TM 9-6115-484-14 MEP-PU-810A/B PART 6

8/14/2019 TM 9-6115-484-14 MEP-PU-810A/B PART 6

1/266

USAF TO 35C2-3-518-1USA 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 Zerkfittings using Figure 18.3.2.6.1-2 as reference.

For camshaft roller journals and anchor pins: Lubricate with high temperature anti-seize grease

8/14/2019 TM 9-6115-484-14 MEP-PU-810A/B PART 6

2/266

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


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 ifrequired by removing the rubber oil cap and filling through the opening in the site glass. Refer toAnnex G for type of oil.

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 DUETO POSSIBLE COMPATIBILITY PROBLEMS. WHEN CHANGING FROM ONE TYPEOF GREASE TO ANOTHER, IT IS NECESSARY TO ENSURE ALL THE OLD GREASEHAS 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 andbearings.

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 tothe 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.

WARNING

8/14/2019 TM 9-6115-484-14 MEP-PU-810A/B PART 6

3/266

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


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 asnecessary.

c. Recommended Grease: See Appendix G for Specifications.

8/14/2019 TM 9-6115-484-14 MEP-PU-810A/B PART 6

4/266

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


THIS PAGE INTENTIONALLY BLANK

8/14/2019 TM 9-6115-484-14 MEP-PU-810A/B PART 6

5/266

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


CHAPTER 19HYDRAULIC SYSTEM REPAIR

TABLE OF CONTENTS

SECTION TITLE PAGE

19.0 HYDRAULIC SYSTEM REPAIR 619.1

SAFETY INSTRUCTIONS 6

19.2 HYDRAULIC SYSTEM DESCRIPTION 919.2.1 HYDRAULIC FLUID RESERVOIR 919.2.2 HYDRAULIC SYSTEM PUMP 1319.2.3 PRESSURE RELIEF/CONTROL BLOCK AND PRESSURE GAUGES 1419.2.4 HYDRAULIC SYSTEM FAN MOTORS 1619.2.5 HYDRAULIC SYSTEM COOLER 1719.3 SERVICE REQUIREMENTS FOR HYDRAULIC SYSTEM 1819.3.1 SERVICE THE RETURN-LINE FILTER, STRAINER, AND HYDRAULIC FLUID 1819.3.1.1 REPLACING THE FILTER ELEMENT 2019.3.1.2 CHANGING HYDRAULIC FLUID, VENT CAP, CLEANING THE STRAINERS 2319.4 COMPONENT REPAIR PROCEDURES 2619.4.1 PRESSURE RELIEF/CONTROL BLOCK 2619.4.1.1 INSPECTING PRESSURE RELIEF/CONTROL BLOCK 2719.4.1.2 REMOVE PRESSURE RELIEF/CONTROL BLOCK 2819.4.1.3 INSTALL PRESSURE RELIEF/CONTROL BLOCK 2919.4.2 HYDRAULIC PUMP 3019.4.2.1 INSPECT HYDRAULIC PUMP 3019.4.2.2 REMOVE HYDRAULIC PUMP 3119.4.2.3 INSTALL HYDRAULIC PUMP 3219.4.3 RADIATOR HYDRAULIC MOTOR 3419.4.3.1 INSPECT RADIATOR HYDRAULIC MOTOR 3419.4.3.2 REMOVE RADIATOR HYDRAULIC MOTOR 3519 4 3 3 INSTALL RADIATOR HYDRAULIC MOTOR 36

8/14/2019 TM 9-6115-484-14 MEP-PU-810A/B PART 6

6/266

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


19.4.5.1 INSPECT ENGINE COMPARTMENT VENT-HYDRAULIC MOTOR 4119.4.5.2 REMOVE ENGINE COMPARTMENT VENT-HYDRAULIC MOTOR 4219.4.5.3 INSTALL ENGINE COMPARTMENT VENT-HYDRAULIC MOTOR 4319.4.6 RADIATOR-MOTOR FAN ASSEMBLY 4419.4.6.1 INSPECT RADIATOR-MOTOR FAN ASSEMBLY 4519.4.6.2 REMOVE RADIATOR-MOTOR FAN ASSEMBLY 4519.4.6.3 INSTALL RADIATOR-MOTOR FAN ASSEMBLY 4619.4.7 AFTER COOLER-MOTOR FAN ASSEMBLY 4719.4.7.1 INSPECT AFTER COOLER-MOTOR FAN ASSEMBLY 4719.4.7.2 REMOVE AFTER COOLER-MOTOR FAN ASSEMBLY 4819.4.7.3 INSTALL AFTER COOLER-MOTOR FAN ASSEMBLY 4919.4.8 ENGINE COMPARTMENT VENT-MOTOR FAN ASSEMBLY 5019.4.8.1 INSPECT ENGINE COMPARTMENT VENT-MOTOR FAN ASSEMBLY 5119.4.8.2 REMOVE ENGINE COMPARTMENT VENT-MOTOR FAN ASSEMBLY 5119.4.8.3 INSTALL ENGINE COMPARTMENT VENT-MOTOR FAN ASSEMBLY 5219.4.9 RADIATOR-MOTOR FAN BLADES 5319.4.9.1 REMOVE RADIATOR-MOTOR FAN BLADES 5419.4.9.2 INSTALL RADIATOR-MOTOR FAN BLADES 5619.4.10 AFTER COOLER-MOTOR FAN BLADES 5819.4.10.1 REMOVE AND INSTALL AFTER COOLER-MOTOR FAN BLADES 5919.4.11 ENGINE COMPARTMENT VENT-MOTOR FAN BLADES 6019.4.11.1 REMOVE AND INSTALL ENGINE COMPARTMENT VENT-MOTOR FAN BLADES 6019.4.12 HYDRAULIC TANK LOW LEVEL SHUTDOWN SWITCH (HTLL) 6119.4.12.1 TEST HYDRAULIC TANK LOW LEVEL SHUTDOWN SWITCH (HTLL) 6119.4.12.2 REMOVE HYDRAULIC TANK LOW LEVEL SHUTDOWN SWITCH (HTLL) 6319.4.12.3 INSTALL HYDRAULIC TANK LOW LEVEL SHUTDOWN SWITCH (HTLL) 66

8/14/2019 TM 9-6115-484-14 MEP-PU-810A/B PART 6

7/266

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


LIST OF FIGURES

FIGURE TITLE PAGE

FIGURE 19.2-1HYDRAULIC 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 32FIGURE 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

8/14/2019 TM 9-6115-484-14 MEP-PU-810A/B PART 6

8/266

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


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 19.4.11.11 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

8/14/2019 TM 9-6115-484-14 MEP-PU-810A/B PART 6

9/266

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


LIST OF TABLES

TABLE TITLE PAGE

TABLE19.4.12.1-1 HTLLSWITCHCONTACTPOSITIONS 62

8/14/2019 TM 9-6115-484-14 MEP-PU-810A/B PART 6

10/266

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


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. Safetyprecautions must be observed to ensure that the operator/technician cannot have contact with thefollowing:

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 safetyprecautions are taken.

c. Minor maintenance can be performed while one generator set is running and the othergenerator 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.

Ch k Fl id l l d dd i d fl id

8/14/2019 TM 9-6115-484-14 MEP-PU-810A/B PART 6

11/266

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


(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 PUMUST be shutdown, isolated from anypower plant electrical bus or utility connection, isolated from any power plant controlsystem, 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 andany other electrical source that can back feed into the PU. All medium voltage cables need tobe 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 SwitchingCenter (PSC), then disconnect Load Cables (Using the proper safety gear) on the PU andplace them on the Parking Stands.

NOTE 3: When the DC Control Power Circuit Breaker is in the (OFF) position (Pulled Out), all controlpower is turned off to the PU. This will cause the HUB to stop functioning. This causes thenetwork to not see the equipment shutdown and all PUs after it. When pulling majormaintenance the (A) (B) Communication Cable must be routed to the next PU in order toreestablish the communication network.

NOTE 4: The fuel transfer pump electrical power is normally fed directly from the G1 generator set
http://0.0.0.0/http://0.0.0.0/http://0.0.0.0/http://0.0.0.0/http://0.0.0.0/http://0.0.0.0/

8/14/2019 TM 9-6115-484-14 MEP-PU-810A/B PART 6

12/266

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


e. Material safety information:

Composition and Information on Ingredients: This information is not formulated to containingredients, which have exposure limits established by U.S. agencies. It is not hazardous to healthas defined by the European Union Dangerous Substance/Preparation Directives.

Hazards Identification:

(1) US OSHA HAZARDS COMMUNICATION STANDARDS: Product assessed in accordancewith 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 liter (pint) is

ingested, immediately give 1 to 2 glasses of water and call a physician, hospital emergencyroom or poison control center for assistance. Do not induce vomiting or give anything bymouth to an unconscious person.

(5) EXPOSURE LIMITS: This product does not contain any components that have recognizedexposure limits. However, an exposure limit of 5.00 mg/m

3is 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 fromexposure. Prevent runoff from fire control or dilution from entering streams, sewers, ordrinking water supply.

(3) UNUSUAL FIRE AND EXPLOSION HAZARDS: None. Flash point 176C, 349F.(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 forfuel value or disposal by supervised incineration. Such burning may be limited to theRecovery Conservation and Recovery Act (RCRA). In addition, the product is suitable forprocessing by an approved recycling facility or can be disposed of at an appropriategovernment waste disposal facility. Use of these methods is subject to user compliance withapplicable laws and regulations and consideration of product characteristics at time of

8/14/2019 TM 9-6115-484-14 MEP-PU-810A/B PART 6

13/266

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


19.2 HYDRAULIC SYSTEM DESCRIPTION

Figure 19.2-1 illustrates the Hydraulic System Schematic. The hydraulic system used in Power Unitprovides 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 PSIbypass mounted inside the tank, and provides high-pressure fluid to the hydraulic fan motors that drivethe system. The high-pressure fluid from the hydraulic pumps is then forced through a PressureRelief/Control Block, which contains a 3,200 + 100-PSI pressure relief valve. From the control block thehigh-pressure fluid is transferred through the hydraulic motors, which drive the cooling fans. After thefluid passes through the hydraulic motors, the low-pressure fluid is then carried through a hydraulic fluidheat 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 cavityin the motor, to drain back to the reservoir at atmospheric pressure.

FIGURE 19 2-1 HYDRAULIC SYSTEM SCHEMATIC

8/14/2019 TM 9-6115-484-14 MEP-PU-810A/B PART 6

14/266

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


NOTE: The reservoir is not pressurized. It is very important that the reservoir is filled through the topof 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 thatcontaminants are not introduced into the system. Keep the fluid level between the red and blacklines on the sight gauge (See Figure 19.2.1-3) and do not overfill. This will ensure that the AirVent Cap is kept open and the reservoir does not overflow. The reservoir also includes aHydraulic Tank Low Level (HTLL) shutdown switch installed in the back of the reservoir, which isactivated at 33% fluid remaining. This switch is wired to the GSC+ and the Hydraulic Tank LowLevel Light (HTLLL) (Red LED) on the Generator Control Panel. When activated, it willautomatically 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 shutoffvalve, located in the rear of the Hydraulic Reservoir, where the fluid line is connected (See Figure19.2.1-4). These valves are held open during normal operation.

NOTE: Prior to disconnecting any hose from a component of the system, the valves must be closedto 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

8/14/2019 TM 9-6115-484-14 MEP-PU-810A/B PART 6

15/266

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


FIGURE 19.2.1-2 HYDRAULIC TANK

FULL LEVEL

JIC FILL PORT

FILTER FILL PORT

DIFFERENTIAL GAUGE

SIGHT GLASSTANK BREATHER

8/14/2019 TM 9-6115-484-14 MEP-PU-810A/B PART 6

16/266

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


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 F. The temperature gauge is important to determine the ambienttemperature (prior to plant start up) in order to ensure that the correct type of hydraulic fluid isbeing 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

8/14/2019 TM 9-6115-484-14 MEP-PU-810A/B PART 6

17/266

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


19.2.2 HYDRAULIC SYSTEM PUMP

Figure 19.2.2-1 illustrates the Hydraulic System Pump. The hydraulic pump is a positive displacementpump. This means that the pump delivers a constant flow rate at a constant RPM. The engines frontaccessory drive gears drive the pump. The pump rotates at 2,160 RPM, when the engine speed is 1,800RPM. At this speed, the pump will deliver approximately 17.05 gallons per minute optimum flow. Thepump delivers high-pressure fluid, through the control block, to the radiator cooling fan motor, to theengine air after-cooler fan motor, and the area ventilation motor. See Figure 19.2-1 for additionalinformation.

FIGURE 19.2.2-1 HYDRAULIC SYSTEM PUMP

HYDRAULICPUMP

8/14/2019 TM 9-6115-484-14 MEP-PU-810A/B PART 6

18/266

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


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 theactual 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 reliefvalve (RV), that is factory set to relieve the system pressure at 3,200 100 PSI to ensure that the positivedisplacement 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 softpump start feature before the engine reaches rated RPM during start up. The Pressure Relief/ControlBlock also has two pressure gauge connections (G1, G2). G1 measures the pressure on the Air-VentCircuit 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 onthe Engine Filter Differential Gauge Panel. The Radiator Circuit pressure gauge reads between 2,100and 3,100 PSI, during normal operations. The Air-Vent pressure gauge reads between 2,300 and 3,100PSI, during normal steady-state operations. The hydraulic gauges are 0 5000 PSI rated liquid filledgauges for anti-vibration and long life.

FIGURE 19.2.3-1 PRESSURE RELIEF/CONTROL BLOCK DIAGRAM

8/14/2019 TM 9-6115-484-14 MEP-PU-810A/B PART 6

19/266

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


FIGURE 19.2.3-2 PRESSURE RELIEF/CONTROL BLOCK

UV

RV

G2

P1

T

G1

A1

A2

8/14/2019 TM 9-6115-484-14 MEP-PU-810A/B PART 6

20/266

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


19.2.4 HYDRAULIC SYSTEM FAN MOTORS

Figure 19.2.4-1 illustrates the Hydraulic System Fan Motors. The hydraulic gear motors are also fixeddisplacement. This means that the motors will operate at a constant RPM under a constant flow rate. Thehigh-pressure fluid delivered by the pumps drives the motors. There are three motors per coolingsystem: Radiator Coolant, After Cooler, and Ventilation Fan Motors. These motors are part of twoseparate circuits. One circuit is for the Radiator Cooling Motor only. The other includes both the AfterCooler and Ventilation Fan Motors in series. All cooling motors operate between 1,750 and 2,400 RPM.

FIGURE 19.2.4-1 HYDRAULIC SYSTEM FAN MOTORS

ATAAC HYDRAULIC MOTOR

RADIATOR HYDRAULIC MOTOR

ENGINE COMPARTMENT VENT MOTOR

8/14/2019 TM 9-6115-484-14 MEP-PU-810A/B PART 6

21/266

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


19.2.5 HYDRAULIC SYSTEM COOLER

Figure 19.2.5-1 illustrates the Hydraulic System Cooler. The Hydraulic System is equipped with ahydraulic-oil heat exchanger, which cools the fluid prior to the fluid returning to the reservoir. It is locatedin 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 dustyconditions, daily cleaning may be necessary.

FIGURE 19.2.5-1 HYDRAULIC SYSTEM COOLER

HYDRAULIC SYSTEM COOLER

8/14/2019 TM 9-6115-484-14 MEP-PU-810A/B PART 6

22/266

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


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.FAILURE TO DO SO COULD CAUSE SEVERE INJURY OR DEATH.

HYDRAULIC FLUID PRESSURES CAN REACH 3,000 PSI WHILE THE PU ISOPERATING. DO NOT TOUCH ANY SUSPECTED LEAKS OF THE HYDRAULICSYSTEM. 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 DURINGPERFORMANCE OF INSPECTION, MAINTENANCE, TESTING, ADJUSTING ANDREPAIR OF THE PU. BE PREPARED TO COLLECT THE FLUID WITH SUITABLECONTAINERS BEFORE OPENING ANY COMPARTMENT OR DISASSEMBLY ANY

COMPONENT CONTAINING FLUIDS. DISPOSE OF FLUIDS ACCORDING TOLOCAL REGULATIONS AND MANDATES.

CAUTION

HYDRAULIC FLUIDS MAY BE HOT

a. This maintenance requires that the PU MUST be shutdown, isolated from any power plantelectrical bus or utility connection, isolated from any power plant control system, and rendered

unable to start. This is accomplished by performing the following:


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.

WARNING

WARNING

8/14/2019 TM 9-6115-484-14 MEP-PU-810A/B PART 6

23/266

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


(13) Disconnect both 7P1 and 7P2 Connectors located on the inside panel of the PDC.(14) Close and Lock both generator set control panels.




b. The Hydraulic System: incorporates an In-tank fluid strainer, (Figure 19.3.1.2-3), and an In-tankreturn line filter (Figure 19.3.1.1-4). The In-tank Return Line Filter is located inside the hydraulicfilter assembly at the top of the reservoir. The In-tank Return Line Filter has a color-codedpressure 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 abypass built into the housing (Figure 19.3.1.1-3). This bypass is set to 25 PSI and will open whenthe pressure drop across the element exceeds 25 PSI. The Return-Line Filter is designed tohave a very low pressure drop when new and at operating temperatures. As contaminants collecton the elements 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 (bypasssetting) 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 anycomplete fluid change or every 12 months. This must be done even if the indicator gauge isin the green (below 20 PSI).

Inspect: the new Return-Line Filter element for any damage; prior to installation see Figure19.3.1.1-4. 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 microscopiccontaminants. The size particles this filter element removes are smaller than the human eyecan see. Caution must be taken during the cleaning and replacement process not tointroduce any contaminates into the system. The strainer must be removed and cleanedevery time the hydraulic fluid is changed and the hydraulic fluid should be changed every16,000 hours, or 3 years. Yearly hydraulic fluid samples should be taken and analyzed to

8/14/2019 TM 9-6115-484-14 MEP-PU-810A/B PART 6

24/266

USAF TO 35C2-3-518-1USA 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 intothe tank, during change out. You should also have a clean work area for components andelements.

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 torqueeach bolt to 22 2 Ft-Lbs.

8/14/2019 TM 9-6115-484-14 MEP-PU-810A/B PART 6

25/266

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


FIGURE 19.3.1.1-2 FILTER CAP AND BYPASS ASSEMBLY

O-RING

BYPASS

8/14/2019 TM 9-6115-484-14 MEP-PU-810A/B PART 6

26/266

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


FIGURE 19.3.1.1-4 3-MICRON ABSOLUTE HYDRAULIC FILTER

USAF TO 35C2 3 518 1

8/14/2019 TM 9-6115-484-14 MEP-PU-810A/B PART 6

27/266

USAF TO 35C2-3-518-1USA 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 thegenerator 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 forreference.

c. Drain fluid into an appropriate container (20 gal).

d. Clean and reinstall the Hydraulic Reservoir Drain Plug.

e. Remove the eight -20 bolts from the Hydraulic Reservoir Access Cover, attached to the ventcap. 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 thestrainer 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, donot 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-tankReturn Line Filter Assembly Fill Port or through the 1 JIC Fill Port, see Figure 19.2.1-2 forreference.

USAF TO 35C2 3 518 1

8/14/2019 TM 9-6115-484-14 MEP-PU-810A/B PART 6

28/266

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


FIGURE 19.3.1.2-1 TANK ACCESS COVER AND VENT CAP

USAF TO 35C2 3 518 1

8/14/2019 TM 9-6115-484-14 MEP-PU-810A/B PART 6

29/266

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


FIGURE 19.3.1.2-3 100-MESH STRAINER (141 MICRON)

FIGURE 19.3.1.2-4 JIC FILL PORT

JIC FILL PORT

100-MESH STRAINER

USAF TO 35C2-3-518-1

8/14/2019 TM 9-6115-484-14 MEP-PU-810A/B PART 6

30/266

USAF TO 35C2-3-518-1USA 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

USAF TO 35C2-3-518-1

8/14/2019 TM 9-6115-484-14 MEP-PU-810A/B PART 6

31/266

USAF TO 35C2 3 518 1USA 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 isrunning 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 berendered 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 ShutdownGenerators.

(2) Push to OPEN the Emergency Stop Switch.(3) Place the Engine Control Switch (ECS) in the OFF position.(4) Place a DO NOT OPERATE tag on the generator control panel.(5) Turn the Battery Bank Parallel Switch to the OFF position.(6) De-energize the Battery Charger.(7) Disconnect the negative and positive cables from the Battery Bank for the engine due

maintenance.(8) Place a DO NOT OPERATE tag on the Battery Bank.

(9) Place the generator Circuit Breaker in the LOCK OUT position.(10) Disconnect the 7P1 and 7P2 Connectors located on the inside panel of the PDC.(11) Close and Lock the generator set control panel.

NOTE: The fuel transfer pump electrical power is normally fed directly from the G1 generator setbattery bank. If you disconnect the G1 battery bank, the external fuel transfer pump will notfunction. Place the Fuel Pump Source Switch (S2) into the (G1 or G2 position). Place the S2in the (G1 or G2) position, for the generator set not receiving maintenance.

c. Prior to starting the Power Unit, inspect the engine compartment for any hydraulic fluid leaks.Correct any leaks as necessary.

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 operatingtemperature 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.

USAF TO 35C2-3-518-1
http://0.0.0.0/http://0.0.0.0/http://0.0.0.0/http://0.0.0.0/http://0.0.0.0/http://0.0.0.0/http://0.0.0.0/http://0.0.0.0/

8/14/2019 TM 9-6115-484-14 MEP-PU-810A/B PART 6

32/266

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

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:

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


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.



NOTE 2: Ensure cables are not energized by opening the circuit breaker of the Primary SwitchingCenter (PSC), then disconnect Load Cables (Using the proper safety gear) on the PU and

place them on the Parking Stands.


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.

USAF TO 35C2-3-518-1

8/14/2019 TM 9-6115-484-14 MEP-PU-810A/B PART 6

33/266


19.4.1.3 INSTALL PRESSURE RELIEF/CONTROL BLOCK

To install the Pressure Relief/Control Block perform the following:

a. This maintenance requires that the PU MUST be shutdown, isolated from any power plantelectrical bus or utility connection, isolated from any power plant control system, and renderedunable to start. See procedures in paragraph 19.4.1.2.

b. Reinstall the Pressure Relief/Control Block and reinstall the Pressure Relief/Control Blockmounting bolts. Torque the mounting bolts to 30 + 5 Ft-Lbs.

c. Reinstall and torque the hydraulic hoses according to specifications found in Caterpillar ManualSENR3130-6 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 andending at Section 19.4.12.

k. The unit is now ready to operate.

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

8/14/2019 TM 9-6115-484-14 MEP-PU-810A/B PART 6

34/266


19.4.2 HYDRAULIC PUMP

The following maintenance procedures are provided for the Hydraulic Pump:

Inspect

Remove

Install

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.Correct any leaks as necessary.

HYDRAULICPUMP

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

8/14/2019 TM 9-6115-484-14 MEP-PU-810A/B PART 6

35/266


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 operatingtemperature and shutdown the Power Unit according to Chapter 5.

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 pumpmounting surface gets hot and must breathe (vent to the outside). As a result, small bubbles can formon 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:


unable to start. This is accomplished by performing the following:


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 tobe placed on the standoff insulators by use of hot sticks and other safety gear.


USAF TO 35C2-3-518-1USA TM 9 6115 484 14
http://0.0.0.0/http://0.0.0.0/http://0.0.0.0/http://0.0.0.0/http://0.0.0.0/http://0.0.0.0/http://0.0.0.0/http://0.0.0.0/http://0.0.0.0/http://0.0.0.0/http://0.0.0.0/http://0.0.0.0/

8/14/2019 TM 9-6115-484-14 MEP-PU-810A/B PART 6

36/266


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.

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.

HYDRAULICPUMP

O-RINGFLANGEGASKET

ENGINE

HOUSING

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

8/14/2019 TM 9-6115-484-14 MEP-PU-810A/B PART 6

37/266


d. Reinstall the pump assembly and reinstall the two, pump mounting bolts. Torque the pumpmounting bolts mounting bolts to 75 + 5 Ft-Lbs.

e. Reinstall and torque the hydraulic hoses according to specifications found in Table 7, Torquesfor 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 andending at Section 19.4.12.

n. The unit is now ready to operate.

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

8/14/2019 TM 9-6115-484-14 MEP-PU-810A/B PART 6

38/266

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

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 fluidleaks. Correct any leaks as necessary.

b Check the hydraulic fluid level and add fluid as necessary

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

8/14/2019 TM 9-6115-484-14 MEP-PU-810A/B PART 6

39/266


19.4.3.2 REMOVE RADIATOR HYDRAULIC MOTOR

To remove the Radiator-Hydraulic Motor, perform the following:



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.





b. Remove the Front Side Panel from the PU. See Figure 19.4.3.2-1 for reference.

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

8/14/2019 TM 9-6115-484-14 MEP-PU-810A/B PART 6

40/266


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:


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

8/14/2019 TM 9-6115-484-14 MEP-PU-810A/B PART 6

41/266


d. Reinstall the input and output hoses and torque the hydraulic fittings according to specificationsfound in Table 7, (Torques for flared and O-Ring fittings), Caterpillar Manual SENR3130. Torquethe 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 batterybank 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 andending at Section 19.4.12.

m. The unit is now ready to operate.

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

DRS RADIAN CTM 01646 1R0253/1R0254

8/14/2019 TM 9-6115-484-14 MEP-PU-810A/B PART 6

42/266


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.Correct any leaks as necessary.

b Check the hydraulic fluid level and add fluid as necessary

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


8/14/2019 TM 9-6115-484-14 MEP-PU-810A/B PART 6

43/266


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

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


8/14/2019 TM 9-6115-484-14 MEP-PU-810A/B PART 6

44/266


e. Tag the input/output and case drain hoses for proper replacement. See Figure 19.4.4-1 forreference.

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 forreference.

h. Remove the two Air to Air After Cooler-Hydraulic Motor Fan Assembly mounting bolts and lift themotor 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 WILLROTATE IN THE WRONG DIRECTION. ENSURE THE FAN MOTOR IS INSTALLED IN THESAME DIRECTION AS THE ONE REMOVED (RELIEF PORT ORIENTATION).

b. Reinstall the motor back on the mounting bracket and reinstall mounting bolts. Torque the 3/8bolts to 35 + 7 Ft-Lbs per Caterpillar SENR3130, Torque Specifications.

c. Reinstall and torque the hydraulic hoses according to specifications found in Table 7, Torquesfor flared and O-Ring fittings, Caterpillar Manual SENR3130. Torque the 5/8 fittings to 26 + 4Ft-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 thebattery bank reconnected.

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


8/14/2019 TM 9-6115-484-14 MEP-PU-810A/B PART 6

45/266



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.Correct any leaks as necessary.



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


8/14/2019 TM 9-6115-484-14 MEP-PU-810A/B PART 6

46/266


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 PowerUnit. 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.

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


8/14/2019 TM 9-6115-484-14 MEP-PU-810A/B PART 6

47/266

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 3/8bolts to 35 + 7 Ft-Lbs per Caterpillar SENR3130, Torque Specifications.

c. Reinstall the input and output hoses and torque the fittings according to specifications found inTable 7, Torques for flared and O-Ring fittings, Caterpillar Manual SENR3130. Torque the 1fittings 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 19.4.8.3for 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 batterybank 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.

l. Shut-down the Power Unit and inspect the hydraulic system starting at Section 19.4.1 andending at Section 19.4.12.


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


8/14/2019 TM 9-6115-484-14 MEP-PU-810A/B PART 6

48/266

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

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


8/14/2019 TM 9-6115-484-14 MEP-PU-810A/B PART 6

49/266

19.4.6.1 INSPECT RADIATOR-MOTOR FAN ASSEMBLY

To inspect the Radiator-Motor Fan Assembly, proceed as follows:




d. Check under the Power Unit for any hydraulic fluid leaks. Correct any leaks as necessary.

e. Check the Radiator-Motor Fan Assembly for leaks, missing or loose hardware.

f. Check the Radiator-Motor Fan Blades for broken fan blades, missing or loose hardware.

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.

(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 andany other electrical source that can back feed into the PU. All medium voltage cables need to

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


i t th (A) (B) C i ti C bl t b t d t th t PU i d t

8/14/2019 TM 9-6115-484-14 MEP-PU-810A/B PART 6

50/266

maintenance the (A) (B) Communication Cable must be routed to the next PU in order toreestablish the communication network.

b. Remove the bolts and keeper washers from the Bottom Plenum Screen on the bottom of the

Power Unit. Remove the Bottom Plenum Screen and Front Side Panel. See Section 8.4.1.2 andSection 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 thethree un-mounting holes and tighten each screw one 360 degree turn and then move to the nextscrew and tighten 360 degree turn, continue until the fan assembly falls free from the shaftmounting 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 bladeassembly facing down.

c. Reinstall the three mounting bolts into the unthreaded mounting holes in the fan blade hub, andinsert them into the threaded holes on the shaft-mounting hub. See Figure 19.4.6-1 for referenceand 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 batterybank 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 andending at Section 19.4.12.

i. The unit is now ready to operate.

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

http://0.0.0.0/http://0.0.0.0/http://0.0.0.0/http://0.0.0.0/

8/14/2019 TM 9-6115-484-14 MEP-PU-810A/B PART 6

51/266

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


c Start the Power Unit according to Chapter 5 Allow the Power Unit to reach operating

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

http://0.0.0.0/http://0.0.0.0/http://0.0.0.0/

8/14/2019 TM 9-6115-484-14 MEP-PU-810A/B PART 6

52/266

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 thePower 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.

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

http://0.0.0.0/http://0.0.0.0/http://0.0.0.0/http://0.0.0.0/http://0.0.0.0/http://0.0.0.0/http://0.0.0.0/http://0.0.0.0/http://0.0.0.0/http://0.0.0.0/

8/14/2019 TM 9-6115-484-14 MEP-PU-810A/B PART 6

53/266

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 bladeassembly 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 referenceand torque to 108 inch lbs.

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. Preparethe 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 andending at Section 19.4.12.

k. The unit is now ready to operate.

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


8/14/2019 TM 9-6115-484-14 MEP-PU-810A/B PART 6

54/266

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


UN-MOUNTING THREADED HOLE

MOUNTING UNTHREADED HOLE

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


8/14/2019 TM 9-6115-484-14 MEP-PU-810A/B PART 6

55/266

19.4.8.1 INSPECT ENGINE COMPARTMENT VENT-MOTOR FAN ASSEMBLY

To inspect the Engine Compartment Vent-Motor Fan Assembly, proceed as follows:




d. Check under the Power Unit for any hydraulic fluid leaks. Correct any leaks as necessary.

e. Check the Engine Compartment Vent-Motor Fan Assembly for leaks, missing or loose hardware.

f. Check the Engine Compartment Vent-Motor Fan blades for broken fan blades, missing or loosehardware.

19.4.8.2 REMOVE ENGINE COMPARTMENT VENT-MOTOR FAN ASSEMBLY

To remove the Engine Compartment Vent-Motor Fan Assembly, proceed as follows:



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 andany other electrical source that can back feed into the PU. All medium voltage cables need to

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


maintenance the (A) (B) Communication Cable must be routed to the next PU in order to

8/14/2019 TM 9-6115-484-14 MEP-PU-810A/B PART 6

56/266

reestablish the communication network.

b. Remove the bolts and keeper washers from the Top Plenum Screen on the Top of the Power

Unit. Remove the Top Plenum Screen and Front Side Panel. See Section 8.4.1.2 and Section8.4.2.2 for reference.

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 360 turn and then move to the next screw andtighten 360 turn, continue until the fan assembly pulls free from the shaft mounting hub. SeeFigure 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 assemblyfacing the Radiator Assembly.

c. Reinstall the three mounting bolts into the unthreaded mounting holes in the fan blade hub, andinsert them into the threaded holes on the shaft-mounting hub. See Figure 19.4.8-1 for referenceand torque to 60 inch lbs.

d. Reinstall the Air Deflector Assembly.

e. Prepare the Power Unit to be started. All lockout and tag-out, tags must be removed, the batterybank 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 andending at Section 19.4.12.

i. The unit is now ready to operate.

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


8/14/2019 TM 9-6115-484-14 MEP-PU-810A/B PART 6

57/266

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

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


19 4 9 1 REMOVE RADIATOR MOTOR FAN BLADES

8/14/2019 TM 9-6115-484-14 MEP-PU-810A/B PART 6

58/266

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 washersare used to balance the Fan Hub assembly.

FIGURE 19.4.9.1-1 RADIATOR FAN ASSEMBLY (TOP HALF REMOVED)

FIGURE 19.4.9.1-2 RADIATOR FAN ASSEMBLY (BOTTOM HALF WITH KEEPER INSTALLED)

PLASTIC KEEPER

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


c Place the fan hub assembly on a flat surface

8/14/2019 TM 9-6115-484-14 MEP-PU-810A/B PART 6

59/266

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.

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


19 4 9 2 INSTALL RADIATOR-MOTOR FAN BLADES

8/14/2019 TM 9-6115-484-14 MEP-PU-810A/B PART 6

60/266

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:

a. This maintenance requires that the PU MUST be shutdown, isolated from any power plant

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


d. Place the top half of the hub assembly on to the bottom half of the hub assembly. See Figure19 4 9 2-2 for reference

8/14/2019 TM 9-6115-484-14 MEP-PU-810A/B PART 6

61/266

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 forreference.

g. Reinstall the Radiator-Motor Fan Assembly. See Section 19.4.6.3 for reference.

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


19.4.10 AFTER COOLER-MOTOR FAN BLADES

8/14/2019 TM 9-6115-484-14 MEP-PU-810A/B PART 6

62/266

The following maintenance procedures are provided for the After Cooler-Motor Fan Blades:

Remove

Install

FIGURE 19.4.10-1 AFTERCOOLER FAN HUB DISASSEMBLY

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


19.4.10.1 REMOVE AND INSTALL AFTER COOLER-MOTOR FAN BLADES

8/14/2019 TM 9-6115-484-14 MEP-PU-810A/B PART 6

63/266



FIGURE 19.4.10.1-1 AFTERCOOLER FAN ASSEMBLY (TOP HALF REMOVED)

PLASTIC KEEPER

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


b. After the Aftercooler-Motor Fan Assembly has been removed, Disassembly and Reassemblyprocedures are the same as the Radiator Fan Motor. See Section 19.4.9.1 and 19.4.9.2 for

8/14/2019 TM 9-6115-484-14 MEP-PU-810A/B PART 6

64/266

reference.

19.4.11 ENGINE COMPARTMENT VENT-MOTOR FAN BLADES

The following maintenance procedures are provided for the Engine Compartment Vent Motor Fan Blades:

RemoveInstall

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 duringassembly. The washers must be returned to the same place to balance the Fan Hubassembly.

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


8/14/2019 TM 9-6115-484-14 MEP-PU-810A/B PART 6

65/266

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 andReassembly procedures are the same as the Radiator Fan Motor. See Section 19.4.9.1 and19.4.9.2 for reference.

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. Thefloat type switch is mounted on the back of the hydraulic tank. See Figure 19.2.1-1 and refer to Section19.2.1 for an explanation on the operation of the switch.

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


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

8/14/2019 TM 9-6115-484-14 MEP-PU-810A/B PART 6

66/266

c. Replace the switch if it fails any of the above requirements.

TABLE 19.4.12.1-1 HTLL SWITCH CONTACT POSITIONSHYDRAULIC TANK LOW LEVEL SHUTDOWN SWITCH (HTLL) SWITCH

SWITCH POSITION SWITCH CONTACTS

HYDRAULIC TANK FULL Infinite OHMS

HYDRAULIC TANK BELOW 33% OHMS

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


19.4.12.2 REMOVE HYDRAULIC TANK LOW LEVEL SHUTDOWN SWITCH (HTLL)

8/14/2019 TM 9-6115-484-14 MEP-PU-810A/B PART 6

67/266

FIGURE 19.4.12.2-1 TANK ACCESS COVER

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


8/14/2019 TM 9-6115-484-14 MEP-PU-810A/B PART 6

68/266

FIGURE 19.4.12.2-3 HTLL SWITCH DEUTSCH CONNECTOR

HTLL DEUTSCHCONNECTION

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


To remove the Hydraulic Tank Low Level Shutdown Switch (HTLL) Switch, proceed as follows

8/14/2019 TM 9-6115-484-14 MEP-PU-810A/B PART 6

69/266

To remove the Hydraulic Tank Low Level Shutdown Switch (HTLL) Switch, proceed as follows



5.9.6.15, U

TM 9-6115-484-14 MEP-PU-810A/B PART 6

Documents