TM-9-6115-604-34 Generator Set Diesel Engine Driven Tactical Skid Mtd 5 Kw. 1 Phase-2 Wire 1 Phase -3 Wire 3 Phase -4 Wire 120. 120/240 and 120/208 Volts Manual

CHAPTER 1 INTRODUCTION - TM-9-6115-604-34_20
1-8. DIFFERENCES BETWEEN MODELS
Table 1-1. Special Torque Data (Continued)
Special Torque Data (Continued) - TM-9-6115-604-34_23
Special Torque Data (Continued)
Special Torque Data (Continued) - TM-9-6115-604-34_25
Special Torque Data (Continued) - TM-9-6115-604-34_26
Special Torque Data (Continued) - TM-9-6115-604-34_27
Table 1-2. Capscrew Markings and Torque Values
Capscrew Markings and Torque Values ( Continued)
Table 1-3. Prevailing Torque of Locknuts and Lockscrews
Table 1-4. Repair and Replacement Standards
Repair and Replacement Standards (Continued) - TM-9-6115-604-34_32
Repair and Replacement Standards (Continued) - TM-9-6115-604-34_33
Repair and Replacement Standards (Continued) - TM-9-6115-604-34_34
Repair and Replacement Standards (Continued) - TM-9-6115-604-34_35
Repair and Replacement Standards (Continued) - TM-9-6115-604-34_36
Repair and Replacement Standards (Continued) - TM-9-6115-604-34_37
Repair and Replacement Standards (Continued) - TM-9-6115-604-34_38
Repair and Replacement Standards (Continued) - TM-9-6115-604-34_39
Table 1-5. System Capacities and Detailed Data on Components Generator Set Manufacturer
System Capacities and Detailed Data on Components (Continued) - TM-9-6115-604-34_41
System Capacities and Detailed Data on Components (Continued) - TM-9-6115-604-34_42
System Capacities and Detailed Data on Components (Continued) - TM-9-6115-604-34_43
System Capacities and Detailed Data on Components (Continued) - TM-9-6115-604-34_44
System Capacities and Detailed Data on Components (Continued) - TM-9-6115-604-34_45
System Capacities and Detailed Data on Components (Continued) - TM-9-6115-604-34_46
System Capacities and Detailed Data on Components (Continued) - TM-9-6115-604-34_47
System Capacities and Detailed Data on Components (Continued) - TM-9-6115-604-34_48
System Capacities and Detailed Data on Components (Continued) - TM-9-6115-604-34_49
System Capacities and Detailed Data on Components (Continued) - TM-9-6115-604-34_50
System Capacities and Detailed Data on Components (Continued) - TM-9-6115-604-34_51
System Capacities and Detailed Data on Components (Continued) - TM-9-6115-604-34_52
System Capacities and Detailed Data on Components (Continued) - TM-9-6115-604-34_53
CHAPTER 2 GENERAL MAINTENANCE INSTRUCTIONS - TM-9-6115-604-34_54
Special Tools, Test, and Support Equipment (Continued)
Table 2-1. Special Tools, Test, and Support Equipment
Special Tools, Test, and Support Equipment -cont - TM-9-6115-604-34_57
Special Tools, Test, and Support Equipment -cont - TM-9-6115-604-34_58
Special Tools, Test, and Support Equipment -cont - TM-9-6115-604-34_59
Special Tools, Test, and Support Equipment -cont - TM-9-6115-604-34_60
Table 2-2. Fabricated Tools and Equipment
Fabricated Tools and Equipment (Continued) - TM-9-6115-604-34_62
Fabricated Tools and Equipment (Continued) - TM-9-6115-604-34_63
SECTION II. TROUBLESHOOTING - TM-9-6115-604-34_64
Table 2-3. Engine Troubleshooting (Continued)
Engine Troubleshooting (Continued) - TM-9-6115-604-34_66
Engine Troubleshooting (Continued) - TM-9-6115-604-34_67
Engine Troubleshooting (Continued) - TM-9-6115-604-34_68
Engine Troubleshooting (Continued) - TM-9-6115-604-34_69
Engine Troubleshooting (Continued) - TM-9-6115-604-34_70
Engine Troubleshooting (Continued) - TM-9-6115-604-34_71
2-6. CLEANING
2-12. THREADED HOLE REPAIR
Figure 2-1. Removing and Installing Helical Coil Thread Inserts
SECTION IV. REMOVAL AND INSTALLATION OF MAJOR COMPONENTS
Figure 2-2. Removal of Roof Panels
Figure 2-4. Engine and Generator G1, Removal, Installation, and Alignment (Sheet 1 of 4)
Figure 2-4. Engine and Generator G1, Removal, Installation, and Alignment (Sheet 2 of 4)
Figure 2-4. Engine and Generator G1, Removal, Installation, and Alignment (Sheet 3 of 4)
Figure 2-4. Engine and Generator G1, Removal, Installation, and Alignment (Sheet 4 of 4)
b. Install - TM-9-6115-604-34_81
Figure 2-5. Engine and Generator G1, Alignment
Figure 2-6. Engine, Lifting
Figure 2-7. Removal of Conduit Box Cover Assembly
Figure 2-8. Conduit Box Assembly
Figure 2-9. Generator G1, Lifting
(17) Install hexagon head capscrews
(25) Using feeler gages
Figure 2-10. Generator G1, Torque Sequence of Adapter Ring and Drive Plates (Flexible Discs)
Figure 2-11. Generator G1, Checking Exciter Air Gap
2-16. GENERATOR G1 REMOVAL AND INSTALLATION
Figure 2-12. Removal of Cabinet B Rear Cover
Figure 2-13. Generator G1, Ground and Power Leads Installation
Figure 2-14. Generator, Ground and Power Leads Routing
b. Install - TM-9-6115-604-34_95
(11) Using feeler gages
(21) Install cover and screen assembly
2-17. LOAD CIRCUIT BREAKER CB1O1 REMOVAL AND INSTALLATION
Figure 2-15. Load Circuit Breaker CB101, Removal and Installation
b. Install - TM-9-6115-604-34_100
Figure 2-16. Fuel Tank, Exploded View (Sheet 1 of 2)
Figure 2-16. Fuel Tank, Exploded View (Sheet 2 of 2)
b. Install - TM-9-6115-604-34_103
Figure 2-17. Fuel Tank, Removal and Installation of Floor Plates and Cover Plates
Figure 2-18. Fuel Tank, Removal and Installation
CHAPTER 3 MAINTENANCE OF SKID BASE
CHAPTER 4 MAINTENANCE OF DC ELECTRICAL AND CONTROL SYSTEM
Figure 4-1. Battery Charger BC1, Schematic
4-5. BATTERY CHARGER BC1 DISASSEMBLY
Figure 4-2. Battery Charger BC1, Exploded View (Sheet 1 of 2)
Figure 4-2. Battery Charger BC1, Exploded View (Sheet 2 of 2)
4-7. BATTERY CHARGER BC1 ASSEMBLY
4-11. STARTER MOTORS B1 AND B2 REPAIR
Figure 43. Starter Motors B1 and B2 and Related Parts (Sheet 1 of 2)
Figure 4-3. Starter Motor and Related Parts (Sheet 2 of 2)
Figure 4-4. Starter Motors B1 and B2, Location of Field Loads
Figure 4-6. Testing Starter Armature for Grounds and Opens
(15) Using a 110 V ac test lamp or multimeter set
(33) Replace the armature
(38) Make simple electrical repairs
d. Assemble.
To prevent overheating damage
Figure 4-7. Adjusting Starter Pinion Clearance
CHAPTER 5 MAINTENANCE OF AC ELECTRICAL POWER GENERATION AND CONTROL SYSTEM
5-5. GENERATOR G1 CLEANING AND INSPECTION.
Megohmmeter reading
Figure 5-1. Generator G1 and Related Parts (Sheet 1 of 3)
Figure 5-1. Generator G1 and Related Parts (Sheet 2 of 3)
Figure 5-1. Generator Gl and Related Parts (Sheet 3 of 3)
5-7. GENERATOR GI DISASSEMBLY
Figure 5-2. Current Boost Transformers CT2 and CT3
b. Rotating Rectifier Assembly
(3) Test
c. Exciter Rotor Assembly
e. Current Transformers CT2 and CT3
5-8. GENERATOR G1 MAIN ROTOR ASSEMBLY MAINTENANCE
Figure 5-3. Bracket, Grease Pipes and Plugs
Figure 5-5. Rotor Assembly, Removal and Installation
b. Disassemble and Service.
Dry deaning solvent
(6) Main Rotor Core and Winding
5-9. GENERATOR G1 ASSEMBLY.
Figure 5-6. Bracket Installation
Figure 5-7. Rotor Installation
Figure 5-8. Torque Sequence, Drive Discs
SECTION Ill. VOLTAGE REGULATOR VR101
Figure 5-9. AC Electrical Components and Related Parts (Sheet 1 of 5)
Figure 5-9. AC Electrical Components and Related Parts (Sheet 2 of 5)
Figure 5-9. AC Electrical Components and Related Parts (Sheet 3 of 5)
Figure 5-9. AC Electrical Components and Related Parts (Sheet 4 of 5)
Figure 5-9. AC Electrical Components and Related Parts (Sheet 5 of 5)
Figure 5-10. Voltage Regulator VR101, Diagram
512. VOLTAGE REGULATOR VR101 INSPECTION
Figure 5-11. Voltage Regulator VR101, Test Setup
5-14. VOLTAGE REGULATOR VR101 ADJUSTMENT
SECTION IV. LOAD CIRCUIT BREAKER CB101
Figure 5-12. Load Circuit Breaker CB101, Front View, Installed
Figure 5-13. Load Circuit Breaker CB101, Rear View
Figure 5-14. Load Circuit Breaker CB101, Rear View (Sheet 1 of 2)
Figure 5-14. Load Circuit Breaker CB101, Schematic (Sheet 2 of 2)
Figure 5-15. Load Circuit Breaker CB101, Front Right Side Interior View
Figure 5-16. Load Circuit Breaker CB101, Front Left Side Interior View
Figure 5-17. Load Circuit Breaker CB101, Detail of Drive Spring Charging Mechanism
(2) Closing Operation
Figure 5-18. Load Circuit Breaker CB101, Adjustment
5-18.  LOAD   CIRCUIT   BREAKER   CB101   INSPECTION
5-20. LOAD CIRCUIT BREAKER CB1D1 SERVICE
Table 5-1.    Load Circuit Breaker CB101 Lubrication Chart
Figure i19. Load Circuit Breaker CB101, Exploded View (Sheet 1 of 6)
Figure 5-19. Load Circuit Breaker CB101, Exploded View (Sheet 2 of 6)
Figure 5-19. Load Circuit Breaker CB101, Exploded View (Sheet 3 of 6)
Figure 5-19. Load Circuit Breaker CB101, Exploded View (Sheet 4 of 6)
Figure 5-19. Load Circuit Breaker CB101, Exploded View (Sheet 5 of 6)
Figure 5-19. Load Circuit Breaker CB101, Exploded View (Sheet 6 of 6)
5-22.  LOAD CIRCUIT BREAKER CB1O1AULGNMENT
Figure 5-20. Load Circuit Breaker CB101, Spring Overtravel Setting
Figure 5-21. Load Circuit Breaker CB101, Detail of Vacuum Interrupter Assembly
Figure 5-22. Load Circuit Breaker CB101, Return Spring Preload Setting
5-23. LOAD CIRCUIT BREAKER CBIOI REPLACEMENT
The brass springs
d. Assemble.
Interrupter    module    assemblies
SECTION V. SURGE CAPACITOR C101
SECTION VI. RELAYS
Figure 5-23. Cabinet C Relay Panel Assembly
Figure 5-24. Cabinet A Relay Panel Assembly
Figure 5-25. Component Board Assembly A10 and A11
Figure 5-26. Test Setup, Relays
5-29.   TIME DELAY (LOW FUEL LEVEL SHUTDOWN) RELAY K23
Figure 5-27. Test Setup, Time Delay (Low Fuel Shutdown) Relay K23
5-31.   EMERGENCY LIGHT RELAY K100
5-32. 50 HERTZ AND 60 HERTZ FREQUENCY RELAYS K108 AND K107
5-33. REVERSE POWER RELAY K109
Figure 5-28. Test Setup, Reverse Power Relay K109
5-34. OVER VOLTAGE RELAY KIIO
Figure 5-29. Test Setup, Over/Undervoltage Relay K110 and K111
5-36. OVERCURRENT RELAY K114
Figure 5-30. Test Setup, Overcurrent Relay K114
5-37. GROUND FAULT RELAY K115
Figure 5-31. Ground Fault Relay K115, Time Voltage Curve
Figure 5.32. Ground Fault Relay K115 (Sheet 1 of 3)
Figure 5-32. Ground Fault Relay K115 (Sheet 2 of 3)
5-38. SYNCHRO CHECK RELAY K116
Figure 5-33. Test Setup, Ground Fault Relay K115
Figure 5-34. Test Setup, Synchro Check Relay K116
5-40. COOLANT HEATER CONTACTORS K104A AND K104B
SECTION VII. AC CIRCUIT BREAKERS
SECTION VIII. MAIN DISCONNECT SWITCH S120
Figure 5-35. Main Disconnect Switch S120, Exploded View (Sheet 1 of 2)
Figure 5-35. Main Disconnect Switch S120, Exploded View (Sheet 2 of 2)
5-47. ASSEMBLY OF MAIN DISCONNECT SWITCH S120.
c. Assemble operating mechanism assembly
SECTION IX. PARALLEL CABLE ASSEMBLIES
Figure 5-37. Parallel Cable Assemblies (Sheet 1 of 2)
Figure 5-37. Parallel Cable Assemblies (Sheet 2 of 2)
Figure 5-39. Current Boost Module A101, Adjusting
Figure 5-40. Test Setup, Current Boost Module A101
SECTION XI. LOAD TERMINALS
Figure 5-41. Load Terminals, Exploded View
5-55. LOAD TERMINAL ASSEMBLY
CHAPTER 6 FUEL SYSTEM
Figure 6-1. Fuel Transfer Pump, Exploded View (Sheet 1 of 2)
SECTION II. SOLENOID VALVE L102
Figure 6-2. Solenoid Valve L102, Exploded View
SECTION Ill. MAINTENANCE OF THE FUEL INJECTION PUMP
Figure 6-3. Fuel Injection Pump, Fuel Flow Schematic
Figure 6-4. Fuel Injection Pump, Left Side View
Figure 6-5. Fuel Injection Pump Subassemblies, Exploded View (Sheet 1 of 2)
Figure 6-5. Fuel Injection Pump Subassemblies, Exploded View (Sheet 2 of 2)
e. Reassemble.
Figure 6-6. Actuator Capscrew, Torque Sequence
6-10. FUEL PUMP REBUILD.
b. Damper Assembly.
Figure 6-7. Damper Assembly, Exploded View
Figure 6-8. Gear Pump, Exploded View
To avoid damage to the gear pump assembly
Figure 6-9. Assembly of Gear Pump
Compressed air - TM-9-6115-604-34_238
Figure 6-11. Fuel Injection Pump Housing and Related Parts, Exploded View (Sheet 1 of 3)
Figure 6-11. Fuel Injection Pump Housing and Related Parts, Exploded view (Sheet 2 of 3)
Figure 6-11. Fuel Injection Pump Housing and Related Parts, Exploded View (Sheet 3 of 3)
Drilling operations
Compressed air - TM-9-6115-604-34_243
Table 6-1.   Fuel Pump Throttle Shaft Color Code and Class Size
Table 6-2. Fuel Pump Governor Plunger Color Code and Class Size
Two setscrews
governor plug tool
Figure 612. Mainshaft, Cover, and Governor, Exploded View (Shoot 1 of 2)
Figure 6-12. Mainshaft, Cover, and Governor, Exploded View (Sheet 2 of 2)
Figure 6-13. Measuring Gear Backlash
(e) Replace worn weight pins
(3)   Reassemble.
6-11. FUEL PUMP TEST AND CAUBRATION
Figure 6-15. Fuel Pump Test Stand
Figure 6-16. Test Stand Hose layout
Figure 6-17. Test Stand Control Panel
c. Upper and Lower Governor Cut Off Speeds
e. Idle Speed.
Table 6-3. Fuel Pump Calibration Specifications and Technical Data
SECTION IV. MAINTENANCE OF FUEL INJECTORS
Figure 6-18. Injector Leakage Tester
Figure 6-19. Injector Cup Spray Tester
Figure 6-20. Injector Test Stand (Sheet 1 of 2)
6-15. FUEL INJECTOR CLEANING, INSPECTION, AND REPAIR.
Figure 6-21. Fuel Injector and Related Parts
Figure 6-22. Plunger Link Wear
Figure 6-23. Checking Check Ball Seat Depth
6-17. FUEL INJECTOR TEST
The flowmeter
Figure 6-24. Injector Cam Installation
The damping control handle
Figure 6-26. Loading Injector Into Test Stand
Figure 6-28. Fuel Arm and Supply Valve
Figure 6-29. Calculating Dial Indicator Reading
6-18. FUEL INJECTOR INSTALLATION.
c. Inspection
SECTION VI. ELECTRIC GOVERNOR SYSTEM
Figure 6-30. Load Sharing Panel A104 Controls
e. Electric Governor Control Unit
6-23. ELECTRIC GOVERNOR SYSTEM TEST AND ADJUSTMENT
Figure 6-31. Test Setup (Typical), Electric Governor Control Unit
Figure 6-32. Test Setup, 50/60 Hz Module
Figure 6-33. Test Set (Typical), Precise Load Sharing Module
Figure 6-34. Test Set (Typical), Synchronizer A105 (Sheet 1 of 2)
SECTION VlI. FUEL MANIFOLDS
Figure 6-35. Fuel Manifolds and Related Parts, Exploded View
6-26. FUEL MANIFOLD INSTALLATION.
c. Inspect. - TM-9-6115-604-34_288
Figure 6-36. Accessory Drive, Exploded View
CHAPTER 7 MAINTENANCE OF COOLING SYSTEM
Figure 7-1. Water Pump and Water Pump Drive, Exploded View (Sheet 1 of 2)
Figure 7-1. Water Pump and Water Pump Drive, Exploded View (Sheet 2 of 2)
7-5. WATER PUMP DRIVE REPAIR.
SECTION II. RADIATOR
7-8. RADIATOR CLEANING INSPECTION
Figure 7-2. Radiator, Exploded View (Sheet 1 of 2)
Figure 7-2. Radiator, Exploded View (Sheet 2 of 2)
b. Install.
Figure 7-3. Thermostat Housing Support and Related Parts, Exploded View
CHAPTER 8 MAINTENANCE OF LUBRICATION SYSTEM
Figure 8-1. Regulator Valve Assembly, Exploded View
SECTION II. LUBE OIL COOLER
Figure 8-2. Lube Oil Cooler and Related Parts, Exploded View
SECTION Ill. OIL PUMP ASSEMBLY
8-9. OIL PUMP REMOVAL
Figure 8-3. Removal and Installation of Oil Pan Access Plate
Figure 8-4. Lubricating Oil Pump, Exploded View (Sheet 1 of 2)
Figure 8-4. Lubricating Oil Pump, Exploded View (Sheet 2 of 2)
Figure 8-5. Dimensions of the Bushings In the Lubricating Oil Pump Body
Figure 8-7. Lubricating Oil Pump Fits and Clearances
8-14. OIL PUMP INSTALLATION
SECTION IV. PRELUBE PUMP ASSEMBLY
Figure 8-8. Prelube Pump Assembly, Exploded View (Sheet 1 of 2)
8-17. PRELUBE PUMP B3 CLEANING AND INSPECTION
Turn the end of the drive shaft
CHAPTER 9 MAINTENANCE OF ENGINE
9-2. ENGINE ASSEMBLY REPAIR
SECTION II. MAINTENANCE OF CYLINDER HEAD ASSEMBLIES
9-5. REMOVAL OF CYUNDER HEAD ASSEMBUES
Figure 9-1. Exploded View of Cylinder Head
9-6. CYLINDER HEADS DISASSEMBLY.
Figure 9-2. Disassembly and Assembly of Rocker Arms
9-8. DISASSEMBLED CYLINDER HEAD INSPECTION
Figure 9-3. Inspection of Valves
Figure 9-5. Cylinder Head Installed In ST-1012
(7) Check for loose valve seat
Figure 9-6. Measuring Injector Tip Protrusion
Figure 9-7. Injector Seat Pattern
9-9. CYLINDER HEAD ASSEMBLIES REPAIR
Figure 9-9. Cross-Section of Valve Seat Insert
Figure 9-10. Testing of Valve Seating
Figure 9-11. Vacuum Testing Valve Seats Using ST-1257
9-10. CYLINDER HEAD ASSEMBLES INSTALLATION
Figure 9-12. Cylinder Head Tightening Procedure
(2) Install the crossheads
9-11. CYLINDER HEAD ASSEMBLES OVERHAUL
Table 9-2. Valve Seat Insert Selection
9-12. INTAKE AND EXHAUST VALVES MAINTENANCE
9-13. ROCKER ARM AND CROSSHEAD MAINTENANCE
9-14. PUSH RODS AND FOLLOWERS MAINTENANCE
b. Remove
Figure 9-13. Removal and Replacement of Push Rods and Followers
Figure 9-14. Removing and Installing Cam Rollers and Pins
d. Install - TM-9-6115-604-34_344
SECTION III. MAINTENANCE OF CAMSHAFTS, BUSHINGS, AND COVER GEARS
Figure 9-15. Removal and Installation of Camshafts, Bushings, and Timing Gears (Sheet 1 of 2)
Figure 9-15. Removal and Installation of Camshafts, Bushings, and Timing Gears (Sheet 2 of 2)
d. Install - TM-9-6115-604-34_348
Figure 9-16. Installation of Timing Gears
9-16. CAMSHAFT BUSHINGS REPLACEMENT
Figure 9-18. Camshaft Bushing Driver Set, ST-1 228
9-18. TIMING GEARS AND COVER REPLACEMENT
c. Inspect and Repair
d. Install - TM-9-6115-604-34_354
Figure 9-19. Measuring Camshaft End Clearance
Figure 9-21. Injector Timing Setup
Figure 9-22. Injection Timing Diagram
Figure 9-23. Timing of Camshafts
SECTION IV. MAINTENANCE OF PISTON AND CONNECTING ROD ASSEMBLIES, MAIN AND CONNECTING ROD BEARINGS, AND CYLINDER LINERS
Figure 9-24. Cylinder Block and Related Parts (Sheet 1 of 2)
Figure 9-24. Cylinder Block and Related Parts (Sheet 2 of 2)
Figure 9-25. Inspection of Connecting Rods
c. Disassemble
Figure 9-26. Connecting Rod Inspection
Table 9-3. Connecting Rod Bolt Tightening Sequence and Torque
Figure 9-27. Chamfering Connecting Rod Piston Pin Bore Using ST-861
Figure 9-28. Removal and Installation of Connecting Rod Piston Pin Bushing Using ST-1285
Dry cleaning solvent PD-680
Figure 9-29. Inspection of Connecting Rod Bolt
Figure 9-30. Piston Ring End Gap
Figure 9-31. Identification of Top Side of Piston Ring
During assembly and Installation procedures
9-21. CONNECTING ROD BEARINGS REPLACEMENT
e. Install.
Figure 9-32. Using Plastigage to Determine Bearing Clearance
9-22. MAIN BEARINGS REPLACEMENT
Figure 9-33. Removing Upper Main Bearing Shell with Fabricated Removal Tool
e. Install
Plastigage
Table 9-4. Main Bearing Capscrew Tightening Sequence and Torque
Figure 9-34. Checking Cylinder Liner Protrusion
9-23. CYLINDER LINERS AND SEALS INSPECTION
Figure 9-35. Cylinder Liner Measurements
Figure 9-37. Checking Cylinder Block Counterbore Depth
Table 9-5. Cylinder Liner Counterbore Shims
SECTION V. MAINTENANCE OF CRANKSHAFT
b. Clean and Inspect
The weight of the crankshaft
9-28. CRANKSHAFT REBUILD
Figure 9-38. Disassembly and Assembly of Crankshaft
d. Inspect.
Figure 9-39. Crankshaft Alignment Checks
Figure 9-40. Measurement of Gear Step Size and Keyway Width
Figure 9-41. Crankshaft Journal Measurements
Figure 9-42. Magnetic Inspection of Crankshaft
Figure 9-43. Magnetic Inspection Limits of Acceptability
Figure 9-44. Straightening Crankshaft
Figure 9-45. Straightening Nose Section and Flywheel Pilot Run-out
Figure 9-46. Grooved Sidewall Grinding Wheel
Figure 9-47. Air Baffle and Side Washer Equipment
Figure 9-48. Wheel Dressing Tool
Figure 9-50. Crankshaft Offset To Grind Connecting Rod Bearing Journals
Excessive off-stroking
Excessive grinding
Figure 9-51. Connecting Rod Bossing Surface Dimensions
Figure 9-52. Checking Fillet Radius
The crankshaft thrust flange surfaces
Grinder bum
Figure 9-53. Seal Surface Wear Sleeve Kit
g. Assemble
Figure 9-54. Identification of Rod and Main Bearing Journal Sizes
h. Balance
SECTION VI. MAINTENANCE
b. Inspect.
Figure 9-56. Checking Counterbore
Figure 9-57. Measuring Lower Liner Bore Concentricity Using ST-1252
c. Clean and Repair
d. Assemble and Install
Figure 9-58. Cylinder Block Height Measurement
9-32. VIBRATION DAMPER REPLACEMENT
Figure 9-59. Removal and Installation of Vibration Damper and Crankshaft Pulley
9-33.  FRONT AND REAR CRANKSHAFT AND ACCESSORY DRIVE SEALS REPLACEMENT.
Figure 9-61. LDL-TFE Seal Installation
c. Rear Crankshaft Seal.
Figure 9-62. Exploded View of Rear Housing, Flywheel Housing, and Flywheel
9-34.  FLYWHEEL ASSEMBLY MAINTENANCE
Figure 9-63. Flywheel Capscrew Tightening Procedure
Figure 9-64. Checking Flywheel Runout
c. Inspect. - TM-9-6115-604-34_429
Figure 9-65. Checking Flywheel Housing Alignment
Figure 9-66. Front Support Assembly
9-37.  INSPECTION COVER MAINTENANCE.
Figure 9-67. Inspection Covers
Figure 9-68. Removal and Installation of Oil Pan Assembly (Sheet 1 of 2)
Figure 9-68. Removal and Installation of Oil Pan Assembly (Sheet 2 of 2)
Figure 9-69. Tightening Procedure, Oil Pan Adapter
SECTION VII. MAINTENANCE OF TURBOCHARGERS
Figure 9-70. Disassembly and Assembly of Turbocharger (Sheet 1 of 2)
Figure 9-70. Disassembly and Assembly of Turbocharger (Sheet 2 of 2)
c. Inspect
Figure 9-72. Inspection of Turbine Housing
Figure 9-74. Inspection of Turbine Wheel and Shaft
Repair procedures
Figure 9-75. Balance of Turbine Wheel and Shaft
Figure 9-76. Balance of Impeller and Turbine Wheel Shaft Assembly
Figure 9-77. Turbine Locknut Tightening
When removing or Installing the locknut
SECTION VII. MAINTENANCE OF AFTERCOOLER, INTAKE AND EXHAUST MANIFOLDS, AND WATER MANIFOLDS
Figure 9-78. Aftercooler and Intake Manifolds (Sheet 1 of 2)
Figure 9-78. Aftercooler and Intake Manifolds (Sheet 2 of 2)
e. Inspect
Figure 9-79. Tightening Sequence, Aftercooler Housing Covers
i. Install.
9-43. INTAKE MANIFOLDS MAINTENANCE
d. Install - TM-9-6115-604-34_455
Figure 9-80. Tightening Sequence, Air Balance Connections
Figure 9-82. Exhaust Manifolds
b. Clean and Inspect
CHAPTER 10 MAINTENANCE OF CONTROLS, INSTRUMENTS, AND SWITCHGEAR
Figure 10-1. Annunciator Alarm System, Simplified Schematic Diagram
10-2. ANNUNCIATOR ALARM SYSTEM REPAIR
Figure 10-2. Annunciator Panel A9, Exploded View
SECTION II. TRANSFORMERS
10-4. TRANSFORMER REPLACEMENT
b. Ground Fault Transformer Ti00.
Figure 10-3. Generator G1 Lines T1, T2, T3, L1, L2, and L3
c. Stepdown Transformer T1 01
Figure 10-5. Transformers T100, T102, T104, and T106 through T110, Exploded View
Figure 10-6. Fuse F101
Figure 10-7. Transformers T101 and T103, Exploded View
d. Isolation Transformer T102
Station power cable assembly
Generator set output power cable assemblies
Figure 10-8. Transducers and Transformer T105, Exploded View
SECTION III. TRANSDUCERS
Figure 10-9. Current Transducer AMT, On Equipment Test Setup
b. Current-Transducer AMT Removal
f. Frequency Transducer Al03 Removal and Installation
Figure 10-10. Current Transducer AMT, Bench Test Setup
Figure 10-11. Frequency Transducer A103, On Equipment Test Setup
h. Power Factor Transducer PFT Removal and Installation
Figure 10-12. Power Factor Transducer PFR, On Equipment Test Setup
j. Watt Transducer WMT Removal and Installation
CHAPTER 11 MAINTENANCE OF THE REMOTE CONTROL SYSTEM
Figure 11-1. Receptacle Connector J26, Removal and installation
Figure 11-2. Remote Control Cable Assembly
CHAPTER 12 GENERATOR SET TEST AND INSPECTION AFTER REPAIR OR OVERHAUL
Figure 12-1. Test Equipment Installation Points
g. Engine Run-In
Figure 12-2. Test Log
Table 12-1. Engine Run-In
SECTION lIl. INSPECTION
SECTION IV. OPERATIONAL TEST
Table 12-3. Operational Tests
Operational Tests (Continued)
Figure 12-3. Meter Hookup (Sheet 1 of 7)
Figure 12-3. Meter Hookup (Sheet 2 of 7)
Figure 12-3. Meter Hookup (Sheet 3 of 7)
Figure 12-3. Meter Hookup (Sheet 4 of 7)
Figure 12-3. Meter Hookup (Sheet 5 of 7)
Figure 12-3. Meter Hookup (Sheet 6 of 7)
Figure 12-3. Meter Hookup (Sheet 7 of 7)
12-11. OIL PRESSURE ALARM AND SHUTDOWN SWITCH OP1/OP2.
Figure 12-4. Oil Pressure Alarm and Shutdown Switch OP1/OP2 Test Setup
12-14. LOW FUEL LEVEL SWITCH FL3.
Figure 125. Load Instrumentation (Sheet 1 of 2)
Figure 12-5. Load Instrumentation (Sheet 2 of 2)
12-16. CIRCUIT INTERRUPTER (SHORT CIRCUIT)
Figure 12-6. Apparatus Connection for Circuit Breaker (Short Circuit) Test
12-17. CIRCUIT INTERRUPTER (OVERLOAD CURRENT)
12-18. CIRCUIT INTERRUPTER (OVER-VOLTAGE AND UNDERVOLTAGE)
Figure 12-8. Voltage Divider Transformer Network
12-21. PHASE BALANCE (VOLTAGE).
12-22. REGULATOR RANGE
12-23. FREQUENCY AND VOLTAGE REGULATION, STABlLITY, AND TRANSIENT RESPONSE (SHORT TERM).
c. Procedure
d. Results
Figure 12-9. Overshoot and Undershoot Chart Recording
(3) The maximum voltage variation
12-24. FREQUENCY ADJUSTMIENT RANGE AND UNDERFREQUENCY TRIP.
12-25. PARALLEL OPERATION (REAL POWER)
12-28. START AND STOP TEST.
APPENDIX A REFERENCES - TM-9-6115-604-34_523
FO-1. DC Schematic Diagram (Sheet 1 of 8) - TM-9-6115-604-34_536
FO-1. DC Schematic Diagram (Sheet 2 of 8) - TM-9-6115-604-34_537
FO-1. DC Schematic Diagram (Sheet 3 of 8) - TM-9-6115-604-34_538
FO-1. DC Schematic Diagram (Sheet 4 of 8) - TM-9-6115-604-34_539
FO-1. DC Schematic Diagram (Sheet 5 of 8) - TM-9-6115-604-34_540
FO-1. DC Schematic Diagram (Sheet 6 of 8) - TM-9-6115-604-34_541
FO-1 DC Schematic Diagram (Sheet 7 of 8)
FO-1 DC Schematic Diagram (Sheet 8 of 8)
FO-2 AC Schematic Diagram (Sheet 1 of 8)
FO-2 AC Schematic Diagram (Sheet 2 of 8)
FO-2 AC Schematic Diagram (Sheet 3 of 8)
FO-2 AC Schematic Diagram (Sheet 4 of 8)
FO-2 AC Schematic Diagram (Sheet 5 of 8)
FO-2. AC Schematic Diagram (Sheet 6 of 8) - TM-9-6115-604-34_549
FO-2 AC Schematic Diagram (Sheet 7 of 8)
FO-2 AC Schematic Diagram (Sheet 8 of 8)
FO-3. Remote Control Module AC and DC Schematic Diagram - TM-9-6115-604-34_552
FO-4 Generator Connection Box Wiring Diagram
FO-5 Engine Accessories Wiring Diagram (Sheet 1 of 2)
FO-5 Engine Accessories Wiring Diagram (Sheet 2 of 2)
FO-6 Control Room Wiring Diagra m (Sheet 1 of 2)
FO.6 Control Room Wiring Diagram (Sheet 2 of 2)
FO-7. Cabinet A Wiring Diagram (Sheet 1 of 4)
FO-7. Cabinet A Wiring Diagram (Sheet 2 of 4)
FO-7. Cabinet A Wiring Diagram (Sheet 3 of 4)
FO-7. Cabinet A Wiring Diagram (Sheet 4 of 4)
FO-8. Cabinet A Door Wiring Diagram - TM-9-6115-604-34_562
FO-9. Cabinet B Wiring Diagram (Sheet 1 of 3) - TM-9-6115-604-34_563
FO-9. Cabinet B Wiring Diagram (Sheet 2 of 3) - TM-9-6115-604-34_564
FO-9. Cabinet B Wiring Diagram (Sheet 3 of 3) - TM-9-6115-604-34_565
FO-10. Cabinet B Door Wiring Diagram - TM-9-6115-604-34_566
FO-11. Cabinet C wiring Diagram (Sheet 1 of 5)
FO-11. Cabinet C Wiring Diagram (Sheet 2 of 5)
FO-11. Cabinet C Wiring Diagram (Sheet 3 of 5)
FO-11. Cabinet C Wiring Diagram (Sheet 4 of 5 )
FO-11. Cabinet C Wiring Diagram (Sheet 5 of 5) - TM-9-6115-604-34_571
FO-12. Remote Control Module Wiring Diagram - TM-9-6115-604-34_572
FO-13. Cabinet A Interconnect Wiring Harness
FO-14. Fuel Monitor Wiring Harness
FO-15. Remote Control Module Wiring Harness (Sheet 1 of 3)
FO-15. Remote Control Module Wiring Harness (Sheet 2 of 3)
FO-15. Remote Control Module Wiring Harness (Sheet 3 of 3)
FO-16. Cabinet B Rear Wiring Harness (Sheet 1 of 2)
FO-16. Cabinet B Rear Wiring Harness (Sheet 2 of 2)
FO-17. Cabinet C Connectors Wiring Harness (Sheet 1 of 3)
FO-17. Cabinet C Connectors Wiring Harness (Sheet 2 of 3)
FO-17. Cabinet C Connectors Wiring Harness (Sheet 3 of 3)
FO-18. Cabinet C Forward Wiring Harness
FO-19. Cabinet A Divider Wiring Harness (Sheet 1 of 2)
FO-19. Cabinet A Divider Wiring Harness (Sheet 2 of 2)
FO-20. Cabinet C Divider Panel Wiring Harness (Sheet 1 of 2)
FO-20. Cabinet C Divider Panel Wiring Harness (Sheet 2 of 2)
FO-21. Load Circuit Breaker CB101 Wiring Harness
FO-22. Cabinet B Door Wiring Harness (Sheet 1 of 8)
FO-22. Cabinet B Door Wiring Harness (Sheet 2 of 8)
FO-22. Cabinet B Door Wiring Harness (Sheet 3 of 8)
FO-22. Cabinet B Door Wiring Harness (Sheet 4 of 8)
FO-22. Cabinet B Door Wiring Harness (Sheet 5 of 8)
FO-22. Cabinet B Door Wiring Harness (Sheet 6 of 8)
FO-22. Cabinet B Door Wiring Harness (Sheet 7 of 8)
FO-22. Cabinet B Door Wiring Harness (Sheet 8 of 8)
FO-23. Cabinet A XFMR Panel High Tension Wiring Harness
FO-24. Cabinet A Forward Wiring Harness (Sheet 1 of 3)
FO-24. Cabinet A Forward Wiring Harness (Sheet 2 of 3)
FO-24. Cabinet A Forward Wiring Harness (Sheet 3 of 3)
FO-25. Cabinet A Door Wiring Harness (Sheet 1 of 3)
FO-25. Cabinet a Door Wiring Harness (Sheet 2 of 3)
FO-25. Cabinet A Door Wiring Harness (Sheet 3 of 3)
FO-26 Cabinet A Rear Transfer Wiring Harness
FO-27. Engine to Cabinet Wiring Harness (Sheet 1 of 3)
FO-27. Engine to Cabinet Wiring Harness (Sheet 2 of 3)
FO-27. Engine to Cabinet Wiring Harness (Sheet 3 of 3)
FO-28. Cabinet B Divider Panel Wiring Harness (Sheet 1 of 3)
FO-28. Cabinet B Divider Panel Wiring Harness (Sheet 2 of 3)
FO-28. Cabinet B Divider Panel Wiring Harness (Sheet 3 of 3)
FO-29. Cabinet C Door Wiring Harness (Sheet 1 of 3)
FO-29. Cabinet C Door Wiring Harness (Sheet 2 of 3)
FO-29. Cabinet C Door Wiring Harness (Sheet 3 of 3)
FO-30. Cabinet C Forward Wiring Harness
FO-31. Control Center Wiring Harness
FO-32. Generator Connection Box Wiring Harness (Sheet 1 of 2)
FO-32. Generator Connection Box Wiring Harness (Sheet 2 of 2)
FO-33. Cabinet C Interconnect Wiring Harness
FO-34. Cabinet B-A Interconnect Wiring Harness
FO-35. Cabinet C Right Hand Upper Wiring Harness (Sheet 1 of 2)
FO-35. Cabinet C Right Hand Upper Wiring Harness (Sheet 2 of 2)
FO-36 Cabinet C Divider Panel Wiring Harness (Sheet 1 of 3)
FO-36 Cabinet C Divider Panel Wiring Harness (Sheet 2 of 3)
FO-36 Cabinet C Divider Panel Wiring Harness (Sheet 3 of 3)
FO-37 Cabinet C Interconnect Wiring Harness (Sheet 1 of 3)
FO-37 Cabinet C Interconnect Wiring Harness (Sheet 2 of 3)
FO-37 Cabinet C Interconnect Wiring Harness (Sheet 3 of 3)
FO-38 Cabinet A Divider Panel Wiring Harness (Sheet 1 of 2)
FO-38 Cabinet A Divider Panel Wiring Harness (Sheet 2 of 2)
FO-39 Miscellaneous Wiring

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