TM-5-6115-593-34 Generator Set Diesel Engine Driven Tactical Skid Mtd. 600 Kw 3 Phase 4 Wire 120/208 and 240/416 Volts Manual

CHAPTER 1 INTRODUCTION - TM-5-6115-593-34_13
TABULATED DATA - TM-5-6115-593-34_14
TABULATED DATA (cont)
Engine and Controls
Table 1-1. Special Torque Data
Table 1-1. Special Torque Data - Continued
Table 1-2. Repair and Replacement Standards
Table 1-2. Repair and Replacement Standards - Continued - TM-5-6115-593-34_20
Table 1-2. Repair and Replacement Standards - Continued - TM-5-6115-593-34_21
Table 1-2. Repair and Replacement Standards - Continued - TM-5-6115-593-34_22
Table 1-2. Repair and Replacement Standards - Continued - TM-5-6115-593-34_23
Table 1-2. Repair and Replacement Standards - Continued - TM-5-6115-593-34_24
Table 1-2. Repair and Replacement Standards - Continued - TM-5-6115-593-34_25
Table 1-2. Repair and Replacement Standards - Continued - TM-5-6115-593-34_26
Table 1-3. Parameters AC-0% Droop
Table 1-4. Electrical Performance Characteristic Parameters AC-3% Droop
CHAPTER 2 GENERAL MAINTENANCE INSTRUCTIONS - TM-5-6115-593-34_29
WELDING
Table 2-1. Special Tools, Test, and Support Equipment (Cont'd)
Table 2-2. Generator Set, Troubleshooting
Table 2-2. Generator Set, Troubleshooting - Continued - TM-5-6115-593-34_33
Table 2-2. Generator Set, Troubleshooting - Continued - TM-5-6115-593-34_34
AC-DC CONTROL BOX ASSEMBLY.
Figure 2-1. Location of Major Components
Figure 2-2. AC-DC Control Box Assembly, Removal and Installation
Figure 2-3. External Power Box Assembly, Removal and Installation (Sheet 1 of 2)
Figure 2-3. External Power Box Assembly, Removal and Installation (Sheet 2 of 2)
RADIATOR ASSEMBLY
Figure 2-4. Radiator Assembly, Removal and Installation
Installation - TM-5-6115-593-34_42
Figure 2-5. Engine, Removal and Installation.
CHAPTER 3 MAINTENANCE OF EXTERNAL POWER ASSEMBLY
Figure 3-1. External Power Box Assembly, Exploded View
LEGEND FOR FIGURE 3-1
Figure 3-2. Preheat System Contactor K107 and Heater Contactor K109, Exploded View
Figure 3-3. Transfer Contactor K108, Exploded View
Figure 3-4. Contactor K120 Exploded View and Test Setup
CHAPTER 4 MAINTENANCE OF AC-DC CONTROL BOX ASSEMBLY
Section II. BATTERY CHARGER
Figure 4-1. AC-DC Control Box Assembly, Exploded View
Figure 4-2. Fuel Transfer Pump Relay K20, Test Setup
Diodes
REPAIR. - TM-5-6115-593-34_55
Figure 4-3. Battery Charger Schematic
Figure 4-4. Battery Charger, Exploded View
Section III. GOVERNOR CONTROLLER
REMOVAL   AND   REPLACEMENT
Figure 4-5. Governor A106, Test Setup
Figure 4-6. Governor Controller, Exploded View
REPAIR - TM-5-6115-593-34_62
Section IV. VOLTAGE REGULATOR
On-Equipment   Power   Output   Test
Section V. PANEL COMPONENT BASE ASSEMBLY
Figure 4-8. Voltage Regulator
AC-DC   CONTROL   RELAY   ASSEMBLY   TB9
Figure 4-9. Voltage Regulator Schematic
Figure 4-10. Component Base Assembly, Exploded View
Figure 4-11. Component Assembly Panel, Relay K1 and K50, Test Setup
Figure 4-12. AC-DC Control Relay Assembly, Test Setup
Test of TD1
Figure 4-13. Time Delay Module TD1
Figure 4-14. Time Delay Module TD3
Test.
Figure 4-15. Motor Operated Potentiometer, Exploded View
Figure 4-16. Motor-Operated Potentiometer, Test Setup
Figure 4-17. Motor-Operated Potentiometers, Cam Adjustment
Section VI. CAPACITOR, DIODE, AND CIRCUIT CARDS
CHAPTER 5 MAINTENANCE OF CONTROL CUBICLE
Figure 5-1. Control Cubicle, Exploded View (Sheet 1 of 2 )
Figure 5-1. Control Cubicle, Exploded View (Sheet 2 of 2)
Replacement. - TM-5-6115-593-34_83
Figure 5-2. Transducers A107 and A108, Test Setup
Figure 5-3. Transducer A103, Test Setup
Figure 5-4. Transformers T101 and T102, Schematic
Figure 5-5. Transformer T103, Schematic
Figure 5-6. Relay K23, Test Setup
Figure 5-7. Overvoltage Relay K102, Test Setup
Figure 5-8. Phase Sequence Relay K103, Test Setup
Figure 5-9. Sync Check Relay K106, Test Setup
Figure 5-10. Undervoltage Relay K111, Test Setup
Figure 5-11. Reverse Power Relay K112, Test Setup
Figure 5-12. Short Circuit Relay K113, Test Setup
Figure 5-13. Overload Relay K114, Test Setup
Figure 5-14. Time Delay TD2, Test Setup
Figure 5-15. Control Relay Assembly TB10, Test Setup
Figure 5-16. Annunciator Control Assembly, TB6 (Sheet 1 of 2)
5-16. Annunciator Control Assembly, TB6 (Sheet 2 of 2)
Figure 5-17. Synchroscope, Test Setup
SYNCHROSCOPE
Figure 5-18. Digital Clock, M111
Figure 5-19. Control Cubicle, Relay Panel
Figure 5-20. Under and Overfrequency Devices, Test Setup
Figure 5-21. Over/under Voltage Device, Test Setup
Figure 5-22. Relay Test Setup
Figure 5-23. Synchronizer, Test Setup
SYNCHRONIZING RELAY
CHAPTER 6 MAINTENANCE OF THE SUPPORT FRAME ASSEMBLY
Figure 6-1. Support Frame Assembly
CHAPTER 7 MAINTENANCE OF RADIATOR ASSEMBLY
RADIATOR REPAIR, CODE A
Figure 7-1. Radiator Assembly, Code A, Exploded View
LEGEND FOR FIGURE 7-1
FAN AND BEARING REPLACEMENT, CODE A
Figure 7-2. Radiator Fan Motor, Code A
Replacement - TM-5-6115-593-34_117
Figure 7-3. Radiator Assembly, Code B, Exploded View (Sheet 1 of 2)
Figure 7-3. Radiator Assembly, Code B, Exploded View (Sheet 2 of 2)
LEGEND FOR FIGURE 7-3
RADIATOR REPAIR, CODE B.
Reassembly.
Figure 7-4. Radiator Fan Motor, Code B
CHAPTER 8 MAINTENANCE OF ENGINE PREHEAT ASSEMBLY
Figure 8-1. Preheat Installation
Figure 8-2. Heater Assembly
Figure 8-4. Thermostate Test Set-up
CHAPTER 9 MAINTENANCE OF FUEL TRANSFER PUMP ASSEMBLY
Solenoid Valve L3
Figure 9-1. Fuel Transfer Pump Installation, Exploded View
LEGEND FOR FIGURE 9-1
Figure 9-2. Fuel Transfer Pump, Exploded View
Section I. MAINTENANCE OF INTERCONNECTING ELECTRICAL HARNESSES
Figure 10-1. Parallel Cables, Diagram
CHAPTER 11 MAINTENANCE OF GENERATOR AND RECONNECTION ASSEMBLY
Figure 11-1. Generator Reconnection and Box Assembly, Exploded View (Sheet 1 of 2)
Legend for Figure 11-1 (Sheet 1)
Figure 11-1. Generator-Reconnection and Box Assembly (Sheet 2 of 2)
LEGEND FOR FIGURE 11-1 (Sheet 2)
Figure 11-2. Current Transformer Assembly, Exploded View
GENERATOR.
Generator and excitation system test
Generator and excitation system test (cont)
Replacement. - TM-5-6115-593-34_144
Air Cleaners
Figure 11-3. Generator Assembly, Exploded View
LEGEND FOR FIGURE 11-3
Figure 11-4. Air Cleaner Assembly Removal
Figure 11-5. Generator Mounting Bolts
Figure 11-6. Checking Flywheel Face Runout
Figure 11-8. Checking Flywheel Housing Runout
Figure 11-9. Obtaining Dimension Y
Figure 11-10. Obtaining Dimension C
Table 11-1. Repair of Generator Components
PERMANENT MAGNET STATOR AND FRAME ASSEMBLY
Figure 11-11. Removing Exciter Armature and Rotating Rectifier Assembly
Figure 11-12. Installing Exciter Armature and Rotating Rectifier Assembly
ROTATING RECTIFIER
Figure 11-14. Testing Rotation Rectifiers with an Ohmmeter
Figure 11-15. Removing Bearing from Generator Shaft
Figure 11-16. Install Bearing on Generator Shaft
Figure 11-17. Drive Plate Assembly
ROTOR ASSEMBLY
Replacement - TM-5-6115-593-34_164
EXCITER STATOR
Replacement.
Rebuild. - TM-5-6115-593-34_167
Rebuild. (cont)
EXCITER ARMATURE
Figure 11-19. Exciter Stator Winding Data
Figure 11-20. Exciter Rotor Winding Data
FRAME AND STATOR COMBINATION
Repair - TM-5-6115-593-34_173
CHAPTER 12 MAINTENANCE OF ELECTRIC HYDRAULIC ACTUATOR
Figure 12-1. Speed Setting Adapter Plate
Figure 12-2. Actuator Test Circuit
Figure 12-3. Governor Actuator, Exploded View
LEGEND FOR FIGURE 12-3
ADJUSTMENTS - TM-5-6115-593-34_179
Figure 12-4. Governor/Actuator Mounting on Engine and Actuator Test Connections
Figure 12-5. Pilot Valve Wrench P/N 370109
REPAIR - TM-5-6115-593-34_182
Figure 12-7. Check Valve Installation
OVERHAUL
Figure 12-9. Governor Pilot Valve Assembly
Figure 12-11. Clamp Bracket Subassembly
Figure 12-14. Power Piston Linkage Assembly
Figure 12-15. Power Piston Assembly
Figure 12-17. Piston Placement
Figure 12-18. Piston Link Assembly
Figure 12-22. Ball Head Assembly
Figure 12-28. Speed Droop Lever Assembly
GOVERNOR LINKAGE ADJUSTMENT
CHAPTER 13 MAINTENANCE OF ENGINE ASSEMBLY
Figure 13-1. Speed Switch,-Exploded View (Mechanical Type Switch) (Code "A")
Figure 13-2. Speed Switch Sensitivity Tests (Mechanical Type Switch) (Code A")
Speed Switch Disassembly
Figure 13-3. Speed Switch Test (Electronic Type) (Code B)
Inspection - TM-5-6115-593-34_199
Cleaning. - TM-5-6115-593-34_200
LEGEND FOR FIGURE 13-4
Figure 13-4. Starter Assembly, Exploded View (Code A)
Figure 13-6. Checking Solenoid Hold-In and Pull-In Windings (Code A)
Figure 13-7. Circuit for Checking Pinion Clearance (Code A)
STARTER ASSEMBLY - TM-5-6115-593-34_205
Figure 13-9. Starter Assembly, Exploded View (Code B)
LEGEND FOR FIGURE 13-9
Figure 13-10. No-Load Test Circuit (Code B)
Figure 13-11. Adjusting Starter Pinion Clearance
Armature Test.
Repair/Overhaul. - TM-5-6115-593-34_211
Repair/Overhaul. - TM-5-6115-593-34_212
Assembly - TM-5-6115-593-34_213
Installation - TM-5-6115-593-34_214
Figure 13-12. Mainshaft-Cover and Tachometer Drive, Exploded View, Code A
Assembly. - TM-5-6115-593-34_216
Removal. - TM-5-6115-593-34_217
Section III. OIL FILTER AND SENSORS
Figure 13-13. Mainshaft Cover and Tachometer Drive, Exploded View, Code B
LEGEND FOR FIGURE 13-14
Figure 13-14. Lubricating Oil Cooler, Exploded View, Code A
Inspection and Test. - TM-5-6115-593-34_222
Figure 13-15. Lubricating Oil Cooler, Exploded View, Code B
Flow Test.
Figure 13-16. Injector, Exploded View
Adjustment and Reassembly
Adjustment and Reassembly (cont)
Figure 13-17. Injection Leakage Tester
Figure 13-18. Spray Angle Tester
Figure 13-19. Injector Test Stand
Figure 13-20. Fuel Injection Pump, Exploded View, Code A
Figure 13-21. Fuel Injection Pump, Exploded View, Code B
Figure 13-22. Fuel Shut-off Valve, Exploded View
Figure 13-23. Governor Spring Pack, Exploded View
Figure 13-25. Fuel Pump Damper, Exploded View
Setting Idle Speed.
Housing Porosity Check
Figure 13-26. Fuel Pump Test Stand
Adjustment on Engine
Overhaul and Rebuilding
Governor Barrel Replacement
Throttle Shaft Replacement.
Governor Barrel Replacement.
Pulsation Damper Overhaul.
Governor Spring Pack Overhaul.
Figure 13-27. Turbocharger, Exploded View, Code A
LEGEND FOR FIGURE 13-27
Figure 13-28. Turbocharger, Exploded View, Code B
Section IV. WATER PUMP
Figure 13-29. Water Pump, Exploded View
LEGEND FOR FIGURE 13-29
Water Pump With Idler Assembly
Figure 13-30. Water Pump with Idler Assembly
LEGEND FOR FIGURE 13-30
Repair. - TM-5-6115-593-34_255
Figure 13-31. Crankshaft Pulley Vibration Damper, Exploded View
Figure 13-32. Vibration Damper Wobble Check Points
Figure 13-33. Engine Front Support, Exploded View
Figure 13-34. Oil Pan Assembly, Exploded View
Repair. - TM-5-6115-593-34_260
OIL PUMP - TM-5-6115-593-34_261
Figure 13-35. Oil Pump, Exploded View
Section VI. FLYWHEEL AND HOUSING
Figure 13-35A. Ring Gear, Flywheel, and Flywheel Housing
Figure 13-36. Gear Case, Exploded View
Figure 13-37. Timing Gear, Exploded View
Section VII. CYLINDER HEAD AND VALVE OPERATING MECHANISM
Figure 13-38. Rocker Arm Shaft and Rocker Arm Assembly, Exploded View
PUSHRODS AND TAPPETS
Figure 13-39. Pushrods and Tappets, Code A
Figure 13-40. Pushrods and Tappets, Code B
Figure 13-41. Cylinder Head, Exploded View
Figure 13-42. Head Capscrew Tightening Sequence
Hydrostatic Testing
Figure 13-43. Crosshead Dimensions
Rebuilding.
Figure 13-44. Valve Seat Insert, Cross Sections
Rebuilding. (cont)
Assembly and Testing
INTAKE AND EXHAUST VALVES AND SPRINGS
Figure 13-45. Minimum Valve Head Rim Thk
Section VIII. PISTON AND.RINGS
Figure 13-47. Piston and Connecting Rod, Exploded View
Connecting rods
Figure 13-48. Piston Check Points
Installation - TM-5-6115-593-34_286
Figure 13-49. Cylinder Liner Check Points
Removal. - TM-5-6115-593-34_288
Figure 13-50. Cylinder Block, Exploded View
Camshaft Bushings.
Figure 13-51. Crankshaft, Exploded View
Hole Repair
Figure 13-52. Cylinder Block Height Checking Location
Cylinder Liner Lower Bore.
Figure 13-53. Sleeve and Block Boring Dimensions 13-102
Reassembly. - TM-5-6115-593-34_296
Reassembly. (cont) - TM-5-6115-593-34_297
Figure 13-54. Engine Injection Timing Procedure Diagram
INJECTION TIMING
CHAPTER 14 MAINTENANCE OF BASE ASSEMBLY
Figure 14-1. Base Assembly, Exploded View
CHAPTER 15 MATERIEL USED IN CONJUNCTION WITH THE GENERATOR SET
Figure 15-1. Remote Cable Assembly
Figure 15-2. Synchroscope, Test Setup
Figure 15-3. Remote Control Module, Plate Assembly, Exploded View
Figure 15-4. Undervoltage Relay K115, Test Setup
Figure 15-5. Underfrequency Relay K116, Test Setup
Replacement. Transducers
Figure 15-6. Transducer A103, Test Setup
Figure 15-7. Transducer A107 and A108, Test Setup
Figure 15-8. Annunciator Control Assembly A20 (Sheet 1 of 2)
Figure 15-8. Annunciator Control Assembly A20 (Sheet 2 of 2)
TRANSFORMER T103
Figure 15-9. Automatic Control Module
LEGEND FOR FIGURE 15-9
Figure 15-10. Under/Over Voltage Relay, Test Setup
Figure 15-11. Underfrequency and Overfrequency-Relay, Test Setup
Replacement - TM-5-6115-593-34_318
Replacement - TM-5-6115-593-34_319
Figure 15-12. Time Delay Relay, Test Setup
Figure 15-14. LR, LRDT, Test Setup
Section IV. HOUSING KIT
Figure 15-16. Housing Kit, Door and Shutter Assembly
Right Side
Figure 15-17. Housing kit, Right Side
LEGEND FOR FIGURE 15-17
Figure 15-18. Housing Kit Front
Figure 15-19. Housing Kit, Left Side
LEGEND FOR FIGURE 15-19
Rear.
Figure 15-20. Housing Kit, Rear
LEGEND FOR FIGURE 15-20
Figure 15-21. Housing Kit, Top (Sheet 1 of 2)
Figure 15-21. Housing Kit, Top (Sheet 2 of 2)
Figure 15-22. Housing Kit, Shutter Assembly
Shutter Assembly - TM-5-6115-593-34_336
Figure 15-23. Housing Kit Wiring
Shutter Assembly - TM-5-6115-593-34_338
Left Side.
Front.
Door and Shutter Assembly.
LIMIT SWITCHES
Figure 15-24. Actuator Control Relay Assembly
CHAPTER 16 GENERATOR SET TEST AND INSPECTION AFTER REPAIR OR OVERHAUL
Table 16-1. OPERATIONAL TESTS
Table 16-1. OPERATIONAL TESTS - Continued
Section III. OPERATIONAL TESTS
PARALLEL OPERATION PROVISIONS (Real Power)
REGULATOR RANGE TEST. - TM-5-6115-593-34_349
Preparation for Test.
FREQUENCY AND VOLTAGE REGULATION, STABILITY AND TRANSIENT RESPONSE TEST (SHORT TERM)
Test. - TM-5-6115-593-34_352
Test. (cont)
Figure 16-1. Overshoot and Undershoot Chart Recording
FREQUENCY ADJUSTMENT RANGE TEST
Procedure - TM-5-6115-593-34_356
OVERSPEED PROTECTIVE DEVICE TEST
CIRCUITS INTERRUPTER TEST (OVERLOAD CURRENT)
CIRCUIT   INTERRUPTER   TEST   (OVERVOL- TAGE AND UNDERVOLTAGE)
Test. - TM-5-6115-593-34_360
Results. - TM-5-6115-593-34_361
LOW OIL PRESSURE PROTECTIVE DEVICE TEST
MAXIMUM POWER TEST
Test - TM-5-6115-593-34_364
Test (cont) - TM-5-6115-593-34_365
CHAPTER 17 GENERATOR SET INSTALLATION PRACTICES
Section II. LOCATION
Figure 17-1. Generator Set Operational Requirements (Sheet 1 of 2)
Figure 17-1. Generator Set Operational Requirements (Sheet 2 of 2)
Table 17-1. Weight and Dimensions
Figure 17-2. Mounting Bolt Layout in Concrete Pad
Figure 17-3. Cross Section View of Pad and Mounting Bolt Installation
Figure 17-4. Vibration Isolator (12 required)
Figure 17-5. 500 KW Generator Set Installation
Figure 17-6. Fixed Louvers for Air Inlet
Figure 17-9. Exhaust Fan
Table 17-4. Radiator and Crankcase Capacities
Figure 17-10. 500 KW Deaerating Top Tank Design
Figure 17-11. 500 KW DOD Deaerating Top Tank Piping
Figure 17-12. Recommended Auxiliary Tank Piping
Figure 17-13. Remote Radiator Application "A"
Figure 17-14. Remote Radiator Application "B"
Figure 17-15. Remote Radiator Application "C"
Table 17-5. 500 KW DOD Generator Set Radiator data
Table 17-6. Fuel Consumption for 500 KW DOD Generator Set
Figure 17-16. Auxiliary Diesel Fuel System
Figure 17-17. 500 KW Generator Set Installation
Figure 17-18. 500 KW Generator Set Anti-Siphon Installation
Section VIII. EXHAUST SYSTEM
Figure 17-19. 500 KW Levelometer System Installation
Section IX. ELECTRICAL REQUIREMENTS
Figure 17-20. Double Thimble-Wall Outlet Details
Figure 17-21. 500 KW Exhaust System
SYSTEM DESCRIPTION
Figure 17-22. Installation of Mufflers on Generator Set.
Figure 17-23. Muffler Provided with Generator Set
Figure 17-24. Generator Voltages and Schematic
Figure 17-25. Service Points on 500 KW Generator Set
Table 17-10. Installation Check List
APPENDIX A REFERENCES - TM-5-6115-593-34_400
APPENDIX A REFERENCES (cont) - TM-5-6115-593-34_401
iINDEX (cont)
iINDEX (cont) - TM-5-6115-593-34_410
iINDEX (cont) - TM-5-6115-593-34_411
iINDEX (cont) - TM-5-6115-593-34_412
FO-1. Generator Set, Electrical Layout
FO-2. Main Control Harness (Sheet 1 of 2)
FO-3. Main Control Harness (Sheet 2 of 2)
FO-4. AC Power Wiring Harness
FO-5. External Power Box Harness Assembly (Sheet 1 of 2)
FO-6. External Power Box Harness Assembly (Sheet 2 of 2)
FO 7. AC-DC Control Box Harness Assembly (Sheet 1 of 5)
FO 8. AC-DC Control Box Harness Assembly (Sheet 2 of 5)
FO 9. AC-DC Control Box Harness Assembly (Sheet 3 of 5)
FO 10. AC-DC Control Box Harness Assembly (Sheet 4 of 5)
FO-11. AC-DC Control Box Harness Assembly (Sheet 5 of 5)
FO-12. Control Box Harness Assembly (Sheet 1 of 8)
FO-13. Control Box Harness Assembly (Sheet 2 of 8)
FO-14. Control Box Harness Assembly (Sheet 3 of 8)
FO-15. Control Box Harness Assembly (Sheet 4 of 8)
FO-16. Control Box Harness Assembly (Sheet 5 of 8)
FO-17. Control Box Harness Assembly (Sheet 6 of 8)
FO-18. Control Box Harness Assembly (Sheet 7 of 8)
FO-19. Control Box Harness Assembly (Sheet 8 of 8)
FO-20. Reconnection Box Harness Assembly
FO-21. Reconnection Harness
FO-22. Engine Accessory Harness (Sheet 1 of 3)
FO-23. Engine Accessory Harness (Sheet 2 of 3)
FO-24. Engine Accessory Harness (Sheet 3 of 3)
FO-25. Remote Control Cable Assembly (Sheet 1 of 2)
FO-26. Remote Control Cable Assembly (Sheet 2 of 2)
FO-27. Remote Control Box Harness Assembly (Sheet 1 of 4)
FO-28. Remote Control Box Harness Assembly (Sheet 2 of 4)
FO-29. Remote Control Box Harness Assembly (Sheet 3 of 4)
FO-30. Remote Control Box Harness Assembly (Sheet 4 of 4)
FO-31. Paralleling Cables, Governor Control
FO-32. Paralleling Cables, Voltage Regulator
FO-33. Louver Harness Assembly (Sheet 1 of 2 )
FO-34. Louver Harness Assembly (sheet 2 of 2 )
FO-35. Louver Control Harness (External Power Box )
FO-36. Auxiliary Power Harness
FO-37. Electrical Cable Assembly
FO-38. AC Neutral Power Cable
FO-39. AC-DC Control Cable Assembly
FO-40. Battery Cables
FO-41. Cables 25- and 37 -Conductor
FO-42. ACM Wiring Harness (Sheet 1 of 3)
FO-43. ACM Wiring Harness (Sheet 2 of 3)

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