CHAPTER 1 INTRODUCTION - TM-5-6115-545-34_29Exciter Field Voltage and Current Versus LoadTurbocharger.Short circuit relay.Alternator.Table 1-1. Time StandardsTable 1-1. Time Standards (Cont)Figure 1-1. Schematic Diagram, Control Panel Relay, A4Figure 1-2. Schematic Diagram, Fault Indicator PanelFigure 1-3. Wiring Diagram, Fault Indicator PanelFigure 1-10. Wiring Schematic Diagram, Voltage RegulatorFigure 1-13. Schematic Diagram, Fuel Burning Winterization KitFigure 1-14. Wiring Diagram, Fuel Burning Winterization KitFigure 1-15. Schematic Wiringf Diagram Electric Winterization Kit Table 1-2. Repair and Replacement Standards - TM-5-6115-545-34_63Table 1-2. Repair and Replacement Standards - (Cont) - TM-5-6115-545-34_64Table 1-2. Repair and Replacement Standards - (Cont) - TM-5-6115-545-34_65Table 1-2. Repair and Replacement Standards - (Cont) - TM-5-6115-545-34_66Table 1-2. Repair and Replacement Standards - (Cont) - TM-5-6115-545-34_67Table 1-2. Repair and Replacement Standards - (Cont) - TM-5-6115-545-34_68Table 1-2. Repair and Replacement Standards - (Cont) - TM-5-6115-545-34_69Table 1-2. Repair and Replacement Standards - (Cont) - TM-5-6115-545-34_70Table 1-2. Repair and Replacement Standards - (Cont) - TM-5-6115-545-34_71Table 1-2. Repair and Replacement Standards - (Cont) - TM-5-6115-545-34_72Table 1-2. Repair and Replacement Standards - (Cont) - TM-5-6115-545-34_73Table 1-2. Repair and Replacement Standards - (Cont) - TM-5-6115-545-34_74Table 1-3. Specified Torque ValuesTable l-3. Specified Torque Values - (Cont)Table 1-4. Engine Generator Set ClassificationTable 1-5. Electrical Performance Characteristic Parameters AC Precise (Class 1)Table 1-5. Electrical Performance Characteristic Parameters AC Precise (Class 1) (Cont)Table 1-6. Electrical Performance Characteristic Parameters AC Utility (Class 2)Table 1-6. Electrical Performance Characteristic Parameters AC Utility (Class 2) (Cont)CHAPTER 2 GENERAL MAINTENANCE INSTRUCTIONSTable 2-1. TOOLS AND SUPPORT EQUIPMENT, TEST, REPAIR CALIBRATION AND HANDLINGFigure 2-0. Breakout Cable (Sheet 1 of 2)Figure 2-O. Breakout Cable (Sheet 2 of 2)Table 2-1. TOLLS AND SUPPORT EQUIPMENT, TEST, REPAIR CALIBRATION AND HANDLINGTABLE 2-1. TOOLS AND SUPPORT EQUIPMENT, TEST, REPAIR CALIBRATION AND HANDLING (CONT) - TM-5-6115-545-34_88TABLE 2-1. TOOLS AND SUPPORT EQUIPMENT, TEST, REPAIR CALIBRATION AND HANDLING (CONT) - TM-5-6115-545-34_89TABLE 2-1. TOOLS AND SUPPORT EQUIPMENT, TEST, REPAIR CALIBRATION AND HANDLING (CONT) - TM-5-6115-545-34_90TABLE 2-1. TOOLS AND SUPPORT EQUIPMENT, TEST, REPAIR CALIBRATION AND HANDLING (CONT) - TM-5-6115-545-34_91TABLE 2-1. TOOLS AND SUPPORT EQUIPMENT, TEST, REPAIR CALIBRATION AND HANDLING (CONT) - TM-5-6115-545-34_92TABLE 2-1. TOOLS AND SUPPORT EQUIPMENT, TEST, REPAIR CALIBRATION AND HANDLING (CONT) - TM-5-6115-545-34_93Table 2-2. Generator Set TroubleshootingTable 2-2. Generator Set Troubleshooting (Cont) - TM-5-6115-545-34_95Table 2-2. Generator Set Troubleshooting (Cont) - TM-5-6115-545-34_96Table 2-2. Generator Set Troubleshooting (Cont) - TM-5-6115-545-34_97Table 2-2. Generator Set Troubleshooting (Cont) - TM-5-6115-545-34_98Table 2-2. Generator Set Troubleshooting (Cont) - TM-5-6115-545-34_99Table 2-2. Generator Set Troubleshooting (Cont) - TM-5-6115-545-34_100Table 2-2. Generator Set Troubleshooting (Cont) - TM-5-6115-545-34_101Table 2-2. Generator Set Troubleshooting (Cont) - TM-5-6115-545-34_102Table 2-2. Generator Set Troubleshooting (Cont) - TM-5-6115-545-34_103Section IV. REMOVAL AND INSTALLATION OF MAJOR COMPONENTSFigure 2-1. Component Locations (Right and Left Side)Figure 2-2. Generator RemovalEngine RemovalFigure 2-3. Engine RemovalEngine Generator Assembly RemovalFigure 2-4. Engine Generator RemovalCHAPTER 3 GENERATOR SET CONTROLS REPAIR INSTRUCTIONSFigure 3-1. Fault Locating IndicatorFigure 3-2. Assembly, Fault IndicatorSection III. CONTROL CUBICLEFigure 3-3. Relay AssemblyFigure 3-4. Control Cubicle Transducer, Test SetupControl Cubicle Wiring HarnessPanel light test.Voltage adjusting rheostat testCHAPTER 4 HOUSING GROUP REPAIR INSTRUCTIONSCHAPTER 5 WIRING HARNESS REPAIR INSTRUCTIONSFigure 5-1. AC Power Control 50/60 Hz Wiring HarnessFigure 5-2. AC Power Control 400 Hz, Wiring Harness (Sheet 1 of 2)Figure 5-2. AC Power Control 400 Hz, Wiring Harness (Sheet 2 of 2)Figure 5-4. DC Power Cables Wiring Harness (Sheet 1 of 2)Figure 5-4. DC Power Cables Wiring Harness (Sheet 2 of 2)Figure 5-6. Convenience and Paralleling, Wiring Harness (Sheet 1 of 2)Figure 5-8. Fault Indicator Panel, Interconnecting Wiring HarnessFigure 5-9. Control Cubicle, Interconnecting Wiring Harness (Sheet 1 of 2)Figure 5-9. Control Cubicle, Interconnecting Wiring Harness (Sheet 2 of 2)Figure 5-10. Control cubicle, wiring harness (sheet 1 of 3)Figure 5-10. Control cubicle, wiring harness (sheet 2 of 3)Figure 5-11. Special AC Power Cablesfigure 5-12. Curennt Transformer Assembly Figure 5-13. Current Transformer Assembly Mode II Sets Wiring HarnessFigure 5-14. Electric Governor Control (Class 1 Mode I) Sets, Wiring Harness (Sheet 1 of 2)Figure 5-14. Electric Governor Control (Class 1 Mode I) Sets, Wiring Harness (Sheet 2 of 2)Figure 5-15. Electric Governor Control (Class 1 Mode II) Sets, Wiring HarnessFigure 5-16. Electric Governor Control To Actuator Wiring Harness, Class 1 SetsFigure 5-17. Electric Governor Control To Actuator Class 1 Sets Feedback CableFigure 5-19. Tactical RElay Assembly, Wwiring harnessFigure 5-20. Tactical Relay Assembly, Interconnecting Wiring HarnessFigure 5-21. Load Bank Interconnect, Tactical RelayFigure 5-23. Precise Relay Assembly (Class 1 Mode I) Sets, Wiring HarnessFigure 5-24. Excitation System Assembly, Wiring Harness Figure 5-25. Excitation System Assembly Interconnecting Wiring HarnessFigure 5-26. Voltage Regulator Wiring HarnesFigure 5-27. Set Special Relay Assembly (Class 1, Mode I) Sets. Wiring Harness (Sheet 2 of 5)Figure 5-27. Set Special Relay Assembly (Class 1, Mode I) Sets, Wiring Harness (Sheet 3 of 5)Figure 5-27. Set Special Relay Assembly (Class 1, Mode I) Sets, Wiring Harness (Sheet 4 of 5)Figure 5-27. Set Special Relay Assembly (Class 1, Mode I) Sets, Wiring Harness (Sheet 5 of 5)Figure 5-28. Set Special Relay Assembly (Class 1, Mode II) Sets, Wiring Harness (Sheet 2 of 5)Figure 5-28. Set Special Relay Assembly (Class 1, Mode II) Sets, Wiring Harness (Sheet 3 of 5)Figure 5-28. Set Special Relay Assembly (Class 1, Mode II) Sets, Wiring Harness (Sheet 4 of 5)Figure 5-28. Set Special Relay Assembly (Class 1, Mode II) Sets, Wiring Harness (Sheet 5 of 5)Figure 5-29. Load Measuring Unit Interconnecting, Wiring HarnessFigure 5-30. Engine Accessories, Wiring Harness (Sheet 2 of 3)Figure 5-30. Engine Accessories, Wiring Harness (Sheet 3 of 3)Figure 5-31. Paralleling Cable AssemblyFigure 5-32. Fuel Burning Winterization Kit, Wiring HarnessFigure 5-33. Fuel Burning Winterization Control, Wiring HarnessFigure 5-34. Electric Winterization Kit, Wiring Harness (Sheet 1 of 2)Figure 5-34. Electric Winterization Kit, Wiring Harness (Sheet 2 of 2)Figure 5-35. Electric Heater Control Box, Wiring Harness (Sheet 1 of 2)Figure 5-35. Electric Heater Control Box, Wiring Harness (Sheet 2 of 2)Figure 5-36. Load Bank, Wirng HarnessFigure 5-36. Load Bank, Wiring Harness (Sheet 2 of 3)Figure 5-36. Load Bank, Wiring Harness (Sheet 3 of 3)Figure 5-37. Load Bank Capacitor (Sheet 1 of 2)Figure 5-37. Load Bank Capacitor (Sheet 2 of 2)Figure 5-38. Load Bank Control Panel, Wiring Harness (Sheet 1 of 2)Figure 5-38. Load Bank Control Panel, Wiring Harness (Sheet 2 of 2)Figure 5-39. Special Purpose Cables AssemblyFigure 5-40. RFI Capacitors, Wiring HarnessSection II. MAIN LOAD CONTACTORFigure 6-1. Main Load Contactor (Sheet 1 of 3)Figure 6-1. Main Load Control (sheet 2 of 3)Figure 6-1. Main Load Contactor (Sheet 3 of 3)Remove clampFigure 6-1B. Actuator Assembly Adjustment ProcedureFigure 6-1C. Contactor AdjustmentFigure 6-lD. Main Load Contactor (Sheet l of 3)Figure 6-lD. Main Load Contactor (Sheet 2 of 3)Figure 6-1D. Main Load Contactor (Sheet 3 of 3)Figure 6-2. Routing Main Generator Leads Through Current TransformersFigure 6-3. Current Transformer Assembly and Load Connecting Group Mounting BracketsFigure 6-4. Current Transformer AssemblyCleaning, Inspection, and Testing.CHAPTER7 ELECTRO-HYDRAULIC GOVERNING SYSTEMDisassembly and RepairFigure 7-1. Electric Governor Control Unit RemovalFigure 7-2. Electric Governor Control UnitFigure 7-3. Electric Governor Control Unit, Magnetic Amplifier Bias Test (50/60 Hz)Figure 7-4. Electric Governor Control Unit, Frequency Sensing CheckTable 7-2. Electric Governor Control Unit Component ValuesFigure 7-5. Electric Governor Control Unit, Rectifier Bridge and Feedback Winding TestFigure 7-6. Electric Governor Control Unit Parallel Winding Test (50/60 Hz)Table 7-3. Resistance Test (400 Hz)Figure 7-7. Electric Governor Control Unit, Magnetic Amplifier Bias Test (400 Hz)Figure 7-8. Electric Governor Control Unit, Frequency Sensing Check (400 Hz)Figure 7-9. Electric Governor Control Unit, Rectifier Bridge and Feedback Winding Test (400 Hz)Figure 7-11. Electric Governor Control Unit, Test Position for Unpotted UnitsFigure 7-12. Electric Governor Wiring Board Assembly (Sheet 1 of 2)Figure 7-12. Electric Governor Wiring Board Assembly (Sheet 2 of 2)KEY to fig. 7-12Figure 7-13. Electric Governor Control Unit, Location of Adjustments and ControlsGOVERNOR CONTROL UNIT Figure 7-14. Functional Theory of OperationTable 7-4. Governor Malfunction TestingACTUATOR UNITFigure 7-15. Governor Control Unit Removal and InstallationFigure 7-16. Actuator Removal And InstallationFigure 7-17. Magnetic Puckup Removal and installationFigure 7-18. 400 Hz Electric Governor System Wiring Harness Assembly Drawfing No. 84-704 (Sheet 1 of 2)CHAPTER 8 RELAY TABLE GROUP REPAIR INSTRUCTIONSTable 8-1. Relay Table Group Equipment TestsTable 8-1. Relay Table Group Equipment Tests (Cont)Figure 8-1. Relay Table and Related PartsFigure 8-2. Tactical Relay Box AssemblyFigure 8-3. Tactical Relay Resistor AssemblyFigure 8-4. Precise Relay Box AssemblyFigure 8-5. Resistor Assembly (A6)Special Relay Box Assembly.Key to fig. 8-6Figure 8-6. Special Relay Box Assembly (Sheet 1 of 2)Figure 8-6. Special Relay Box Assembly (Sheet 2 of 2)Figure 8-7. DC Relay Assembly (A5)Figure 8-8. Short (e) Repeat paragraph (d) for autotrans- formers T-2 and T3. The test results should be the same as for T1. Repeat paragraph (d) for all 3 autotransformers. The test results should be the same. (6) Make a point-to-point check of all wiring and chassis -mounted components. (See schematic diagrams in Chapter 1.) 8-14 Change 1 Circuit ME 6115-545-34/8-8 Cl Relay Test Set-upFigure 8-9. Overvoltage Relay Test Set-UpFigure 8-10. Reverse Power Relay Test Set-UpFigure 8-11. Overload Relay Test Set-UpFigure 8-12. Underfrequency Relay Test Set-UpFigure 8-13. Undervoltage Relay Test Set-UpFigure 8-13A. DC Relay Assembly (A5) Test SetupSpecial Relay AssemblyFigure 8-14. Permissive Parallel Relay Test Set-UpSection III. EXCITATION SYSTEM ASSEMBLYFigure 8-15. Excitation System AssemblyVoltage RegulatorFigure 8-16. Voltage RegulatorFigure 8-17. Voltage Regulator Printed Circuit Board AssemblyFigure 8-18. Electronic Component AssemblyFigure 8-19. Excitation Assembly System Test Set-UpSection IV. LOAD MEASURING UNITFigure 8-20. Load Measuring Unit DisassemblyFigure 8-21. Load Measuring Unit Test, Schematic DiagramFigure 8-22. Load Measuring Unit Test, Voltage Relationship GraphCHAPTER 9 GENERATOR ASSEMBLY REPAIR INSTRUCTIONSFigure 9-1. AC Generator AssemblyKey to fig. 9-1Removal of Bearing with Generator Installed.Figure 9-2. Rectifier AssemblyStator winding proceduresFigure 9-3. Strator Winding and Coil Connection Table 9-1. Stator Winding Data (50/60 Hz)Table 9-2. Rotor Winding Data (50/60 Hz)Figure 9-5. Stator Winding and Coil Connection (400 Hz) (Sheet 2 of 2)Table 9-4. Rotor Winding Data (400 Hz)Figure 9-7. Exciter Rotor Winding and Coil Connection Figure 9-8. Exciter Rotor Winding and Coil Connection Table 9-6. Exciter Rotor Winding Data (50/60 and 400 Hz)CHAPTER 10 DAY TANK ASSEMBLY REPAIR INSTRUCTIONSCHAPTER 11 LIFTING FRAME REPAIR INSTRUCTIONSFigure 11-1. Lifting Frame AssemblyCHAPTER 12 COOLING GROUP REPAIR INSTRUCTIONSFigure 12-1. Control AssemblyFigure 12-2. Shutter AssemblyTM-5-6115-545-34_315Figure 13-1. Hydraulic Actuator and Related PartsFigure 13-2. Hydraulic ActuatorInstallation - TM-5-6115-545-34_318Figure 13-3. Hydraulic Actuator Tests, Schematic DiagramSection II. HYDRAULIC SUMP AND FILTERCHAPTER 14 ENGINE ASSEMBLY AND COMPONENTS REPAIR INSTRUCTIONSSection II. BATTERY CHARGING ALTERNATORFigure 14-1. Voltage Regulator and Alternator TestDisassembly, Cleaning and InspectionFigure 14-2. Alternator AssemblyFigure 14-3. Regulator Excitation Test CircuitFigure 14-5. Hydraulic Pump and Related PartsCleaning, Inspection, and Repair. - TM-5-6115-545-34_328Section IV. SPEED SWITCH, TACHOMETER DRIVE AND ADAPTERFigure 14-6. Speed Switch Sensitivity TestsFigure 14-7. Speed SwitchFigure 14-7A. Speed SwitchFigure 14-8. Tachometer DriveSection V. ELECTRIC STARTERFigure 14-10. Electrical Starter Brush and Solenoid AssemblyFigure 14-11. Electric Starter AssemblyFigure 14-12. Frame and Field AssemblyFigure 14-13. Solenoid AssemblyCleaning and InspectionDrive Assembly.Figure 14-14. Solenoid AdjustmentsFigure 14-15. Drive Assembly Pinion, Clearance AdjustmentsFigure 14-16. Electric Starter, Test CircuitsSection VI. LUBE OIL COOLER AND FILTER BYPASS VALVEFigure 14-17. Lube Oil CoolerFigure 14-18. Lube Oil Bypass ValveSection VII. NOZZLE HOLDER ASSEMBLIESFigure 14-19. Nozzle Holder AssemblyTest and Adjustment.Section VIII. FUEL INJECTION PUMP AND RELATED PARTSTable 14-1. Fuel Injection Pump Troubleshooting ChartTable 14-1. Fuel Injection Pump Troubleshooting Chart (Cont) - TM-5-6115-545-34_354Table 14-1. Fuel Injection Pump Troubleshooting Chart (Cont)Table 14-1. Fuel Injection Pump Troubleshooting Chart (Cont) - TM-5-6115-545-34_356Table 14-1. Fuel Injection Pump Troubleshooting Chart (Cont) - TM-5-6115-545-34_357Table 14-1. Fuel Injection Pump Troubleshooting Chart (Cont) - TM-5-6115-545-34_358Disassembly - TM-5-6115-545-34_359Figure 14-20. Injector Pump and Related PartsFuel Injection Pump, Inspection and RepairKEY to fig. 14-21Figure 14-21. Fuel Injection Pump Assembly (Sheet 1 of 7)Figure 14-21. Fuel Injection Pump Assembly (Sheet 2 of 7)Figure 14-21. Fuel Injection Pump Assembly (Sheet 3 of 7)Figure 14-21. Fuel Injection Pump Assembly (Sheet 4 of 7)Figure 14-21. Fuel Injection Pump Assembly (Sheet 5 of 7)Figure 14-21. Fuel Injection Pump Assembly (Sheet 6 of 7)Figure 14-21. Fuel Injection Pump Assembly (Sheet 7 of 7)Drive shaftFuel Injection Pump Reassembly and AdjustmentSolenoid Inspection and Repair.Figure 14-22. ThrottIe Linkage AdjustmentFigure 14-23. Solenoid Armature AdjustmentsFigure 14-24. Variable speed droop adjustmentTable 14-2. Fuel DeliveryFigure 14-25. Fuel Pump and Engine TimingFuel Pump Installation, Fuel Pump and Engine TimingSection IX. TURBOCHARGERFigure 14-26. Turbocharger AssemblyTurbocharger Cleaning and InspectionTurbocharger Reassembly and InstallationSection X. WATER PUMP AND FANSection XI. CRANKSHAFT PULLEY AND VIBRATION DAMPENER, AND ENGINE FRONT SUPPORTFigure 14-28. Crankshaft Pulley and Related PartsFigure 14-29. Engine Front SupportSection XII. OIL PUMP AND OIL PAN ASSEMBLYFigure 14-30. Oil Pan and HeaterFigure 14-31. Oil Pump and Related PartsFigure 14-32. Oil Pump AssemblyCleaning, Inspection and Repair - TM-5-6115-545-34_391Section XIII. FLYWHEEL AND HOUSINGFigure 14-33. Flywheel and HousingSection XIV. TIMING SYSTEMFigure 14-34. Timing Gear and CoverFigure 14-35. Idler Gear Shaft InstallationFuel Pump Drive Gear InstallationSection XV. CYLINDER HEAD AND VALVE OPERATING MECHANISMRemoval and DisassemblyRocker Arm Shaft Assembly DisassemblyCleaning, Inspection and RepairFigure 14-36. Cylinder Head and Valve Operating MechanismFigure 14-37. Rocker Arm Shaft AssemblyFigure 14-39. Valve Seat Insert Welding DetailsFigure 14-41. Piston, Crankshaft, and Block (Sheet 1 of 3)Figure 14-41. Piston, Crankshaft, and Block (sheet 2 of 3)Figure 14-41. Piston, Crankshaft, and BIock (Sheet 3 of 3)Rocker Arm, Shaft Inspection and Repair.Cylinder Head Reassembly and InstallationFigure 14-42. Cylinder Head Capscrew Locations and Torquing SequenceSection XVI PISTON AND RINGSFigure 14-43. Conneting Rod, Crankshaft EndSection XVI PISTON AND RINGSSection XVI PISTON AND RINGS (cont)Section XVII. CRANKSHAFT AND CYLINDER BLOCCrankshaftFigure 14-44. Cylinder Sleeve Hold-Down BarFigure 14-45. MainBearing CapsCamshaft beari ng installationCHAPTER 15 BASE GROUP REPAIR INSTRUCTIONFigure 15-1. Base GroupCHAPTER 15A PAINT AND WING REQUIREMENTS AFTER OVERHAULCHAPTER 16 GENERATOR SET TESTS AFTER OVERHAUL REPAIR INSTRUCTIONSFrequency Adjust ControlTable 16-1. Operating TestsGenerator with separate excitationSample Calculations.Test - TM-5-6115-545-34_430Figure 16-1. Overshoot and Undershoot Chart RecordingFrequency Adjustment Range Test.Overspeed Protective Device TestCircuit Interrupter Test (overload Current)Circuit Interrupter Test (Overvoltage and Undervoltage)Preparation for test.Phase Sequence Test (Rotation)Under Frequency Protective Device TestCHAPTER 17 KIT AND OPTIONAL EQUIPMENT REPAIR INSTRUCTIONSTable 17-1. Fuel-Burning Winterization Kit Troubleshooting ChartTable 17-1. Fuel-Burning Winterization Kit Troubleshooting Chart (Cont)Figure 17-1. Fuel Burning Engine Coolant HeaterFigure 17-2. Fuel Burning Heater Control BoxTable 17-2. Fuel Burning Winterization Coolant Pump Wear LimitsTesting - TM-5-6115-545-34_445Troubleshooting - TM-5-6115-545-34_446Table 17-3. Electric Winterization Kit Troubleshooting ChartFigure 17-3. Electric Winterization PumpFigure 17-4. Electric Heater Control Box AssemblyFigure 17-5. Electric Winterization Kit Heater Control Box Test Set-UpTable 17-4. Electric Winterization Coolant Pump Wear LimitsTable 17-5. Electric Winterization Heater Control Box TestingFigure 17-6. Wheel Mounting KitSection IV. LOAD BANKInspection. - TM-5-6115-545-34_455Figure 17-7. Load BankFigure 17-8. Load Reject Relay Test Circuit.Figure 17-9. Load Bank Fan and Motor AssemblyAPPENDIX A REFERENCES - TM-5-6115-545-34_459APPENDIX A REFERENCES (cont) - TM-5-6115-545-34_460ALPHABETICAL INDEX (Cont) - TM-5-6115-545-34_462ALPHABETICAL INDEX (Cont) - TM-5-6115-545-34_463ALPHABETICAL INDEX (Cont) - TM-5-6115-545-34_464ALPHABETICAL INDEX (Cont) - TM-5-6115-545-34_465ALPHABETICAL INDEX (Cont) - TM-5-6115-545-34_466ALPHABETICAL INDEX (Cont) - TM-5-6115-545-34_467ALPHABETICAL INDEX (Cont) - TM-5-6115-545-34_468