TM-5-6115-584-34 Generator Set Diesel Engine Driven Tactical Skid Mtd. 30 Kw 3 Phase 4 Wire 120/208 and 240/416 Volts Manual

CHAPTER 1 INTRODUCTION - TM-5-6115-584-34_25
Generator Frame Assembly
Table 1-1. Torque Valuee (Ft-Lb Dry)
Table 1-1. Torque Values Dry) (Cont'd)
Table   1-2.   Repair   and   Replacement Standards
Table   1-2.   Repair   and   Replacement   standards   (Cont) - TM-5-6115-584-34_31
Table 1-2. Repair and Replacement Standards (Cont) - TM-5-6115-584-34_32
Table 1-2. Repair and Replacement Standards (Cont) - TM-5-6115-584-34_33
Table 1-2. Repair and Replacement Standards (Cont) - TM-5-6115-584-34_34
Figure 11. Generator set Electrical Schematic diagram
CHAPTER 2 GENERAL NMJNTENANCE INSTRUCTIONS
Table   2-2.   Fabricated   Tools   and   Equipment - TM-5-6115-584-34_37
Table 2-2. Fabricated Tools and Equipment (Cont)
Table 2-2. Fabricated Tools and Equipment (Cont) - TM-5-6115-584-34_39
Table 2-2. Fabricated Tools and Equipment (Cont) - TM-5-6115-584-34_40
Table 2-3.   Troubleshooting
Table   2-3.   Troubleshooting   (Cont) - TM-5-6115-584-34_42
Table   2-3.   Troubleshooting   (Cont) - TM-5-6115-584-34_43
Table   2-3.   Troubleshooting   (Cont) - TM-5-6115-584-34_44
Table   2-3.   Troubleshooting   (Cont) - TM-5-6115-584-34_45
Table   2-3.   Troubleshooting   (Cont) - TM-5-6115-584-34_46
Section III. GENERAL MAINTENANCE
Figure 2-1. Speed Control Assembly
Figure 2-2. Disconnecting Engine from Generator
Figure 2-3. Lifting Engine
GENERATOR ASSEMBLY - TM-5-6115-584-34_51
Figure 2-4. Lifting Engine and Generator Assembly - TM-5-6115-584-34_52
CHAPTER 3 MAINTENANCE OF COOLING SYSTEM
Figure 3-1. Engine Cooling System
Test - TM-5-6115-584-34_56
CHAPTER 4 MAINTENANCE OF FUEL SYSTEM
CHAPTER 5 MAINTENANCE OF STARTING SYSTEM
Figure 5-1.Electric Starter Assembly STYLE I
Figure 5-2.Electric Starter Assembly STYLE II
Figure 5-3.    Pinion Gear Stopper Removal - TM-5-6115-584-34_63
Figure 5-4.    Testing Armature for Grounds
Figure 5-8. Checking Armature Shaft Runout
Figure 5-9.   Testing Brush Spring Tension STYLE I Starter Only
Figure 5-10.   Testing Solenoid Switch
Install cover with screws
Figure 5-12. Brush Replacement STYLE I Starter only
Figure 5-13 Checking Pinion Clearance. STYLE I Starter
Figure 5-14.   Checking Pinion Travel STYLE II Starter - TM-5-6115-584-34_71
CHAPTER 6 MAINTENANCE OF CONTROL SYSTEM - TM-5-6115-584-34_72
Figure 6-1. Control Cubicle Wiring Harness
Table 6-1. Control Cubicle Wiring Harness - TM-5-6115-584-34_74
Table 6-1. Control Cubicle Wiring Harness (Cont)
Table   6-2.   5KW   Generator   Set   Wiring   Harness
Figure 6-2. Generator Set Wiring Harness - TM-5-6115-584-34_77
Table 6-3. AC Output Control Box Wiring Harness
Table 6-3. AC Output Control Box Wiring Harness (Cont)
Remove
Installation - TM-5-6115-584-34_82
Figure 6-3. Control Cubicle (Sheet 1 of 2)
Figure 6-3. Control Cubicle (Sheet 2 of 2) - TM-5-6115-584-34_84
Figure 6-4. Testing Voltage Regulator
Figure 6-5. AC Voltage Regulator Schematic - TM-5-6115-584-34_86
Figure 6-5.1 AC Voltage Regulator Schematic
Figure 6-6. AC Output Control Box Wiring Harness
Figure 6-7. AC Output Control Box Test Setup
Table 6-5. Reconnection Switch Continuity
Figure 6-7.1 CVT and CT Wiring
Figure 6-8. AC Control Box Removal - TM-5-6115-584-34_93
Table 6-6. Testing Bridge Assembly
Figure 6-9. AC Output Control Assembly (Sheet 1 of 2)
Figure 6-9. AC Output Control Assembly (Sheet 2 of 2) - TM-5-6115-584-34_96
Figure 6-10. Ac Output Control Assembly
Figure 6-10.1 Switch Assembly, Rotary
Figure 6-10.2 Switch Assembly, Rotary
Figure 6-11. Bridge Rectifier Assembly A-4
CHAPTER 7 MAINTENANCE OF ENGINE
Figure 7-1. Injector Fuel Lines
Figure 7-2. Speed Control Assembly and Governor Control Assembly
Figure 7-3. Engine Flywheel and Ring Gear Assembly
Figure 7-4. Timing Port and Port Closing Mark
Figure 7-5. Measuring Top Dead Center
Figure 7-7. Battery Charge Alternator and Blower Wheel - TM-5-6115-584-34_108
Figure 7-8. Resistively Loading the Batteries - TM-5-6115-584-34_109
Section III. ENGINE INTERNAL ASSEMBLIES - TM-5-6115-584-34_110
CYLINDER HEAD.
Figure 7-8.1. Testing Engine Compression
Figure   7-9.   Cylinder   Head   Removal
Figure 7-10. Valve Spring Removal
Figure 7-11. Cylinder Head Assembly
Figure 7-12. Valve Seat Replacement - TM-5-6115-584-34_116
Figure 7-13. Cylinder Head Bolt Tightening Sequence
Figure 7-14. Piston and Connecting Rod
Figure 7-15.Crankshaft Pistons and Connecting Rod (Sheet 1 of 2)
Figure 7-15. Crankshaft Pistons and Connecting Rod (Sheet 2 of 2) - TM-5-6115-584-34_120
Figure 7-17. Connecting Rod and Bushings
Figure   7-18.   Connecting   Rod   Installation
Figure 7-19. Oil Pump Removal (Sheet 1 of 2) - TM-5-6115-584-34_123
Figure 7-19. Oil Pump Removal (Sheet 2 of 2)
Figure 7-21. Internal Engine Assembly (Sheet 1 of 2)
Figure 7-22. Gear Cover Components
Figure   7-23.   Gear   Cover   Inspection - TM-5-6115-584-34_127
Figure 7-24. Governor Cup Assembly - TM-5-6115-584-34_128
Installation - TM-5-6115-584-34_129
Figure 7-25. Camshaft Bearing Installation - TM-5-6115-584-34_130
Figure   7-27.   Timing   Gear   Backlash
Figure   7-28.   Crankshaft   Gear   Removal - TM-5-6115-584-34_133
Figure 7-30. Crankshaft Bearing Installation - TM-5-6115-584-34_134
Figure 7-32. Injection Pump - TM-5-6115-584-34_135
Figure 7-33. Injection Pump Adjustment and Button Removal
Figure 7-34. Disassembly of Fuel Injection Pump (Sheet 1 of 2)
Figure 7-34. Disassembly of Fuel Injection Pump (Sheet 2 of 2) - TM-5-6115-584-34_138
Figure 7-36. Delivery Valve Test Assembly - TM-5-6115-584-34_139
Figure 7-38. Assembling Hydraulic Head
Figure   7-39.   Control   Unit   Assembly - TM-5-6115-584-34_141
Figure 7-40. Checking Plunger Sleeve Alignment - TM-5-6115-584-34_142
Figure 7-42. Injection Pump Installation
Figure   7-43.   Delivery   Valve - TM-5-6115-584-34_144
Figure 7-44. Timing Port and Port Closing Mark
FUEL   INJECTOR
Figure 7-45. Injector Nozzle Removal
Figure 7-46. Fuel Injector - TM-5-6115-584-34_148
Figure   7-47.   Centering   Sleeve   Installation
Section   II.   MAINTENANCE - TM-5-6115-584-34_150
Figure   8-1.   Generator   Exploded   View   (Sheet   1   of   2)
Figure 8-1. Generator Exploded View (Sheet 2 of 2) - TM-5-6115-584-34_152
Test. - TM-5-6115-584-34_153
Figure 8-2. Testing Exciter Rotor
Generator Winding Data.
Figure 8-3.   Generator Frame Assembly Winding Data
Figure   8-4.   Exciter   Rotor   Assembly   Winding   Data
Figure 8-5. Generator Rotor Winding Data
CHAPTER 9 GENERATOR SET TEST AND INSPECTION AFTER REPAIR OR OVERHAUL
Table 9-1. Test Schedule
Test   Procedure
Section I. AUXILIARY EQUIPMENT
ACOUSTIC SUPPRESSION KIT
Table 10-1. Acoustic Suppression Kit Parts and Required Hardware (Cont)
PRELIMINARY PROCEDURES - TM-5-6115-584-34_166
Figure 10-1. Installation of Right Support, Rear Panel, and Rear Flap Assemblies
Left Support Assembly
Figure 10-2. Installation of Left Support Assembly
Rear Flap Assembly - TM-5-6115-584-34_170
Figure 10-3. Installation of Rear and Side Closure and Exhaust Plenum Assemblies
Exhaust Plenum Assembly - TM-5-6115-584-34_172
Figure   10-4.   Installation   of   Right   Panel   Assembly
Left Panel Assembly (Short Side)
Figure 10-5. Installation of Left Panel, Front Panel and Top Panel Assemblies
POST INSTALLATION PROCEDURES
A P P E N D I X    A REFERENCES
ALPHABETICAL INDEX - TM-5-6115-584-34_179

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