Maintenance of Exhaust Pipes Elbows Gaskets and Thermocouples

MAINTENANCE OF CONTROLS, INSTRUMENTS, AND SWITCHGEAR

TM-9-6115-604-12 Generator Set Diesel Engine Driven Tactical Skid Rtd. 60 Kw 3 Phase 4 Wire 120/208 and 240/416 Volts Manual
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ARMY TM 9-6115-604-12 NAVY NAVFAC P-8-633-12 d. Maintenance of Exhaust Pipes Elbows Gaskets and Thermocouples. (1) Inspect. (a) Visually inspect exhaust pipe (11, Figure 3-23) for damage Check for cracks, ruptures, excessive corro- sion, damage, and secure mounting to the roof Visually inspect exhaust elbow assembly (12) for damage, excessive corrosion, ruptures and secure connection to the turbocharger exhausts. Also check the exhaust thermocouples TC1 and TC2 (14) for damage and secure mounting. The engine exhaust system becomes extremely hot during and immediately after generator set operation. Avoid all physical contact with exhaust system when performing checks and inspection under such conditions. (b) With the generator engine operating, check the exhaust pipe (11) and exhaust elbow assembly (12) for leakage Pay particular attention to pipe connections with exhaust gasket seals (10) at the roof and at the exhaust elbow assembly (12). Exhaust leakage inside the generator housing may be detected visually (soot marks), audibly, through the sense of smell, or any combination thereof Replace damaged pipes, elbows, and leaking gaskets as described below. (2) Remove exhaust elbow assemblies (12, Figure 3-23) (Replacement procedures apply for both exhaust elbow assemblies ) (a) Tag and disconnect wiring to exhaust thermocouple TC1 or TC2 (14, Figure 3-23) mounted on exhaust elbow assembly (12). Remove exhaust thermocouple TC1 or TC2 by unscrewing. (b) Loosen V band clamp (13) holding exhaust elbow assembly (12) to the turbocharger exhaust rim (c) Remove damaged exhaust elbow assembly (12) by removing hexagon head capscrews (4), lockwashers (5), and hexagonal nuts (6) holding the exhaust elbow assembly to the exhaust pipe (11). Remove and discard exhaust gasket (15) from exhaust elbow assembly (12) flange. (3) Install exhaust elbow assemblies (12). (a) Pass the V band clamp (13) across the exhaust elbow assembly Position unflanged elbow end over turbocharger exhaust rim and the flanged elbow end directly under the exhaust pipe (11) flange. Tighten the V band clamp (13) only when capscrew mounting holes on the flanged ends of both the exhaust elbow assembly (12) and exhaust pipe (11) are precisely aligned. (b) Install exhaust gasket (15) between exhaust elbow assembly (12) and exhaust pipe (11) flanges. Bolt the exhaust elbow assembly (12) and exhaust pipe (11) flanges together tightly using hexagon head capscrews (4), lockwashers (5), and hexagonal nuts (6). (c) Reinstall exhaust thermocouple TC1 or TC2 (14, Figure 3-23), removed in step (a), above, on the exhaust elbow assembly (12). Connect wiring and discard tags. (4) Remove exhaust pipes (11). NOTE Two people may be required to perform the following procedure. (a) Remove hexagon head capscrews (4), hexagonal nuts (6), and lockwashers (5) holding the bottom flange of exhaust pipe (11) to the exhaust elbow assembly (12). (b) Remove exhaust pipe (11) by removing the hexagon head capscrews (4), hexagonal nuts (6), and lock washers (5) securing exhaust pipe to roof. Discard gasket (10). 3-61

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