Section I. GENERAL INFORMATION - TM-9-6115-668-13_31
Figure 1-1 Generator Set 150 kW.
Table 1-1 Nomenclature Cross-Reference List.
Section II. EQUIPMENT DESCRIPTION
Table 1-2 Description of Major Components, Generator Set 150 kW
1.11 CONSTRUCTION
1.11.3 Generator Compartment.
The tank has a filler tube
Figure 1-2 Generator Set 150 kW, Location of Major Components.
1.12 EQUIPMENT DATA.
Table 1-3 Tabulated Data for Generator Set 150 kW (continued).
Tabulated Data for Generator Set 150 kW (continued).
Figure 1-3 Generator Set 150 kW, Dimensions.
Section III. PRINCIPLES OF OPERATION
1.13.3 Maintenance Free Battery Set Assembly.
Figure 1-4 Generator Set 150 kW, Block Diagram.
1.14 FUNCTIONAL DESCRIPTION.
1.14.1.3 Time t approximately 2.8 minutes
Manual Shutdown
OIL PRESSURE indicator lamp
1.14.2.3 Voltages Present at Control Cabinet Assembly Receptacles.
1.14.3 BATTLE SHORT Mode.
1.14.3.2 Emergency Shutdown.
Table 1-5 J9 PARALLEL OPERATION Receptacle, Monitoring and Control Functions
J9 PARALLEL OPERATION Receptacle, Monitoring and Control Functions (continued).
CHAPTER 2 OPERATING INSTRUCTIONS
Section I. DESCRIPTION AND USE OF CONTROLS AND INDICATORS
Table 2-1 Control Cabinet Assembly, Description of Controls and Indicators.
Control Cabinet Assembly, Description of Controls and Indicators (continued). - TM-9-6115-668-13_59
Control Cabinet Assembly, Description of Controls and indicators (continued). - TM-9-6115-668-13_60
Control Cabinet Assembly, Description of Controls and indicators (continued).
Figure 2-2 Control Cabinet Assembly, Circuit Breakers (sheet 1 of 2)
Figure 2-2 Control Cabinet Assembly, Circuit Breakers (sheet 2 of 2).
Table 2-2 Control Cabinet Assembly Description of Circuit Breakers
2.1.3 Receptacles
Figure 2-4 Base Frame Assembly, J3 SLAVE RECEPTACLE 24 VOLTS
Section II. OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SER- VICES (PMCS)
2.2.4 Special Instructions
2.2.5 Leakage Definitions.
Figure 2-5 Operator PMCS Routing Diagram (sheet 1 of 6).
Figure 2-5 Operator PMCS Routing Diagram (sheet 2 of 6).
Figure 2-6 Operator PMCS Routing Diagram (sheet 3 of 6).
Figure 2-4 Operator PMCS Routing Diagram Tm (sheet 4 of 6).
Figure 2-5 Operator PMCS Routing Diagram (sheet 5 of 6).
Figure 2-5 Operator PMCS Routing Diagram (sheet 6 of 6).
Table 24 Operator Preventive Maintenance Checks and Services.
Operator Preventive Maintenance Checks and Services-continued. - TM-9-6115-668-13_77
Operator Preventive Maintenance Checks and Services-continued. - TM-9-6115-668-13_78
Operator Preventive Maintenance Checks and Services-continued. - TM-9-6115-668-13_79
Operator Preventive Maintenance Checks and Services-continued. - TM-9-6115-668-13_80
Operator Preventive Maintenance Checks and Services-continued. - TM-9-6115-668-13_81
Operator Preventive Maintenance Checks and Services-continued. - TM-9-6115-668-13_82
Operator Preventive Maintenance Checks and Services-continued. - TM-9-6115-668-13_83
Operator Preventive Maintenance Checks and Services-continued. - TM-9-6115-668-13_84
Operator Preventive Maintenance Checks and Services-continued. - TM-9-6115-668-13_85
Operator Preventive Maintenance Checks and Services-continued. - TM-9-6115-668-13_86
Section III. OPERATION UNDER USUAL CONDITIONS - TM-9-6115-668-13_87
Figure 2-6 Control Cabinet Assembly Lamp Test.
2.3.2.3 Replace Diesel Engine Oil.
2.3.2.4 Check Diesel Engine Oil Level after Engine Shutdown.
2.3.2.5 Check Diesel Engine Oil Level before starting engine.
Figure 2-7 Diesel Engine Oil Removal Maintenance
Figure 2-8 Diesel Engine oil Level Maintenance.
Table 2-5 SHPD Oils Approved for Diesel Engine BF8L513.
Figure 2-9 Viscosity Class (SAE C/ass).
Table 2-6 Oil change intervals
2.3.4.2.1 Refueling with the Fuel Pump
Figure 2-10 Refueling.
Figure 2-11 Connect Battery Cable
2.3.6 Connecting Control and Power Cables
Figure 2-12 Connecting Control and Power Cables
2.4 DECALS AND INSTRUCTION PLATES
Figure 2-16 Engine Preheating Plate.
Figure 2-17 Generator Set 150 kW Short Operating Instructions Plate (sheet 1 of 2).
Figure 2-17 Generator Set 150 kW Short Instructions P/ate (sheet 2 of 2).
2.5 OPERATING PROCEDURES
2.5.1.2 Switching Voltage to the Control Cabinet Assembly Receptacles
MASTER SWITCH
Figure 2-18 Operating the Generator Set 150 kW.
2.5.2.1 Normal Shutdown
2.6 EMERGENCY PROCEDURES
Figure 2-20 BATTLE SHORT Mode.
2.7 PREPARATION FOR MOVEMENT
Figure 2-21 Disconnecting Control and Power Cables
Figure 2-22 Disconnect Battery Cable.
Section IV. OPERATION UNDER UNUSUAL CONDITIONS
Figure 2-24 Operating the Engine Preheating Assembly
2.9 OPERATING THE FLAME GLOWPLUG SYSTEM (BELOW 32 F (0 C))
Figure 2-25 Operating the Flame Glowplug System
2.10 OPERATION IN EXTREME COLD (BELOW -22 F (-30 C))
Figure 2-26 Fuel Infection Pump Actuator Linkage
CHAPTER 3 OPERATOR MAINTENANCE INSTRUCTIONS
Section I. OPERATOR LUBRICATION
Section II. TROUBLESHOOTING - TM-9-6115-668-13_124
Figure 3-1 BATTERY CHARGING CONTROL and OIL PRESSURE lamps do not light up
Figure 3-2 HEATING FAILURE lamp lights up or READY TO START IF HEATING IS ON lamp does not light up
Figure 3-3 GLOWPLUG ON lamp does not light up
Figure 3-4 Oil pressure too low, or no oil pressure indication
Figure 3-5 Generator frequency cannot be adjusted, or no frequency indication
Figure 3-6 Generator voltage cannot be adjusted, or no voltage indication.
Figure 3-7 AC CIRCUIT INTERRUPTER ON lamp does not light up.
Section III. MAINTENANCE PROCEDURES
3.4 AIR FILTER DUST COLLECTOR MAINTENANCE
Figure 3-8 Air Filter Assembly Maintenance.
CHAPTER 4 UNIT MAINTENANCE INSTRUCTIONS
Subject Index - TM-9-6115-668-13_136
Subject Index - TM-9-6115-668-13_137
Subject Index - TM-9-6115-668-13_138
Section I. REPAIR PARTS; TOOLS; SPECIAL TOOLS; TEST, MEASUREMENT AND DIAGNOSTIC EQUIPMENT (TMDE); AND SUPPORT EQUIPMENT - TM-9-6115-668-13_139
Section II. SERVICE UPON RECEIPT OF EQUIPMENT
4.4.2 Unpacking Equipment.
4.4.3 Checking Unpacked Generator Set 150 kW
Figure 4-1 Original Packaging in Container.
Figure 4-2 Unpacking the Container.
Figure 4-3 Generator Set 150 kW, Unpacked.
4.5 INSTALLATION INSTRUCTIONS
4.6.3 Lubricating Oil.
Section III. Unit Lubrication
Section IV. UNIT PREVENTIVE MAINTENANCE CHECKS AND SERVICES
Dry cleaning solvent
Figure 4-5. Unit PMCS Routing Diagram.
Table 4-3. Unit Preventive Maintenance Checks and Services for Generator Set 150 kW.
Unit Preventive Maintenance Checks and Services for Generator Set 150 kW-continued
Section V. TROUBLESHOOTING - TM-9-6115-668-13_154
SYMPTOM INDEX - TM-9-6115-668-13_155
Figure 4-6 BATTERY CHARGING CONTROL and OIL PRESSURE lamps do not light up.
Figure 4-7 HEATING FAILURE lamp lights up or READY TO START IF HEATING IS ON lamp does not light up
Figure 4-8 GLOWPLUG ON lamp does not light up.
Figure 4-9 Diesel engine cannot be started
Figure 4-10 Oil pressure too low, or no oil pressure indication.
Figure 4-11 Battery set is not being charged, or no charging current indication.
Figure 4-12 Generator frequency cannot be adjusted, or no frequency indication.
Figure 4-13 Generator voltage cannot be adjusted, or no voltage indication
Figure 4-14 AC CIRCUIT INTERRUPTER ON lamp does not light up.
Figure 4-15 No line currents are flowing, or no line current indication.
Figure 4-16 No power indication
Figure 4-17 BATTERY CHARGING CONTROL lamp lights up during operation.
Figure 4-18 OIL PRESSURE lamp lights up during operation.
Figure 4-19 OIL TEMP-CYLINDER HEAD lamp lights up during operation.
Figure 4-20 UNDER/OVER FREQUENCY lamp lights up during operation.
Figure 4-21 UNDER/OVER VOLTAGE lamp lights up during operation.
Figure 4-22 GENERATOR OVER TEMPERATURE lamp lights up during operation.
Figure 4-23 OVERLOAD lamp lights up during operation.
Section VI. RADIO INTERFERENCE SUPPRESSION
SECTION VII. MAINTENANCE PROCEDURES
Removal/ Installation operation
4.13 UNIT HOOD FLAP GROUND STRAP MAINTENANCE
Figure 4-24 Unit Hood Flap Ground Strap Maintenance.
4.14 UNIT HOOD ASSEMBLY MAINTENANCE.
INSTALLATION - TM-9-6115-668-13_180
Figure 4-25. Unit Hood Assembly Maintenance
4.15 UNlT HOOD-BASE FRAME GROUND STRAP MAINTENANCE.
Figure 4-26 Unit Hood-Base Frame Ground Strap Maintenance.
4.16 SUPPLY AIR DUCT MAINTENANCE
4.17 AIR LEADING DUCT MAINTENANCE
4.18 AIR COOLING INLET GRATE MAINTENANCE
4.19 COVER AND CASE FOR CONNECTION PANEL MAINTENANCE
Figure 4-27 Unit Hood Assembly Air Ducts and Air Cooling Inlet Grate Maintenance
4.20 TWIST GRIP AND LOCK MAINTENANCE
4.21 GAS-CYLINDER AND PROP MAINTENANCE.
4.22 FLAP MOUNT MAINTENANCE.
Figure 4-28 Unit Hood Flap Maintenance.
4.23 LIGHT INDICATOR ASSEMBLY MAINTENANCE
INSTALLATION - TM-9-6115-668-13_194
Figure 4-29 Control Cabinet Assembly, Light Indicator Assembly Maintenance
4.24 BULB IN INDICATOR LAMP MAINTENANCE
Figure 4-30 Bulb in Indicator Lamps Maintenance.
4.25 BULB IN ILLUMINATED SWITCH MAINTENANCE
Figure 4-31 Bulb in Illuminated Switch Maintenance
4.26 REPLACE BULB IN PANEL LIGHT H6
Figure 4-32 Panel Light H6 Maintenance
4.27 REPLACE BULB IN ILLUMINATED METER.
Figure 4-33 Illuminated Meter Maintenance.
4.28 REPLACE BULB IN CABINET LIGHT H7.
Figure 4-34 Cabinet Light Maintenance.
4.29 AIR FILTER CARTRIDGE MAINTENANCE
INSTALLATION - TM-9-6115-668-13_207
Figure 4-35. Air Filter Cartridge Maintenance
4.30 OIL FILTER MAINTENANCE
4.31 SUBCURRENT FILTER CARTRIDGE MAINTENANCE
Figure 4-36. Oil Filter, Subcurrent Filter Maintenance
4.32 FUEL PREFILTER CARTRIDGE MAINTENANCE
INSTALLATION - TM-9-6115-668-13_213
4.33 TWO STEP FUEL FILTER CARTRIDGE MAINTENANCE
INSTALLATION - TM-9-6115-668-13_215
Figure 4-37 Fuel Prefilter Cartridge, Two Step Fuel Filter Cartridges Maintenance.
4.34 BATTERY CHARGING ALTERNATOR V BELT
4.35 BATTERY CHARGING ALTERNATOR V BELT MAINTENANCE
Bleed screws
Figure 4-38. Battery Charging AIternator of V Belt Malntenance.
4.36 DIESEL ENGINE CYLINDER COOLING FINS AND OIL COOLER MAINTENANCE
Figure 4-39 Diesel Engine Cylinder Cooling Fins and Oil Cooler Maintenance
4.37 PRIMING PUMP MAINTENANCE
Figure 4-40. Priming Pump Assembly Maintenance.
4.38 FUEL LINES AND PREFILTER ASSEMBLY MAINTENANCE
4.39 FUEL LINES AND TWO STEP FUEL FILTER ASSEMBLY MAINTENANCE
Figure 4-41 Diesel Engine Fuel Pipes and Fuel Filter Assembly Maintenance
4.40 FUEL PREFILTER ASSEMBLY MAINTENANCE
INSTALLATION - TM-9-6115-668-13_229
4.41 TWO STEP FUEL FILTER ASSEMBLY MAINTENANCE.
INSTALLATION - TM-9-6115-668-13_231
Figure 4-42. Fuel Prefilter, Two Step Fuel Filter Maintenance
4.42 FUEL LINE ASSEMBLY MAINTENANCE.
7. Fuel supply line
INSTALLATION - TM-9-6115-668-13_235
6. Fuel line
Figure 4-43. Fuel Line Assembly Maintenance
4.43 CONTROL CABINET ASSEMBLY MAINTENANCE
6. Record labeling and position of cables
Contact with filter box FK
Figure 4-44 Control Cabinet Assembly Maintenance (Sheet 1 of 2)
Figure 4-44 Control Cabinet Assembly Maintenance (Sheet 2 of 2)
INSTALLATION - TM-9-6115-668-13_243
21. Place cover
4.44 PUSHBUTTON SWITCH AND INDICATOR ASSEMBLY MAINTENANCE
INSTALLATION - TM-9-6115-668-13_246
Figure 4-45 Control Cabinet Assembly, Pushbutton Switch and Indicator Assembly Maintenance.
4.45 PUSHBUTTON SWITCH MAINTENANCE.
INSTALLATION - TM-9-6115-668-13_249
Figure 4-46 Control Cabinet Assembly, Pushbutton Switch Maintenance.
4.46 PANEL ILLUMINATION H6 MAINTENANCE.
Figure 4-47 Control Cabinet Assembly, Panel Illumination H6 Maintenance.
4.47 PREHEATING RESISTOR R1 MAINTENANCE
INSTALLATION - TM-9-6115-668-13_254
4.48 BATTLE SHORT SWITCH S21 MAINTENANCE
5. Connect cable
4.49 VOLTAGE SELECTOR SWITCH S11 MAINTENANCE
INSTALLATION - TM-9-6115-668-13_258
4.50 GLOWPLUG/START SWITCH S2 MAINTENANCE.
4.51 MASTER SWITCH S1 MAINTENANCE
Figure 4-48 Control Cabinet Assembly, Preheating Resistor R1, BATTLE SHORT Switch S21, VOLTAGE SELECTOR SWITCH S11 GLOWPLUG/START Switch S2, MASTER SWITCH S1 Maintenance
4.52 FREQUENCY ADJUST R4 MAINTENANCE
INSTALLATION - TM-9-6115-668-13_263
4.53 VOLTAGE ADJUST R3 MAINTENANCE
INSTALLATION - TM-9-6115-668-13_265
4.54 PANEL DIMMER S16/R2 MAINTENANCE
INSTALLATION - TM-9-6115-668-13_267
Figure 4-49 Control Cabinet Assembly, FREQUENCY ADJUST R4, VOLTAGE ADJUST R3, PANEL DIMMER S16/R2 Maintenance.
4.55 FREQUENCY METER P5 MAINTENANCE
4. Install cover panel
4.56 METER MAINTENANCE.
INSTALLATION - TM-9-6115-668-13_272
Figure 4-50 Control Cabinet Assembly, Meter Maintenance
4.57 CABINET ILLUMINATION H7 MAINTENANCE.
4.58 DOOR CONTACT SWITCH S3 MAINTENANCE.
4.59 BRIGHTNESS CONTROL N5 MAINTENANCE.
Figure 4-51 Control Cabinet Assembly, Cabinet Illumination H7, Door Contact Switch S3, Brightness Control N5 Maintenance.
4.60 LIGHT INDICATOR ASSEMBLY MAINTENANCE.
INSTALLATION - TM-9-6115-668-13_279
Figure 4-52 Control Cabinet Assembly, Auxiliary Contactor with Semiconductor, Auxiliary Contactor, Transformer Maintenance
4.61 DIODE MAINTENANCE.
INSTALLATION - TM-9-6115-668-13_282
4.62 DIODE V3 MAINTENANCE
INSTALLATION - TM-9-6115-668-13_284
Figure 4-53 Diodes, Time Relay, Power Supply Maintenance
4.63 CIRCUIT BREAKER MAINTENANCE.
INSTALLATION - TM-9-6115-668-13_287
4. Close cable conduit
4.64 TRUE POWER MEASURING TRANSFORMER P4A MAINTENANCE.
INSTALLATION - TM-9-6115-668-13_290
Figure 4-54 Control Cabinet Assembly, Circuit Breaker F1 to F11, Thermistor relay F12, True Power Measuring Transformer P4A Maintenance
4.65 RESISTOR R100 TO R102 MAINTENANCE
INSTALLATION - TM-9-6115-668-13_293
Figure 4-55 Control Cabinet Assembly, Relays K19, K20, Digital lsochronous Load Sharing Module N4, Speed Governor Assembly N1, Resistor Maintenance.
4.66 CONTACTOR K1 MAINTENANCE.
REPAIR - TM-9-6115-668-13_296
6. Install six serrated lock washers
Figure 4-56 Control Cabinet Assembly, Contactor K1 Maintenance.
4.67 ENGINE PREHEATING CONTROL BOARD MAINTENANCE.
INSTALLATION - TM-9-6115-668-13_300
4.68 CIRCUIT BREAKER MAINTENANCE
INSTALLATION - TM-9-6115-668-13_302
2. Circuit breaker assembly F102
Figure 4-57 Control Cabinet Assembly, Engine Preheating Control Board, Circuit Breaker Maintenance.
4.69 CONNECTOR J9 MAINTENANCE.
INSTALLATION - TM-9-6115-668-13_306
4.70 J1/120 V 400 HZ DOUBLE CONNECTOR RECEPTACLE MAINTENANCE
INSTALLATION - TM-9-6115-668-13_308
4.71 J2/24 V CONNECTOR RECEPTACLE MAINTENANCE.
INSTALLATION - TM-9-6115-668-13_310
Figure 4-58 Control Cabinet Assembly, Connection Panel, Connector Maintenance.
4.72 SERVICE SWITCH MAINTENANCE.
Figure 4-59. Air Filter Assembly, J3 Slave Receptacle 24 V Connector Maintenance
4.73 SHUNT R11 MAINTENANCE
4.74 BATTERY SET MAINTENANCE.
TEST - TM-9-6115-668-13_316
7. Install terminal connector of battery cable
4.75 BATTERY CHARGING ALTERNATOR REGULATOR N6 MAINTENANCE.
4.76 EHG REGULATOR N7 MAINTENANCE.
Figure 4-60. Shunt Resistor R11, EHG Regulator N7, Generator Regulator N6, Battery Set Maintenance
4.77 FUEL TANK MAINTENANCE.
REMOVAL - TM-9-6115-668-13_322
INSTALLATION - TM-9-6115-668-13_323
Hylomar
4.78 ELECTRICAL FUEL PUMP ASSEMBLY MAINTENANCE.
Figure 4-61. Fuel Tank Assembly, Electrical Fuel Pump Maintenance.
4.79 UPPER FUEL LEVEL SWITCH MAINTENANCE.
INSTALLATION - TM-9-6115-668-13_328
4.80 LOWER FUEL LEVEL SWITCH MAINTENANCE.
INSTALLATION - TM-9-6115-668-13_330
4.81 FUEL LEVEL SENSOR 2R4 MAINTENANCE.
2. Noting correct labeling and position, install cable
Figure 4-62. Fuel level Switch and Sensor Maintenance.
4.82 SILENCER ASSEMBLY, LEFT SIDE MAINTENANCE.
4. Remove connector pipes and brackets - TM-9-6115-668-13_335
INSTALLATION - TM-9-6115-668-13_336
f . Align exhaust pipe with header
Figure 4-63. Silencer Assembly, Left Side Maintenance
4.83 SILENCER ASSEMBLY, RIGHT SIDE MAINTENANCE
4. Remove connector pipes and brackets - TM-9-6115-668-13_340
INSTALLATION - TM-9-6115-668-13_341
5. Install unit hood assembly
Figure 4-64. Silencer Assembly, Right Side Maintenance
INSTALLATION - TM-9-6115-668-13_344
2. Insert new sealing ring
4.85 OIL OUTLET PIPE ASSEMBLY MAINTENANCE.
4.86 OIL LINE ASSEMBLY MAINTENANCE.
4.87 OIL PRESSURE SWITCH 1S2 AND OIL PRESSURE SENSOR 1R2 MAINTENANCE.
4.88 OIL TEMPERATURE SWITCH 1S3 AND OIL TEMPERATURE SENSOR 1R3 MAINTENANCE.
2. Install oil temperature switch
Figure 4-65. Scavenge Pump Assembly, Oil Outlet Pipe Oil Pressure Switch 1S2 and Oil Pressure Sensor 1R2, Oil Temperature Switch 1S3 and Oil Temperature Sensor 1R3 Maintenance
4.89 BATTERY CHARGING ALTERNATOR MAINTENANCE
TEST - TM-9-6115-668-13_353
3. Noting correct labeling and position
Figure 4-66. Battery Charging Alternator Maintenance.
4.90 STARTER MAINTENANCE
INSTALLATION - TM-9-6115-668-13_357
Figure 4-67. Generator, Starter Maintenance.
CHAPTER 5 DIRECT SUPPORT MAINTENANCE INSTRUCTIONS
Subject Index
Section I. REPAIR PARTS; TOOLS; SPECIAL TOOLS; TEST, MEASUREMENT AND DIAGNOSTIC EQUIPMENT (TMDE); AND SUPPORT EQUIPMENT - TM-9-6115-668-13_361
Section II. TROUBLESHOOTING - TM-9-6115-668-13_362
24 VDC operating voltage
SYMPTOM INDEX - TM-9-6115-668-13_364
Figure 5-1 BATTERY CHARGING CONTROL and OIL PRESSURE lamps do not light up (sheet 1 of 7).
Figure 5-1 BATTERY CHARGING CONTROL and OIL PRESSURE lamps do not light up (sheet 2 of 7)
Figure 5-1 BATTERY CHARGING CONTROL and OIL PRESSURE lamps do not light up (sheet 3 of 7).
Figure 5-1 BATTERY CHARGING CONTROL and OIL PRESSURE lamps do not light up (sheet 4 of 7).
Figure 5-1 BATTERY CHARGING CONTROL and OIL PRESSURE lamps do not light up (sheet 5 of 7).
Figure 5-1 BATTERY CHARGING CONTROL and OIL PRESSURE lamps do not light up (sheet 6 of 7).
Figure 5-1 BATTERY CHARGING CONTROL and OIL PRESSURE lamps do not light up (sheet 7 of 7).
Figure 5-2 HEATING FAILURE lamp lights up or READY TO START IF HEATING IS ON lamp does not light up (sheet 1 of 7).
Figure 5-2 HEATING FAILURE lamp lights up or READY TO START IF HEATING IS ON lamp does not light up (sheet 2 of 7)
Figure 5-2 HEATING FAILURE lamp lights up or READY TO START IF HEATING IS ON lamp does notlight up (sheet 3 of 7).
Figure 5-2 HEATING FAILURE lamp lights up or READY TO START IF HEATING IS ON lamp does not light up (sheet 4 of 7).
Figure 5-2 HEATING FAILURE lamp lights up or READY TO START IF HEATING IS ON lamp does not light up (sheet 5 of 7).
Figure 5-2 HEATING FAILURE lamp lights up or READY TO START IF HEATING IS ON lamp does not light up (sheet 6 of 7).
Figure 5-2 HEATING FAILURE lamp lights up or READY TO START IF HEATING IS ON lamp does not light up (sheet 7 of 7).
Figure 5-3 GLOWPLUG ON lamp does not light up (sheet 1 of 4).
Figure 5-3 GLOWPLUG ON lamp does not light up (sheet 2 of 4).
Figure 5-3 GLOWPLUG ON lamp does not light up (sheet 3 of 4).
Figure 5-3 GLOWPLUG ON lamp does not Iight up (sheet 4 of 4).
Figure 5-4 Diesel engine cannot be started (sheet 1 of 10).
Figure 5-4 Diesel engine cannot be started (sheet 2 of 10).
Figure 5-4 Diesel engine cannot be started (sheet 3 of 10).
Figure 5-4 Diesel engine cannot be started (sheet 4 of 10).
Figure 5-4 Diesel engine cannot be started (sheet 5 of 10).
Figure 5-4 Diesel engine cannot be started (sheet 6 of 10).
Figure 5-4 Diesel engine cannot be started (sheet 7 of 10).
Figure 5-4 Diesel engine cannot be started (sheet 8 of 10).
Figure 5-4 Diesel engine cannot be started (sheet 9 of 10)
Figure 5-4 Diesel engine cannot be started (sheet 10 of 10)
Figure 5-5 Oil pressure too low, or no oil pressure indication (sheet 1 of 3).
Figure 5-5 Oil pressure too low, or no oil pressure indication (sheet 2 of 3).
Figure 5-5 Oil pressure too low, or no oil pressure indication (sheet 3 of 3).
Figure 5-6 Battery set is not being charged, or no charging current indication (sheet 1 of 2).
Figure 5-6 Battery set is not being charged, or no charging current indication (sheet 2 of 2).
Figure 5-7 Generator frequency cannot be adjusted, or no frequency indication (sheet 1 of 5).
Figure 5-7 Generator frequency cannot be adjusted, or no frequency indication (sheet 2 of 5).
Figure 5-7 Generator frequency cannot be adjusted, or no frequency indication (sheet 3 of 5).
Figure 5-7 Generator frequency cannot be adjusted, or no frequency indication (sheet 4 of 5)
Figure 5-7 Generator frequency cannot be adjusted, or no frequency Indication (sheet 5 of 5).
Figure 5-8 Generator voltage cannot be adjusted, or no voltage lndicatlon (sheet 1 of 7)
Figure 5-8 Generator voltage cannot be adjusted, or no voltage indication (sheet 2 of 7).
Figure 5-8 Generator voltage cannot be adjusted, or no voltage indication (sheet 3 of 7).
Figure 5-8 Generator voltage cannot be adjusted, or no voltage indication (sheet 4 of 7).
Figure 5-8 Generator voltage cannot be adjusted, or no voltage indication (sheet 5 of 7).
Figure 5% Generator voltage cannot be adjusted, or no voltage indication (sheet 6 of 7)
Figure 5-8 Generator voltage cannot be adjusted, or no voltage indication (sheet 7 of 7)
Figure 5-9 AC CIRCUIT INTERRUPTER ON lamp does not light up (sheet 1 of 11).
Figure 5-9 AC CIRCUIT INTERRUPTER ON lamp does not light up (sheet 2 of 11)
Figure 5-9 AC CIRCUIT INTERRUPTER ON lamp does not light up (sheet 3 of 11).
Figure 5-9 AC CIRCUIT INTERRUPTER ON lamp does not light up (sheet 4 of 77)
Figure 5-9 AC CIRCUIT INTERRUPTER ON lamp does not iight up (sheet 5 of 11).
Figure 5-9 AC CIRCUIT INTERRUPTER ON lamp does not light up (sheet 6 of 11).
Figure 5-9 AC CIRCUIT INTERRUPTER ON lamp does not light up (sheet 7 of 11)
Figure 5-9 AC CIRCUIT INTERRUPTER ON lamp does not light up (sheet 8 of 77).
Figure 5-9 AC CIRCUIT INTERRUPTER ON lamp does not light up (sheet 9 of 17)
Figure 5-9 AC CIRCUIT INTERRUPTER ON lamp does not light up (sheet 10 of 11).
Figure 5-9 AC CIRCUIT INTERRUPTER ON lamp does not light up (sheet 11 of 11).
Figure 5-10 No line currents are flowing, or no line current indication (sheet 1 of 5).
Figure 5-10 No line currents are flowing, or no line current indication (sheet 2 of 5).
Figure 5-10 No line currents are flowing, or no line current indication (sheet 3 of 5).
Figure 5-10 No line currents are f/owing, or no line current indication (sheet 4 of 5).
Figure 5-10 No line currents are flowing, or no line current indication (sheet 5 of 5)
Figure 5-11 No power indication (sheet 1 of 2).
Figure 5-11 No power indication (sheet 2 of 2).
Figure 5-12 BATTERY CHARGING CONTROL lamp lights up during operation.
Figure S-13 OIL PRESSURE lamp lights up during operation.
Figure 5-14 OIL TEMP-CYLINDER HEAD lamp lights up during operation (sheet 1 of 3).
Figure 5-14 OIL TEMP-CYLINDER HEAD lamp lights up during operation (sheet 2 of 3).
Figure 5-14 OIL TEMP-CYLINDER HEAD lamps lights up during operation (sheet 3 of 3)
Figure 5-15 UNDER/OVER FREQUENCY lamp lights up during operation (sheet 1 of 6)
Figure 5-15 UNDER/OVER FREQUENCY lamp lights up during operation (sheet 2 of 6).
Figure 5-15 UNDER/OVER FREQUENCY lamp lights up during operation (sheet 3 of 6).
Figure 5-15 UNDER/OVER FREQUENCY lamp lights up during operation (sheet 4 of 6).
Figure 5-15 UNDER/OVER FREQUENCY lamp lights up during operation (sheet 5 of 6).
Figure 5-75 UNDER/OVER FREQUENCY lamp lights up during operation (sheet 6 of 6).
Figure 5-16 UNDER/OVER VOLTAGE lamp lights up during operation (sheet 1 of 6)
Figure 5-16 UNDER/OVER VOLTAGE lamp lights up during operation (sheet 2 of 6).
Figure 5-76 UNDER/OVER VOLTAGE iamp lights up during operation (sheet 3 of 6).
Figure 5-16 UNDER/OVER VOLTAGE lamp lights up during operation (sheet 4 of 6).
Figure 5-76 UNDER/OVER VOLTAGE lamp lights up during operation (sheet 5 of 6)
Figure 5-16 UNDER/OVER VOLTAGE lamp lights up during operation (sheet 6 of 6)
Figure 5-17 GENERATOR OVER TEMPERATURE lamp lights up during operation (sheet 1 of 4).
Figure S-17 GENERATOR OVER TEMPERATURE lamp lights up during operation (sheet 2 of 4).
Figure 5-l 7 GENERATOR OVER TEMPERATURE lamp lights up during operation (sheet 3 of 4).
Figure 5-17 GENERATOR OVER TEMPERATURE lamp lights up during operation (sheet 4 of 4)
Figure 5-18 OVERLOAD lamp lights up during operation (sheet 1 of 4).
Figure 5-18 OVERLOAD lamp lights up during operation (sheet 2 of 4).
Figure 5-18 OVERLOAD lamp lights up during operation (sheet 3 of 4).
Figure 5-18 OVERLOAD lamp lights up during operation (sheet 4 of 4).
Section III. MAINTENANCE PROCEDURES
Performed after any removal/Installation operation
5.6 AUXILIARY CONTACTOR WITH SEMICONDUCTOR DEVICE MAINTENANCE.
INSTALLATION - TM-9-6115-668-13_456
5.7 AUXILIARY CONTACTOR MAINTENANCE
INSTALLATION - TM-9-6115-668-13_458
Figure 5-19 Control Cabinet Assembly, Auxiliary Contactor with Semiconductor, Auxiliary Contactor, Transformer, Maintenance.
5.8 TIME RELAY K3, K10, K13, K17, K25, K26 MAINTENANCE
TESTING - TM-9-6115-668-13_461
ADJUSTMENT - TM-9-6115-668-13_462
Figure 5-20 Time Relays K3, K10, K13 and K26
Figure 5-21 Time Relay k17
Figure 5-22 Time Relay K25
5.9 POWER SUPPLY NT2 24 V MAINTENANCE.
Figure 5-23 Diodes, Time Relay, Power Supply Maintenance.
5.10 THERMISTOR RELAY F12 MAINTENANCE.
Figure 5-24 Control Cabinet Assembly, Circuit Breaker F1 to F11, Thermistor relay F12, True Power Measure Transformer P4A Maintenance
5.11 DIGITAL ISOCHRONOUS LOAD SHARING MODULE N4 MAINTENANCE
ADJUSTMENT
Figure 5-25 Digital lsochronous Load Sharing Module N4, Location of Potentiometers and Test Points.
5.12 RELAY K19 AND K20 WITH RELAY SOCKET AND CONTACT BUSHINGS MAINTENANCE.
INSTALLATION - TM-9-6115-668-13_474
5.13 SPEED GOVERNOR ASSEMBLY N1 MAINTENANCE.
ADJUSTMENT - TM-9-6115-668-13_476
Figure 5-26 Speed Governor Assembly N1, Location of Potentiometers.
Figure 5-27 Control Cabinet Assembly, Relays K19, K20, Digital lsochronous Load Sharing Module N4, Speed Governor Assembly N1, Resistor Maintenance
5.14 VOLTAGE REGULATOR N2 MAINTENANCE.
REPAIR - TM-9-6115-668-13_480
Figure 5-28 Voltage Regulator N2, Location of Circuit Boards and Potentiometers.
INSTALLATION - TM-9-6115-668-13_482
Figure 5-29 Control Cabinet Assembly Voltage Regulator N2 Maintenance
5.15 SAFETY DEVICE N3 MAINTENANCE
REPAIR - TM-9-6115-668-13_485
k. Check trip times
Figure 5-30 Voltage Regulator N2, Location of Circuit Boards and Potentiometers.
To adjust reverse power for Generator Set
2. r. Adjust reverse power for Generator Set 150 kW No. 2: On Generator Set 150 kW No. 1, turn FREQUENCY ADJUST potentiometer (R4) clockwise until KILOWATTS meter (P4) displays 30 kW. Lock control knob with lever. On Generator Set 150 kW No. 2, turn PRmax potentiometer counterclockwise, until indicator REVERSE POWER ON (H11) lights up. Contactor K1 de-energizes and AC CIRCUIT INTER- RUPTER indicator ON (H14) goes out. Press REVERSE POWER (S22) illuminated pushbutton switch: REVERSE POWER indicator goes out. On Generator Set 150 kW No. 1, use FREQUENCY ADJUST potentiometer (R4) to set a fre- quency of 399.8 Hz or 400.2 Hz on FREQUENCY meter (P5). Lock control knob with lever. On Generator Set 150 kW No. 2, press PARALLEL OPERATION ON illuminated pushbutton switch (S9). PARALLEL OPERATION ON indicator (H12) lights up during automatic synchro- nization of Generator Set 150 kW No. 1 and Generator Set 150 kW No. 2. Adjust Voltage/Frequency Error Detection TT1314-./01
f. Adjust undervoltage
j. Adjust underfrequency
INSTALLATION - TM-9-6115-668-13_492
Figure 5-31 Control Cabinet Assembly, Safety Device N3 Maintenance
5.16 FILTER BOX FK MAINTENANCE.
INSTALLATION - TM-9-6115-668-13_495
5.17 CURRENT TRANSFORMER MAINTENANCE
INSTALLATION - TM-9-6115-668-13_497
Installation procedure for current transformer
Figure 5-32 Control Cabinet Assembly, Filter Box FK, Current Transformers, Resistors Maintenance
5.18 AUXILIARY CONTACTOR K109 MAINTENANCE.
5.19 DIODE MAINTENANCE.
INSTALLATION - TM-9-6115-668-13_502
5.20 TIME RELAY MAINTENANCE.
TESTING - TM-9-6115-668-13_504
ADJUSTMENT - TM-9-6115-668-13_505
Figure 5-34 Time Relay K107
Figure 5-35 Time Relay K108
5.21 POWER SUPPLY NT2 24 V~ MAINTENANCE.
Figure 5-36 Time Relay K110
Figure 5-37 Control Cabinet Assembly, Engine Preheating Control Board, Auxiliary Contactor K109, Diodes, Time Relay Maintenance.
5.22 MINIATURE RELAY MAINTENANCE.
INSTALLATION - TM-9-6115-668-13_512
5.23 POWER RELAY K101, K102 MAINTENANCE.XXP
INSTALLATION - TM-9-6115-668-13_514
Figure 5-38 Miniature Relay, Power Relay Maintenance.
5.24 CONNECTOR RECEPTACLE L1 TO L3 AND N MAINTENANCE.
INSTALLATION - TM-9-6115-668-13_517
5.25 INTERLOCK SWlTCH MAINTENANCE.
INSTALLATION - TM-9-6115-668-13_519
Figure 5-39 Control Cabinet Assembly, Connection Panel, Connector Receptacle L1 to L3 and N, lnterlock Switch Maintenance
5.26 J3 SLAVE RECEPTACLE 24 VOLTS CONNECTOR MAINTENANCE
INSTALLATION - TM-9-6115-668-13_522
5.27 AIR FILTER HOUSING AND PIPING MAINTENANCE.
INSTALLATION - TM-9-6115-668-13_524
Figure 5-40 Air filter Assembly, J30 slave receptacle 24 V Connector Maintenance.
5.28 SUBCURRENT FILTER ASSEMBLY MAINTENANCE.
INSTALLATION - TM-9-6115-668-13_527
5.29 SUBCURRENT FILTER OIL LINES MAINTENANCE.
INSTALLATION - TM-9-6115-668-13_529
Figure 5-41 Subcurrent Filter Assembly, Oil Lines Maintenance.
5.30 FLAME GLOWPLUG SYSTEM MAINTENANCE
TEST - TM-9-6115-668-13_532
INSTALLATION - TM-9-6115-668-13_533
Figure 5-42 Flame Glowplug System Maintenance
5.31 ENGINE PREHEATING ASSEMBLY MAINTENANCE.
TEST - TM-9-6115-668-13_536
Figure 5-43 Preheating Assembly Maintenance.
5.32 BURNER MONITORING TEMPERATURE SWlTCH MAINTENANCE.
5.33 GLOWPLUG MAINTENANCE
5.34 OVERTEMPERATURE SWITCH MAINTENANCE
Figure 5-44 Temperature Switch, Glowplug Maintenance.
5.35 PREHEATlNG ASSEMBLY CABLE
INSTALLATION - TM-9-6115-668-13_543
Figure 5-45 Preheating Cable Assembly Maintenance.
5.36 AIR FLAP PULLER MAGNET MAINTENANCE.
5.37 ELECTRIC OIL PUMP MAINTENANCE
INSTALLATION - TM-9-6115-668-13_547
5.38 AIR-OIL HEAT EXCHANGER MAINTENANCE.
INSTALLATION - TM-9-6115-668-13_549
Figure 5-46 Air Flap Puller magnet, Electric Oil Pump, Air- Oil heat Exchanger Maintenance.
5.39 OIL HOSE MAINTENANCE.
INSTALLATION - TM-9-6115-668-13_552
5.40 OIL TEMPERATURE SWITCH MAINTENANCE.
INSTALLATION - TM-9-6115-668-13_554
Figure 5-47 Oil Hose, Oil Temperature Switch Maintenance
5.41 ACTUATOR ASSEMBLY MAINTENANCE.
INSTALLATION - TM-9-6115-668-13_557
Figure 5-48 Actuator Maintenance.
5.42 ACTUATOR CABLE MAINTENANCE.
INSTALLATION - TM-9-6115-668-13_560
5.43 ACTUATOR CABLE MAINTENANCE.
INSTALLATION - TM-9-6115-668-13_562
5.44 PICK-UP CABLE MAINTENANCE.
INSTALLATION - TM-9-6115-668-13_564
Figure 5-49 Actuator Cable, Pick-up Cable Maintenance.
5.45 EHG TEMPERATURE SENSOR MAINTENANCE.
INSTALLATION - TM-9-6115-668-13_567
Figure 5-50 EHG and Cylinder Head Temperature Sensor Maintenance
5.46 GENERATOR WIRING HARNESS MAINTENANCE
INSTALLATION - TM-9-6115-668-13_570
Figure 5-51 Generator Wiring Harness Maintenance.
5.47 DIESEL ENGINE AND SYNCHRONOUS GENERATOR MAINTENANCE.
REMOVAL - TM-9-6115-668-13_573
INSTALLATION - TM-9-6115-668-13_574
8. Remove long eyebolt
5.48 DIESEL ENGINE SHOCK ABSORBERS MAINTENANCE.
INSTALLATION - TM-9-6115-668-13_577
5.49 SYNCHRONOUS GENERATOR SHOCK ABSORBERS MAINTENANCE.
REMOVAL - TM-9-6115-668-13_579
For easier positioning of components
Figure 5-52 Diesel Engine and Synchronous Generator Maintenance (Sheet 1 of 2).
Figure 5-52 Diesel Engine and Synchronous Generator Maintenance (Sheet 2 of 2).
5.50 DIESEL ENGINE MAINTENANCE
3. Remove generator wiring harness
INSTALLATION - TM-9-6115-668-13_585
Figure 5-53 Diesel Engine Maintenance (Sheet 1 of 2)
Figure 5-53 Diesel Engine Maintenance (Shett 2 of 2).
5.51 SYNCHRONOUS GENERATOR MAINTENANCE
INSTALLATION - TM-9-6115-668-13_589
Figure 5-54 Synchronous Generator Maintenance.
5.52 CLUTCH ASSEMBLY MAINTENANCE.
INSTALLATION - TM-9-6115-668-13_592
Figure 5-55 Clutch Assembly Maintenance
5.53 LOAD BANK PROCEDURES (AVTRON 150 kW RESISTIVE).
2. Start generator set.
SHUTDOWN PROCEDURE
5.54 CHECKING AND ADJUSTING VALVES.
INSTALLATION - TM-9-6115-668-13_598
Figure 5-57 -- Figure 5-60
5.55 Cooling Blower Assembly Maintenance.
Figure 5-61. Cooling Blower Assembly
APPENDIX A R E F E R E N C E S
A.7 TECHNICAL MANUALS
APPENDIX B MAINTENANCE ALLOCATION CHART
B.3 EXPLANATION OF COLUMNS IN THE MAC
B.4 EXPLANATION OF COLUMNS IN TOOL AND TEST EQUIPMENT REQUIREMENT
Section II, MAINTENANCE ALLOCATION CHART (MAC) FOR GEN SET 150 KW
COMPONENT/ASSEMBLY - TM-9-6115-668-13_608
COMPONENT/ASSEMBLY - TM-9-6115-668-13_609
COMPONENT/ASSEMBLY - TM-9-6115-668-13_610
COMPONENT/ASSEMBLY - TM-9-6115-668-13_611
COMPONENT/ASSEMBLY - TM-9-6115-668-13_612
COMPONENT/ASSEMBLY - TM-9-6115-668-13_613
COMPONENT/ASSEMBLY - TM-9-6115-668-13_614
COMPONENT/ASSEMBLY - TM-9-6115-668-13_615
COMPONENT/ASSEMBLY - TM-9-6115-668-13_616
Section III, Tool and Test Equipment Requirements FOR GEN SET 150 KW
Section IV, REMARKS FOR GEN SET 150 KW
APPENDIX C COMPONENTS OF END ITEM (COEI) AND BASIC ISSUE ITEMS (BII) LISTS
Section II. COMPONENTS OF END ITEM - TM-9-6115-668-13_620
Section Ill. BASIC ISSUE ITEMS
APPENDIX D ADDITIONAL AUTHORIZATION LIST - TM-9-6115-668-13_622
Section II. ADDITIONAL AUTHORIZED ITEMS LIST
APPENDIX E EXPENDABLE AND DURABLE ITEMS LIST - TM-9-6115-668-13_624
Section II. EXPENDABLE AND DURABLE ITEMS LIST
APPENDIX F OPERATORS LUBRICATION INSTRUCTIONS
APPENDIX G TORQUE LIMITS - TM-9-6115-668-13_627
GLOSSARY - TM-9-6115-668-13_628
Section II. DEFINITION OF UNUSUAL TERMS
FO-1. Generator Set 150kW Wiring Diagram (sheet 1 of 11)
FO-1. Generator Set 150kW Wiring Diagram (sheet 2 of 11)
FO-1. Generator Set 150kW Wiring Diagram (sheet 3 of 11)
FO-1. Generator Set 150kW Wiring Diagram (sheet 4 of 11)
FO-1. Generator Set 150kW Wiring Diagram (sheet 5 of 11)
FO-1. Generator Set 150kW Wiring Diagram (sheet 6 of 11)
FO-1. Generator Set 150kW Wiring Diagram (sheet 7 of 11)
FO-1. Generator Set 150kW Wiring Diagram (sheet 8 of 11)
FO-1. Generator Set 150kW Wiring Diagram (sheet 9 of 11)
FO-1. Generator Set 150kW Wiring Diagram (sheet 10 of 11)
FO-1. Generator Set 150kW Wiring Diagram (sheet 11 of 11)
FO-2. Engine Preheating Assembly Wiring Diagram (sheet 1 of 2)
FO-2. Engine Preheating Assembly Wiring Diagram (sheet 2 of 2)
The Metric System and Equivalents
Figure 1-1 Generator Set 150 kW.
Table 1-1 Nomenclature Cross-Reference List.
Section II. EQUIPMENT DESCRIPTION
Table 1-2 Description of Major Components, Generator Set 150 kW
1.11 CONSTRUCTION
1.11.3 Generator Compartment.
The tank has a filler tube
Figure 1-2 Generator Set 150 kW, Location of Major Components.
1.12 EQUIPMENT DATA.
Table 1-3 Tabulated Data for Generator Set 150 kW (continued).
Tabulated Data for Generator Set 150 kW (continued).
Figure 1-3 Generator Set 150 kW, Dimensions.
Section III. PRINCIPLES OF OPERATION
1.13.3 Maintenance Free Battery Set Assembly.
Figure 1-4 Generator Set 150 kW, Block Diagram.
1.14 FUNCTIONAL DESCRIPTION.
1.14.1.3 Time t approximately 2.8 minutes
Manual Shutdown
OIL PRESSURE indicator lamp
1.14.2.3 Voltages Present at Control Cabinet Assembly Receptacles.
1.14.3 BATTLE SHORT Mode.
1.14.3.2 Emergency Shutdown.
Table 1-5 J9 PARALLEL OPERATION Receptacle, Monitoring and Control Functions
J9 PARALLEL OPERATION Receptacle, Monitoring and Control Functions (continued).
CHAPTER 2 OPERATING INSTRUCTIONS
Section I. DESCRIPTION AND USE OF CONTROLS AND INDICATORS
Table 2-1 Control Cabinet Assembly, Description of Controls and Indicators.
Control Cabinet Assembly, Description of Controls and Indicators (continued). - TM-9-6115-668-13_59
Control Cabinet Assembly, Description of Controls and indicators (continued). - TM-9-6115-668-13_60
Control Cabinet Assembly, Description of Controls and indicators (continued).
Figure 2-2 Control Cabinet Assembly, Circuit Breakers (sheet 1 of 2)
Figure 2-2 Control Cabinet Assembly, Circuit Breakers (sheet 2 of 2).
Table 2-2 Control Cabinet Assembly Description of Circuit Breakers
2.1.3 Receptacles
Figure 2-4 Base Frame Assembly, J3 SLAVE RECEPTACLE 24 VOLTS
Section II. OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SER- VICES (PMCS)
2.2.4 Special Instructions
2.2.5 Leakage Definitions.
Figure 2-5 Operator PMCS Routing Diagram (sheet 1 of 6).
Figure 2-5 Operator PMCS Routing Diagram (sheet 2 of 6).
Figure 2-6 Operator PMCS Routing Diagram (sheet 3 of 6).
Figure 2-4 Operator PMCS Routing Diagram Tm (sheet 4 of 6).
Figure 2-5 Operator PMCS Routing Diagram (sheet 5 of 6).
Figure 2-5 Operator PMCS Routing Diagram (sheet 6 of 6).
Table 24 Operator Preventive Maintenance Checks and Services.
Operator Preventive Maintenance Checks and Services-continued. - TM-9-6115-668-13_77
Operator Preventive Maintenance Checks and Services-continued. - TM-9-6115-668-13_78
Operator Preventive Maintenance Checks and Services-continued. - TM-9-6115-668-13_79
Operator Preventive Maintenance Checks and Services-continued. - TM-9-6115-668-13_80
Operator Preventive Maintenance Checks and Services-continued. - TM-9-6115-668-13_81
Operator Preventive Maintenance Checks and Services-continued. - TM-9-6115-668-13_82
Operator Preventive Maintenance Checks and Services-continued. - TM-9-6115-668-13_83
Operator Preventive Maintenance Checks and Services-continued. - TM-9-6115-668-13_84
Operator Preventive Maintenance Checks and Services-continued. - TM-9-6115-668-13_85
Operator Preventive Maintenance Checks and Services-continued. - TM-9-6115-668-13_86
Section III. OPERATION UNDER USUAL CONDITIONS - TM-9-6115-668-13_87
Figure 2-6 Control Cabinet Assembly Lamp Test.
2.3.2.3 Replace Diesel Engine Oil.
2.3.2.4 Check Diesel Engine Oil Level after Engine Shutdown.
2.3.2.5 Check Diesel Engine Oil Level before starting engine.
Figure 2-7 Diesel Engine Oil Removal Maintenance
Figure 2-8 Diesel Engine oil Level Maintenance.
Table 2-5 SHPD Oils Approved for Diesel Engine BF8L513.
Figure 2-9 Viscosity Class (SAE C/ass).
Table 2-6 Oil change intervals
2.3.4.2.1 Refueling with the Fuel Pump
Figure 2-10 Refueling.
Figure 2-11 Connect Battery Cable
2.3.6 Connecting Control and Power Cables
Figure 2-12 Connecting Control and Power Cables
2.4 DECALS AND INSTRUCTION PLATES
Figure 2-16 Engine Preheating Plate.
Figure 2-17 Generator Set 150 kW Short Operating Instructions Plate (sheet 1 of 2).
Figure 2-17 Generator Set 150 kW Short Instructions P/ate (sheet 2 of 2).
2.5 OPERATING PROCEDURES
2.5.1.2 Switching Voltage to the Control Cabinet Assembly Receptacles
MASTER SWITCH
Figure 2-18 Operating the Generator Set 150 kW.
2.5.2.1 Normal Shutdown
2.6 EMERGENCY PROCEDURES
Figure 2-20 BATTLE SHORT Mode.
2.7 PREPARATION FOR MOVEMENT
Figure 2-21 Disconnecting Control and Power Cables
Figure 2-22 Disconnect Battery Cable.
Section IV. OPERATION UNDER UNUSUAL CONDITIONS
Figure 2-24 Operating the Engine Preheating Assembly
2.9 OPERATING THE FLAME GLOWPLUG SYSTEM (BELOW 32 F (0 C))
Figure 2-25 Operating the Flame Glowplug System
2.10 OPERATION IN EXTREME COLD (BELOW -22 F (-30 C))
Figure 2-26 Fuel Infection Pump Actuator Linkage
CHAPTER 3 OPERATOR MAINTENANCE INSTRUCTIONS
Section I. OPERATOR LUBRICATION
Section II. TROUBLESHOOTING - TM-9-6115-668-13_124
Figure 3-1 BATTERY CHARGING CONTROL and OIL PRESSURE lamps do not light up
Figure 3-2 HEATING FAILURE lamp lights up or READY TO START IF HEATING IS ON lamp does not light up
Figure 3-3 GLOWPLUG ON lamp does not light up
Figure 3-4 Oil pressure too low, or no oil pressure indication
Figure 3-5 Generator frequency cannot be adjusted, or no frequency indication
Figure 3-6 Generator voltage cannot be adjusted, or no voltage indication.
Figure 3-7 AC CIRCUIT INTERRUPTER ON lamp does not light up.
Section III. MAINTENANCE PROCEDURES
3.4 AIR FILTER DUST COLLECTOR MAINTENANCE
Figure 3-8 Air Filter Assembly Maintenance.
CHAPTER 4 UNIT MAINTENANCE INSTRUCTIONS
Subject Index - TM-9-6115-668-13_136
Subject Index - TM-9-6115-668-13_137
Subject Index - TM-9-6115-668-13_138
Section I. REPAIR PARTS; TOOLS; SPECIAL TOOLS; TEST, MEASUREMENT AND DIAGNOSTIC EQUIPMENT (TMDE); AND SUPPORT EQUIPMENT - TM-9-6115-668-13_139
Section II. SERVICE UPON RECEIPT OF EQUIPMENT
4.4.2 Unpacking Equipment.
4.4.3 Checking Unpacked Generator Set 150 kW
Figure 4-1 Original Packaging in Container.
Figure 4-2 Unpacking the Container.
Figure 4-3 Generator Set 150 kW, Unpacked.
4.5 INSTALLATION INSTRUCTIONS
4.6.3 Lubricating Oil.
Section III. Unit Lubrication
Section IV. UNIT PREVENTIVE MAINTENANCE CHECKS AND SERVICES
Dry cleaning solvent
Figure 4-5. Unit PMCS Routing Diagram.
Table 4-3. Unit Preventive Maintenance Checks and Services for Generator Set 150 kW.
Unit Preventive Maintenance Checks and Services for Generator Set 150 kW-continued
Section V. TROUBLESHOOTING - TM-9-6115-668-13_154
SYMPTOM INDEX - TM-9-6115-668-13_155
Figure 4-6 BATTERY CHARGING CONTROL and OIL PRESSURE lamps do not light up.
Figure 4-7 HEATING FAILURE lamp lights up or READY TO START IF HEATING IS ON lamp does not light up
Figure 4-8 GLOWPLUG ON lamp does not light up.
Figure 4-9 Diesel engine cannot be started
Figure 4-10 Oil pressure too low, or no oil pressure indication.
Figure 4-11 Battery set is not being charged, or no charging current indication.
Figure 4-12 Generator frequency cannot be adjusted, or no frequency indication.
Figure 4-13 Generator voltage cannot be adjusted, or no voltage indication
Figure 4-14 AC CIRCUIT INTERRUPTER ON lamp does not light up.
Figure 4-15 No line currents are flowing, or no line current indication.
Figure 4-16 No power indication
Figure 4-17 BATTERY CHARGING CONTROL lamp lights up during operation.
Figure 4-18 OIL PRESSURE lamp lights up during operation.
Figure 4-19 OIL TEMP-CYLINDER HEAD lamp lights up during operation.
Figure 4-20 UNDER/OVER FREQUENCY lamp lights up during operation.
Figure 4-21 UNDER/OVER VOLTAGE lamp lights up during operation.
Figure 4-22 GENERATOR OVER TEMPERATURE lamp lights up during operation.
Figure 4-23 OVERLOAD lamp lights up during operation.
Section VI. RADIO INTERFERENCE SUPPRESSION
SECTION VII. MAINTENANCE PROCEDURES
Removal/ Installation operation
4.13 UNIT HOOD FLAP GROUND STRAP MAINTENANCE
Figure 4-24 Unit Hood Flap Ground Strap Maintenance.
4.14 UNIT HOOD ASSEMBLY MAINTENANCE.
INSTALLATION - TM-9-6115-668-13_180
Figure 4-25. Unit Hood Assembly Maintenance
4.15 UNlT HOOD-BASE FRAME GROUND STRAP MAINTENANCE.
Figure 4-26 Unit Hood-Base Frame Ground Strap Maintenance.
4.16 SUPPLY AIR DUCT MAINTENANCE
4.17 AIR LEADING DUCT MAINTENANCE
4.18 AIR COOLING INLET GRATE MAINTENANCE
4.19 COVER AND CASE FOR CONNECTION PANEL MAINTENANCE
Figure 4-27 Unit Hood Assembly Air Ducts and Air Cooling Inlet Grate Maintenance
4.20 TWIST GRIP AND LOCK MAINTENANCE
4.21 GAS-CYLINDER AND PROP MAINTENANCE.
4.22 FLAP MOUNT MAINTENANCE.
Figure 4-28 Unit Hood Flap Maintenance.
4.23 LIGHT INDICATOR ASSEMBLY MAINTENANCE
INSTALLATION - TM-9-6115-668-13_194
Figure 4-29 Control Cabinet Assembly, Light Indicator Assembly Maintenance
4.24 BULB IN INDICATOR LAMP MAINTENANCE
Figure 4-30 Bulb in Indicator Lamps Maintenance.
4.25 BULB IN ILLUMINATED SWITCH MAINTENANCE
Figure 4-31 Bulb in Illuminated Switch Maintenance
4.26 REPLACE BULB IN PANEL LIGHT H6
Figure 4-32 Panel Light H6 Maintenance
4.27 REPLACE BULB IN ILLUMINATED METER.
Figure 4-33 Illuminated Meter Maintenance.
4.28 REPLACE BULB IN CABINET LIGHT H7.
Figure 4-34 Cabinet Light Maintenance.
4.29 AIR FILTER CARTRIDGE MAINTENANCE
INSTALLATION - TM-9-6115-668-13_207
Figure 4-35. Air Filter Cartridge Maintenance
4.30 OIL FILTER MAINTENANCE
4.31 SUBCURRENT FILTER CARTRIDGE MAINTENANCE
Figure 4-36. Oil Filter, Subcurrent Filter Maintenance
4.32 FUEL PREFILTER CARTRIDGE MAINTENANCE
INSTALLATION - TM-9-6115-668-13_213
4.33 TWO STEP FUEL FILTER CARTRIDGE MAINTENANCE
INSTALLATION - TM-9-6115-668-13_215
Figure 4-37 Fuel Prefilter Cartridge, Two Step Fuel Filter Cartridges Maintenance.
4.34 BATTERY CHARGING ALTERNATOR V BELT
4.35 BATTERY CHARGING ALTERNATOR V BELT MAINTENANCE
Bleed screws
Figure 4-38. Battery Charging AIternator of V Belt Malntenance.
4.36 DIESEL ENGINE CYLINDER COOLING FINS AND OIL COOLER MAINTENANCE
Figure 4-39 Diesel Engine Cylinder Cooling Fins and Oil Cooler Maintenance
4.37 PRIMING PUMP MAINTENANCE
Figure 4-40. Priming Pump Assembly Maintenance.
4.38 FUEL LINES AND PREFILTER ASSEMBLY MAINTENANCE
4.39 FUEL LINES AND TWO STEP FUEL FILTER ASSEMBLY MAINTENANCE
Figure 4-41 Diesel Engine Fuel Pipes and Fuel Filter Assembly Maintenance
4.40 FUEL PREFILTER ASSEMBLY MAINTENANCE
INSTALLATION - TM-9-6115-668-13_229
4.41 TWO STEP FUEL FILTER ASSEMBLY MAINTENANCE.
INSTALLATION - TM-9-6115-668-13_231
Figure 4-42. Fuel Prefilter, Two Step Fuel Filter Maintenance
4.42 FUEL LINE ASSEMBLY MAINTENANCE.
7. Fuel supply line
INSTALLATION - TM-9-6115-668-13_235
6. Fuel line
Figure 4-43. Fuel Line Assembly Maintenance
4.43 CONTROL CABINET ASSEMBLY MAINTENANCE
6. Record labeling and position of cables
Contact with filter box FK
Figure 4-44 Control Cabinet Assembly Maintenance (Sheet 1 of 2)
Figure 4-44 Control Cabinet Assembly Maintenance (Sheet 2 of 2)
INSTALLATION - TM-9-6115-668-13_243
21. Place cover
4.44 PUSHBUTTON SWITCH AND INDICATOR ASSEMBLY MAINTENANCE
INSTALLATION - TM-9-6115-668-13_246
Figure 4-45 Control Cabinet Assembly, Pushbutton Switch and Indicator Assembly Maintenance.
4.45 PUSHBUTTON SWITCH MAINTENANCE.
INSTALLATION - TM-9-6115-668-13_249
Figure 4-46 Control Cabinet Assembly, Pushbutton Switch Maintenance.
4.46 PANEL ILLUMINATION H6 MAINTENANCE.
Figure 4-47 Control Cabinet Assembly, Panel Illumination H6 Maintenance.
4.47 PREHEATING RESISTOR R1 MAINTENANCE
INSTALLATION - TM-9-6115-668-13_254
4.48 BATTLE SHORT SWITCH S21 MAINTENANCE
5. Connect cable
4.49 VOLTAGE SELECTOR SWITCH S11 MAINTENANCE
INSTALLATION - TM-9-6115-668-13_258
4.50 GLOWPLUG/START SWITCH S2 MAINTENANCE.
4.51 MASTER SWITCH S1 MAINTENANCE
Figure 4-48 Control Cabinet Assembly, Preheating Resistor R1, BATTLE SHORT Switch S21, VOLTAGE SELECTOR SWITCH S11 GLOWPLUG/START Switch S2, MASTER SWITCH S1 Maintenance
4.52 FREQUENCY ADJUST R4 MAINTENANCE
INSTALLATION - TM-9-6115-668-13_263
4.53 VOLTAGE ADJUST R3 MAINTENANCE
INSTALLATION - TM-9-6115-668-13_265
4.54 PANEL DIMMER S16/R2 MAINTENANCE
INSTALLATION - TM-9-6115-668-13_267
Figure 4-49 Control Cabinet Assembly, FREQUENCY ADJUST R4, VOLTAGE ADJUST R3, PANEL DIMMER S16/R2 Maintenance.
4.55 FREQUENCY METER P5 MAINTENANCE
4. Install cover panel
4.56 METER MAINTENANCE.
INSTALLATION - TM-9-6115-668-13_272
Figure 4-50 Control Cabinet Assembly, Meter Maintenance
4.57 CABINET ILLUMINATION H7 MAINTENANCE.
4.58 DOOR CONTACT SWITCH S3 MAINTENANCE.
4.59 BRIGHTNESS CONTROL N5 MAINTENANCE.
Figure 4-51 Control Cabinet Assembly, Cabinet Illumination H7, Door Contact Switch S3, Brightness Control N5 Maintenance.
4.60 LIGHT INDICATOR ASSEMBLY MAINTENANCE.
INSTALLATION - TM-9-6115-668-13_279
Figure 4-52 Control Cabinet Assembly, Auxiliary Contactor with Semiconductor, Auxiliary Contactor, Transformer Maintenance
4.61 DIODE MAINTENANCE.
INSTALLATION - TM-9-6115-668-13_282
4.62 DIODE V3 MAINTENANCE
INSTALLATION - TM-9-6115-668-13_284
Figure 4-53 Diodes, Time Relay, Power Supply Maintenance
4.63 CIRCUIT BREAKER MAINTENANCE.
INSTALLATION - TM-9-6115-668-13_287
4. Close cable conduit
4.64 TRUE POWER MEASURING TRANSFORMER P4A MAINTENANCE.
INSTALLATION - TM-9-6115-668-13_290
Figure 4-54 Control Cabinet Assembly, Circuit Breaker F1 to F11, Thermistor relay F12, True Power Measuring Transformer P4A Maintenance
4.65 RESISTOR R100 TO R102 MAINTENANCE
INSTALLATION - TM-9-6115-668-13_293
Figure 4-55 Control Cabinet Assembly, Relays K19, K20, Digital lsochronous Load Sharing Module N4, Speed Governor Assembly N1, Resistor Maintenance.
4.66 CONTACTOR K1 MAINTENANCE.
REPAIR - TM-9-6115-668-13_296
6. Install six serrated lock washers
Figure 4-56 Control Cabinet Assembly, Contactor K1 Maintenance.
4.67 ENGINE PREHEATING CONTROL BOARD MAINTENANCE.
INSTALLATION - TM-9-6115-668-13_300
4.68 CIRCUIT BREAKER MAINTENANCE
INSTALLATION - TM-9-6115-668-13_302
2. Circuit breaker assembly F102
Figure 4-57 Control Cabinet Assembly, Engine Preheating Control Board, Circuit Breaker Maintenance.
4.69 CONNECTOR J9 MAINTENANCE.
INSTALLATION - TM-9-6115-668-13_306
4.70 J1/120 V 400 HZ DOUBLE CONNECTOR RECEPTACLE MAINTENANCE
INSTALLATION - TM-9-6115-668-13_308
4.71 J2/24 V CONNECTOR RECEPTACLE MAINTENANCE.
INSTALLATION - TM-9-6115-668-13_310
Figure 4-58 Control Cabinet Assembly, Connection Panel, Connector Maintenance.
4.72 SERVICE SWITCH MAINTENANCE.
Figure 4-59. Air Filter Assembly, J3 Slave Receptacle 24 V Connector Maintenance
4.73 SHUNT R11 MAINTENANCE
4.74 BATTERY SET MAINTENANCE.
TEST - TM-9-6115-668-13_316
7. Install terminal connector of battery cable
4.75 BATTERY CHARGING ALTERNATOR REGULATOR N6 MAINTENANCE.
4.76 EHG REGULATOR N7 MAINTENANCE.
Figure 4-60. Shunt Resistor R11, EHG Regulator N7, Generator Regulator N6, Battery Set Maintenance
4.77 FUEL TANK MAINTENANCE.
REMOVAL - TM-9-6115-668-13_322
INSTALLATION - TM-9-6115-668-13_323
Hylomar
4.78 ELECTRICAL FUEL PUMP ASSEMBLY MAINTENANCE.
Figure 4-61. Fuel Tank Assembly, Electrical Fuel Pump Maintenance.
4.79 UPPER FUEL LEVEL SWITCH MAINTENANCE.
INSTALLATION - TM-9-6115-668-13_328
4.80 LOWER FUEL LEVEL SWITCH MAINTENANCE.
INSTALLATION - TM-9-6115-668-13_330
4.81 FUEL LEVEL SENSOR 2R4 MAINTENANCE.
2. Noting correct labeling and position, install cable
Figure 4-62. Fuel level Switch and Sensor Maintenance.
4.82 SILENCER ASSEMBLY, LEFT SIDE MAINTENANCE.
4. Remove connector pipes and brackets - TM-9-6115-668-13_335
INSTALLATION - TM-9-6115-668-13_336
f . Align exhaust pipe with header
Figure 4-63. Silencer Assembly, Left Side Maintenance
4.83 SILENCER ASSEMBLY, RIGHT SIDE MAINTENANCE
4. Remove connector pipes and brackets - TM-9-6115-668-13_340
INSTALLATION - TM-9-6115-668-13_341
5. Install unit hood assembly
Figure 4-64. Silencer Assembly, Right Side Maintenance
INSTALLATION - TM-9-6115-668-13_344
2. Insert new sealing ring
4.85 OIL OUTLET PIPE ASSEMBLY MAINTENANCE.
4.86 OIL LINE ASSEMBLY MAINTENANCE.
4.87 OIL PRESSURE SWITCH 1S2 AND OIL PRESSURE SENSOR 1R2 MAINTENANCE.
4.88 OIL TEMPERATURE SWITCH 1S3 AND OIL TEMPERATURE SENSOR 1R3 MAINTENANCE.
2. Install oil temperature switch
Figure 4-65. Scavenge Pump Assembly, Oil Outlet Pipe Oil Pressure Switch 1S2 and Oil Pressure Sensor 1R2, Oil Temperature Switch 1S3 and Oil Temperature Sensor 1R3 Maintenance
4.89 BATTERY CHARGING ALTERNATOR MAINTENANCE
TEST - TM-9-6115-668-13_353
3. Noting correct labeling and position
Figure 4-66. Battery Charging Alternator Maintenance.
4.90 STARTER MAINTENANCE
INSTALLATION - TM-9-6115-668-13_357
Figure 4-67. Generator, Starter Maintenance.
CHAPTER 5 DIRECT SUPPORT MAINTENANCE INSTRUCTIONS
Subject Index
Section I. REPAIR PARTS; TOOLS; SPECIAL TOOLS; TEST, MEASUREMENT AND DIAGNOSTIC EQUIPMENT (TMDE); AND SUPPORT EQUIPMENT - TM-9-6115-668-13_361
Section II. TROUBLESHOOTING - TM-9-6115-668-13_362
24 VDC operating voltage
SYMPTOM INDEX - TM-9-6115-668-13_364
Figure 5-1 BATTERY CHARGING CONTROL and OIL PRESSURE lamps do not light up (sheet 1 of 7).
Figure 5-1 BATTERY CHARGING CONTROL and OIL PRESSURE lamps do not light up (sheet 2 of 7)
Figure 5-1 BATTERY CHARGING CONTROL and OIL PRESSURE lamps do not light up (sheet 3 of 7).
Figure 5-1 BATTERY CHARGING CONTROL and OIL PRESSURE lamps do not light up (sheet 4 of 7).
Figure 5-1 BATTERY CHARGING CONTROL and OIL PRESSURE lamps do not light up (sheet 5 of 7).
Figure 5-1 BATTERY CHARGING CONTROL and OIL PRESSURE lamps do not light up (sheet 6 of 7).
Figure 5-1 BATTERY CHARGING CONTROL and OIL PRESSURE lamps do not light up (sheet 7 of 7).
Figure 5-2 HEATING FAILURE lamp lights up or READY TO START IF HEATING IS ON lamp does not light up (sheet 1 of 7).
Figure 5-2 HEATING FAILURE lamp lights up or READY TO START IF HEATING IS ON lamp does not light up (sheet 2 of 7)
Figure 5-2 HEATING FAILURE lamp lights up or READY TO START IF HEATING IS ON lamp does notlight up (sheet 3 of 7).
Figure 5-2 HEATING FAILURE lamp lights up or READY TO START IF HEATING IS ON lamp does not light up (sheet 4 of 7).
Figure 5-2 HEATING FAILURE lamp lights up or READY TO START IF HEATING IS ON lamp does not light up (sheet 5 of 7).
Figure 5-2 HEATING FAILURE lamp lights up or READY TO START IF HEATING IS ON lamp does not light up (sheet 6 of 7).
Figure 5-2 HEATING FAILURE lamp lights up or READY TO START IF HEATING IS ON lamp does not light up (sheet 7 of 7).
Figure 5-3 GLOWPLUG ON lamp does not light up (sheet 1 of 4).
Figure 5-3 GLOWPLUG ON lamp does not light up (sheet 2 of 4).
Figure 5-3 GLOWPLUG ON lamp does not light up (sheet 3 of 4).
Figure 5-3 GLOWPLUG ON lamp does not Iight up (sheet 4 of 4).
Figure 5-4 Diesel engine cannot be started (sheet 1 of 10).
Figure 5-4 Diesel engine cannot be started (sheet 2 of 10).
Figure 5-4 Diesel engine cannot be started (sheet 3 of 10).
Figure 5-4 Diesel engine cannot be started (sheet 4 of 10).
Figure 5-4 Diesel engine cannot be started (sheet 5 of 10).
Figure 5-4 Diesel engine cannot be started (sheet 6 of 10).
Figure 5-4 Diesel engine cannot be started (sheet 7 of 10).
Figure 5-4 Diesel engine cannot be started (sheet 8 of 10).
Figure 5-4 Diesel engine cannot be started (sheet 9 of 10)
Figure 5-4 Diesel engine cannot be started (sheet 10 of 10)
Figure 5-5 Oil pressure too low, or no oil pressure indication (sheet 1 of 3).
Figure 5-5 Oil pressure too low, or no oil pressure indication (sheet 2 of 3).
Figure 5-5 Oil pressure too low, or no oil pressure indication (sheet 3 of 3).
Figure 5-6 Battery set is not being charged, or no charging current indication (sheet 1 of 2).
Figure 5-6 Battery set is not being charged, or no charging current indication (sheet 2 of 2).
Figure 5-7 Generator frequency cannot be adjusted, or no frequency indication (sheet 1 of 5).
Figure 5-7 Generator frequency cannot be adjusted, or no frequency indication (sheet 2 of 5).
Figure 5-7 Generator frequency cannot be adjusted, or no frequency indication (sheet 3 of 5).
Figure 5-7 Generator frequency cannot be adjusted, or no frequency indication (sheet 4 of 5)
Figure 5-7 Generator frequency cannot be adjusted, or no frequency Indication (sheet 5 of 5).
Figure 5-8 Generator voltage cannot be adjusted, or no voltage lndicatlon (sheet 1 of 7)
Figure 5-8 Generator voltage cannot be adjusted, or no voltage indication (sheet 2 of 7).
Figure 5-8 Generator voltage cannot be adjusted, or no voltage indication (sheet 3 of 7).
Figure 5-8 Generator voltage cannot be adjusted, or no voltage indication (sheet 4 of 7).
Figure 5-8 Generator voltage cannot be adjusted, or no voltage indication (sheet 5 of 7).
Figure 5% Generator voltage cannot be adjusted, or no voltage indication (sheet 6 of 7)
Figure 5-8 Generator voltage cannot be adjusted, or no voltage indication (sheet 7 of 7)
Figure 5-9 AC CIRCUIT INTERRUPTER ON lamp does not light up (sheet 1 of 11).
Figure 5-9 AC CIRCUIT INTERRUPTER ON lamp does not light up (sheet 2 of 11)
Figure 5-9 AC CIRCUIT INTERRUPTER ON lamp does not light up (sheet 3 of 11).
Figure 5-9 AC CIRCUIT INTERRUPTER ON lamp does not light up (sheet 4 of 77)
Figure 5-9 AC CIRCUIT INTERRUPTER ON lamp does not iight up (sheet 5 of 11).
Figure 5-9 AC CIRCUIT INTERRUPTER ON lamp does not light up (sheet 6 of 11).
Figure 5-9 AC CIRCUIT INTERRUPTER ON lamp does not light up (sheet 7 of 11)
Figure 5-9 AC CIRCUIT INTERRUPTER ON lamp does not light up (sheet 8 of 77).
Figure 5-9 AC CIRCUIT INTERRUPTER ON lamp does not light up (sheet 9 of 17)
Figure 5-9 AC CIRCUIT INTERRUPTER ON lamp does not light up (sheet 10 of 11).
Figure 5-9 AC CIRCUIT INTERRUPTER ON lamp does not light up (sheet 11 of 11).
Figure 5-10 No line currents are flowing, or no line current indication (sheet 1 of 5).
Figure 5-10 No line currents are flowing, or no line current indication (sheet 2 of 5).
Figure 5-10 No line currents are flowing, or no line current indication (sheet 3 of 5).
Figure 5-10 No line currents are f/owing, or no line current indication (sheet 4 of 5).
Figure 5-10 No line currents are flowing, or no line current indication (sheet 5 of 5)
Figure 5-11 No power indication (sheet 1 of 2).
Figure 5-11 No power indication (sheet 2 of 2).
Figure 5-12 BATTERY CHARGING CONTROL lamp lights up during operation.
Figure S-13 OIL PRESSURE lamp lights up during operation.
Figure 5-14 OIL TEMP-CYLINDER HEAD lamp lights up during operation (sheet 1 of 3).
Figure 5-14 OIL TEMP-CYLINDER HEAD lamp lights up during operation (sheet 2 of 3).
Figure 5-14 OIL TEMP-CYLINDER HEAD lamps lights up during operation (sheet 3 of 3)
Figure 5-15 UNDER/OVER FREQUENCY lamp lights up during operation (sheet 1 of 6)
Figure 5-15 UNDER/OVER FREQUENCY lamp lights up during operation (sheet 2 of 6).
Figure 5-15 UNDER/OVER FREQUENCY lamp lights up during operation (sheet 3 of 6).
Figure 5-15 UNDER/OVER FREQUENCY lamp lights up during operation (sheet 4 of 6).
Figure 5-15 UNDER/OVER FREQUENCY lamp lights up during operation (sheet 5 of 6).
Figure 5-75 UNDER/OVER FREQUENCY lamp lights up during operation (sheet 6 of 6).
Figure 5-16 UNDER/OVER VOLTAGE lamp lights up during operation (sheet 1 of 6)
Figure 5-16 UNDER/OVER VOLTAGE lamp lights up during operation (sheet 2 of 6).
Figure 5-76 UNDER/OVER VOLTAGE iamp lights up during operation (sheet 3 of 6).
Figure 5-16 UNDER/OVER VOLTAGE lamp lights up during operation (sheet 4 of 6).
Figure 5-76 UNDER/OVER VOLTAGE lamp lights up during operation (sheet 5 of 6)
Figure 5-16 UNDER/OVER VOLTAGE lamp lights up during operation (sheet 6 of 6)
Figure 5-17 GENERATOR OVER TEMPERATURE lamp lights up during operation (sheet 1 of 4).
Figure S-17 GENERATOR OVER TEMPERATURE lamp lights up during operation (sheet 2 of 4).
Figure 5-l 7 GENERATOR OVER TEMPERATURE lamp lights up during operation (sheet 3 of 4).
Figure 5-17 GENERATOR OVER TEMPERATURE lamp lights up during operation (sheet 4 of 4)
Figure 5-18 OVERLOAD lamp lights up during operation (sheet 1 of 4).
Figure 5-18 OVERLOAD lamp lights up during operation (sheet 2 of 4).
Figure 5-18 OVERLOAD lamp lights up during operation (sheet 3 of 4).
Figure 5-18 OVERLOAD lamp lights up during operation (sheet 4 of 4).
Section III. MAINTENANCE PROCEDURES
Performed after any removal/Installation operation
5.6 AUXILIARY CONTACTOR WITH SEMICONDUCTOR DEVICE MAINTENANCE.
INSTALLATION - TM-9-6115-668-13_456
5.7 AUXILIARY CONTACTOR MAINTENANCE
INSTALLATION - TM-9-6115-668-13_458
Figure 5-19 Control Cabinet Assembly, Auxiliary Contactor with Semiconductor, Auxiliary Contactor, Transformer, Maintenance.
5.8 TIME RELAY K3, K10, K13, K17, K25, K26 MAINTENANCE
TESTING - TM-9-6115-668-13_461
ADJUSTMENT - TM-9-6115-668-13_462
Figure 5-20 Time Relays K3, K10, K13 and K26
Figure 5-21 Time Relay k17
Figure 5-22 Time Relay K25
5.9 POWER SUPPLY NT2 24 V MAINTENANCE.
Figure 5-23 Diodes, Time Relay, Power Supply Maintenance.
5.10 THERMISTOR RELAY F12 MAINTENANCE.
Figure 5-24 Control Cabinet Assembly, Circuit Breaker F1 to F11, Thermistor relay F12, True Power Measure Transformer P4A Maintenance
5.11 DIGITAL ISOCHRONOUS LOAD SHARING MODULE N4 MAINTENANCE
ADJUSTMENT
Figure 5-25 Digital lsochronous Load Sharing Module N4, Location of Potentiometers and Test Points.
5.12 RELAY K19 AND K20 WITH RELAY SOCKET AND CONTACT BUSHINGS MAINTENANCE.
INSTALLATION - TM-9-6115-668-13_474
5.13 SPEED GOVERNOR ASSEMBLY N1 MAINTENANCE.
ADJUSTMENT - TM-9-6115-668-13_476
Figure 5-26 Speed Governor Assembly N1, Location of Potentiometers.
Figure 5-27 Control Cabinet Assembly, Relays K19, K20, Digital lsochronous Load Sharing Module N4, Speed Governor Assembly N1, Resistor Maintenance
5.14 VOLTAGE REGULATOR N2 MAINTENANCE.
REPAIR - TM-9-6115-668-13_480
Figure 5-28 Voltage Regulator N2, Location of Circuit Boards and Potentiometers.
INSTALLATION - TM-9-6115-668-13_482
Figure 5-29 Control Cabinet Assembly Voltage Regulator N2 Maintenance
5.15 SAFETY DEVICE N3 MAINTENANCE
REPAIR - TM-9-6115-668-13_485
k. Check trip times
Figure 5-30 Voltage Regulator N2, Location of Circuit Boards and Potentiometers.
To adjust reverse power for Generator Set
2. r. Adjust reverse power for Generator Set 150 kW No. 2: On Generator Set 150 kW No. 1, turn FREQUENCY ADJUST potentiometer (R4) clockwise until KILOWATTS meter (P4) displays 30 kW. Lock control knob with lever. On Generator Set 150 kW No. 2, turn PRmax potentiometer counterclockwise, until indicator REVERSE POWER ON (H11) lights up. Contactor K1 de-energizes and AC CIRCUIT INTER- RUPTER indicator ON (H14) goes out. Press REVERSE POWER (S22) illuminated pushbutton switch: REVERSE POWER indicator goes out. On Generator Set 150 kW No. 1, use FREQUENCY ADJUST potentiometer (R4) to set a fre- quency of 399.8 Hz or 400.2 Hz on FREQUENCY meter (P5). Lock control knob with lever. On Generator Set 150 kW No. 2, press PARALLEL OPERATION ON illuminated pushbutton switch (S9). PARALLEL OPERATION ON indicator (H12) lights up during automatic synchro- nization of Generator Set 150 kW No. 1 and Generator Set 150 kW No. 2. Adjust Voltage/Frequency Error Detection TT1314-./01
f. Adjust undervoltage
j. Adjust underfrequency
INSTALLATION - TM-9-6115-668-13_492
Figure 5-31 Control Cabinet Assembly, Safety Device N3 Maintenance
5.16 FILTER BOX FK MAINTENANCE.
INSTALLATION - TM-9-6115-668-13_495
5.17 CURRENT TRANSFORMER MAINTENANCE
INSTALLATION - TM-9-6115-668-13_497
Installation procedure for current transformer
Figure 5-32 Control Cabinet Assembly, Filter Box FK, Current Transformers, Resistors Maintenance
5.18 AUXILIARY CONTACTOR K109 MAINTENANCE.
5.19 DIODE MAINTENANCE.
INSTALLATION - TM-9-6115-668-13_502
5.20 TIME RELAY MAINTENANCE.
TESTING - TM-9-6115-668-13_504
ADJUSTMENT - TM-9-6115-668-13_505
Figure 5-34 Time Relay K107
Figure 5-35 Time Relay K108
5.21 POWER SUPPLY NT2 24 V~ MAINTENANCE.
Figure 5-36 Time Relay K110
Figure 5-37 Control Cabinet Assembly, Engine Preheating Control Board, Auxiliary Contactor K109, Diodes, Time Relay Maintenance.
5.22 MINIATURE RELAY MAINTENANCE.
INSTALLATION - TM-9-6115-668-13_512
5.23 POWER RELAY K101, K102 MAINTENANCE.XXP
INSTALLATION - TM-9-6115-668-13_514
Figure 5-38 Miniature Relay, Power Relay Maintenance.
5.24 CONNECTOR RECEPTACLE L1 TO L3 AND N MAINTENANCE.
INSTALLATION - TM-9-6115-668-13_517
5.25 INTERLOCK SWlTCH MAINTENANCE.
INSTALLATION - TM-9-6115-668-13_519
Figure 5-39 Control Cabinet Assembly, Connection Panel, Connector Receptacle L1 to L3 and N, lnterlock Switch Maintenance
5.26 J3 SLAVE RECEPTACLE 24 VOLTS CONNECTOR MAINTENANCE
INSTALLATION - TM-9-6115-668-13_522
5.27 AIR FILTER HOUSING AND PIPING MAINTENANCE.
INSTALLATION - TM-9-6115-668-13_524
Figure 5-40 Air filter Assembly, J30 slave receptacle 24 V Connector Maintenance.
5.28 SUBCURRENT FILTER ASSEMBLY MAINTENANCE.
INSTALLATION - TM-9-6115-668-13_527
5.29 SUBCURRENT FILTER OIL LINES MAINTENANCE.
INSTALLATION - TM-9-6115-668-13_529
Figure 5-41 Subcurrent Filter Assembly, Oil Lines Maintenance.
5.30 FLAME GLOWPLUG SYSTEM MAINTENANCE
TEST - TM-9-6115-668-13_532
INSTALLATION - TM-9-6115-668-13_533
Figure 5-42 Flame Glowplug System Maintenance
5.31 ENGINE PREHEATING ASSEMBLY MAINTENANCE.
TEST - TM-9-6115-668-13_536
Figure 5-43 Preheating Assembly Maintenance.
5.32 BURNER MONITORING TEMPERATURE SWlTCH MAINTENANCE.
5.33 GLOWPLUG MAINTENANCE
5.34 OVERTEMPERATURE SWITCH MAINTENANCE
Figure 5-44 Temperature Switch, Glowplug Maintenance.
5.35 PREHEATlNG ASSEMBLY CABLE
INSTALLATION - TM-9-6115-668-13_543
Figure 5-45 Preheating Cable Assembly Maintenance.
5.36 AIR FLAP PULLER MAGNET MAINTENANCE.
5.37 ELECTRIC OIL PUMP MAINTENANCE
INSTALLATION - TM-9-6115-668-13_547
5.38 AIR-OIL HEAT EXCHANGER MAINTENANCE.
INSTALLATION - TM-9-6115-668-13_549
Figure 5-46 Air Flap Puller magnet, Electric Oil Pump, Air- Oil heat Exchanger Maintenance.
5.39 OIL HOSE MAINTENANCE.
INSTALLATION - TM-9-6115-668-13_552
5.40 OIL TEMPERATURE SWITCH MAINTENANCE.
INSTALLATION - TM-9-6115-668-13_554
Figure 5-47 Oil Hose, Oil Temperature Switch Maintenance
5.41 ACTUATOR ASSEMBLY MAINTENANCE.
INSTALLATION - TM-9-6115-668-13_557
Figure 5-48 Actuator Maintenance.
5.42 ACTUATOR CABLE MAINTENANCE.
INSTALLATION - TM-9-6115-668-13_560
5.43 ACTUATOR CABLE MAINTENANCE.
INSTALLATION - TM-9-6115-668-13_562
5.44 PICK-UP CABLE MAINTENANCE.
INSTALLATION - TM-9-6115-668-13_564
Figure 5-49 Actuator Cable, Pick-up Cable Maintenance.
5.45 EHG TEMPERATURE SENSOR MAINTENANCE.
INSTALLATION - TM-9-6115-668-13_567
Figure 5-50 EHG and Cylinder Head Temperature Sensor Maintenance
5.46 GENERATOR WIRING HARNESS MAINTENANCE
INSTALLATION - TM-9-6115-668-13_570
Figure 5-51 Generator Wiring Harness Maintenance.
5.47 DIESEL ENGINE AND SYNCHRONOUS GENERATOR MAINTENANCE.
REMOVAL - TM-9-6115-668-13_573
INSTALLATION - TM-9-6115-668-13_574
8. Remove long eyebolt
5.48 DIESEL ENGINE SHOCK ABSORBERS MAINTENANCE.
INSTALLATION - TM-9-6115-668-13_577
5.49 SYNCHRONOUS GENERATOR SHOCK ABSORBERS MAINTENANCE.
REMOVAL - TM-9-6115-668-13_579
For easier positioning of components
Figure 5-52 Diesel Engine and Synchronous Generator Maintenance (Sheet 1 of 2).
Figure 5-52 Diesel Engine and Synchronous Generator Maintenance (Sheet 2 of 2).
5.50 DIESEL ENGINE MAINTENANCE
3. Remove generator wiring harness
INSTALLATION - TM-9-6115-668-13_585
Figure 5-53 Diesel Engine Maintenance (Sheet 1 of 2)
Figure 5-53 Diesel Engine Maintenance (Shett 2 of 2).
5.51 SYNCHRONOUS GENERATOR MAINTENANCE
INSTALLATION - TM-9-6115-668-13_589
Figure 5-54 Synchronous Generator Maintenance.
5.52 CLUTCH ASSEMBLY MAINTENANCE.
INSTALLATION - TM-9-6115-668-13_592
Figure 5-55 Clutch Assembly Maintenance
5.53 LOAD BANK PROCEDURES (AVTRON 150 kW RESISTIVE).
2. Start generator set.
SHUTDOWN PROCEDURE
5.54 CHECKING AND ADJUSTING VALVES.
INSTALLATION - TM-9-6115-668-13_598
Figure 5-57 -- Figure 5-60
5.55 Cooling Blower Assembly Maintenance.
Figure 5-61. Cooling Blower Assembly
APPENDIX A R E F E R E N C E S
A.7 TECHNICAL MANUALS
APPENDIX B MAINTENANCE ALLOCATION CHART
B.3 EXPLANATION OF COLUMNS IN THE MAC
B.4 EXPLANATION OF COLUMNS IN TOOL AND TEST EQUIPMENT REQUIREMENT
Section II, MAINTENANCE ALLOCATION CHART (MAC) FOR GEN SET 150 KW
COMPONENT/ASSEMBLY - TM-9-6115-668-13_608
COMPONENT/ASSEMBLY - TM-9-6115-668-13_609
COMPONENT/ASSEMBLY - TM-9-6115-668-13_610
COMPONENT/ASSEMBLY - TM-9-6115-668-13_611
COMPONENT/ASSEMBLY - TM-9-6115-668-13_612
COMPONENT/ASSEMBLY - TM-9-6115-668-13_613
COMPONENT/ASSEMBLY - TM-9-6115-668-13_614
COMPONENT/ASSEMBLY - TM-9-6115-668-13_615
COMPONENT/ASSEMBLY - TM-9-6115-668-13_616
Section III, Tool and Test Equipment Requirements FOR GEN SET 150 KW
Section IV, REMARKS FOR GEN SET 150 KW
APPENDIX C COMPONENTS OF END ITEM (COEI) AND BASIC ISSUE ITEMS (BII) LISTS
Section II. COMPONENTS OF END ITEM - TM-9-6115-668-13_620
Section Ill. BASIC ISSUE ITEMS
APPENDIX D ADDITIONAL AUTHORIZATION LIST - TM-9-6115-668-13_622
Section II. ADDITIONAL AUTHORIZED ITEMS LIST
APPENDIX E EXPENDABLE AND DURABLE ITEMS LIST - TM-9-6115-668-13_624
Section II. EXPENDABLE AND DURABLE ITEMS LIST
APPENDIX F OPERATORS LUBRICATION INSTRUCTIONS
APPENDIX G TORQUE LIMITS - TM-9-6115-668-13_627
GLOSSARY - TM-9-6115-668-13_628
Section II. DEFINITION OF UNUSUAL TERMS
FO-1. Generator Set 150kW Wiring Diagram (sheet 1 of 11)
FO-1. Generator Set 150kW Wiring Diagram (sheet 2 of 11)
FO-1. Generator Set 150kW Wiring Diagram (sheet 3 of 11)
FO-1. Generator Set 150kW Wiring Diagram (sheet 4 of 11)
FO-1. Generator Set 150kW Wiring Diagram (sheet 5 of 11)
FO-1. Generator Set 150kW Wiring Diagram (sheet 6 of 11)
FO-1. Generator Set 150kW Wiring Diagram (sheet 7 of 11)
FO-1. Generator Set 150kW Wiring Diagram (sheet 8 of 11)
FO-1. Generator Set 150kW Wiring Diagram (sheet 9 of 11)
FO-1. Generator Set 150kW Wiring Diagram (sheet 10 of 11)
FO-1. Generator Set 150kW Wiring Diagram (sheet 11 of 11)
FO-2. Engine Preheating Assembly Wiring Diagram (sheet 1 of 2)
FO-2. Engine Preheating Assembly Wiring Diagram (sheet 2 of 2)
The Metric System and Equivalents
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