V-20A-LA
SYSTEMS
DRS RADIAN SUPPLEMENTAL MANUALS

NUMBER TITLE
CTM
TROUBLESHOOTING PROCEDURES FOR
01646.1R0253/1R0254 TR
POWER UNIT-840KW MEP-PU-810A/B
JULY 6, 2006
CTM
01646.1R0253P/1R0254P
POWER UNIT, 840 KW, MEP-PU-810A/B PARTS
R1
MANUAL
AUGUST 9, 2006,
(Revision 1)
A-2
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USA TM 9-6115-484-14
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
0-for engine shutdown.

P006 - Shutdown Override For Coolant Loss Fault: GSC+
1-for alarm only (shutdown override, no engine 0 0
response to an engine coolant loss fault.
shutdown).
P007 - System Voltage, 24 Or 32 Volts: system voltage (battery
24 or 32. 24 24
voltage) of the genset.
P008 - This setpoint is not currently being used by the GSC+
N/A N/A N/A
and cannot be programmed.
P009 - Number Of Ring Gear Teeth: number of teeth on the
ring gear of the engine. Used by the GSC+ to determine engine 95 to 350 teeth in increments of one tooth. 136 teeth 136 teeth
speed.
P010 - Engine Overspeed: engine speed used by the GSC+ to
declare that an engine overspeed fault exists. The engine
500 to 4330 rpm in increments of 10 rpm. 2120 rpm 2120 rpm
overspeed setpoint (for all 60 Hz applications) is 1.18 times the
rated speed.
P011 - Crank Terminate Speed: engine speed used by the
100 to 1000 rpm in increments of 10 rpm. 400 rpm 400 rpm
GSC+ to disengage the starting motor during engine cranking.
P012 - Oil Step Speed: engine speed used by the GSC+ for
distinguishing between rated speed and idle speed when a low 400 to 1800 rpm in increments of 10 rpm. 1350 rpm 1350 rpm
oil pressure fault exists.
P013② - Low Oil Pressure Shutdown At Rated Speed: oil

30 PSI 30 PSI
pressure used by the GSC+ to declare that a low oil pressure 5 to 61PSI (34 to 420kPa) in increments of 1
shutdown fault exists with engine at rated speed (the engine (205 kPa) (205 kPa)
speed must have exceeded the oil step speed for nine seconds).
P014② - Low Oil Pressure Shutdown At Idle Speed: oil

pressure used by the GSC+ to declare that a low oil pressure 10 PSI 10 PSI
shutdown fault exists with the engine at idle speed (the engine 20 to 336kPa (3 to 49PSI) in increments of 1
(70 kPa) (70 kPa)
must have been running for at least 9 seconds and the engine
speed must be less than oil step speed).
P015③ - High Water Temperature Shutdown: coolant 225ºF 225ºF

temperature used by the GSC+ to declare a high coolant 185 to 253ºF (85 to 123ºC) in increments of 1
(107ºC) (107ºC)
temperature shutdown fault exists (after a 10 second delay).
P016 - Low Water Temperature Alarm: coolant temperature 70ºF 70ºF
used by the GSC+ to declare that a low coolant temperature 32 to 97ºF (0 to 36ºC) in increments of 1
alarm fault exists (after a 2 second delay). (21ºC) (21ºC)
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OP5-0 SETPOINTS (CONTINUED)

SETPOINTS OP5-0 ENGINE/GENERATOR PROGRAMMING①
FACTORY DPGDS
DEFAULT SETPOINT
P017 - Total Cycle Crank Time: cycle crank time used by the 5 to 120 seconds in increments of 1
90 seconds 90 seconds
GSC+ to declare that an overcrank fault exists. second.
P018 - Cycle Crank Time: amount of time the GSC+ cranks and 5 to 60 seconds in increments of 1 second.
10 seconds 10 seconds
then rests the starting motor during a single crank cycle.
P019 - Cooldown Time: amount of time the GSC+ allows the
0 to 30 minutes in increments of 1 minute. 5 minutes 5 minutes
engine to run after a normal shutdown is initiated.
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
P022⑤ - GSC+ Engine Number: informs other devices on the

01 (Gen 1)
01 through 08 01
CAT Data Link of the engine number for the GSC+. 02 (Gen 2)
SETPOINTS - OP5-0-ENGINE/GENERATOR PROGRAMMING①

RANGE OF FACTORY 60HZ 50HZ
SETPOINT-NAME-DESCRIPTIONS
VALUES DEFAULT SETPOINT SETPOINT
P023 - Engine Type: identifies the engine as a 0 - MUI diesel
mechanical unit injector (MUI) diesel, spark ignited 1 - Gas 0 2 2
(gas), or electronic unit injector (EUI) diesel engine. 2 - EUI diesel
P024 - Crank Time Delay: amount of time the GSC+
delays activation of the fuel control relay (FCR) during
0 to 20 seconds in increments of 1
a crank cycle. This setpoint is for Gas engines only. 5 Seconds 5 Seconds 5 Seconds
second.
The P024 setpoint only functions when the P023
setpoint is set to 1 (gas engine).
0 - for gensets without an oil temperature
P025 - Oil Temperature Sensor Installed: tells sensor
whether or not the optional engine oil temperature 0 0 0
sensor is installed on the genset. 1 - for gensets with an oil temperature
sensor
P026 - High Oil Temperature Shutdown: oil
temperature used by the GSC+ to declare a high oil 185 to 253ºF (85 to 123ºC) in increments
225ºF (107ºC) 225ºF (107ºC) 225ºF (107ºC)
temperature shutdown fault exists (after a 10 second of 1
delay). Refer to the panel model number.
P027 - Shutdown Override For High Oil 0 - for alarm only (shutdown override, no
Temperature Fault: GSC+ response to an engine high engine shutdown). 0 0 0
oil temperature fault. 1 - for engine shutdown.
P028 - Nameplate Voltage: rated voltage of the
generator. This setpoint is used for protective relaying 100 to 25kV in increments of 1 480V 4160V 3800V
functions.
P029 - Nameplate Current: rated current output of the
0 to 4000 A in increments of 1 600A 80A 73A
generator.
P030 - Nameplate Power: rated power capability of
0 through 10MW in increments of 1kW. 400kW 420kW 350kW
the generator.
P031 - Rated Frequency: nominal frequency rating of
50 or 60Hz 60Hz 60Hz 50Hz
genset.
P032 - Connection Configuration Of Generator: 0 - wye
0 0 0
wye or delta configuration of generator. 1 - delta
P033 - Number Of Generator Poles. 0 through 254 in increments of 2. 4 4 4
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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)
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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
increments of 1%.
overvoltage shutdown.
P106 - Generator Overvoltage Shutdown Time
issuing an overvoltage shutdown.
P107 - Generator Undervoltage Alarm Enable: 0 - disabled
undervoltage alarm function. 1 - enabled
P108 - Generator Undervoltage Alarm
increments of 1%.
undervoltage alarm.
P109 - Generator Undervoltage Alarm Time
issuing an undervoltage alarm.
P110 - Generator Undervoltage Shutdown 0 - disabled
generator undervoltage shutdown function. 1 - enabled
P111 - Generator Undervoltage Shutdown
60 through 100% of rated voltage in
increments of 1%.
undervoltage shutdown.
P112 - Generator Undervoltage Shutdown Time
issuing an undervoltage shutdown.
P113 - Generator Overfrequency Alarm Enable: 0 - disabled
overfrequency alarm function. 1 - enabled
P114 - Generator Overfrequency Alarm 50-60Hz, for 50Hz Gen 53Hz

Threshold: frequency the GSC+ uses to issue an 60-70Hz, for 60Hz Gen 63Hz 63 Hz 53 Hz
overfrequency alarm. 400-480, for 400Hz Gen 422Hz
P115 - Generator Overfrequency Alarm Time
issuing an overfrequency alarm.
P116 - Generator Overfrequency Shutdown 0 - disabled
generator overfrequency shutdown function. 1 - enabled
P117 - Generator Overfrequency Shutdown 50-60Hz, for 50Hz Gen 55Hz

Threshold: frequency the GSC+ uses to issue an 60-70Hz, for 60Hz Gen 66Hz 66Hz 55Hz
overfrequency shutdown. 400-480, for 400Hz Gen 440Hz
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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
generator underfrequency alarm function. 1 - enabled
P120 - Generator Underfrequency Alarm 30-50Hz, for 50Hz Gen 48Hz

underfrequency alarm. 240-400, for 400Hz Gen 378Hz
P121 - Generator Underfrequency Alarm Time
issuing an underfrequency alarm.
P122 - Generator Underfrequency Shutdown 0 - disabled
generator underfrequency shutdown function. 1 - enabled
P123 - Generator Underfrequency Shutdown 30-50Hz, for 50Hz Gen 45Hz

underfrequency shutdown. 240-400, for 400Hz Gen 360Hz
P124 - Generator Underfrequency Shutdown
before issuing an underfrequency shutdown.
P125 - Generator Reverse Power Shutdown 0 - disabled
generator reverse power shutdown function. 1 - enabled
P126 - Generator Reverse Power Shutdown
0 through 20% of rated power in increments
Threshold: level of reverse power the GSC+ uses 15% 4% 4%
of 1%.
to issue a reverse power shutdown.
P127 - Generator Reverse Power Shutdown
before issuing a reverse power shutdown.
P128 - Generator Overcurrent Alarm Enable: 0 - disabled
the GSC+ enables or disables the overcurrent 1 1 1
alarm. 1 - enabled
P129 - Generator Phase Overcurrent Alarm
100 through 160% of nameplate current in
Threshold: level of current the GSC+ uses to issue 105% 150% 150%
increments of 5%
a phase overcurrent alarm.
P130 - Generator Phase Overcurrent Alarm
before issuing a phase overcurrent alarm.
P131 - Generator Total Overcurrent Alarm
100 through 160% of three times nameplate
Threshold: level of current the GSC+ uses to issue 105% 150%. 150%
current in increments of 5%
a total overcurrent alarm.
P132 - Generator Total Overcurrent Alarm
before issuing a total overcurrent alarm.
P133 – Generator Overcurrent Shutdown 0 – disabled
overcurrent shutdown. 1 – enabled
P134 – Generator Phase Overcurrent Shutdown
100 through 160% in increments of 5%
Threshold: level of current the 110% 150% 150%
GSC+ uses to issue a phase overcurrent shutdown.
P135 – Generator Phase Overcurrent Shutdown
before issuing a phase overcurrent shutdown.
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SETPOINT-NAME- FACTORY 60HZ 50HZ
RANGE OF VALUES SETPOINT SETPOINT
DESCRIPTION DEFAULT
P136 - Generator Total Overcurrent Shutdown
100 through 160% of three times nameplate
Threshold: level of current the GSC+ uses to issue 110% 150%. 150%
current in increments of 5%
a total overcurrent shutdown.
P137 - Generator Total Overcurrent Shutdown
before issuing a total overcurrent shutdown.
P138 - KW Level Relay Enable : the GSC+ 0 - disabled
1 1 1
enables or disables the kW level relay function. 1 - enabled
P139 - KW Level Relay Threshold: level of
0 through 110% of nameplate power in
power the GSC+ uses to activate the kW level relay 105% 105% 105%
increments of 1%
function.
P140 - KW Level Relay Time Delay: amount of
time the GSC+ waits before activating the kW level 0 through 120 seconds② in increments of 1 0 seconds 0 seconds 0 seconds
relay function.
P141 - KW Level Relay Disengage Threshold:
0 through 110% of nameplate power in
level of power the GSC+ uses to deactivate the kW 100% 100% 100%
increments of 1%.
level relay function.
P142 - KW Level Relay Disengage Time Delay:
amount of time the GSC+ waits before deactivating 0 through 120 seconds② in increments of 1 10 seconds 10 seconds 10 seconds
the kW level relay function.
① The setpoints are programmed at the factory to the default value.

② When programmed to 0 seconds, the actual time is from 0.5 to 1.0 seconds.
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OP6 SETPOINTS
SETPOINTS OP6 SPARE INPUT/OUTPUT PROGRAMMING
FACTORY DPGDS
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.
0 1
0-shutdown
1-alarm
0 - 250 seconds in increments of 1 0 seconds 0 seconds
0 0
0-shutdown
1-alarm
0 0
0-shutdown
1-alarm
SP13 - Spare Output Response: GSC+ response to the spare output 0-active low
0 0
trigger condition. 1-active high
0-unused
1-active SP1 fault②

SP14 - Spare Output Trigger Condition: The condition used by the
5-any combination of active SP faults②
8 8
GSC+ to trigger the spare output response
6-any active shutdown
7-any active alarm or shutdown
8-cooldown mode
9-coolant loss mode②
10-high oil temp fault②

11-CCM control
SP15 – Spare Relay Output Response: GSC+ response to the spare 0-relay inactive when triggered
relay trigger condition. 1-relay active when triggered
1 1
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OP6 SETPOINTS (CONTINUED)

SETPOINTS OP6 SPARE INPUT/OUTPUT PROGRAMMING
FACTORY DPGDS
DEFAULT SETPOINT
0-unused

SP16 - Spare Relay Output Trigger Condition: The condition used
5-any combination of active SP faults②
8 1
by the GSC+ to trigger the spare relay.
6-any active shutdown
7-any active alarm or shutdown
8-cooldown mode
9-coolant loss mode②
10-high oil temp fault②

11-CCM control
0-unused

SP17 - Spare Indicator 1 Trigger Condition: The condition used by
4-active SP4 fault② 0 6
the GSC+ to trigger spare indicator①.
5-any combination of active SP1, SP2, SP3 or
SP4 faults②
6-Coolant loss fault②
7-high oil temperature fault②

SP18 - Spare Indicator 2 Trigger Condition: The condition used by
Battle Short mode. 0 0 Battleshort③
the GSC+ to trigger spare indicator②.
SP19 - Spare Indicator 3 Trigger Condition: The condition used by 0 In 50Hz
Not in 60 Hz mode. 0
the GSC+ to trigger spare indicator③. Mode③
① The setpoints are programmed at the factory to the default value.
② Either alarm or shutdown faults are valid trigger conditions
③ Battleshort and 50Hz Mode are unique features to DPGDS for spare indicators 2 and 3.
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ANNEX C
ENGINE/GENERATOR ALARM AND SHUTDOWN POINTS
ENGINE – GSC
CONDITION ALARM POINT SHUTDOWN POINT
Low Oil Pressure:
1 • At Rated Speed N/A 30 psi

• At Idle Speed N/A 10 psi
2 Engine Overspeed N/A 2120 rpm
3 High Coolant Temperature N/A 225°F
4 Low Coolant Temperature N/A 70°F
5 High Oil Temperature N/A 225°F
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GENERATOR - GSC
CONDITION ALARM POINT SHUTDOWN POINT
Over Voltage: 10 Seconds at - 10 Seconds at -
6 • 50Hz - 105% 3990 Volts - 110% 4180 Volts

• 60Hz - 105% 4368 Volts - 110% 4576 Volts
Under Voltage: 10 Seconds at - 15 Seconds at -
7 • 50Hz - 90% 3420 Volts - 85% 3230 Volts

• 60Hz - 90% 3744 Volts - 85% 3536 Volts
Over Frequency: 10 Seconds at - 10 Seconds at -
8 • 50Hz - 53Hz - 55Hz

• 60Hz - 63Hz - 66Hz
Under Frequency: 10 Seconds at – 15 Seconds at –
9 • 50Hz - 48 Hz - 45 Hz
• 60Hz - 57 Hz - 54Hz
10 Reverse Power 10 Seconds at 10%
11 Phase Overcurrent 0 Seconds at 150% 10 Seconds at 150%
12 Total Overcurrent 0 Seconds at 150% 10 Seconds at 150%
C-2
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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
INSTANTANEOUS TRIP SETTINGS

PHASE NEUTRAL NEGATIVE SEQUENCE
INSTANTANEOUS INSTANTANEOUS TRIP
BREAKER RELAY
TRIP 50TP TRIP 50TN 50 TQ
PU TD PU TD PU TD
GENERATOR 0.0 0m 3.0 0m 3.0 0m
FEEDER 7.5 84m 1.25 84m 0 0m
TIE 0.0 0m 0 0m 0.0 0m
TIME OVERCURRENT TRIP SETTINGS

PHASE TIME OVERCURRENT NEUTRAL TIME OVERCURRENT
BREAKER RELAY TRIP 51P TRIP 51N
PU TD C PU TD C
GENERATOR 4.50 0.5 VV2 1.25 0.5 VV2
FEEDER 2.50 1.0 VV2 1.00 1.0 VV2
TIE 5.00 2.0 VV2 1.50 2.0 VV2
D-1
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D-2
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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
02 Ratio of Output Voltage To Sensing Program 001.0-100.0 001.0 17.3 17.3

Voltage
03 Generator Type Program 0000-0004 0004 4 4
04 Rated Generator Output Current Program Amps 0000-9999 0600 80 73
05② CT Voltage At Rated Generator Program Volts 01.00-05.00 05.00 4.00 3.66
Current
06 Knee Frequency Program Hz 045.0-065.0 050.0 59.8 49.8
07 Decreasing Volts/Hz Slope I Program Volts/Hz 001.0-010.0 002.0 2.0 2.0
08 Decreasing Volts/Hz Slope 2 Program Volts/Hz 001.0-010.0 002.0 2.0 2.0
09 Minimum Voltage Program % 050.0-100.0 050.0 50.0 50.0
10 Under Frequency Point Program Hz 020.0-040.0 025.0 25.0 25.0
11 Overvoltage Trip Point Program % 0105-0140 014.0 125.0 125.0
12 Overvoltage Trip Time Program Seconds 0002-0030 0002 5 5
13 Under Voltage Trip Point Program % 0060-0095 0060 75 75
14 Under Voltage Trip Time Program Seconds 0030-0120 0030 30 30
15 Voltage Gain (IR Compensation) Program % 000.0-0 10.0 0000 0 0
16⑤ Integral Gain Program 001.0-020.0 006.0 6.0 6.0
17⑥ Proportional Gain Program 001.0-020.0 005.0 5.0 5.0
18 Single Phase Sensing Select Program 0000,0001 0000 0000 0000

(0=three_phase,_1=single phase)
19 Diode Monitor Trip Point Program Amps 001.0-010.0 002.0 2.0 2.0
30 Droop Percentage Program % 000.0-010.0 0000 3 3
31③ pf/kVAR Select (0=pf, 1=kVAR) Program 0000, 0001 0000 0 0
32③ Pf Reference Program 00.60-01.10 01.00 0.8 0.8
33③ KVAR Reference Program Per Unit 00.00-01.00 0000 .10 .10
34③ Reverse Power Trip Point Program % 000.0-020.0 010.0 15 15
35③ Reverse Power Trip Time Program Seconds 000.0-020.0 010.0 5 5
50 Generator Output Frequency View Hz

51 Generator Output Voltage View Volts
52 Generator Output Current View Amps
53 Generator Reactive Output Current View Amps
54 Generator Real Current View Amps
55 Exciter Field Current View Amps
56③ Three Phase Kilowatts (KB and View KW
later)
57③ Power Factor View
E-1
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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
60 Hours View Hours 0000-9999

90 Password Program 0009 0009
91 Software ID View
92 Latest Fault View 0000 0000 0000
93 Previous Fault View 0000 0000 0000
94 Fault Clear View
96 Shutdown Fault Reset Switch
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
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DRS RADIAN CTM: 01646.1R0253/1RO254
ANNEX F
3456 EPG ADEM SETPOINTS
CAT ELECTRONIC TECHNICIAN ET3.0 (OCT99)

ECM Summary
01/12/2000 2:36 PM
3456 EPG Engine (9BZ00002)
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
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Configuration
Parameter Value
Description Value Unit TT
Selected Engine Rating

Rating Number 2
Rated Power 669 HP at 1800 RPM
Rated Peak Torque 2655 lb-ft at 1200 RPM
Top Engine Speed Range 1500 - 1945 RPM
Test Spec 0K1501
ECM Identification Parameters
Equipment ID 0
Engine Serial Number use data plate value 9BZ00002 0
ECM Serial Number 08390151CG
Personality Module Part Number 1730820-00
Personality Module Release Date May99
Personality Module Description EPG 3456
Security Access Parameters
Total Tattletale 1
Engine/Gear Parameters
Rated Engine Speed 1800 RPM
Acceleration Delay Time 0 Sec 0
Engine Accel. Rate 250 RPM/s 0
Low Idle Speed 1200 RPM 0
Cooldown Speed 1800 RPM 0
Engine Cooldown Duration 0 min 0
Crank Duration 0 Sec 0
Maximum No of Crank Cycles 0 0
Configuration Continued
Crank Terminate Speed 400 RPM 0
I/O Configuration Parameters
Ether Control Enabled 0
Configuration Continued-
Parameter Value
Description Value Unit TT

Fuel Pressure Sensor Not Installed 0
F-2
USAF TO 35C2-3-518-1
USA TM 9-6115-484-14
CAT ELECTRONIC TECHNICIAN ET3.0 (OCT99) (CONTINUED)

Exhaust Temperature Sensor Installation Status Not Installed 0
Engine Oil Temperature Sensor Installation Status Not Installed 0
User Defined Switch Installation Status Not Installed 0
User Defined Switch Active State Configuration Low 0
System Parameters
FLS use data plate value -28 0
FTS use data plate value 22 0
System Gain 0 0
F-3
USAF TO 35C2-3-518-1
USA TM 9-6115-484-14

Monitoring System Tool
01/12/2000 2:43 PM
Parameter Value
Description State Trip Point Delay Time
Low System Voltage

Warn Operator On 20 Volts 5 Sec
Low Engine Oil Pressure

Warn Operator On None 5 Sec
Engine Shutdown Off None 10 Sec
High Engine Coolant Temperature

Warn Operator On 217 Deg F 5 Sec
Engine Derate On 221 Deg F 5 Sec
Engine Shutdown Off 223 Deg F 20 Sec
Low Engine Coolant Temperature

Monitoring System Tool Continued

Engine Overspeed
Warn Operator On 2200 RPM 0 Sec
Engine Shutdown Off 2300 RPM 0 Sec
Monitoring System Tool Continued-
Altitude (atmospheric pressure)

Engine Derate On 12.8 PSI 0 Sec
High Engine Inlet Air Temperature

172.4 Deg
Warn Operator On 30 Sec
F
High Fuel Temperature

F-4
USAF TO 35C2-3-518-1
USA TM 9-6115-484-14

Current Totals
01/12/2000 2:44 PM
Parameter Value
Description Value Unit
Total Time 2 hours

Total Fuel 31 Gal
Ether Usage 0 Gal

Injector Codes Calibration
01/12/2000 2:43 PM

Parameter Value
Injector Code
use data from each individual engine and the injector
Injector 1 engine specific value 8837
F-5
USAF TO 35C2-3-518-1
USA TM 9-6115-484-14

Active Code
01/12/2000 2:42 PM
Parameter Value
Code Description
No Active Codes

Logged Diagnostic Codes
01/12/2000 2:42 PM
Parameter Value
Code Description Occur First Last
3456 EPG Engine (9BZ00002) -

Diagnostic Clock = 2 hours
Throttle Position signal
91- 8 11 0 0
abnormal
F-6
USAF TO 35C2-3-518-1
USA TM 9-6115-484-14
Cat Electronic Technician ET3.0 (OCT99)

Event Code
01/12/2000 2:42 PM
Parameter Value
Code Description Occur First Last
3456 EPG Engine (9BZ00002) -

Diagnostic Clock = 2 hours
High Inlet Air Temperature
E027 1 2 2
Warning
E043 Low System Voltage Warning 2 0 0

Status Group 1
01/12/2000 2:39 PM
Parameter Value
3456 EPG Engine (9BZ00002) : 3456 EPG Engine Group 1

Engine Speed 0 RPM
Desired Engine Speed 400 RPM
Boost Pressure 0 PSI
Throttle Position 74 %
Fuel Position 0
Rated Fuel Limit 50
FRC Fuel Limit 30
Engine Speed Droop 0 %
F-7
USAF TO 35C2-3-518-1
USA TM 9-6115-484-14

Status Group 2
01/12/2000 2:40 PM
Parameter Value
3456 EPG Engine (9BZ00002) : 3456

EPG Engine Group 2
Engine Coolant Temperature 66 Deg F
Inlet Air Temperature 66 Deg F
Fuel Temperature 66 Deg F
Engine Oil Pressure 0 PSI
Engine Oil Pressure (abs) 14 PSI
Atmospheric Pressure 14.5 PSI
Turbo Outlet Pressure (abs) 15 PSI
Fuel Pressure Unavailable Parameter PSI
Fuel Pressure (abs) Unavailable Parameter PSI
F-8
USAF TO 35C2-3-518-1
USA TM 9-6115-484-14

Status Group 3
01/12/2000 2:41 PM
Parameter Value
3456 EPG Engine (9BZ00002) : 3456

EPG Engine Group 3
Fuel Pressure Unavailable Parameter PSI
Fuel Pressure (abs) Unavailable Parameter PSI
Engine Oil Temperature Unavailable Parameter Deg F
Exhaust Temperature Abnormal Signal Deg F
F-9
USAF TO 35C2-3-518-1
USA TM 9-6115-484-14

Status Group 4
01/12/2000 2:41 PM
Parameter Value
3456 EPG Engine (9BZ00002) : 3456 EPG Engine Group

4
Engine Control Switch Stop
Remote E-Stop Switch Off
Startup Mode Off
Overspeed Test Switch Off
Ether Injection Off
Unavailable
Remote Start
Parameter

Status Group 5
01/12/2000 2:41 PM
Parameter Value
3456 EPG Engine (9BZ00002) : 3456 EPG Engine Group 5

Fuel Rate 0 GPH
Engine Load Factor 0 %
Battery Voltage 25 Volts
Remaining Cooldown Time 0 Sec
Shutdown Notify Status Off
Engine Power Derate 0 %
F-10
USAF TO 35C2-3-518-1
USA TM 9-6115-484-14

Monitoring System Tool
01/12/2000 2:43 PM
Parameter Value
Description State Trip Point Delay Time
Low System Voltage

Warn Operator On 20 Volts 5 Sec
Low Engine Oil Pressure

Warn Operator On None 5 Sec
Engine Shutdown Off None 10 Sec
High Engine Coolant Temperature

Engine Derate On 221 Deg F 5 Sec
Engine Shutdown Off 223 Deg F 20 Sec
Low Engine Coolant Temperature

Monitoring System Tool Continued

Engine Overspeed
Warn Operator On 2200 RPM 0 Sec
Engine Shutdown Off 2300 RPM 0 Sec
Monitoring System Tool Continued-
Altitude (atmospheric pressure)

Engine Derate On 12.8 PSI 0 Sec
High Engine Inlet Air Temperature

Warn Operator On 172.4 Deg F 30 Sec
High Fuel Temperature

F-11
USAF TO 35C2-3-518-1
USA TM 9-6115-484-14
F-12
USAF TO 35C2-3-518-1
USA TM 9-6115-484-14
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.
MEP-PU-810 CONSUMABLE MATERIALS

QUANTITY
MEP-PU-810
NSN/ PART REQUIRED
MAJOR SUBSYSTEM ITEM DESCRIPTION
NUMBER FOR INITIAL
COMPONENT
START-UP
120 gallons
Fuel Type 1 Fuel JP-8
(454 liters)
Regular Grade,
DF2 VV-F-800 120 gallons
Fuel Type 2 9140-00-286-5294
Fuel (+20 to+125°F; (454 liters)
System -6.6 to +51.6°C)
Primary
129-0372 2
Fuel Filter
Secondary
1R-0749 2
Fuel Filter
Diesel Engine Oil
3456 (SAE 30)
ENGINE -32 °F to 104 °F
Diesel Engine Oil

(SAE 10W-30)
Oil 36 Gallons
-4 °F to 104 °F
Lubrication
Diesel Engine Oil
(SAE 15W-40)
+5 °F to 122 °F
See Note 1
Lube Oil
1R-0716 2
Filter
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)
♦ CF-4, API GRADE OIL (Minimum requirement for 3456 EPG)

♦ CH-4, API GRADE OIL (Recommended lube for 3456 EPG)
G-1
USAF TO 35C2-3-518-1
USA TM 9-6115-484-14
MEP-PU-810 CONSUMABLE MATERIALS (CONTINUED)

QUANTITY
MEP-PU-810
NSN/ PART REQUIRED
NUMBER FOR INITIAL
COMPONENT
START-UP
Extended Life
Coolant(ELC)
101-2844 1 Gallon, pre-diluted

50/50, -34 ºF
101-2845 55 Gallon, pre-diluted

50/50, -34 ºF
Coolant 32 Gallons
Commercial Antifreeze
meeting
ASTM D5345
COOLING Commercial Antifreeze

meeting
ASTM D4985
119-5152 1 Quart, ELC Extender,

(Quantity needed is
listed on bottle)
ELC 119-5150 1 Gallon, ELC Extender,

Extender (Used for adjusting lower
3456 ENGINE freeze protection
requirements or for
mixing with correct
water by customer)
Ether
2910-00-209- Tank, Primer, Starting
Starting Ether 2
4997 (Ether)
System
Air Intake
Air Filter 4N-0015 2
System
Mobil
AERO HF
(-65˚F to 45˚F
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
MEP-PU-810 CONSUMABLE MATERIALS (CONTINUED)
QUANTITY
MEP-PU-810
NSN/ PART REQUIRED
NUMBER FOR INITIAL
COMPONENT
START-UP
SR-4B 1.8 to 2.0 oz

Bearings 2S-3230
GENERATOR Every 2000 Hours
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
G-4
USAF TO 35C2-3-518-1
USA TM 9-6115-484-14
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:
SPECIAL TOOLS AND TEST EQUIPMENT

CATERPILLAR TOOLS
NSN/
ITEMS USE
REFERENCE NUMBER
Battery Load Tester 4C-4911 Test Battery Condition
Ammeter 8T0900 Test Battery Condition
Coolant and Battery Tests Coolant Freezing Point and Battery Fluid
5P-3514
Tester Condition
Strap Wrench
2P-8250 Remove Oil Filter
Assembly
Oil Filter Cutter 4C-5084 Inspect used Oil Filters for Debris
Pressure Gauge 9S-8138 To perform the Water Pump Pressure Check
Pressurizing Pump 9S-8140 Inspect/Trouble-Shoot Coolant System
Flow Checking Tool Troubleshooting Fuel system and Preserving
1P-0540
Group Engine
Engine Turning Tool 9S-9082 For turning engine for maintenance
Injector Height
9U-7227 Setting Injector Height
Setting
Engine Pressure
1U-5470 Fuel Pressure
Group
Thermistor 8T-470 Cooling System Temperature Troubleshooting
Indicator Group 8S-2328 Reinstall generator to engine
Crimping tool 1U-5804 Repair of Deutsch connectors
Diagnostic Cables 7x-1710 Test/Repair of Deutsch connectors
Wire Removal Tools 151-6320 Test/Repair of Deutsch connectors
Wire Removal Tools 1U-5805 Test/Repair of Deutsch connectors
4mm Hex tool 125-2584 Test/Repair of Deutsch connectors
Deutsch DT
9U-7250 Repair of wiring harness
Connecter Service Kit
Dial Indicator Group 8T-5096 Used to check endplay clearance of the turbocharger
Used to check endplay clearance of the
Holding Rod 7H-1945
turbocharger
Holding Rod 7H-1645
turbocharger
Universal Attachment 7H-1940
turbocharger
Communication
Adapter II Group 171-4400 Engine Diagnostics
(ET Tool)
H-1
USAF TO 35C2-3-518-1
USA TM 9-6115-484-14
SPECIAL TOOLS AND TEST EQUIPMENT (CONTINUED)

SPECIAL TOOLS OTHER THAN CATERPILLAR
NSN/
ITEMS REFERENCE USE
NUMBER
HIPOTRONICS Checking Load Break Bushings, Load Break
880PL
DC Hipot Tester Elbows, Load Cables
BIDDLE
Digital – Low - Resistance 247002 Checking Contact Resistance on Contactors
- Ohmmeter
ELASTIMOLD For installing the 200 Amp High Voltage
200AT
Bushing Installer Bushings
MULTI-AMP
MS-2 Circuit Breaker MS-2-115 Tests Circuit Breaker
Tester
FLUKE 1520 1520
Testing Alternator Insulation Resistance
Meg-Ohm-Meter Or Equivalent
FLUKE 87 III 87 III Trouble-Shoot/test electrical continuity, voltage,
Digital Multimeter Or Equivalent and current less than 10 Amps
8T-0900/
AC/DC Ammeter Trouble-Shoot/test current over 10 Amps
6625-00-892-1497
CRAFTSMAN
12 ton jack; 9 7/8 in. to 18 00950284000 WHEEL AND BRAKE WORK
5/8 in. range
JOHN DOW INDUSTRIES
JS - 12 Wheel and brake work
12 ton jack stands
HIPOTRONICS
Vacuum Interrupter 7BT60A Checking Vacuum Bottles
Tester
SNAP-ON
Torque Wrench ¼ Inch
GTE3A General Maintenance
Drive; 0 to 30 inch pound
range
SNAP-ON
Torque Wrench 3/8 Inch
GTE50FA General Maintenance
Drive; 0 to 50 foot-pound
range
SNAP-ON
GTE250 General Maintenance
range
SNAP-ON
GTE602 General Maintenance
range
AEMC
(Optimum Energy Products) 4630 Testing grounds during plant setup
4 Point Ground Tester
H-2
USAF TO 35C2-3-518-1
USA TM 9-6115-484-14
ANNEX I
POWER UNIT LOGIC FLOWCHART
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
True Is this the initial scan after power on? Virtual

INIT_SCN
Initialize Variables Subroutine

False Initialize (Page I-6)
Variables
PPU configuration Subroutine

Main Logic (Page I-7)
Sets station ID & IP address for network Subroutine

Station ID (Page I-10)
Unpacks data from Caterpillar components into Subroutine

Unpack Data RTU usable variables for each engine
(Page I-15)
1 to 2
Calculates the baseload Subroutine

Calculate (Page I-19)
Baseload
Controls engine (1 & 2) emergency stop button Subroutine

Engine ESTOP (Page I-20)
Control
Controls Genset 86 lockouts Subroutine

Lockout (Page I-21)
Page Subprogram continues…

I-4
Note: Program runs as a continuous loop from

power on until power off.
I-3
Page
I-3
Frequency Controls 50/60Hz mode Subroutine

(Page I-23)
Unpacks PDC data into usable variables Subroutine

PDC Status (Page I-25)
Unpack
LS Check True Is automated load sharing enabled? Virtual

Enabled
False Automated load sharing control Subroutine

Load Share (Page I-27)
GenSet Load Unpacks Caterpillar GSC+ data into variables Subroutine

Share Control (Page I-29)
1 to 2
Alarm and fault summary Subroutine

Alarms (Page I-30)
Genarator Calculates total KW load, and number of Subroutine

Count generators needed for load
(Page I-38)
Determines which genset to turn on/off Subroutine

Economy if needed.
(Page I-43)
Page
I-5
I-4
Page
I-4
True Is PPU unit A? DIM1-IN15

Unit A
False
Operate Logic Specific for operating unit A Subroutine
PPU A (Page I-61)
Operate Logic Specific for operating units B, C & D Subroutine

PPU (Page I-66)
1 to 3
Status Controls PDC status LEDs Subroutine

(Page I-70)
DBC Control Logic to control DBC Subroutine

(Page I-73)
Engine Controls engines, first iteration for engine 1, Subroutine

Control second for engine 2.
(Page I-76)
1 to 2
Tie / Feeder
Control Controls tie & feeder breakers Subroutine
(Page I-95)
Announce Controls PPU buzzer. Subroutine

(Page I-102)
Page
I-3
I-5
Start - Initialize Variables Entry point for initialize variables routine
IP Address Sets the Versatrak IP address Virtual
Genset Condition Set each genset condition to "Off" Virtual
Engine Start Set each engine start command to "Off" Virtual
Breaker Control Set each generator remote open/close Virtual

toggle relay to "Off"
Remote Start/Stop Set each generator remote start/stop relay Virtual

to "Off"
1 to 2
Engine Econ. Set engine economizing blocking to "Off" Virtual

Blocking
Baseload Set default baseload setpoint to 500 Virtual

Setpoint
Return End of subprogram.
I-6
Start - Main Logic Entry point for main logic subprogram
SMS True
Not Auto System Mode Switch (SMS) not set to Auto RTU-IN1
False SMS True

Not Manual System Mode Switch (SMS) not set to Manual RTU-IN2
The 3 second delay allows the SMS to Function

False Time Delay transition through OFF to MAN and AUTO
3 seconds positions without start.
No SMS is set to OFF and three second time

True
SMS Change delay has expired.
False PDC Off Set PDC state variable to "Off" Virtual
INIT_SCN Reset initial scan variable to "True". This Virtual

restores the system to power-up state.
Is Master System Enable Toggle bit set to Virtual

True
MSPB_TOG "False"?
=F
False
Genset Initial Set genset initial startup lockout to "False". Virtual

Startup Lockout
Reset
Genset True Check Gen. 1 & 2 Ready variables to see if Virtual

Ready both or only 1 are ready for Auto operation.
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
Page
I-7
Are neither generator 1 nor generator 2 DIM1-IN3 &

Breakers True breakers closed? DIM2-IN3
not closed
Qty Generators Set QTY_GEN_ON internal variable to 0. Virtual

False
On = 0
Is generator 1 breaker open and gen. 2 closed, DIM1-IN3 &

1 breaker True or is gen. 1 breaker closed and gen. 2 open? DIM2-IN3
closed

False
On = 1
Are both generator 1 and generator 2 DIM1-IN3 &

2 breakers True breakers closed? DIM2-IN3
closed

False
On = 2
GMS Is the Generator Mode Switch in Prime Power RTU-IN5

True
Prime Power position?
False LS Check True Is load sharing routine disabled? Virtual

disabled
False
Total KW True Is total system KW load for ORT > 50? Virtual
> 50
Enable Enable the load sharing routine. Virtual

False
LS Check
Sets the auxillary relay for generator breaker Virtual

Set auxillary status to breaker open/close current status.
generator relays
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
Page
I-8
Fuel transfer Enable / disable the fuel transfer pump if DOM1-OUT11

pump Fuel_Permissive relay is on / off.
Did 2500 ms pass since power on? Virtual

True
Startup timer
expired
Turn on the PCM (or keep it on). DOM1-OUT16
False PCM on
B RTU True Is the B designated unit online (connected to Virtual

online the ethernet network)?
False
B_Status_Word Set network value used by "A" unit to check for Virtual
=0 overcurrent on "B" unit to 0.
C RTU True Is the C designated unit online (connected to Virtual

False
C_Status_Word Set network value used by "A" unit to check for Virtual
=0 overcurrent on "C" unit to 0.
D RTU True Is the D designated unit online (connected to Virtual

False
D_Status_Word Set network value used by "A" unit to check for Virtual
=0 overcurrent on "D" unit to 0.
I-9
Start - Station ID Start of Station ID subprogram.
True
MSPB Is the Master Start Enable Switch in either RTU-IN3
ENABLE position?
False Is the System Mode Switch not in the OFF Virtual

True
System mode position (MAN or AUTO)?
<> Off
False True Unit Select Switch is in the A position. DIM1-IN15

USS A
False Station # Set station # variable to 1. Virtual

=1
IP address Set IP address to constant ip1. Virtual

=ip1
Unit Select Switch is in the B position. DIM1-IN16

True
USS B

=2

=ip2
Unit Select Switch is in the C position. DIM2-IN15

True
USS C

=3

=ip3
True Unit Select Switch is in the D position. DIM2-IN16

USS D

=4

=ip4
Page
I-11
I-10
Page
I-10
Is Master System Enable Toggle bit set to Virtual

"False"?
True
MSPB_TOG
=F
Is the PPU System Mode Switch in the 'Off' Virtual
False SMS True position?
=Off
Local PPU configured and ready for operation, Virtual

False
RTU_EN True or False.
=T
PPU station ID set and ready for operation, Virtual

RTU_ON True or False.
=T
Is the local PPU configured and ready for Virtual

True
RTU_ON operation?
=T
False Is the PPU station ID not set and ready for Virtual
True
RTU_EN operation?
=F
False
Is the local PPU not configured and ready for Virtual

True
RTU_ON operation?
=F
False Is the PPU station ID set and ready for Virtual

True
RTU_EN operation?
=T
False
Set IP selection fault to T or F. This block of Virtual

Select Select code is legacy code, and only used to flag a
Fault = F Fault = T mismatch between these variables.
Is the PPU station ID set and ready for Virtual

True
RTU_EN operation?
=F
False Is Master System Enable Toggle bit set to Virtual

True
MSPB_TOG "False"?
=F
False
Page Page
I-12 A I-12 B
I-11
Page Page
I-11 A I-11 B
Is there no IP selection fault? Virtual

True
Select Flt
=F
False MSPB_TOG Set the Master System Enable Toggle bit to T. Virtual
=T
Is the PPU System Mode Switch in the 'OFF' Virtual

SMS True position?
= Off
False MSPB_TOG Set the Master System Enable Toggle bit to F. Virtual
=F
RTU_ON PPU station ID set and ready for operation, Virtual

=F reset to False.
RTU_EN Local PPU configured and ready for operation, Virtual

=F reset to False.
Is local PPU configured and ready for operation, Virtual

RTU_EN True variable changing from T to F?
to F
False
If the input is changing from T to F and the Virtual

Start or Maintain Reset timer timer has been reset, a 1 second timer will start.
Off Timer If the input changes from F to T while the timer
is running, the timer will cancel and reset.
Timer True Did the timer expire? Virtual

expired
False Set the station number to 6. Having a station Virtual

Station # number of 6 means the PPU is locked out of
=6 automated load sharing.
Set the IP address to the constant ip6. Virtual

Set IP Addr.
to ip6
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
Page
I-12
Is the PPU System Mode Switch in the 'OFF' Internal

SMS False position?
= Off
Was IP set as station 1? Internal

True
IP 1 was True
set
False
Is the Unit Select Switch in the "A" position? RTU-OUT1

USS True
=A
False
USS A USS A USS A PPU is configured as unit "A", T or F. RTU-OUT1

=F =F =T

IP 2 was True
set
False
Is the Unit Select Switch in the "B" position? RTU-OUT2

USS True
=B
False
USS B USS B USS B PPU is configured as unit "B", T or F. RTU-OUT2

=F =F =T

IP 3 was True
set
False
Is the Unit Select Switch in the "C" position? RTU-OUT3

USS True
=C
False
USS C USS C USS C PPU is configured as unit "C", T or F. RTU-OUT3

=F =F =T
Page Page
I-14 A I-14 B
I-13
Page Page
I-14 A I-14 B

IP 4 was True
set
False
Is the Unit Select Switch in the "D" position? RTU-OUT4

USS True
=D
False
USS D USS D USS D PPU is configured as unit "D", T or F. RTU-OUT4

=F =F =T
I-14
Start - Unpack Data Entry point for unpack data routine
Gen. Is the generator x breaker closed? DIM1-IN3 or

True
breaker closed DIM2-IN3
False
Is the Engine Control Switch in the MAN Virtual

ECS True position?
Manual
False
Unpack GSC Takes 16-bit analog from GSC and unpacks Function
Alarm Data into 16 1-bit booleans.
High coolant temperature alarm variable is Virtual

HCT Alarm HCT Alarm false or the value from the Cat GSC.
=F =GSC T/F
Low coolant temperature alarm variable is Virtual

LCT Alarm LCT Alarm false or the value from the Cat GSC.
=F =GSC T/F
Low oil pressure alarm variable is false or the Virtual

LOP Alarm LOP Alarm value from the Cat GSC.
=F =GSC T/F
Engine control switch alarm variable is false or Virtual

ECS Alarm ECS Alarm the value from the Cat GSC.
=F =GSC T/F
High oil temperature alarm variable is false or Virtual

HOT Alarm HOT Alarm the value from the Cat GSC.
=F =GSC T/F
ADEM unit control alarm variable is false or Virtual

Control Alarm Control Alarm the value from the Cat GSC.
=F =GSC T/F
Is the Engine Control Switch in the OFF RESET Virtual

True
ECS Position position?
=1
False
Set ESC_OFF boolean to T or F. Virtual

ESC_OFF ESC_OFF
=F =T
Page
I-16
I-15
Page
I-15
Is the Engine Control Switch in the OFF RESET Virtual

True
=2
False
Set ESC_MAN boolean to T or F. Virtual

ESC_MAN ESC_MAN
=F =T
Is the Engine Control Switch in the COOLDOWN Virtual

True
=3
False
Set ESC_STOP boolean to T or F. Virtual

ESC_STOP ESC_STOP
=F =T
Is the Engine Control Switch in the AUTO Virtual

True
=4
False
Set ESC_AUTO boolean to T or F. Virtual

ESC_AUTO ESC_AUTO
=F =T
Takes 16-bit analog from GSC and unpacks Function

Unpack GSC into 16 1-bit booleans.
Shutdown Data
ADEM fault shutdown from Cat GSC, T or F. Virtual

CL Shdn
=GSC T/F
Emergency stop shutdown from Cat GSC, T or F. Virtual

EStop Shdn
=GSC T/F
ORT immediate stop shutdown from Cat GSC, Virtual

SF Shdn T or F.
=GSC T/F
High coolant temperature shutdown from Virtual

HCT Shdn Cat GSC, T or F.
=GSC T/F
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I-17
I-16
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I-16
Low oil pressure shutdown from Cat GSC, T or F. Virtual

LOP Shdn
=GSC T/F
Overcrank shutdown from Cat GSC, T or F. Virtual

OC Shdn
=GSC T/F
Overspeed shutdown from Cat GSC, T or F. Virtual

OSS Shdn
=GSC T/F
Gen. Is the generator x breaker closed? DIM1-IN3 or

True
breaker closed DIM2-IN3
False
Is the generator in cooldown status? Virtual

Gen. In True
Cooldown
False Takes 16-bit analog from GSC and unpacks Function

Unpack into 16 1-bit booleans.
Generator Alarms
Generator underfrequency alarm variable is Virtual

Gen UnFreq Gen UnFreq false or the value from the Cat GSC.
=F =GSC T/F
Generator overfrequency alarm variable is Virtual

Gen OvFreq Gen OvFreq false or the value from the Cat GSC.
=F =GSC T/F
Generator undervoltage alarm variable is Virtual

Gen UnVolt Gen UnVolt false or the value from the Cat GSC.
=F =GSC T/F
Generator overvoltage alarm variable is Virtual

Gen OvVolt Gen OvVolt false or the value from the Cat GSC.
=F =GSC T/F
Generator frequency sensing alarm variable is Virtual

Gen FreqSense Gen FreqSense false or the value from the Cat GSC.
=F =GSC T/F
Generator reverse power alarm variable is Virtual

Gen RevPow Gen RevPow false or the value from the Cat GSC.
=F =GSC T/F
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I-17
Page
I-17
Unpack Gen. Takes 16-bit analog from GSC and unpacks Function
Shutdown Data into 16 1-bit booleans.
Generator underfrequency shutdown variable is Virtual

Gen UnFreq set to the value from the Cat GSC.
=GSC T/F
Generator overfrequency shutdown variable is Virtual

Gen OvFreq set to the value from the Cat GSC.
=GSC T/F
Generator undervoltage shutdown variable is Virtual

Gen UnVolt set to the value from the Cat GSC.
=GSC T/F
Generator overvoltage shutdown variable is Virtual

Gen OvVolt set to the value from the Cat GSC.
=GSC T/F
Generator frequency sensing shutdown variable Virtual

Gen FreqSense is set to the value from the Cat GSC.
=GSC T/F
Generator reverse power shutdown variable is Virtual

Gen RevPow set to the value from the Cat GSC.
=GSC T/F
Generator running status variable = engine Virtual

Gen. Run = running status variable.
Eng. Run
I-18
Start - Calculate Baseload
GMS Is the Generator Mode Switch in the RTU-IN5

Baseload True BASELOAD position?
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
Start - Engine Emg. Stops
ECS 1 Did Engine Control Switch for engine 1 change Virtual

True
to OFF positions to OFF RESET?
Reset engine 1's remote emergency stop toggle Virtual

False Reset Engine 1 to false.
Emerg. Stop
Eng. 1 Is the emergency stop toggle true for engine 1? Virtual

True
Emerg. Stop
False
NGR 1 Is there a Neutral Ground Resister fault on DIM1-IN7

True
Fault gererator 1?
False
Set Spare Immediate Shutdown to True or DOM2-OUT15

Spare Immediate Spare Immediate False for generator 1.
Shutdown = F Shutdown = T
ECS 2 Did Engine Control Switch for engine 2 change Virtual

True
to OFF positions to OFF RESET?
Reset engine 2's remote emergency stop toggle Virtual

False Reset Engine 2 to false.
Emerg. Stop
Eng. 2 Is the emergency stop toggle true for engine 2? Virtual

True
Emerg. Stop
False
NGR 2 Is there a Neutral Ground Resister fault on DIM2-IN7

True
Fault gererator 2?
False
Set Spare Immediate Shutdown to True or DOM2-OUT16

Spare Immediate Spare Immediate False for generator 2.
Shutdown = F Shutdown = T
I-20
Start - Lockout
Run for each genset (1 and 2) in local PPU.
Gen. True Is there an overcurrent relay trip signal on DIM1-IN5 or

OC Trip generator x? DIM2-IN5
False
NGR True Is there a Neutral Ground Resister fault on DIM1-IN7 or

Fault gererator x? DIM2-IN7
False
Eng. True Is engine x flagged to shutdown? Virtual

Shutdown
False
Gen. True Is generator x flagged to shutdown? Virtual

Shutdown
False
MSES Is the Master Start Enable Switch not in either RTU-IN3

True
Not enable ENABLE position?
False Gen. True Is generator x lockout control set to True? Virtual

Lockout
False
Set generator x lockout control to True or False. Virtual

Gen. Lockout Gen. Lockout
=F =T
1 to 2
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I-21
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I-21
Tie True Is there a tie overcurrent relay trip? DIM1-IN13

OC Trip
False
MSES Is the Master Start Enable Switch not in either RTU-IN3

True
Not enable ENABLE position?
False
Is tie lockout set to T? Virtual
True
Tie lockout
False
Tie lockout Tie lockout Set tie lockout to T or F. Virtual

=F =T
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
Return End of subroutine.
I-22
Start - Frequency
FSS Switch set for 50 Hz operation. RTU-IN6

True
50 Hz
False System mode switch is in the OFF position and Virtual

True
SMS Off parameters have been cleared.
False PLC output shows 60 Hz. DOM1-OUT10

PLC True
60 Hz
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
KW Setpoint Set KW setpoint for loadsharing at 391 Virtual

=391
Rating 60Hz Rating 60Hz Current rating of 60Hz variable is T or F. Virtual

=F =T
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I-23
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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
KW Setpoint Set KW setpoint for loadsharing at 334. Virtual

=334
Rating 50Hz Rating 50Hz Current rating of 50Hz variable is T or F. Virtual

=F =T
I-24
Start - PDC Status
PPU A True Is the PPU configured as A on? RTU-OUT1

is on
Break B Status from 16-bit word into 16 1-bit Function

False
Unpack B Status booleans. B status is the network value used
Data by A PPU to check for overcurrents on B PPU.
B PPU Gen. 1 Set overcurrent flag on B PPU generator 1 to Virtual

overcurr. = T/F T or F, as reported by B PPU.
B PPU Gen. 2 Set overcurrent flag on B PPU generator 2 to Virtual

B PPU Tie Set overcurrent flag on B PPU tie connector to Virtual

Break C Status from 16-bit word into 16 1-bit Function

Unpack C Status booleans. C status is the network value used
Data by A PPU to check for overcurrents on C PPU.
C PPU Gen. 1 Set overcurrent flag on C PPU generator 1 to Virtual

overcurr. = T/F T or F, as reported by C PPU.
C PPU Gen. 2 Set overcurrent flag on C PPU generator 2 to Virtual

C PPU Tie Set overcurrent flag on C PPU tie connector to Virtual

Break D Status from 16-bit word into 16 1-bit Function

Unpack D Status booleans. D status is the network value used
Data by A PPU to check for overcurrents on D PPU.
D PPU Gen. 1 Set overcurrent flag on D PPU generator 1 to Virtual

overcurr. = T/F T or F, as reported by D PPU.
D PPU Gen. 2 Set overcurrent flag on D PPU generator 2 to Virtual

D PPU Tie Set overcurrent flag on D PPU tie connector to Virtual

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I-26 A I-26 B
I-25
Page Page
I-25 A I-25 B
Is the overcurrent flag set to T for the A PPU Virtual

A Gen. 1 True generator 1?
Overcurr.
False
Is the overcurrent flag set to T for the A PPU Virtual

A Gen. 2 True generator 2?
Overcurr.
False
Is the overcurrent flag set to T for the B PPU Virtual

B Gen. 1 True generator 1?
Overcurr.
False
Is the overcurrent flag set to T for the B PPU Virtual

B Gen. 2 True generator 2?
Overcurr.
False
Is the overcurrent flag set to T for the C PPU Virtual

C Gen. 1 True generator 1?
Overcurr.
False
Is the overcurrent flag set to T for the C PPU Virtual

C Gen. 2 True generator 2?
Overcurr.
False
Is the overcurrent flag set to T for the D PPU Virtual

D Gen. 1 True generator 1?
Overcurr.
False
Is the overcurrent flag set to T for the D PPU Virtual

D Gen. 2 True generator 2?
Overcurr.
Genset True Is the summary genset lockout boolean flag Virtual

lockout set to T?
MSES Is the Master Start Enable Switch not set to RTU-IN3

False True
=F one of the ENABLE positions?
Genset lockout False Genset lockout Set summary genset lockout boolean flag to Virtual
=F =T T or F.
I-26
Start - Load Share
Load Share True Is automated load sharing enabled? Virtual

Enabled
Calculate load per online generator, = total KW Virtual

False
Set load per load ÷ the number of online generators. This
online generator value is then converted into a Real number.
Gen. True Does the number of online generators = 0? Virtual

online=0
False
per_gen_1 per_gen_1 Set load sharing error control #1 to T or F. Virtual

=F =T
Calculate the maximum load per online Virtual

Set maximum generator, = load per online generator + 50.
load per generator

=F =T
Calculate the minimum load per online Virtual

Set minimum generator, = load per online generator - 50.
load per generator

=F =T
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I-27
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I-27
Total KW True Is total load < 50 KW? Virtual

< 50
False
Tie Is the tie breaker open? DIM1-IN12

True
not closed
False
Gen. 1 Is the breaker for local PPU generator 1 open? DIM1-IN3

True
breaker not
closed
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
Disable automated load sharing. Virtual

Load sharing
enable = F
I-28
Start - GenSet Load Share This program runs twice on each PPU: once for
generator 1 and once for generator 2.
Is the breaker closed for generator x (1 or 2, DIM1-IN3 or

True
Gen. breaker depending on which generator this subroutine DIM2-IN3
closed is run for)?
False
Is automated loadsharing enabled? Virtual

True
Load share
enabled
False
Gen. Is the KW load on generator x (1 or 2) Virtual

True
KW out of LS outside the limits Min and Max previously set
range for load sharing, including a 10 KW hysteresis?
False Is the value changing from F to T? Function

Changing F
to T
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
Start - Alarms
Is there a high coolant temperature alarm on GSC

True
High coolant generator 1 from the GSC?
temp
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
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
Is the output of the above logic structure

True
Changing Changing True changing from T to F or F to T?
T to F F to T
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.
Timer True Did the 2 second timer expire? Function

expired
False
Engine 1 alarm Engine 1 alarm Set engine 1 alarm status to T or F. Virtual

=F =T
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I-31
I-30
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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
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I-31
Page Page
I-31B I-31B
True
fault
False
Is there low fuel level in PPU daytank? DIM2-IN13

True
Low fuel
in daytank
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.
Timer True Did the low fuel level timer expire?

expired
False
Eng. 1 shutdown Eng. 1 shutdown Eng. 1 shutdown Engine 1 shutdown = T or F. Virtual

=F =F =T
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.
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I-33
I-32
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I-32
Is there a high coolant temperature alarm on GSC

True
High coolant generator 2 from the GSC?
temp
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
False
True
High oil Is there a high oil ressure alarm on generator 2 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
Is the output of the above logic structure

True
Changing Changing True changing from T to F or F to T?
T to F F to T
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.
Timer True Did the 2 second timer expire? Function

expired
False
Engine 2 alarm Engine 2 alarm Set engine 2 alarm status to T or F. Virtual

=F =T
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I-33
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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
fault
False
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I-35A I-35B
I-34
Page Page
I-34B I-34B
True
fault
False
Is there low fuel level in PPU daytank? DIM2-IN13

True
Low fuel
in daytank
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.
Timer True Did the low fuel level timer expire?

expired
False
Eng. 2 shutdown Eng. 2 shutdown Eng. 2 shutdown Engine 2 shutdown = T or F. Virtual

=F =F =T
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
False
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I-36A I-36B
I-35
Page Page
I-35A I-35B
True
Undervolt. Is there an undervoltage alarm on generator x GSC
False
True
Overvolt. Is there an overvoltage alarm on generator x GSC
False
True
Rev. power Is there a reverse power alarm on generator x 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
Gen. alarm Gen. alarm Summary alarm for generator x =T or F. Virtual

=F =T
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
Gen. shutdown Gen. shutdown Generator x shutdown is T or F. Virtual

=F =T
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I-36
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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
Page Loop, first time for genset 1 then for genset 2.

I-35
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).
Take modulo of Take the modulo (remainder) of the division,

divided delay time, divide by 1000 to get seconds. Function
divide by 1,000
Set the minutes and seconds remaining until Virtual

Set minutes until Set seconds until the PPU shuts down for low fuel alarm.
LF shutdown LF shutdown
I-37
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.
Sum generator Take the KW loads from generators 1 & 2 on Function

KW loads PPU A, B, C and D and sum them.
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.
Total KVA Set total KVA variable to the sum. Virtual

= sum
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
r1gen = F r1gen = T Plant requires 1 generator, T or F. Virtual
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I-38
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I-38
True
Total KW Is the total KW load > the KW setpoint × 1? Virtual
load > sp
False
True
load <= sp
False
True
Total KVA Is the total KVA load > the KVA setpoint × 1? Virtual
load > sp
False
True
load <= sp
False
True
False
r2gen = F r2gen = T Plant requires 2 generators, T or F. Virtual
True
load > sp
False
True
load <= sp
False
True
load > sp
False
True
load <= sp
False
True
False
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I-40
I-39
Page
I-39
True
load > sp
False
True
load <= sp
False
True
load > sp
False
True
load <= sp
False
True
False
True
load > sp
False
True
load <= sp
False
True
load > sp
False
True
load <= sp
False
True
False
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I-41
I-40
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I-40
True
load > sp
False
True
load <= sp
False
True
load > sp
False
True
load <= sp
False
True
False
True
load > sp
False
True
load <= sp
False
True
load > sp
False
True
load <= sp
False
True
False
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I-41
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I-41
True
load > sp
False
True
load > sp
False
I-42
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
2 gen.
False
True
<2
False
True
3 gen.
False
True
<3
False
True
4 gen.
False
True
<4
False
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I-43
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I-43A I-43B
True
5 gen.
False
True
<5
False
True
6 gen.
False
True
<6
False
True
7 gen.
False
True
<7
False
True
8 gen.
False
True
<8
False
True
No genset Is the no genset currently locked out? Virtual
lockout
False
Add_Gen Add_Gen Set the Add_Gen flag to T or F (flags logic Virtual

=F =T to start another genset).
True
7 gen.
False
True
Gen. online Is the number of generators online > 7? Virtual
>7
False
Page Page Page

I-45A I-45B I-45C
I-44
Page Page Page
I-44A I-44B I-44C
True
6 gen.
False
True
>6
False
True
5 gen.
False
True
>5
False
True
4 gen.
False
True
>4
False
True
3 gen.
False
True
>3
False
True
2 gen.
False
True
>2
False
True
1 gen.
False
True
>1
False
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I-46A I-46B I-46C
I-45
Page Page
I-45A I-45C
Page
I-45B
True
No load Is automated load management enabled? Virtual
mgt. block
False
Sub_Gen Sub_Gen Set the Sub_Gen flag to T or F (flags logic Virtual

=F =T to turn off a genset).
Is flag set to turn off one genset? Virtual

True
Sub-Gen
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
I-46
Page Page Page
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
Sub-Gen
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 Does the D PPU have exactly one genset Virtual

True
D unit available?
single
False
True
D unit Does the D PPU have no gensets available? Virtual
none
False
Page Page Page

I-48A I-48B I-48C
I-47
Page Page Page
I-47A I-47B I-47C
True
A unit Does the A PPU have exactly one genset Virtual
single available?
False
True
none
False
True
single available?
False
True
none
False
True
single available?
False
True
none
False
True True
T to F F to T
False False
Reset timer Start 3 minute timer Start or reset a 3 minute timer. Function
True
expired
False
Subtract C Gen. Subtract C Gen. Flag C PPU to shut off a genset, T or F. Virtual
=F =T

True
Sub-Gen
False
Page Page
I-49A I-49B
I-48
Page Page
I-48A I-48B
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 Does the C PPU have exactly one genset Virtual

True
C unit available?
single
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
D unit True Does the D PPU have no gensets available? Virtual

none
False
Does the A PPU have exactly one genset Virtual

True
A unit available?
single
False
True
none
False
True
single available?
False
True
none
False
True
none
False
Page Page
I-50A I-50B
I-49
Page Page
I-49A I-49B
True True
T to F F to T
False False
True
expired
False
Subtract B Gen. Subtract B Gen. Flag B PPU to shut off a genset, T or F. Virtual
=F =T

True
Sub-Gen
False True
A unit Does the A PPU have both gensets available? Virtual
dual
False
True
single available?
False
True
none
False
True
single available?
False
True
none
False
Page Page
I-51A I-51B
I-50
Page Page
I-50A I-50B
single available?
False
D unit True Does the D PPU have no gensets available? Virtual

none
False
True True
T to F F to T
False False
True
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
Page Page Page

I-52A I-52B I-52C
I-51
Page Page Page
I-51A I-51B I-51C
local unit True Does the local PPU not have either genset Virtual
not single online?
False
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
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
Page Page
I-53A I-53B
I-52
Page Page
I-52A I-52B
True True
T to F F to T
False False
True
expired
False
Add A Gen. Add A Gen. Flag A PPU to start a genset, T or F. Virtual

=F =T
True
False
True
A unit Does the A unit recognize the B unit? Virtual
sees B
False
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
single available?
False
A unit True Does the A unit have neither genset online? Virtual
none
False
Page Page Page Page

I-54A I-54B I-54C I-54D
I-53
Page Page Page Page
I-53A I-53B I-53C I-53D
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
single available?
False
single available?
False
B unit True Does the B PPU have no gensets available? Virtual

none
False
single available?
False
C unit True Does the C PPU have no gensets available? Virtual

none
False
see C
False
D unit True Does the C PPU have exactly one genset Virtual
single available?
False
D unit True Does the C PPU have no gensets available? Virtual

none
False
see D
False
Page Page
I-54A I-54B
I-54
Page Page
I-54A I-54B
True True
T to F F to T
False False
True
expired
False
Add B Gen. Add B Gen. Flag B PPU to start a genset, T or F. Virtual

=F =T
True
False
True
A unit Does the A unit recognize the C unit? Virtual
sees C
False
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
single available?
False
dual available?
False
Page Page Page

I-56A I-56B I-56C
I-55
Page Page Page
I-55A I-55B I-55C
single available?
False
B unit True Does the B PPU have both gensets Virtual

dual available?
False
single available?
False
dual available?
False
single available?
False

dual available?
False
single available?
False
C unit True Does the C PPU have neither genset Virtual

none available?
False
single available?
False
D unit True Does the D PPU have both gensets Virtual

dual available?
False
A unit not True Does the A unit not recognize the D unit? Virtual
see D
False
Page Page
I-57A I-57B
I-56
Page Page
I-56A I-56B
True True
T to F F to T
False False
True
expired
False
Add C Gen. Add C Gen. Flag C PPU to start a genset, T or F. Virtual

=F =T
True
False
True
A unit Does the A unit recognize the D unit? Virtual
sees D
False
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
single available?
False
dual available?
False
Page Page Page

I-58A I-58B I-58C
I-57
Page Page Page
I-57A I-57B I-57C
single available?
False

dual available?
False
single available?
False
C unit True Does the B PPU have both gensets Virtual

dual available?
False
single available?
False
dual available?
False
single available?
False

dual available?
False
single available?
False
C unit True Does the C PPU have both gensets Virtual

dual available?
False
single available?
False
Page Page
I-59A I-59B
I-58
Page Page
I-58A I-58B
True True
T to F F to T
False False
True
expired
False
Add D Gen. Add D Gen. Flag D PPU to start a genset, T or F. Virtual

=F =T
local unit True Does the local PPU not have exactly one Virtual
not single genset available?
False
not dual available?
False
A_No_Gen A_No_Gen A unit has no gensets available, T or F. Virtual

=F =T
B unit True Does the B PPU not have exactly one genset Virtual
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
B_No_Gen B_No_Gen B_No_Gen B_No_Gen B unit has no gensets available, T or F. Virtual

=F =T =F =T
Page
I-58A
I-59
Page
I-58A
C unit True Does the C PPU not have exactly one genset Virtual
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
C_No_Gen C_No_Gen C_No_Gen C_No_Gen C unit has no gensets available, T or F. Virtual

=F =T =F =T
D unit True Does the D PPU not have exactly one genset Virtual
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
D_No_Gen D_No_Gen D_No_Gen D_No_Gen D unit has no gensets available, T or F. Virtual

=F =T =F =T
I-60
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
Return Return Exit Subroutine.
local PPU True Is the local PPU configured and ready for Virtual
enabled operation?
False
A_RTU_EN A_RTU_EN Set A PPU enabled variable, T or F. Virtual

=F =T
station True Is the local PPU station ID set and ready for Virtual
ready operation?
False
A_RTU_ON A_RTU_ON Set A PPU station ID set variable, T or F. Virtual

=F =T
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
Page Page
I-62A I-62B
I-61
Page Page
I-61A I-61B
B_Qty_On Set B PPU generator quantity online to 0. Virtual

=0
B_0_Generators B_0_Generators Set B 0 generators online variable, T or F. Local

=T =F
single online?
False

=1
B_1_Generator B_1_Generator Set B 1 generator online variable, T or F. Local

=F =T
B unit True Does the B PPU have both genset online? Virtual
dual
False

=2
B_2_Generators B_2_Generators Set B 2 generator online variable, T or F. Local

=F =T
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
Page Page
I-63A I-63B
I-62
Page Page
I-62A I-62B
C_Qty_On Set C PPU generator quantity online to 0. Virtual

=0
C_0_Generators C_0_Generators Set C 0 generators online variable, T or F. Local

=T =F
single online?
False

=1
C_1_Generator C_1_Generator Set C 1 generator online variable, T or F. Local

=F =T
C unit True Does the C PPU have both genset online? Virtual
dual
False

=2
C_2_Generators C_2_Generators Set C 2 generator online variable, T or F. Local

=F =T
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
Page Page
I-64A I-64B
I-63
Page Page
I-63A I-63B
D_Qty_On Set D PPU generator quantity online to 0. Virtual

=0
D_0_Generators D_0_Generators Set D 0 generators online variable, T or F. Local

=T =F
single online?
False

=1
D_1_Generator D_1_Generator Set D 1 generator online variable, T or F. Local

=F =T
D unit True Does the C PPU have both genset online? Virtual
dual
False
=2
D_2_Generators D_2_Generators Set D 2 generator online variable, T or F. Local

=F =T
Gen. 1 Total KW Divide generator 1 total KW by 1000. Function

/ 1000
Gen. 1 KW Set generator 1 KW to calculated value. Virtual

= Value

/ 1000

= Value
Page
I-65
I-64
Page
I-64
Gen. 1 Total KVA Divide generator 1 total KVA by 1000. Function

/ 1000
Gen. 1 KVA Set generator 1 KVA to calculated value. Virtual

= Value

/ 1000

= Value
Gen. 1 Total KVAR Divide generator 1 total KVAR by 1000. Function

/ 1000
Gen. 1 KVAR Set generator 1 KVAR to calculated value. Virtual

= Value

/ 1000

= Value
I-65
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
Unit True Is the PPU configured as "A"? Virtual

is A
False
Unit True Is the PPU configured as Y (C if first iteration, Virtual

is Y B otherwise)?
False
Unit True Is the PPU configured as Y (C if third iteration, Virtual

is Z D otherwise)?
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).
SMS True Is the System Mode Switch in the AUTO RTU-IN1

AUTO position?
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
Gen. 1 True Is generator 1 auto sync run enabled? Virtual

auto sync.
False
Page Page
I-67A I-67B
I-66
Page Page
I-66A I-66B
Gen. 1 RB True Is generator 1 remote breaker open? Virtual

open
False Gen. 1 breaker Close generator 1's breaker for PPU X. Virtual
= close
Gen. 1 RB True Is generator 1 remote breaker closed? Virtual

closed
False
Gen. 1 B True Is generator 1 breaker open enabled? DOM1-OUT6

enabled
False
E1 Autorun True Is engine 1 autorun enabled? Virtual

enabled
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
SMS True Is the System Mode Switch in the AUTO RTU-IN1

AUTO position?
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
Gen. 2 True Is generator 2 auto sync run enabled? Virtual

auto sync.
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
Page
I-68
I-67
Page
I-67
Gen. 2 RB True Is generator 2 remote breaker closed? Virtual

closed
False
Gen. 2 B True Is generator 2 breaker open enabled? DOM2-OUT6

enabled
False
E2 Autorun True Is engine 1 autorun enabled? Virtual

enabled
False
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

/ 1000

= Value

/ 1000

= Value

/ 1000

= Value
Page
I-69
I-68
Page
I-68

/ 1000

= Value

/ 1000

= Value

/ 1000

= Value
PPU X status Set status word for PPU X to 1. Virtual

word = 1
I-69
Start - Status Start of subroutine to control status LEDs.
Eng. 1 True Is there an alarm on engine 1? Virtual

alarm
False
Gen. 1 True Is there an alarm on generator 1? Virtual

alarm
False
Eng. 2 True Is there an alarm on engine 2? Virtual

alarm
False
Gen. 2 True Is there an alarm on generator 2? Virtual

alarm
False
Buzzer True Is the alarm buzzer energized DOM1-OUT15

energized
False
Blink Blink output on/off, 1 second per state. Function
Amber SSL Amber SSL Amber SSL Turn the amber system status light on/off. DOM2-OUT14
= Off = On = On/Off
Gen. 1 True Is generator 1 lockout set? Virtual

lockout
False

lockout
False
Tie True Is tie contactor lockout set? Virtual

lockout
False
Page Page
I-71A I-71B
I-70
Page Page
I-70A I-70B
Buzzer True Is the alarm buzzer energized? DOM1-OUT15

energized
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
Gen. 1 True Is generator 1 ready for automatic operation? Virtual

ready
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
No gen. 1 True Is generator 1 lockout not set? Virtual

lockout
False
Eng. 1 True Is there an engine 1 alarm? Virtual

alarm
False
Gen. 1 True Is there a generator 1 alarm? Virtual

alarm
False

lockout
False
Page Page Page

I-72A I-72B I-72C
I-71
Page Page Page
I-72A I-72B I-72C
Blink Blink output on/off, 500 millisecond per state. Function
Gen. 1 SSL Gen. 1 SSL Gen. 1 SSL Turn the generator 1 status light on/off. DOM1-OUT13
= Off = On/Off = On
Gen. 2 True Is generator 2 ready for automatic operation?

ready Virtual
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
No gen. 2 True Is generator 2 lockout not set?

lockout Virtual
False
Eng. 2 True Is there an engine 2 alarm?

alarm Virtual
False
Gen. 2 True Is there a generator 2 alarm?

alarm Virtual
False
Gen. 2 True Is generator 2 lockout set?

lockout Virtual
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
I-72
Start - DBC Control Subroutine to control DBC.
PPU not True Is the PPU not configured as "A"? RTU-OUT1

A
False Return Exit subroutine.
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
Blink Blink output on/off, 2.5 seconds per state. Function
Counter of Counter of Pulse On/Off to transfer dead bus close Virtual

DBP = Off DBP = On/Off permissive between generators.
DBP pulse True Is the dead bus close permissive transfer pulse Virtual
Off to On changing from Off to On?
False
Increment counter Increment a counter. Function
Counter True Has the counter reached 4 (4 DBP pulses)? Function

=4
False
Reset counter Reset the counter to 0. Function
DBC current Set dbc current value variable to the counter. Virtual
value = counter
Page
I-74
I-73
Page
I-73
Tie output True Is the tie output bus energized? DIM2-IN11

energ.
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
Reset counter Reset the dbc counter to 0. Function
DBC curr. True Does the dbc current value = 0? Virtual

val. = 0
False
A DBC A DBC Dead bus permissive set to "A" PPU, T or F. Virtual

=F =T

val. = 1
False
B DBC B DBC Dead bus permissive set to "B" PPU, T or F. Virtual

=F =T

val. = 2
False
C DBC C DBC Dead bus permissive set to "C" PPU, T or F. Virtual

=F =T
Page
I-75
I-74
Page
I-74

val. = 3
False
D DBC D DBC Dead bus permissive set to "D" PPU, T or F. Virtual

=F =T
Current DBC Set current DBC value to 0. Virtual

value = 0
I-75
Start - Engine Control Subroutine to control engines. This subroutine
runs twice, once for each engine (X = 1, 2).
MSPB_TOG True Is the master system enable toggle = T? Virtual

=T
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
Eng. X True Is engine X flagged to start for initial power Virtual

initial start plant startup?
False
Eng. X block Block engine X from starting on initial power Virtual
from start = T plant startup.
Gen. X True Is generator X not available for auto operation? Virtual

ready
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
Gen. 1 True Is generator 1 not configured and ready for Virtual

not ready operation?
False
X= True Does X = 2 (second iteration of this program)?

genset 2
False
Gen. X start Gen. X start Flag generator X to start on initial power plant Virtual
=F =T startup, T or F.
Page
I-77
I-76
Page
I-76
Eng. X ECS True Is the engine control switch for engine X in the Virtual
AUTO AUTO position?
False
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
Gen. X True Is the generator X lockout control set to F? Virtual

lockout = F
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
Page Page Page

I-78A I-78B I-78C
I-77
Page Page Page
I-77A I-77B I-77C
Start 2 second Start a 2 second timer.

Timer
Changing True Is the output changing from T to F?

T to F
False
Reset Reset the timer.
Timer
Timer True Did the timer expire?

expire
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.
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
USS True Is the unit select switch in the B position? RTU-OUT2

B
False
B sub. gen. True Is the B PPU flag to shut down one genset Virtual
False
Page Page Page

I-79A I-79B I-79C
I-78
Page Page Page
I-78A I-78B I-78C
USS True Is the unit select switch in the C position? RTU-OUT3

C
False
C sub. gen. True Is the C PPU flag to shut down one genset Virtual
False
USS True Is the unit select switch in the D position? RTU-OUT4

D
False
D sub. gen. True Is the D PPU flag to shut down one genset Virtual
False
Gen. X br. True Is the breaker for generator X closed? DIM1-IN3 or

closed DIM2-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
Gen. X Aux. Gen. X Aux. Set generator X auxillary stop 1 to T or F. Virtual

stop 1 = F stop 1 = T
OFF OFF / RESET position?
False
PDC True Is the system mode switch in the OFF position Virtual
OFF and parameters have cleared?
False
Page Page
I-80A I-80B
I-79
Page Page
I-79A I-79B
Gen. X True Is lockout set for generator X? Virtual

lockout
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
Genset True Is the summary genset lockout flag set to T? Virtual

lockout
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.
Gen. X True Is start/stop permissive for generator X = F? Virtual

start/stop
False
Gen. X True Is auxillary stop relay #1 for generator X Virtual
aux. stop 1 from F to T?
False
Gen. X True Is auxillary stop relay #1 for generator X Virtual

aux. stop 2 from F to T?
False
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
Gen. X RSS Reset remote start/stop for generator X to F. Virtual

=F
Page
I-81
I-80
Page
I-80
AUTO AUTO position?
False
=T
False
Eng. X True Is engine X not running? Virtual
not running
False
Gen. X True Is generator X in cooldown? Virtual

cooldown
False
Gen. X True Is the summary failure set to F for generator X? Virtual
no failure
False
Gen. Y True Is the summary failure set to F for generator Y Virtual

no failure (the generator this iteration is not running for)?
False
MSES True Is the master start eneable switch is changing RTU-IN3
F to T to either of the two enable positions?
False

running
False
SMS trans. True Is the system mode switch transfering between Virtual
=T AUTO and MAN?
False
Gen. X True Is generator X flagged to run on initial power Virtual

init. run planr startup?
False
Start 2 = F Start 2 = T T or F.
Page
I-82
I-81
Page
I-81
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
Gen. Y True Is generator Y not available for auto operation? Virtual

not ready
False
Gen. X True Is generator X available for auto operation? Virtual
ready
False
Gen. Y True Is the breaker for generator Y closed (the DIM2-IN3 or

brk. Closed generator this iteration is not run for)? DIM1-IN3
False
PPU True Is the PPU configured as "A"? RTU-OUT1

A
False
A add gen. True Is the flag for the A PPU to add a genset Virtual
False
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I-83A I-83B I-83C
I-82
Page Page Page
I-82A I-82B I-82C
PPU True Is the PPU configured as "B"? RTU-OUT2

B
False
B add gen. True Is the flag for the B PPU to add a genset Virtual
False
PPU True Is the PPU configured as "C"? RTU-OUT2

C
False
C add gen. True Is the flag for the C PPU to add a genset Virtual
False
PPU True Is the PPU configured as "D"? RTU-OUT2

D
False
D add gen. True Is the flag for the D PPU to add a genset Virtual
False
Start 1 = F Start 1 = T T or F.
Gen. X True Is start/stop permissive for generator X = F? Virtual

start/stop
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
Page Page Page

I-84A I-84B I-84C
I-83
Page Page Page
I-83A I-83B I-83C
AUTO AUTO position?
False
Gen. X RSS True Is the remote start/stop flag for generator X Virtual
False
Gen. X Set start/stop permissive for generator X to F. Virtual
start/stop = F
Gen. X RSS Set remote start/stop flag for generator X to T. Virtual

=T

=T
False
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
Page Page
I-85A I-85B
I-84
Page Page
I-84A I-84B
Changing True Is the input changing from T to F?

T to F
False
Reset timer Reset the timer. Function
Timer True Has the 250 ms timer expired?

expired
False
Eng. X autorun Eng. X autorun Set engine X autorun, T or F. Virtual

=F =T
Autostart True Is generator X flagged to autostart? DOM1-OUT2 or

gen. X DOM2-OUT2
False
MAN MAN position?
False
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-86A I-86B I-86C
I-85
Page Page Page
I-85A I-85B I-85C
60 Hz True Is the PPU set for 60 Hz? Virtual

mode
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

F to T
False
Start 3 second Start a 3 second timer. Function
timer

T to F
False
Reset timer Reset the timer. Function
Timer True Has the 3 second timer expired?

expired
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.
Page
I-87
I-86
Page
I-86
Gen. X True Is generator X running and ready for load? Virtual

ready
False
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
X=2 True Does X = 2 (is this the second iteration of this

program, run for genset 2)?
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
Input is True Is the blink input on (in the on/off cycle)?

on
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
PPU True Is the PPU configured as "B"? RTU-OUT2

B
False
B DBC True Is the B PPU dead bus permissive close relay Virtual
=T set to T?
False
Page Page Page

I-88A I-88B I-88C
I-87
Page Page Page
I-87A I-87B I-87C
PPU True Is the PPU configured as "C"? RTU-OUT3

C
False
C DBC True Is the C PPU dead bus permissive close relay Virtual
=T set to T?
False
PPU True Is the PPU configured as "D"? RTU-OUT3

D
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.
Eng. X True Is engine X available for autorun? Virtual

autorun
False
Eng. Y no True Is the PLC output to autostart genset Y set to DOM1-OUT2 or
autostart F? DOM1-OUT2 or
False
Eng. X True Is the PLC output to autostart genset X set to DOM1-OUT2 or

autostart T? DOM1-OUT2 or
False
Gen. X True Is generator X in cooldown? Virtual

cooldown
False
Eng. Y True Is engine Y running? Virtual

running
False
Eng. X not True Is engine X not running? Virtual
running
False
Page Page
I-89A I-89B
I-88
Page Page
I-88A I-88B
Autostart gen. X Autostart gen. X Autostart generator X, T or F. DOM1-OUT2 or

=F =T DOM2-OUT2
Gen. X True Is generator X running and ready for load? Virtual

RTL
False
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
Gen. X autosync Gen. X autosync Autosync for generator X = T or F. Virtual

=F =T
Gen. X True Is generator X set to autosync? Virtual

autosync
False
Gen. X rem. True Is the rempte breaker control for generator X Virtual
br. open open?
False
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
Page
I-90
I-89
Page
I-89
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).
br. open open?
False
Local PPU True Is the local PPU configured and ready for Virtual
ready operation?
False
Gen. X True Is the engine control switch for generator X in Virtual

ECS OFF the OFF position?
False
AUTO position?
False

ECS STOP the STOP position?
False
Gen. X True Is generator X lockout set to T? Virtual

lockout
False
Gen. X True Is the generator X breaker switch in the DIM3-IN1 or

br. PTL Pull-To-Lock position? DIM3-IN2
False
Eng. X no True Is engine X autorun not enabled? Virtual

autorun
False
Page Page Page

I-91A I-91B I-91C
I-90
Page Page Page
I-90A I-90B I-90C

ECS AUTO the AUTO position?
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
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
Gen. X True Is generator X dead bus close permissive set Virtual

DBC to T?
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
Gen. X True Is generator X's breaker closed? DIM1-IN3 or

brkr open DIM2-IN3
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

ECS AUTO the AUTO position?
False
Page Page
I-92A I-92B
I-91
Page Page
I-91A I-91B
Gen. X no True Is the PLC output to autostart generator X set DOM1-OUT2 or

autostart to F? DOM2-OUT2
False
running
False
ECS STOP STOP position?
False
Gen. X cooldown Gen. X cooldown Generator X is in cooldown, T or F. Virtual

=F =T
AVRS True Is the automatic voltage regulator switch in the RTU-IN7

UP utility parallel position?
False
Gen. X True Is generator X's breaker closed? DIM1-IN3
br. closed DIM2-IN3
False
Utility parallel Utility parallel Generator X utilty parallel mode = T or F. DOM1-OUT9 or

=F =T DOM2-OUT9

=T
False
Eng. X rpm True Is engine X's rpm >= 800? Virtual
>=800
False
Eng. X running Eng. X running Engine X is running, T or F. Virtual

=F =T
Page
I-93
I-92
Page
I-92
Eng. X True Is engine X available for autorun? Virtual

autorun
False
Eng. X not True Is engine X not running? Virtual
running
False
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
Timer True Has the 2 minute timer expired?

expired
False
Page
I-94C
Gen. X True Is the PLC output to autosyn generator X set DOM1-OUT3 or

autosync to T? DOM2-OUT3
False
Gen. X True Is generator X dead bus close permissive set Virtual

DBC to T?
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
Page Page
I-94A I-94B
I-93
Page Page Page
I-93A I-93B I-93C
Changing True
T to F
False
Stop and reset Stop and reset the 1 minute timer.
timer
Timer True Has the 1 minute timer expired?

expired
False
Gen. X True Is the summary failure for generator X set to T? Virtual

fail
False
Gen. X True Is the lockout for generator X set to T? Virtual

lockout
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
Start - Tie / Feeder Control Controls tie & feeder breakers.

AUTO position?
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
Tie bus True Is the tie output bus energized? DIM2-IN11

energized
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
No tie True Is there no tie breaker overcurrent relay alarm? DIM1-IN4

OC relay
alm.
False
No tie True Is there no tie breaker overcurrent trip? DIM1-IN13
OC trip
False
Battleshort True Is the battleshort switch not in the NORMAL RTU-IN4

not normal position?
False
Enable tie close Enable tie close Enable tie breaker to close, T or F. Virtual
=F =T
Page
I-96
I-95
Page
I-95
Tie close True Is the tie breaker enabled to close? Virtual

enable
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
No tie True Is the tie breaker lockout set to F? Virtual

lockout
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
AUTO position?
False
Tie OC True Is the tie breaker tripped due to overcurrent? DIM1-IN13

trip
False
Battleshort True Is the battleshort switch in the NORMAL RTU-IN4
NORMAL position?
False
Page Page
I-97A I-97B
I-96
Page Page
I-96A I-96B
Tie True Is the tie breaker lockout set to T? Virtual

lockout
False
Tie True Is the tie breaker switch in the Pull-To-Lock DIM3-IN3

PTL position?
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).

AUTO position?
False
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
No feeder 1 True Is there not an overcurrent alarm on feeder 1? DIM1-IN10

OC alarm
False
No feeder 1 True Is there no overcurrent trip on feeder 1? DIM1-IN9
OC trip
False
Page Page Page

I-98A I-98B I-98C
I-97
Page Page Page
I-97A I-97B I-97C

not NORM. position?
False
Enable feeder 1 Enable feeder 1 Enable feeder 1 breaker to close, T or F. Virtual

close = F close = T
not energ.
False
Feeder 1 True Is the PLC output to enable feeder 1 breaker DOM1-OUT8

open en. to open set to T?
False
Feeder 1 True Is the PLC output to enable feeder 1 breaker Virtual

close en. to close set to T?
False
Feeder 1 True Is feeder 1 not closed (open)? DIM1-IN8
open
False
F to T
False
timer
Changing True
T to F
False
Stop and reset Stop and reset the 1 second timer.
timer

expired
False
Page Page
I-99A I-99B
I-98
Page Page
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
Feeder 1 True Is feeder 1 tripped because of overcurrent? DIM1-IN9

OC trip
False
NORMAL position?
False
Feeder 1 True Is the toggle for remote open/close of feeder 1 Virtual

rem. close changing from T to F?
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
Page
I-99
I-99
Page
I-99

AUTO position?
False
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
No feeder 2 True Is there not an overcurrent alarm on feeder 2? DIM2-IN10

OC alarm
False
No feeder 2 True Is there no overcurrent trip on feeder 2? DIM2-IN9
OC trip
False

not NORM. position?
False
Enable feeder 2 Enable feeder 2 Enable feeder 2 breaker to close, T or F. Virtual

close = F close = T
not energ.
False
Feeder 2 True Is the PLC output to enable feeder 2 breaker DOM2-OUT8

open en. to open set to T?
False
Page Page
I-100A I-100B
I-100
Page Page
I-99A I-99B

False
Feeder 2 True Is feeder 2 not closed (open)? DIM2-IN8
open
False
F to T
False
timer
Changing True
T to F
False
Stop and reset Stop and reset the 1 second timer.
timer

expired
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
Page Page
I-101A I-101B
I-101
Page Page
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
Feeder 2 True Is feeder 2 tripped because of overcurrent? DIM1-IN9

OC trip
False
NORMAL position?
False
Feeder 2 True Is the toggle for remote open/close of feeder 2 Virtual

rem. close changing from T to F?
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
I-102
Start - Announce Controls the PPU buzzer.

running
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
False
Eng. 1 LOP True Is the low oil pressure alarm for engine 1 GSC
False
Eng. 1 HOT True Is the high oil temperature alarm for engine 1 GSC
False
Eng. 1 ADEM True Is the ADEM unit alarm for engine 1 changing GSC
F to T from F to T?
False
Gen. 1 UF True Is the generator 1 underfrequency alarm GSC

False
Add 1 to Add 1 to the Alarm_Count variable. Virtual

Alarm_Count
Alarm1a Set alarm1a variable to T. Virtual

=T

running
False
Gen. 1 OF True Is the generator 1 overfrequency alarm GSC
False
Gen. 1 UV True Is the generator 1 undervoltage alarm changing GSC

F to T from F to T?
False
Page Page Page

I-103A I-103B I-103C
I-103
Page Page Page
I-102A I-102B I-102C
Gen. 1 OV True Is the generator 1 overvoltage alarm changing GSC

F to T from F to T?
False
Gen. 1 RP True Is the generator 1 reverse power alarm changing GSC

F to T from F to T?
False
Gen. 1 FS True Is the generator 1 frequency sensing alarm GSC

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
Alarm_Count
Alarm1b Set alarm1b variable to T. Virtual

=T
Alarm1a True Is alarm1a set to T? Virtual

=T
False
Alarm1b True Is alarm1b set to T? Virtual

=T
False
Alarm1 Alarm1 Set alarm1 variable, T or F. Virtual

=F =T
Page
I-104
I-104
Page
I-103

running
False
Eng. 2 HCT True Is the high coolant temperature alarm for engine GSC
False
Eng. 2 LCT True Is the low coolant temperature alarm for engine GSC
False
Eng. 2 LOP True Is the low oil pressure alarm for engine 2 GSC
False
Eng. 2 HOT True Is the high oil temperature alarm for engine 2 GSC
False
Eng. 2 ADEM True Is the ADEM unit alarm for engine 2 changing GSC
F to T from F to T?
False
Gen. 2 UF True Is the generator 2 underfrequency alarm GSC

False

Alarm_Count
Alarm2a Set alarm2a variable to T. Virtual

=T

running
False
Gen. 2 OF True Is the generator 2 overfrequency alarm GSC
False
Gen. 2 UV True Is the generator 2 undervoltage alarm changing GSC

F to T from F to T?
False
Page Page Page

I-105A I-105B I-105C
I-105
Page Page Page
I-104A I-104B I-104C
Gen. 2 OV True Is the generator 2 overvoltage alarm changing GSC

F to T from F to T?
False
Gen. 2 RP True Is the generator 2 reverse power alarm changing GSC

F to T from F to T?
False
Gen. 2 FS True Is the generator 2 frequency sensing alarm GSC

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
Alarm_Count
Alarm2b Set alarm2b variable to T. Virtual

=T
Alarm2a True Is alarm2a set to T? Virtual

=T
False
Alarm2b True Is alarm2b set to T? Virtual

=T
False
Alarm2 Alarm2 Set alarm2 variable, T or F. Virtual

=F =T
LFL True Is the low fuel level in the PPU daytank DIM2-IN13
False
Page Page
I-106A I-106B
I-106
Page Page
I-105A I-105B
Tie OC trip True Is the overcurrent trip signal for the tie contactor DIM1-IN13
False
LSE alm. True Is the load sharing error alarm changing from Virtual
F to T F to T?
False
Alarm_Count
Alarm3 Set alarm3 variable to T. Virtual

=T
Gen. 1 estop True Is the emergency stop shutdown flag for GSC
F to T generator 1 changing from F to T?
False
Gen. 1 spare True Is the generator 1 spare shutdown (ORT GSC

F to T immediate) changing from F to T?
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
False
Gen. 1 OC True Is the generator 1 shutdown for overcrank GSC

False
Gen. 1 OS True Is the generator 1 shutdown for overspeed GSC

False
Gen. 1 UF True Is the generator 1 shutdown for underfrequency GSC

False
Page Page
I-107A I-107B
I-107
Page Page
I-106A I-106B
Gen. 1 OF True Is the generator 1 shutdown for overfrequency GSC

False
Alarm_Count
Shutdown1a Set shutdown1a variable to T. Virtual

=T
Gen. 1 UV True Is the generator 1 shutdown for undervoltage GSC

False
Gen. 1 OV True Is the generator 1 shutdown for overvoltage GSC

False
Gen. 1 RP True Is the generator 1 shutdown for reverse power GSC

False
Gen. 1 FS True Is the generator 1 shutdown for frequency GSC

F to T sensing changing from F to T?
False
Gen. 1 NGR True Is the generator 1 neutral ground resistor fault DIM1-IN7
False
Gen. 1 OC True Is the generator 1 overcurrent trip signal DIM1-IN5

False
Gen. 1 SF True Is the generator 1 summary failure changing Virtual

F to T from F to T?
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
Page Page
I-107A I-107B

Alarm_Count
Shutdown1b Set shutdown1b variable to T. Virtual

=T
Shutdown1a True Does shutdown1a = T? Virtual

=T
False
Shutdown1b True Does shutdown1b = T? Virtual

=T
False
Shutdown1 Shutdown1 Set shutdown1 variable, T or F. Virtual

=F =T
Gen. 2 estop True Is the emergency stop shutdown flag for GSC
F to T generator 2 changing from F to T?
False
Gen. 2 spare True Is the generator 2 spare shutdown (ORT GSC

F to T immediate) changing from F to T?
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
False
Gen. 2 OC True Is the generator 2 shutdown for overcrank GSC

False
Gen. 2 OS True Is the generator 2 shutdown for overspeed GSC

False
Page Page
I-109A I-109B
I-109
Page Page
I-108A I-108B
Gen. 2 UF True Is the generator 2 shutdown for underfrequency GSC

False
Gen. 2 OF True Is the generator 2 shutdown for overfrequency GSC

False
Alarm_Count
Shutdown2a Set shutdown2a variable to T. Virtual

=T
Gen. 2 UV True Is the generator 2 shutdown for undervoltage GSC

False
Gen. 2 OV True Is the generator 2 shutdown for overvoltage GSC

False
Gen. 2 RP True Is the generator 2 shutdown for reverse power GSC

False
Gen. 2 FS True Is the generator 2 shutdown for frequency GSC

F to T sensing changing from F to T?
False
Gen. 2 NGR True Is the generator 2 neutral ground resistor fault DIM1-IN7
False
Gen. 2 OC True Is the generator 2 overcurrent trip signal DIM1-IN5

False
Gen. 2 SF True Is the generator 2 summary failure changing Virtual

F to T from F to T?
False
Page Page
I-110A I-110B
I-110
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
Alarm_Count
Shutdown2b Set shutdown2b variable to T. Virtual

=T
Shutdown2a True Does shutdown2a = T? Virtual

=T
False
Shutdown2b True Does shutdown2b = T? Virtual

=T
False
Shutdown2 Shutdown2 Set shutdown2 variable, T or F. Virtual

=F =T
LF ORT True Is the PPU daytank low fuel fault for ORT Virtual
False
Tie OC trip True Is the tie overcurrent trip signal changing from DIM1-IN13
F to T F to T?
False
F1 OC trip True Is the feeder 1 overcurrent trip signal changing DIM1-IN9

F to T from F to T?
False
F2 OC trip True Is the feeder 2 overcurrent trip signal changing DIM2-IN9

F to T from F to T?
False Add 1 to Add 1 to the Alarm_Count variable. Virtual

Alarm_Count
Shutdown3 Set shutdown3 variable to T. Virtual

=T
Page
I-111
I-111
Page
I-110
Alarm1 True Does alarm1 = T? Virtual

=T
False

=T
False

=T
False
Shutdown1 True Does shutdown1 = T? Virtual

=T
False

=T
False

=T
False
Energize buzzer Energize buzzer Energize the alarm buzzer, T or F. Virtual

=F =T
Silence PB True Is the Silence pushbutton depressed, changing DIM1-IN11

F to T from F to T?
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
Page Page
I-111A I-111B
Silence PB True Is the Silence pushbutton depressed? DIM1-IN11

=T
False
Alarm count True Is the current alarm count <= 0? Virtual
<= 0
False
Alarm_Count Set the alarm_count variable to 0. Virtual
=0
Alarm1a Reset alarm1a variable to F. Virtual

=F
Alarm1b Reset alarm1b variable to F. Virtual

=F
Alarm2a Reset alarm2a variable to F. Virtual

=F
Alarm2b Reset alarm2b variable to F. Virtual

=F
Alarm3 Reset alarm3 variable to F. Virtual

=F
Buzzer sil. True Is the buzzer silence command set to T? Virtual

=T
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.
Buzzer sil. True Is the buzzer silence command set to T? Virtual

=T
False Shutdown1a Reset shutdown1a to F. Virtual

=F
Shutdown1b Reset shutdown1b to F. Virtual

=F
Page Page
I-113A I-113B
I-113
Page Page
I-112A I-112B
Shutdown2a Reset shutdown2a to F. Virtual

=F
Shutdown2b Reset shutdown2b to F. Virtual

=F
Shutdown3 Reset shutdown3 to F. Virtual

=F
I-114
USAF TO 35C2-3-518-1
USA TM 9-6115-484-14&P
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 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
TABLE OF CONTENTS
TITLE PAGE
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
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
J-2
USAF TO 35C2-3-518-1
USA TM 9-6115-484-14&P
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, ABS BRAKE SYSTEM FOLDOUT 55
J-3
USAF TO 35C2-3-518-1
USA TM 9-6115-484-14&P
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

TM 9-6115-484-14 Mep-Pu-810a/b Part 6

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USAF TO 35C2-3-518-1

FIGURE 18.3.2.6.1-2 SUPPORT AND SPIDER BUSHING LUBRICATION POINTS

18.3.2.6.2 HUB LUBRICATION

b. Recommended Lubrication: See Annex G for Specifications.

18.3.2.6.3 SERVICE BEARINGS

DO NOT MIX LITHIUM, CALCIUM, SODIUM OR BARIUM COMPLEX GREASES DUE

The following schedule is appropriate:

a. Replace grease annually.

c. Bearings should be packed by machine if possible.

(1) Place a quantity of grease onto the palm of your hand.

18.3.2.6.4 LANDING GEAR ASSEMBLY LUBRICATION

FIGURE 18.3.2.6.4-1 ZERK FITTINGS (GREASE POINTS)

c. Recommended Grease: See Appendix G for Specifications.

THIS PAGE INTENTIONALLY BLANK

SECTION TITLE PAGE

19.4.5.1 INSPECT ENGINE COMPARTMENT VENT-HYDRAULIC MOTOR 41

FIGURE TITLE PAGE

TABLE TITLE PAGE

19.0 HYDRAULIC SYSTEM REPAIR

19.1 SAFETY INSTRUCTIONS

• Hot engine parts

• Lubrication System – Oil and Filter Change.

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

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

e. Material safety information:

Composition and Information on Ingredients: This information is not formulated to contain

(1) US OSHA HAZARDS COMMUNICATION STANDARDS: Product assessed in accordance

f. First aid measures:

g. Fire fighting measures:

19.2 HYDRAULIC SYSTEM DESCRIPTION

FIGURE 19.2-1 HYDRAULIC SYSTEM SCHEMATIC

19.2.1 HYDRAULIC FLUID RESERVOIR

FIGURE 19.2.1-1 HYDRAULIC FLUID RESERVOIR

JIC FILL PORT

TANK BREATHER SIGHT GLASS

FIGURE 19.2.1-2 HYDRAULIC TANK

FIGURE 19.2.1-3 FLUID LEVEL/TEMPERATURE SIGHT GAUGE

FIGURE 19.2.1-4 HYDRAULIC TANK SHUTOFF VALVE

19.2.2 HYDRAULIC SYSTEM PUMP

FIGURE 19.2.2-1 HYDRAULIC SYSTEM PUMP

19.2.3 PRESSURE RELIEF/CONTROL BLOCK AND PRESSURE GAUGES

FIGURE 19.2.3-1 PRESSURE RELIEF/CONTROL BLOCK DIAGRAM

FIGURE 19.2.3-2 PRESSURE RELIEF/CONTROL BLOCK

FIGURE 19.2.3-3 HYDRAULIC SYSTEM PRESSURE GAUGES

19.2.4 HYDRAULIC SYSTEM FAN MOTORS

ENGINE COMPARTMENT VENT MOTOR

RADIATOR HYDRAULIC MOTOR

ATAAC HYDRAULIC MOTOR

FIGURE 19.2.4-1 HYDRAULIC SYSTEM FAN MOTORS

19.2.5 HYDRAULIC SYSTEM COOLER

HYDRAULIC SYSTEM COOLER

FIGURE 19.2.5-1 HYDRAULIC SYSTEM COOLER

19.3 SERVICE REQUIREMENTS FOR HYDRAULIC SYSTEM

19.3.1 SERVICE THE RETURN-LINE FILTER, STRAINER, AND HYDRAULIC FLUID

REMOVE ALL RINGS, NECKLACES, JEWELERY AND LOOSE CLOTHING.

HYDRAULIC FLUID PRESSURES CAN REACH 3,000 PSI WHILE THE PU IS

CARE MUST BE TAKEN TO ENSURE THAT FLUIDS ARE CONTAINED DURING

HYDRAULIC FLUIDS MAY BE HOT

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

19.3.1.1 REPLACING THE FILTER ELEMENT

Replace Filter every 8,000 hours of use or annually.

d. Discard the old O-ring and replace with new