Chapter 1. INTRODUCTION - TM-5-6115-400-350006
Table 1. Engine Repair and Replacement Standards
Table 1. Engine Repair and Replacement Standards-Continued - TM-5-6115-400-350008
Table 1. Engine Repair and Replacement Standards-Continued - TM-5-6115-400-350009
Table 1. Engine Repair and Replacement Standards-Continued - TM-5-6115-400-350010
Table 1. Engine Repair and Replacement Standards-Continued - TM-5-6115-400-350011
Table 1. Engine Repair and Replacement Standards-Continued - TM-5-6115-400-350012
Table 1. Engine Repair and Replacement Standards-Continued - TM-5-6115-400-350013
Table 1. Engine Repair and Replacement Standards-Continued - TM-5-6115-400-350014
Chapter 2. GENERAL MAINTENANCE INSTRUCTIONS - TM-5-6115-400-350015
Section II. TROUBLESHOOTING - TM-5-6115-400-350016
Section III. RADIO INTERFERENCE SUPPRESSION
Section IV. REMOVAL AND INSTALLATION OF MAJOR COMPONENTS
Figure 3 (1) . Housing, doors, hood, and panels.
Figure 3 (1) . Housing, doors, hood, and panels. (cont) - TM-5-6115-400-350020
Figure 3 (1) . Housing, doors, hood, and panels. (cont) - TM-5-6115-400-350021
Main Generator
Figure 4. Engine removal and installation.
Installation - TM-5-6115-400-350024
Figure 5. Main generator removal and installation.
Chapter 3. ENGINE REPAIR INSTRUCTIONS - TM-5-6115-400-350026
Figure 7. Lock torque test
Assembly of End Bell and Brush Holder Plate
Figure 8. Electric starter.
Figure 8. Electric starter. (cont)
Generator - Battery Charging
Figure 10. Battery charging generator.
Generator Regulator
Regulator Checks and Adjustments
Current Regulator.
Figure 13. Wiring for generator regulator checks.
Fuel Injection Pump - TM-5-6115-400-350037
Figure 14. Fuel injection pump-cut-away view.
Disassembly. - TM-5-6115-400-350039
Cleaning. - TM-5-6115-400-350040
Figure 15. Fuel injection pump-exploded view.
Figure 15. Fuel injection pump-exploded view. (cont)
Figure 16. Alining plunger and control sleeve assembly marks.
Internal Timing of the Fuel Injection Pump.
Figure 17. Remaining (or installing) temporary tappet retaining pins.
Figure 18. Fuel injection pump torque valves.
Figure 19. Fuel injection pump timing marks for internal timing
Calibrating the Fuel Injection Pump.
Mechanical Governor
Cleaning, Inspection and Repair.
Figure 20. Mechanical governor-exploded view.
Figure 20. Mechanical governor-exploded view. (cont)
Reassembly of Governor.
Figure 21. Measuring inner spring
Water Pump
Reassembly. - TM-5-6115-400-350056
Figure 23. Water pump.
Figure 24. Pulling impeller from pump shaft.
Figure 25. Water pump disassembly using service tools.
Figure 26. Water pump - sectional view.
Figure 27. Water pump reassembly.
Fan Hub
Turbocharger - TM-5-6115-400-350063
Figure 29. Turbocharger - sectional view.
Figure 30. Checking turbine shaft radial movement.
Replacement Center Housing and Rotating Assembly
Figure 32. Turbocharger (exploded view).
Figure 33. Turbocharger disassembly.
Cleaning. - TM-5-6115-400-350069
Figure 34. Center housing - sectional view.
Center Housing Assembly
Turbocharger Reassembly.
Figure 36. Turbine and shaft positioned in holding fixture
Figure 37 (1). Turbocharger reassembly.
Figure 37 (1). Turbocharger reassembly. (cont)
Section II. ENGINE COMPONENTS
Figure 38. Cylinder head assembly details.
Figure 40. Cylinder head guide studs.
Figure 41. Cylinder head capscrew locations.
Figure 42. Cylinder head capscrew torque sequence.
Figure 43. Fuel injection nozzle holder assembly.
Figure 44. Adjusting popping pressure.
Nozzle Valve Body and Valve Disassembly, Cleaning, and Assembly
Figure 47. Lapping fuel injection nozzle valve body
Fuel Injection Nozzle Holder Sleeves
Figure 48. Fuel injection nozzle holder sleves.
Figure 49. Rocker arms, shafts, and brackets.
Push Rods and Valve Lifters
Figure 51. Rocker arm assembly.
Figure 52. Removing valve lifter from bracket.
Valve Springs and Rotators.
Valves and Valve Guides.
Figure 57. Installing exhaust valve guide.
Valve Seat Inserts.
Valve Face and Valve Seat Grinding.
Figure 62. Interference angle.
Accessory Drive
Figure 63. Accessory drive.
Figure 64. Accessory drive removal.
Figure 65. Accessory drive-exploded view.
Figure 66. Installing auxiliary gear and shaft in housing.
Crankshaft Pulley and Damper
Figure 67. Accessory drive installation.
Figure 68. Crankshaft pulley and vibration dampers.
Timing Gear Housing Cover.
Crankshaft Front Oil Seal.
Gear Train and Timing Gear Housing
Oil Pan
Figure 75. Oil pans and level gage.
Oil Pump - TM-5-6115-400-350110
Figure 76. Oil pump and tubing.
Figure 77. Oil pump-exploded view.
Figure 78. Checking radial clearance between gear teeth and pump body.
Piston Cooling Oil Jets
Flywheel and Ring Gear
Figure 80. Flywheel and housing.
Flywheel Housing
Camshaft - TM-5-6115-400-350118
Camshaft Bearings
Figure 87. Installation of camshaft gear.
Figure 88. Checking camshaft bearing clearance.
Figure 89. Removing and installing camshaft front bearing.
Figure 90. Sequence for removing and installing bearing.
Figure 91. Piston and connecting rod.
Figure 92. Removing pin from piston.
Fitting pistons to cylinder sleeves.
Figure 93. Intake valve recess in top of piston.
Connecting Rods and Connecting Rod Bearings.
Main Bearing Caps
Main Bearings
Main Bearing Installation.
Figure 95. Removing main bearing upper shells.
Crankshaft and Crankshaft Gear
Figure 96. Crankshaft and main bearings.
Figure 97. Main bearing caps locations.
Cylinder Block
Cylinder Sleeves
Figure 99. Checking cylinder sleeve for roundness.
Figure 101. Removing cylinder sleeve-top view.
Figure 103. Measuring out-of-8quare relationship of cylinder sleeve counterbore.
Figure 105. Measuring cylinder sleeve flange height (standout) block.
Figure 106. Cylinder sleeve.
Assembly of Tool.
Adjusting and Operating Tool.
Adjusting and Operating Tool. (cont)
Chapter 4. MAIN GENERATOR AND AUXILIARY EQUIPMENT REPAIR INSTRUCTIONS
Winding Resistance Measurements
Figure 114. Voltage regulator.
Figure 115. Excitor and rectifier.
Bearing Lubrication
Figure 116. Main generator-exploded view.
Section II. STATIC EXCITER AND VOLTAGE REGULATOR
Figure 118. Voltage regulator and excitation unit-block diagram
Figure 119. Static exciter and voltage regulator.
Figure 120. Simplified schematic diagram of static exciter.
Figure 121. Static exciter-exploded view.
Figure 122. Exciter with voltage regulator removed
Voltage Regulator
Figure 124. Simplified schematic diagram of voltage regulator.
Figure 125. CCCT, CT1, and CT3 transformer
Bench testing.
Figure 126. Voltage regulator.
Cleaning and Inspection - TM-5-6115-400-350163
Figure 127 (1). Relay box.
Figure 127 (1). Relay box. (cont)
Table 5. Specification for Under Voltage Relay
Figure 129. Relay brat-exploded vies
Figure 129. Relay brat-exploded vies (cont)
Section IV. CONTROL PANEL
Frequency Meter and Transducer
Figure 130. Control pane! and cubicle contents.
Figure 131. AC power circuit breaker.
Section V. ELECTRIC GOVERNOR
Load Measurement Unit
Figure 134. Electric governor hydraulic actuator.
Hydraulic System
Figure 135. KFAR adjust and KW adjust.
Isochronous Operation.
Section VI. OVERSPEED GOVERNOR
Figure 136. Overspeed governor.
Figure 157. Overspeed governor-exploded view.
Appendix I. REFERENCES
Wiring Diagram Legend
Figure 128. Wiring diagram-interconnecting wiring harness
TM-5-6115-400-35 Generator Set Diesel Engine Driven 200 KW 60 Cycle AC 120/208V 240/416V 3 Phase Convertible to 167Kw 50 Cycle 120/208V 240/416 V Manual
Table 1. Engine Repair and Replacement Standards
Table 1. Engine Repair and Replacement Standards-Continued - TM-5-6115-400-350008
Table 1. Engine Repair and Replacement Standards-Continued - TM-5-6115-400-350009
Table 1. Engine Repair and Replacement Standards-Continued - TM-5-6115-400-350010
Table 1. Engine Repair and Replacement Standards-Continued - TM-5-6115-400-350011
Table 1. Engine Repair and Replacement Standards-Continued - TM-5-6115-400-350012
Table 1. Engine Repair and Replacement Standards-Continued - TM-5-6115-400-350013
Table 1. Engine Repair and Replacement Standards-Continued - TM-5-6115-400-350014
Chapter 2. GENERAL MAINTENANCE INSTRUCTIONS - TM-5-6115-400-350015
Section II. TROUBLESHOOTING - TM-5-6115-400-350016
Section III. RADIO INTERFERENCE SUPPRESSION
Section IV. REMOVAL AND INSTALLATION OF MAJOR COMPONENTS
Figure 3 (1) . Housing, doors, hood, and panels.
Figure 3 (1) . Housing, doors, hood, and panels. (cont) - TM-5-6115-400-350020
Figure 3 (1) . Housing, doors, hood, and panels. (cont) - TM-5-6115-400-350021
Main Generator
Figure 4. Engine removal and installation.
Installation - TM-5-6115-400-350024
Figure 5. Main generator removal and installation.
Chapter 3. ENGINE REPAIR INSTRUCTIONS - TM-5-6115-400-350026
Figure 7. Lock torque test
Assembly of End Bell and Brush Holder Plate
Figure 8. Electric starter.
Figure 8. Electric starter. (cont)
Generator - Battery Charging
Figure 10. Battery charging generator.
Generator Regulator
Regulator Checks and Adjustments
Current Regulator.
Figure 13. Wiring for generator regulator checks.
Fuel Injection Pump - TM-5-6115-400-350037
Figure 14. Fuel injection pump-cut-away view.
Disassembly. - TM-5-6115-400-350039
Cleaning. - TM-5-6115-400-350040
Figure 15. Fuel injection pump-exploded view.
Figure 15. Fuel injection pump-exploded view. (cont)
Figure 16. Alining plunger and control sleeve assembly marks.
Internal Timing of the Fuel Injection Pump.
Figure 17. Remaining (or installing) temporary tappet retaining pins.
Figure 18. Fuel injection pump torque valves.
Figure 19. Fuel injection pump timing marks for internal timing
Calibrating the Fuel Injection Pump.
Mechanical Governor
Cleaning, Inspection and Repair.
Figure 20. Mechanical governor-exploded view.
Figure 20. Mechanical governor-exploded view. (cont)
Reassembly of Governor.
Figure 21. Measuring inner spring
Water Pump
Reassembly. - TM-5-6115-400-350056
Figure 23. Water pump.
Figure 24. Pulling impeller from pump shaft.
Figure 25. Water pump disassembly using service tools.
Figure 26. Water pump - sectional view.
Figure 27. Water pump reassembly.
Fan Hub
Turbocharger - TM-5-6115-400-350063
Figure 29. Turbocharger - sectional view.
Figure 30. Checking turbine shaft radial movement.
Replacement Center Housing and Rotating Assembly
Figure 32. Turbocharger (exploded view).
Figure 33. Turbocharger disassembly.
Cleaning. - TM-5-6115-400-350069
Figure 34. Center housing - sectional view.
Center Housing Assembly
Turbocharger Reassembly.
Figure 36. Turbine and shaft positioned in holding fixture
Figure 37 (1). Turbocharger reassembly.
Figure 37 (1). Turbocharger reassembly. (cont)
Section II. ENGINE COMPONENTS
Figure 38. Cylinder head assembly details.
Figure 40. Cylinder head guide studs.
Figure 41. Cylinder head capscrew locations.
Figure 42. Cylinder head capscrew torque sequence.
Figure 43. Fuel injection nozzle holder assembly.
Figure 44. Adjusting popping pressure.
Nozzle Valve Body and Valve Disassembly, Cleaning, and Assembly
Figure 47. Lapping fuel injection nozzle valve body
Fuel Injection Nozzle Holder Sleeves
Figure 48. Fuel injection nozzle holder sleves.
Figure 49. Rocker arms, shafts, and brackets.
Push Rods and Valve Lifters
Figure 51. Rocker arm assembly.
Figure 52. Removing valve lifter from bracket.
Valve Springs and Rotators.
Valves and Valve Guides.
Figure 57. Installing exhaust valve guide.
Valve Seat Inserts.
Valve Face and Valve Seat Grinding.
Figure 62. Interference angle.
Accessory Drive
Figure 63. Accessory drive.
Figure 64. Accessory drive removal.
Figure 65. Accessory drive-exploded view.
Figure 66. Installing auxiliary gear and shaft in housing.
Crankshaft Pulley and Damper
Figure 67. Accessory drive installation.
Figure 68. Crankshaft pulley and vibration dampers.
Timing Gear Housing Cover.
Crankshaft Front Oil Seal.
Gear Train and Timing Gear Housing
Oil Pan
Figure 75. Oil pans and level gage.
Oil Pump - TM-5-6115-400-350110
Figure 76. Oil pump and tubing.
Figure 77. Oil pump-exploded view.
Figure 78. Checking radial clearance between gear teeth and pump body.
Piston Cooling Oil Jets
Flywheel and Ring Gear
Figure 80. Flywheel and housing.
Flywheel Housing
Camshaft - TM-5-6115-400-350118
Camshaft Bearings
Figure 87. Installation of camshaft gear.
Figure 88. Checking camshaft bearing clearance.
Figure 89. Removing and installing camshaft front bearing.
Figure 90. Sequence for removing and installing bearing.
Figure 91. Piston and connecting rod.
Figure 92. Removing pin from piston.
Fitting pistons to cylinder sleeves.
Figure 93. Intake valve recess in top of piston.
Connecting Rods and Connecting Rod Bearings.
Main Bearing Caps
Main Bearings
Main Bearing Installation.
Figure 95. Removing main bearing upper shells.
Crankshaft and Crankshaft Gear
Figure 96. Crankshaft and main bearings.
Figure 97. Main bearing caps locations.
Cylinder Block
Cylinder Sleeves
Figure 99. Checking cylinder sleeve for roundness.
Figure 101. Removing cylinder sleeve-top view.
Figure 103. Measuring out-of-8quare relationship of cylinder sleeve counterbore.
Figure 105. Measuring cylinder sleeve flange height (standout) block.
Figure 106. Cylinder sleeve.
Assembly of Tool.
Adjusting and Operating Tool.
Adjusting and Operating Tool. (cont)
Chapter 4. MAIN GENERATOR AND AUXILIARY EQUIPMENT REPAIR INSTRUCTIONS
Winding Resistance Measurements
Figure 114. Voltage regulator.
Figure 115. Excitor and rectifier.
Bearing Lubrication
Figure 116. Main generator-exploded view.
Section II. STATIC EXCITER AND VOLTAGE REGULATOR
Figure 118. Voltage regulator and excitation unit-block diagram
Figure 119. Static exciter and voltage regulator.
Figure 120. Simplified schematic diagram of static exciter.
Figure 121. Static exciter-exploded view.
Figure 122. Exciter with voltage regulator removed
Voltage Regulator
Figure 124. Simplified schematic diagram of voltage regulator.
Figure 125. CCCT, CT1, and CT3 transformer
Bench testing.
Figure 126. Voltage regulator.
Cleaning and Inspection - TM-5-6115-400-350163
Figure 127 (1). Relay box.
Figure 127 (1). Relay box. (cont)
Table 5. Specification for Under Voltage Relay
Figure 129. Relay brat-exploded vies
Figure 129. Relay brat-exploded vies (cont)
Section IV. CONTROL PANEL
Frequency Meter and Transducer
Figure 130. Control pane! and cubicle contents.
Figure 131. AC power circuit breaker.
Section V. ELECTRIC GOVERNOR
Load Measurement Unit
Figure 134. Electric governor hydraulic actuator.
Hydraulic System
Figure 135. KFAR adjust and KW adjust.
Isochronous Operation.
Section VI. OVERSPEED GOVERNOR
Figure 136. Overspeed governor.
Figure 157. Overspeed governor-exploded view.
Appendix I. REFERENCES
Wiring Diagram Legend
Figure 128. Wiring diagram-interconnecting wiring harness
TM-5-6115-400-35 Generator Set Diesel Engine Driven 200 KW 60 Cycle AC 120/208V 240/416V 3 Phase Convertible to 167Kw 50 Cycle 120/208V 240/416 V Manual
