TM-5-6115-457-34 Generator Set Diesel Engine Driven Tactical Skid Mtd. 100 Kw 3 Phase 4 Wire 120/208 and 240/416 Volts Manual

Chapter 1. INTRODUCTION - TM-5-6115-457-340055
RECORD OF APPLICABLE TIME COMPLIANCE TECHNICAL ORDERS.
Section II. DESCRIPTION AND DATA - TM-5-6115-457-340057
TABULATED DATA.
Over Voltage Relay
Under Voltage Relay
Under Frequency Relays
Short Circuit Relay
Short Circuit Relay (cont)
Reverse Power Relay
Overload Relay
Permissive Paralleling Relay
RADIATOR - TM-5-6115-457-340067
Convenience Receptacle Box Assembly
Load Contactor (CB2) (50/60 hertz generator sets)
Load Contactor (CB2) (50/60 hertz generator sets) (cont)
Circuit Breaker Assembly (CB2) (400 hertz generator sets)
Current Transformer Assembly
Current Transformer CT 4 (50/60 Hertz Generator Sets)
Current transformer CT5 and CT6 (50/60 Hertz Generator Sets)
Precise Governor System (LEH GOVERNOR)
Load Measuring Unit
GENERATOR
ENGINE - TM-5-6115-457-340079
Starter Motor
Day Tank Fuel Level Switch
Fuel Transfer Pump
Utility Governor
FUEL BURNING WINTERIZATION KIT (Optional)
Coolant Thermostat Switch
Electric coolant heater 2500 Watts
Control Box
Power Transformer
Electrical Heating Element
Table 1-1. Repair and Replacement Standards
Table 1-1. Repair and Replacement Standards (continued) - TM-5-6115-457-340091
Table 1-1. Repair and Replacement Standards (continued) - TM-5-6115-457-340092
Table 1-1. Repair and Replacement Standards (continued) - TM-5-6115-457-340093
Table 1-1. Repair and Replacement Standards (continued) - TM-5-6115-457-340094
Table 1-1. Repair and Replacement Standards (continued) - TM-5-6115-457-340095
Table 1-1. Repair and Replacement Standards (continued) - TM-5-6115-457-340096
Table 1-1. Repair and Replacement Standards (continued) - TM-5-6115-457-340097
Table 1-1. Repair and Replacement Standards (continued) - TM-5-6115-457-340098
Table 1-1. Repair and Replacement Standards (continued) - TM-5-6115-457-340099
Table 1-1. Repair and Replacement Standards (continued) - TM-5-6115-457-340100
Table 1-2. Special Torque Data - TM-5-6115-457-340101
Table 1-2. Special Torque Data (continued)
Table 1-3. Time Standards
Table 1-3. Time Standards (continued) - TM-5-6115-457-340104
Table 1-3. Time Standards (continued) - TM-5-6115-457-340105
Table 1-3. Time Standards (continued) - TM-5-6115-457-340106
Table 1-3. Time Standards (continued) - TM-5-6115-457-340107
Table 1-3. Time Standards (continued) - TM-5-6115-457-340108
Table 1-3. Time Standards (continued) - TM-5-6115-457-340109
Table 1-3. Time Standards (continued) - TM-5-6115-457-340110
Table 1-3. Time Standards (continued) - TM-5-6115-457-340111
Table 1-3. Time Standards (continued) - TM-5-6115-457-340112
Table 1-3. Time Standards (continued) - TM-5-6115-457-340113
Table 1-3. Time Standards (continued) - TM-5-6115-457-340114
Table 1-3. Time Standards (continued) - TM-5-6115-457-340115
Table 1-3. Time Standards (continued) - TM-5-6115-457-340116
Table 1-3. Time Standards (continued) - TM-5-6115-457-340117
Table 1-3. Time Standards (continued) - TM-5-6115-457-340118
Table 1-3. Time Standards (continued) - TM-5-6115-457-340119
Table 1-3. Time Standards (continued) - TM-5-6115-457-340120
Figure 1-l. Hydraulic system schematic, precise generation sets.
Figure 1-6. Control cubicle (A3) schematic
Figure 1-8. Fault locating indicator (A9) schematic
Figure 1-9. Fault locating indicator (A9) wiring diagram
Figure 1-11. Exciter regulator (A10 and A11) 50/60 Hertz wiring diagram (sheet 1 of 2)
Figure 1-11. Exciter regulator (Al0 and Al1) 50/60 Hertz wiring diagram (sheet 2 of 2)
Figure 1-13. Exciter regulator (A10 and All) 400 Hertz wiring diagram (sheet 1 of 2)
Figure 1-13. Exciter regulator (A10 and All) 400 Hertz wiring diagram (sheet 2 of 2)
Figure 1-19. tactical relay box (A29) wiring diagram
Figure 1-21. Precise relay box (A25) wiring diagram precise 50/60 Hertz generator sets
Figure 1-24. 50/60 Hertz precise governor control unit (A23) wiring diagram
Figure 1-25. 400 Hertz precise governor control unit (A23) wiring diagram
Figure l-26. Precise governor actuator (A24) wiring diagram
Figure 1-27. Load measuring unit (A8) wiring diagram
Figure 1-28. Generator assembly simplified schematic diagram
Figure 1-30. Electric winterization kit schematic.
Figure 1-31. Dummy load kit (A28) schematic (sheet 1 of 2)
Figure 1-31. Dummy load kit (A28) schematic (sheet 2 of 2)
Chapter 2. GENERAL MAINTENANCE INSTRUCTIONS - TM-5-6115-457-340143
Figure 2-1. Specially designed tools (fabricated)
Section II. TROUBLESHOOTING - TM-5-6115-457-340145
Figure 2-2. Control cubicle, removal and installation
Figure 2-3. Rear housing and upper sides housing, removal and installation
GENERATOR - Removal
Figure 2-4. Generator controls, removal and installation
Figure 2-4. Generator controls, removal and installation (cont)
Figure 2-5. Generator, removal and installation
Installation - TM-5-6115-457-340153
Installation (cont) - TM-5-6115-457-340154
ENGINE, D333C(T)
ENGINE, D333C(T) - Removal - TM-5-6115-457-340156
ENGINE, D333C(T) - Removal - TM-5-6115-457-340157
Figure 2-6. Engine, removal and installation
Installation - TM-5-6115-457-340159
Installation (cont) - TM-5-6115-457-340160
WHEEL MOUNTING KIT.
Figure 2-7. Wheel mounting kit, removal and installation
Legend to figure 2-7
Table 2-1. Recommended Tools and Equipment
Table 2-1. Recommended Tools and Equipment (Continued) - TM-5-6115-457-340165
Table 2-1. Recommended Tools and Equipment (Continued) - TM-5-6115-457-340166
Table 2-1. Recommended Tools and Equipment (Continued) - TM-5-6115-457-340167
Table 2-1. Recommended Tools and Equipment (Continued) - TM-5-6115-457-340168
Table 2-1. Recommended Tools and Equipment (Continued) - TM-5-6115-457-340169
Table 2-1. Recommended Tools and Equipment (Continued) - TM-5-6115-457-340170
Table 2-1. Recommended Tools and Equipment (Continued) - TM-5-6115-457-340171
Table 2-1. Recommended Tools and Equipment (Continued) - TM-5-6115-457-340172
Table 2-1. Recommended Tools and Equipment (Continued) - TM-5-6115-457-340173
Table 2-1. Recommended Tools and Equipment (Continued) - TM-5-6115-457-340174
Table 2-1. Recommended Tools and Equipment (Continued) - TM-5-6115-457-340175
Table 2-1. Recommended Tools and Equipment (Continued) - TM-5-6115-457-340176
Table 2-3. Troubleshooting
GENERATOR SET
GENERATOR SET (Continued) - TM-5-6115-457-340179
GENERATOR SET (Continued) - TM-5-6115-457-340180
GENERATOR SET (Continued) - TM-5-6115-457-340181
GENERATOR SET (Continued) - TM-5-6115-457-340182
GENERATOR SET (Continued) - TM-5-6115-457-340183
GENERATOR SET (Continued) - TM-5-6115-457-340184
GENERATOR SET (Continued) - TM-5-6115-457-340185
GENERATOR SET (Continued) - TM-5-6115-457-340186
GENERATOR SET (Continued) - TM-5-6115-457-340187
GENERATOR SET (Continued) - TM-5-6115-457-340188
GENERATOR SET (Continued) - TM-5-6115-457-340189
GENERATOR SET (Continued) - TM-5-6115-457-340190
GENERATOR SET (Continued) - TM-5-6115-457-340191
GENERATOR SET (Continued) - TM-5-6115-457-340192
GENERATOR SET (Continued) - TM-5-6115-457-340193
GENERATOR SET (Continued) - TM-5-6115-457-340194
GENERATOR SET (Continued) - TM-5-6115-457-340195
FUEL BURNING WINTERIZATION KIT
FUEL BURNING WINTERIZATION KIT (Continued) - TM-5-6115-457-340197
FUEL BURNING WINTERIZATION KIT (Continued) - TM-5-6115-457-340198
ELECTRIC WINTERIZATION KIT - TM-5-6115-457-340199
DUMMY LOAD KIT
DUMMY LOAD KIT (Continued)
Section IV. ENGINE CHANGE INSTRUCTIONS, D3306(T) ENGINE
Figure 2-8. Engine assembly, D3306(T) (sheet 1 of 2)
Figure 2-8. Engine assembly, D3306(T) (sheet 2 of 2)
Legend to figure 2-8
Legend to figure 2-8 (continued)
INSTALLATION OF COMPONENTS, D3306(T) ENGINE.
INSTALLATION OF COMPONENTS, D3306(T) ENGINE. (cont) - TM-5-6115-457-340208
INSTALLATION OF COMPONENTS, D3306(T) ENGINE. (cont) - TM-5-6115-457-340209
Figure 2-9. Front lower right panel drilling dimensions for fuel bleed line tubing
Chapter 3. HOUSING AND LIFTING FRAME ASSEMBLY REPAIR INSTRUCTIONS
Figure 3-1. Housing frame, exploded view
Legend to figure 3-1
CLEANING. - TM-5-6115-457-340214
Section II. LIFTING FRAME ASSEMBLY
Figure 3-2. Lifting frame assembly, exploded view
REASSEMBLY. - TM-5-6115-457-340217
Legend to figure 3-3
Figure 3-3. Housing, partially exploded view
Figure 3-3. Housing, partially exploded view (cont)
Chapter 4. RADIATOR AND SHUTTER ASSEMBLY REPAIR INSTRUCTIONS
Pressure Test.
Figure 4-1. Radiator assembly
Section II. SHUTTER AND CONTROL ASSEMBLY
INSPECTION. - TM-5-6115-457-340225
Figure 4-3. Shutter, exploded view
INSPECTION. - TM-5-6115-457-340227
INSTALLATION. - TM-5-6115-457-340228
Chapter 5. ELECTRICAL CONTROLS WIRING HARNESSES REPAIR INSTRUCTIONS
REMOVAL. - TM-5-6115-457-340230
Figure 5-1. Relay box to control cubicle wire harness
Figure 5-1. Relay box to control cubicle wire harness (cont)
Figure 5-2. Relay box to exciter regulator wire harness
Figure 5-3. Tactical relay box to load measuring unit wire harness
Figure 5-4. Relay box to precise relay box wire harness, 50/60 Hertz generator sets
Figure 5-5. Relay box to governor control unit wire harness precise generator sets
Figure 5-6. Governor control unit to governor actuator unit wire harness, precise generator sets
Figure 5-7. Relay box to reconnection panel wire harness, 50/60 Hertz generator sets
Figure 5-7. Relay box to reconnection panel wire harness, 50/60 Hertz generator sets (cont)
Figure 5-8. Relay box to reconnection panel wire harness, 400 Hertz generator sets (sheet 1 of 2)
Figure 5-8. Relay box to reconnection panel wire harness, 400 Hertz generator sets (sheet 2 of 2)
Figure 5-9. Relay box to fault locator indicator wire harness
Figure 5-10. Parallel receptacle wire harness
Figure 5-11. Relay box to tactical relay box wire harness
Chapter 6. GENERATOR SET CONTROL GROUP REPAIR INSTRUCTIONS
TEST - TM-5-6115-457-340246
Figure 6-1. Thermal watt converter (Al) test setup
CONTROL BOX RELAY ASSEMBLY (A4)
Removal. - TM-5-6115-457-340249
Figure 6-3. Control box relay assembly (A4) test setup
Table 6-1. Control Box Relay Assembly (A4) Procedural Analysis
REASSEMBLY. - TM-5-6115-457-340252
Figure 6-5. Plug in relay test setup
CONTROL CUBICLE.
Figure 6-6. AC current meter (M8) test setup
Figure 6-7. Control cubicle exploded view
REASSEMBLY
Figure 6-8. Control cubicle wire harness (sheet 1 of 4)
Figure 6-8. Control cubicle wire harness (sheet 4 of 4)
Section II. DC CIRCUIT BREAKER BOX
Figure 6-9. DC circuit breaker box, exploded view
Table 6-2. Circuit Breaker Box Hookup Wire Data
Section III. FAULT LOCATING INDICATOR BOX
DISASSEMBLY. - TM-5-6115-457-340265
Figure 6-10. Fault locating indicator box (A9), test setup
Table 6-3. Fault Locating Indicator Box (A9) Procedural Analysis
Table 6-3. Fault Locating Indicator Box (A9) Procedural Analysis (cont)
REPAIR. - TM-5-6115-457-340269
Figure 6-11. Fault locating indicator box, exploded view
INSTALLATION. - TM-5-6115-457-340271
Table 6-4. Fault Locating Indicator (A9) Hook Up Wire Data
Figure 6-12. Fault Locating Indicating Box wiring harness (sheet 1 of 2)
Figure 6-12. Fault Locating Indicating Box wiring harness (sheet 2 of 2)
Section IV. CONVENIENCE RECEPTACLE ASSEMBLY
Figure 6-13. 50/60 hertz convenience receptacle assembly, exploded view
400 HERTZ CONVENIENCE RECEPTACLE ASSEMBLY.
Table 6-5. 50/60 Hertz Convenience Receptacle Assembly
Table 6-6. 400 Hertz Convenience Receptacle Assembly
Figure 6-14. 400 hertz convenience receptacle assembly, exploded view
Section V. EXCITER-REGULATOR
TEST AND REMOVAL.
TEST AND REMOVAL. (cont)
TEST. - TM-5-6115-457-340284
Figure 6-16. Exciter regulator (Al0, All) test setup
Table 6-7. Exciter-Regualtor (A10-A11) Procedural Analysis
Table 6-7. Exciter-Regualtor (A10-A11) Procedural Analysis (cont) - TM-5-6115-457-340287
Table 6-7. Exciter-Regualtor (A10-A11) Procedural Analysis (cont) - TM-5-6115-457-340288
Table 6-7. Exciter-Regualtor (A10-A11) Procedural Analysis (cont) - TM-5-6115-457-340289
Table 6-7. Exciter-Regualtor (A10-A11) Procedural Analysis (cont) - TM-5-6115-457-340290
CLEANING. - TM-5-6115-457-340291
Figure 6-17. Exciter regulator, exploded view
INSTALLATION. - TM-5-6115-457-340293
Figure 6-18. Voltage regulator exploded view
Legend to figure 6-18
Figure 6-19. Voltage regulator subassembly
Figure 6-20. Exciter regulator wiring harness (Sheet 1 of 2)
Figure 6-20. Exciter regulator wiring harness (Sheet 2 of 2)
Figure 6-21. Voltage regulator wiring harness
Table 6-8. Voltage Regulator Sub-Assembly Wire Data
Section VI. MODE I RELAY BOX ASSEMBLY
Figure 6-22. Mode I and mode II relay box assembly, cover removed
DISASSEMBLY - TM-5-6115-457-340303
Figure 6-23. DC relay assembly (A5) test setup
Table 6-9. DC Relay Assembly (A5) Procedural Analysis
Table 6-9. DC Relay Assembly (A5) Procedural Analysis (cont) - TM-5-6115-457-340306
Table 6-9. DC Relay Assembly (A5) Procedural Analysis (cont) - TM-5-6115-457-340307
MODE I RE LAY BOX ASSEMBLY (A27)
BENCH TEST. - TM-5-6115-457-340309
Figure 6-25. Mode I relay box assembly (A27) test setup
Table 6-10. Mode I Relay Box Assembly (A27) Continuity Test
Table 6-10. Mode I Relay Box Assembly (A27) Continuity Test (Continued) - TM-5-6115-457-340312
Table 6-10. Mode I Relay Box Assembly (A27) Continuity Test (Continued) - TM-5-6115-457-340313
Table 6-10. Mode I Relay Box Assembly (A27) Continuity Test (Continued) - TM-5-6115-457-340314
Table 6-11. Mode I Relay Assembly (A27) Procedural Analysis
Table 6-11. Mode I Relay Assembly (A27) Procedural Analysis (cont)
INSPECTION AND BENCH TEST.
Figure 6-26. Mode I relay box assembly (A-27), exploded view
INSTALLATION - TM-5-6115-457-340319
Figure 6-27. Mode I relay box wiring harness (sheet 1 of 4)
Figure 6-27, Mode I relay box wiring harness (Sheet 2 of 4)
Figure 6-27. Mode I relay box wiring harness (Sheet 3 of 4)
Figure 6-27. Mode I relay box wiring harness (Sheet 4 of 4)
Section VII. MODE II RELAY BOX ASSEMBLY
DC RELAY ASSEMBLY (A5).
BENCH TEST. - TM-5-6115-457-340326
400 HERTZ UNDERVOLTAGE RELAY (K11).
Figure 6-29. Undervoltage relay (K11), test setup
400 HERTZ ELECTRONIC COMPONENTS ASSEMBLY (A6)
DISASSEMBLY - TM-5-6115-457-340330
REPAIR. - TM-5-6115-457-340331
Table 6-12. Electronics Components Assembly (A6) Hook Up Wire Data
Table 6-13. Mode II Relay Box Assembly (A27) Continuity Test
Table 6-13. Mode II Relay Box Assembly (A27) Continuity Test (Continued) - TM-5-6115-457-340334
Table 6-13. Mode II Relay Box Assembly (A27) Continuity Test (Continued) - TM-5-6115-457-340335
Table 6-13. Mode II Relay Box Assembly (A27) Continuity Test (Continued) - TM-5-6115-457-340336
Table 6-13. Mode II Relay Box Assembly (A27) Continuity Test (Continued) - TM-5-6115-457-340337
Figure 6-33. Mode II relay box assembly (A27) test setup
Figure 6-34. Mode II relay box assembly (A27), exploded view
CLEANING
Table 6-14. Mode II Relay Assembly (A27) Procedural Analysis
Table 6-14. Mode II Relay Assembly (A27) Procedural Analysis (cont) - TM-5-6115-457-340342
Table 6-14. Mode II Relay Assembly (A27) Procedural Analysis (cont) - TM-5-6115-457-340343
REPAIR. - TM-5-6115-457-340344
Figure 6-35. Mode II relay box assembly (A27) wiring diagram (Sheet 2 of 4)
Figure 6-35. Mode II relay box assembly (A27) wiring diagram (Sheet 3 of 4)
Figure 6-35. Mode II relay box assembly (A27) wiring diagram (Sheet 4 of 4)
Section VIII. RECONNECTION BOARD ASSEMBLY, LOAD CONTACTOR, MOTOR OPERATED CIRCUIT BREAKER ASSEMBLY, LOAD BOARD ASSEMBLY, AND TRANSFORMER ASSEMBLY
LOAD CONTACTOR.
Figure 6-36. Reconnection board assembly, load contactor, and load board assembly, removal and installation
Legend to figure 6-36
Legend to figure 6-36A
Figure 6-36A. Main load contactor (sheet 1 of 2)
Figure 6-36A. Main load contactor (sheet 2 of 2)
Removal - TM-5-6115-457-340355
Figure 6-37. Reconnection board assembly, exploded view
REMOVAL - TM-5-6115-457-340357
INSPECTION. - TM-5-6115-457-340358
ADJUSTMENT. - TM-5-6115-457-340359
Table 6-15. Load Contactor (CB2), Test
TEST. - TM-5-6115-457-340361
Figure 6-37A. Motor operated circuit breaker assembly (CB2), removal and installation
Figure 6-37B. Circuit breaker assembly (CB2), test setup
Table 6-15A. Circuit Breaker Assembly (CB2), Procedural Analysis
Table 6-15A. Circuit Breaker Assembly (CB2), Procedural Analysis (cont)
Figure 6-37C. Motor operated circuit breaker assembly (CB2), exploded view
Legend to figure 6-37C
CLEANING. - TM-5-6115-457-340369
Figure 6-37D. Motor operated circuit breaker assembly (CB2), wiring diagram
Figure 6-37E. Motor operated circuit breaker assembly (CB2), schematic
INSTALLATION - TM-5-6115-457-340373
LOAD BOARD ASSEMBLY.
Figure 6-38. Transformer assembly, removal and installation
CLEANING. - TM-5-6115-457-340377
Figure 6-39. Transformer assembly, exploded view
Figure 6-40. Transformer inspection
Section IX. TACTICAL RELAY BOX
OVER VOLTAGE RELAY (K2).
Figure 6-41. Tactical relay box (A29), cover removed
REVERSE POWER RELAY (K15).
BENCH TEST. - TM-5-6115-457-340384
SHORT CIRCUIT RELAY (K13).
OVERLOAD RELAY (K14).
BENCH TEST. - TM-5-6115-457-340387
Figure 6-45. Overload Relay (K14), test setup
Table 6-16. Tactical Relay Box (A29) Continuity Test
Table 6-17. Tactical relay box (A29) Procedural Analysis
Table 6-17. Tactical relay box (A29) Procedural Analysis (cont) - TM-5-6115-457-340392
Table 6-17. Tactical relay box (A29) Procedural Analysis (cont) - TM-5-6115-457-340393
Figure 6-47. Tactical Relay Box (A29), exploded view
INSPECTION AND TEST. - TM-5-6115-457-340395
Figure 6-48. Tactical Relay Box (A29), wiring harness (sheet 1 of 2)
Figure 6-48. Tactical Relay Box (A29), wiring harness (sheet 2 of 2)
Section X. PRECISE RELAY BOX
50/60 HERTZ UNDER FREQUENCY RELAY (K12).
Figure 6-49. Precise relay box (A25) 50/60 Hz precise generator sets, cover removed
Figure 6-50. 50/60 Hertz under frequency relay (K12), test setup
PRECISE RELAY BOX (A25).
Table 6-18. Precise Relay Box (A25) Continuity and Resistance Test
Table 6-19. Precise Relay Box (A25) Procedural Analysis
Table 6-19. Precise Relay Box (A25) Procedural Analysis (cont)
Figure 6-52. Precise relay box (A25), exploded view
INSPECTION AND TEST. - TM-5-6115-457-340407
Figure 6-53. Precise relay box (A25), wire harness
Figure 6-53. Precise relay box (A25), wire harness (cont)
Section XI. PRECISE GOVERNOR CONTROL UNIT
ON EQUIPMENT TEST
Table 6-20. Precise Governor Control Unit (A23) Resistance Checks
Figure 6-54. Precise governor control unit (A23) adjustments and test points.
Table 6-21. Precise Governor Control Unit (A23) Procedural Analysis
Table 6-21. Precise Governor Control Unit (A23) Procedural Analysis (cont) - TM-5-6115-457-340416
Table 6-21. Precise Governor Control Unit (A23) Procedural Analysis (cont) - TM-5-6115-457-340417
Table 6-21. Precise Governor Control Unit (A23) Procedural Analysis (cont) - TM-5-6115-457-340418
Table 6-21. Precise Governor Control Unit (A23) Procedural Analysis (cont) - TM-5-6115-457-340419
Table 6-21. Precise Governor Control Unit (A23) Procedural Analysis (cont) - TM-5-6115-457-340420
Table 6-21. Precise Governor Control Unit (A23) Procedural Analysis (cont) - TM-5-6115-457-340421
Figure 6-55. Precise governor control unit (A23), test setup
CLEANING. - TM-5-6115-457-340423
Figure 6-56. Precise governor control unit (A23), exploded view
INSTALLATION. - TM-5-6115-457-340425
Legend to figure 6-57
Figure 6-57. Precise governor control unit (A23), printed wiring board assembly
Figure 6-58. Precise governor control unit (A23), wiring harness diagram (Sheet 1 of 2)
Figure 6-58. Precise governor control unit (A23), wiring harness diagram (Sheet 2 of 2)
Isochronous Operation
Parallel Operation Alignment and Adjustment
ALIGNMENT PROCEDURES PECULIAR TO OPERATION OF 400 HZ GENERATOR SETS IN SUPPORT OF E3A AIRCRAFT,
Section XII. LOAD MEASUREMENT UNIT
ON EQUIPMENT TEST. - TM-5-6115-457-340435
INSPECTION. - TM-5-6115-457-340436
ON EQUIPMENT TEST. - TM-5-6115-457-340437
INSPECTION. - TM-5-6115-457-340438
Figure 6-60. Load measurement unit (LMU), test setup
Figure 6-61. Load measurement unit, exploded view
INSTALLATION. - TM-5-6115-457-340441
Table 6-22. Load Measurement Unit Procedural Analysis
Chapter 7. GENERATOR ASSEMBLY REPAIR INSTRUCTIONS
Symptom and Isolation of Malfunction
Figure 7-1. Generator assembly, exploded view
DISASSEMBLY. - TM-5-6115-457-340446
Legend to figure 7-1
DISASSEMBLY. (cont)
CLEANING. - TM-5-6115-457-340449
REPAIR OR REBUILD.
REASSEMBLY. - TM-5-6115-457-340451
Figure 7-2. 50/60 Hertz generator, main strator rewind data (sheet 1 of 2)
Figure 7-2. 50/60 Hertz generator, main strator rewind data (sheet 2 of 2)
Table 7-1. Generator Output Lead Lengths
Figure 7-3. 400 Hertz generator, main stator rewind data
Figure 7-3. 400 Hertz generator, main stator rewind data (Cont)
Figure 7-4. 50/60 Hertz generator, main rotor rewind data
Figure 7-4. 50/60 Hertz generator, main rotor rewind data (cont)
Figure 7-5. 400 Hertz generator, main rot or rewind data
Figure 7-5. 400 Hertz generator, main rot or rewind data (cont)
Figure 7-6. 50/60 Hertz generator, exciter rotor rewind data
Figure 7-6. 50/60 Hertz generator, exciter rotor rewind data (cont)
Figure 7-7. 400 Hertz generator, exciter rotor rewind data
REASSEMBLY. (cont) - TM-5-6115-457-340465
Figure 7-8. 50/60 Hertz generator, exciter stator rewind data
Figure 7-9. 400 Hertz generator , exciter stator rewind data
HIGH POTENTIAL TEST.
INSTALLATION. - TM-5-6115-457-340469
Chapter 8. ENGINE GROUP REPAIR INSTRUCTIONS
Section II. ENGINE HARNESS GROUP
REBUILD. - TM-5-6115-457-340473
Figure 8-1. Engine wire harness (sheet 1 of 2)
Figure 8-1. Engine wire harness (sheet 2 of 2)
Section III. ALTERNATOR
INSPECTION. - TM-5-6115-457-340477
Figure 8-2. Alternator assembly, exploded view (sheet 1 of 2)
Figure 8-2. Alternator assembly, exploded view (sheet 2 of 2)
REASSEMBLY. - TM-5-6115-457-340480
Figure 8-4. Alternator schematic and wiring diagram (sheet 1 of 2)
Figure 8-4. Alternator schematic and wiring diagram (sheet 2 of 2)
Figure 8-6. Alternator output test
Section IV. STARTING MOTOR
REPAIR. - TM-5-6115-457-340485
Figure 8-7. Starter motor, exploded view
Legend to figure 8-7
SOLENOID WINDING TEST.
Figure 8-8. Starting motor, test setup
STALL TORQUE TEST.
Figure 8-9. Starting motor pinion position, test setup
Section V. FAN MOUNTING GROUP
Figure 8-10. Fan and fan drive group, removal and installation
Figure 8-11. Fan drive assembly, exploded view
Section VI. DAY TANK ASSEMBLY
Section VII. OVERSPEED SWITCH
INSPECTION - TM-5-6115-457-340497
ADJUSTMENT. - TM-5-6115-457-340499
Figure 8-12. Overspeed switch, exploded view
Figure 8-13. Overspend switch, test setup
MINOR SPEED ADJUSTMENT.
Section VIII. TACHOMETER DRIVE GROUP
Figure 8-14. Tachometer drive group, exploded view
Section IX. FUEL PUMP GROUP
Figure 8-15. Fuel pump group, exploded view
REPAIR. - TM-5-6115-457-340507
Section X. TURBOCHARGER GROUP
CLEANING. - TM-5-6115-457-340509
Figure 8-16. Turbocharger group, exploded view
REPAIR. - TM-5-6115-457-340511
REASSEMBLY. - TM-5-6115-457-340512
Section XI. OIL COOLER GROUP
Figure 8-19. Oil cooler group, removal and installation
INSPECTION. - TM-5-6115-457-340515
Figure 8-20. Oil cooler group, exploded view
Section XII. HYDRAULIC TANK (PRECISE SETS ONLY)
Figure 8-22. Hydraulic tank, exploded view
CLEANING. - TM-5-6115-457-340519
Section XIII. HYDRAULIC PUMP (PRECISE SETS ONLY)
HYDRAULIC PUMP TEST AND ADJUSTMENT (ON PRECISE GENERATOR SETS ONLY).
Section XIV. HYDRAULIC PUMP DRIVE GROUP
REPAIR. - TM-5-6115-457-340523
Figure 8-24. Hydraulic pump drive group, exploded view
Section XV. GOVERNOR ACTUATOR UNIT (PRECISE SET ONLY)
Figure 8-25. Governor actuator unit, removal and installation (precise sets only)
CLEANING. - TM-5-6115-457-340527
Figure 8-26. Governor actuator unit, exploded view (precise sets only)
REPAIR. - TM-5-6115-457-340529
Figure 8-27. Governor actuator unit, test and adjustment
TEST AND ADJUSTMENT.
INSTALLATION. - TM-5-6115-457-340532
INSTALLATION. (cont)
Section XVI. WATER PUMP GROUP
REPAIR. - TM-5-6115-457-340535
Figure 8-28. Water pump group, exploded view
Section XVII. CRANKSHAFT PULLEY, DAMPER AND TIMING GEAR COVER GROUP
Figure 8-29. Crankshaft pulley, damper, and timing gear cover group, exploded view
Legend to figure 8-29
Figure 8-30. Alignment of timing marks
Section XVIII. UTILITY GOVERNOR GROUP
REMOVAL - TM-5-6115-457-340542
GOVERNOR DRIVE HOUSING
Figure 8-31. Utility governor and linkage, exploded view
Legend to figure 8-31
Figure 8-31A. Overspeed Shutdown Device
Legend to figure 8-31A
Figure 8-32. Governor drive housing, removal and installation
CLEANING. - TM-5-6115-457-340549
Figure 8-33. Utility governor assembly, exploded view
Legend to figure 8-33
Figure 8-34. Governor drive housing, exploded view
Legend to figure 8-34
UTILITY GOVERNOR.
INSTALLATION - TM-5-6115-457-340555
Figure 8-36. Engagement of control rack to control lever
GOVERNOR DRIVE HOUSING ADJUSTMENT
Figure 8-37. Installing fuel rack setting gauge
Figure 8-38. Utility governor droop setting
Section XIX. FUEL INJECTION GROUP
Figure 8-39. Fuel injection group, exploded view - TM-5-6115-457-340561
Figure 8-39. Fuel injection group, exploded view - TM-5-6115-457-340562
Legend to figure 8-39
CLEANING. - TM-5-6115-457-340564
REASSEMBLY. - TM-5-6115-457-340565
INSTALLATION. - TM-5-6115-457-340566
Figure 8-44. Fuel injection timing on the engine
Figure 8-45. Aligning timing pointer on flywheel
Table 8-1. Timing Plate Degree Settings
Section XX. ACCESSORY DRIVE GROUP
DISASSEMBLY. - TM-5-6115-457-340571
Figure 8-47. Accessory drive group, exploded view
REPAIR. - TM-5-6115-457-340573
Figure 8-48. Accessory drive shaft timing
Section XXI. EXHAUST MANIFOLD GROUP
Figure 8-49. Exhaust manifold group, exploded view
Section XXII. OIL PAN GROUP AND RELATED PARTS
Figure 8-50. Oil pan group and related parts, exploded view
INSTALLATION. - TM-5-6115-457-340579
Section XXIII. OIL PUMP GROUP
Figure 8-51. Oil pump group, removal and installation
Figure 8-52. Oil pump group, exploded view
REASSEMBLY. - TM-5-6115-457-340583
Section XXIV. VALVE COVER AND VALVE MECHANISM GROUP
Figure 8-53. Valve cover and valve mechanism group, exploded view
INSPECTION. - TM-5-6115-457-340586
Section XXV. CYLINDER HEAD GROUP
CLEANING. - TM-5-6115-457-340588
REPAIR. - TM-5-6115-457-340589
Figure 8-54. Cylinder head group, exploded view
Legend to figure 8-54
Figure 8-55. Valve and valve seat specifications
Figure 8-56. Tightening sequence for cylinder head
Section XXVI. FLYWHEEL AND FLYWHEEL HOUSING GROUP
INSPECTION. - TM-5-6115-457-340595
Figure 8-57. Flywheel and flywheel housing group, exploded view
Legend to figure 8-57
Figure 8-58. Installing crankshaft seal
Figure 8-59. Flywheel housing bore concentricity check
Section XXVII. CAMSHAFT GROUP
Figure 8-61. Camshaft group, exploded view
INSPECTION. - TM-5-6115-457-340602
Section XXVIII. CONNECTING RODS AND PISTONS GROUP
REMOVAL. - TM-5-6115-457-340604
INSPECTION. - TM-5-6115-457-340605
Figure 8-62. Connecting rods and pistons group, exploded view
INSTALLATION. - TM-5-6115-457-340607
Section XXIX. CRANKSHAFT GROUP AND MAIN BEARINGS
DISASSEMBLY. - TM-5-6115-457-340609
Figure 8-63. Crankshaft group and main bearings, exploded view
CLEANING. - TM-5-6115-457-340611
REPAIR. - TM-5-6115-457-340612
Section XXX. CYLINDER BLOCK AND COVERS GROUP
REMOVAL. - TM-5-6115-457-340614
DISASSEMBLY. - TM-5-6115-457-340615
Figure 8-64. Cylinder block and covers group, exploded view
Figure 8-64. Cylinder block and covers group, exploded view (cont)
Legend to figure 8 - 64
INSTALLATION. - TM-5-6115-457-340619
Section XXXI. ENGINE TEST AFTER OVERHAUL
OPERATIONAL TEST OF OVERSPEED SHUTDOWN DEVICE.
UTILITY GOVERNOR SPEED SETTING ADJUSTMENT.
Chapter 9. BASE ASSEMBLY, STOWAGE TOOL BOX, AND FUEL TANK REPAIR INSTRUCTIONS
Figure 9-1. Base assembly, exploded view
INSPECTION. - TM-5-6115-457-340625
Section II. STOWAGE TOOL BOX
Figure 9-2. Stowage tool box, exploded view
Section III. FUEL TANK ASSEMBLY
Figure 9-3. Fuel tank assembly, exploded view
REPAIR. - TM-5-6115-457-340630
INSTALLATION. - TM-5-6115-457-340631
Chapter 9A. PAINT AND MARKING REQUIREMENTSAFTER OVERHAUL
Chapter 10. TEST AFTER OVERHAUL
INSTRUMENT CHECK.
HIGH COOLANT TEMPERATURE TRIP TEST.
OVER AND UNDER VOLTAGE TRIP TEST .
PHASE BALANCE TEST.
REGULATOR RANGE TEST. - TM-5-6115-457-340640
LONG TERM STEADY STATE STABILITY TEST
ENGINE EFFICIENCY TEST.
Chapter 11. FUEL BURNING WINTERIZATION KIT REPAIR INSTRUCTIONS
Figure 11-1. Fuel burning winterization kit control box, exploded view
Table 11-1. Fuel Burning Winterization Kit Control Box Wire Termination Data
Section II. HEATER
DISASSEMBLY. - TM-5-6115-457-340647
Figure 11-2. Fuel burning winterization kit heater, exploded view
Legend to figure 11-2
Repair - TM-5-6115-457-340650
Figure 11-3. Coolant pump wear limits
COMPONENT TEST AND ADJUSTMENTS.
Figure 11-4. Coolant pump test set-up
Chapter 12. ELECTRIC WINTERIZATION KIT REPAIR INSTRUCTIONS
Table 12-1. Electric Winterization Kit Control Procedural Analysis
Figure 12-2. Electric winterization kit control box, exploded view
CLEANING. - TM-5-6115-457-340658
Figure 12-3. Electric winterization kit control box wiring harness
Figure 12-4. Electric winterization kit control box connector wiring harness
Section II. ELECTRIC HEATER
Section III. COOLANT PUMP
REMOVAL. - TM-5-6115-457-340663
Figure 12-6. Electric winterization kit coolant pump, exploded view
REASSEMBLY. - TM-5-6115-457-340665
Chapter 13. DUMMY LOAD KIT REPAIR INSTRUCTIONS
Figure 13-1. Dummy load kit, exploded view (sheet 1 of 2)
Figure 13-1. Dummy load kit, exploded view (sheet 2 of 2)
Legend to figure 13-1.
REPAIR. - TM-5-6115-457-340671
Figure 13-2. Dummy load kit right side wiring harness (sheet 1 of 2)
Figure 13-2. Dummy load kit right side wiring harness (sheet 2 of 2)
Figure 13-3. Dummy load kit (left side) wiring harness (sheet 1 of 2)
Figure 13-3. Dummy load kit (left side) wiring harness (sheet 2 of 2)
Section II. CONTROL BOX
Figure 13-4. Dummy load kit control box, exploded view (sheet 1 of 2)
Figure 13-4. Dummy load kit control box, exploded view (sheet 2 of 2)
Legend to figure 13-4
Figure 13-5. Dummy load kit load dumping relay (K5), test setup
Table 13-1. Dummy load kit load dumping relay (K5) Procedural Analysis
Table 13-1. Dummy load kit load dumping relay (K5) Procedural Analysis (cont)
CONTROL BOX.
DISASSEMBLY - TM-5-6115-457-340684
Figure 13-7. Dummy load kit control box harness (sheet 1 of 3)
Figure 13-7. Dummy load kit control box harness (sheet 2 of 3)
Figure 13-7. Dummy load kit control box harness (sheet 3 of 3)
WIRING HARNESS REBUILD
Appendix A. REFERENCES - TM-5-6115-457-340689
SHIPMENT AND STORAGE.
DESTRUCTION OF MATERIEL.
Figure 1-2. 50/60 Hertz DC system schematic
Figure 1-3. 400 Hertz DC system schematic
Figure 1-4. 50/60 Hertz AC system schematic
Figure 1-5.400 Hertz AC system schematic
Figure 1-7. Control cubicle (A3) wiring diagram
Figure 1-10. Exciter regulator (A10 and A11) 50/60 Hertz schematic
Figure 1-12. Exciter regulator (A10 and A11) 400 Hertz schematic
Figure 1-14. Mode I relay box (A27) schematic diagram 50/60 Hertz generator sets
Figure 1-15. Mode I relay box (A27) wiring diagram 50/60 Hertz generator sets
Figure 1-15. Mode I relay box (A27) wiring diagram 50/60 Hertz generator sets (cont)
Figure 1-16. Mode II relay box (A27) schematic 400 Hertz generator sets
Figure 1-17. Mode II relay box (A27) wiring diagram 400 Hertz generator sets
Figure 1-17. Mode II relay box (A27) wiring diagram 400 Hertz generator sets (cont) - TM-5-6115-457-340727
Figure 1-17. Mode II relay box (A27) wiring diagram 400 Hertz generator sets (cont) - TM-5-6115-457-340728
Figure 1-18. Tactical relay box (A29) schematic diagram
Figure 1-22. 50/60 Hertz precise governor system schetic, precise generator sets
Figure 1-23. 400 Hertz precise governor system schetic, precise generator sets
Figure 6-8. Control cubicle wire harness
Figure 6-8. Control cubicle wire harness (cont)
Figure 6-35. Mode II relay box assembly (A27) wiring diagram
Figure 6-46. Tactical Relay Box (A29) test setup
Figure 6-51. Precise relay box (A25), test setup
TM-5-6115-457-34 Generator Set Diesel Engine Driven Tactical Skid Mtd. 100 Kw 3 Phase 4 Wire 120/208 and 240/416 Volts Manual

Western Governors University

Privacy Statement
Press Release
Contact

Integrated Publishing, Inc. - A (SDVOSB) Service Disabled Veteran Owned Small Business