Section I. GENERAL INFORMATION - TM-9-6115-668-13_31Figure 1-1 Generator Set 150 kW.Table 1-1 Nomenclature Cross-Reference List.Section II. EQUIPMENT DESCRIPTIONTable 1-2 Description of Major Components, Generator Set 150 kW1.11 CONSTRUCTION1.11.3 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 OPERATION1.13.3 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 minutesManual ShutdownOIL 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 FunctionsJ9 PARALLEL OPERATION Receptacle, Monitoring and Control Functions (continued).CHAPTER 2 OPERATING INSTRUCTIONSSection I. DESCRIPTION AND USE OF CONTROLS AND INDICATORSTable 2-1 Control Cabinet Assembly, Description of Controls and Indicators.Control Cabinet Assembly, Description of Controls and Indicators (continued). - TM-9-6115-668-13_59Control Cabinet Assembly, Description of Controls and indicators (continued). - TM-9-6115-668-13_60Control 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 Breakers2.1.3 ReceptaclesFigure 2-4 Base Frame Assembly, J3 SLAVE RECEPTACLE 24 VOLTSSection II. OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SER- VICES (PMCS)2.2.4 Special Instructions2.2.5 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_77Operator Preventive Maintenance Checks and Services-continued. - TM-9-6115-668-13_78Operator Preventive Maintenance Checks and Services-continued. - TM-9-6115-668-13_79Operator Preventive Maintenance Checks and Services-continued. - TM-9-6115-668-13_80Operator Preventive Maintenance Checks and Services-continued. - TM-9-6115-668-13_81Operator Preventive Maintenance Checks and Services-continued. - TM-9-6115-668-13_82Operator Preventive Maintenance Checks and Services-continued. - TM-9-6115-668-13_83Operator Preventive Maintenance Checks and Services-continued. - TM-9-6115-668-13_84Operator Preventive Maintenance Checks and Services-continued. - TM-9-6115-668-13_85Operator Preventive Maintenance Checks and Services-continued. - TM-9-6115-668-13_86Section III. OPERATION UNDER USUAL CONDITIONS - TM-9-6115-668-13_87Figure 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 MaintenanceFigure 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 intervals2.3.4.2.1 Refueling with the Fuel PumpFigure 2-10 Refueling.Figure 2-11 Connect Battery Cable 2.3.6 Connecting Control and Power CablesFigure 2-12 Connecting Control and Power Cables2.4 DECALS AND INSTRUCTION PLATESFigure 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 PROCEDURES2.5.1.2 Switching Voltage to the Control Cabinet Assembly ReceptaclesMASTER SWITCH Figure 2-18 Operating the Generator Set 150 kW.2.5.2.1 Normal Shutdown2.6 EMERGENCY PROCEDURESFigure 2-20 BATTLE SHORT Mode.2.7 PREPARATION FOR MOVEMENTFigure 2-21 Disconnecting Control and Power CablesFigure 2-22 Disconnect Battery Cable.Section IV. OPERATION UNDER UNUSUAL CONDITIONSFigure 2-24 Operating the Engine Preheating Assembly2.9 OPERATING THE FLAME GLOWPLUG SYSTEM (BELOW 32 F (0 C))Figure 2-25 Operating the Flame Glowplug System2.10 OPERATION IN EXTREME COLD (BELOW -22 F (-30 C))Figure 2-26 Fuel Infection Pump Actuator LinkageCHAPTER 3 OPERATOR MAINTENANCE INSTRUCTIONSSection I. OPERATOR LUBRICATIONSection II. TROUBLESHOOTING - TM-9-6115-668-13_124Figure 3-1 BATTERY CHARGING CONTROL and OIL PRESSURE lamps do not light upFigure 3-2 HEATING FAILURE lamp lights up or READY TO START IF HEATING IS ON lamp does not light upFigure 3-3 GLOWPLUG ON lamp does not light upFigure 3-4 Oil pressure too low, or no oil pressure indicationFigure 3-5 Generator frequency cannot be adjusted, or no frequency indicationFigure 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 PROCEDURES3.4 AIR FILTER DUST COLLECTOR MAINTENANCEFigure 3-8 Air Filter Assembly Maintenance.CHAPTER 4 UNIT MAINTENANCE INSTRUCTIONSSubject Index - TM-9-6115-668-13_136Subject Index - TM-9-6115-668-13_137Subject Index - TM-9-6115-668-13_138Section I. REPAIR PARTS; TOOLS; SPECIAL TOOLS; TEST, MEASUREMENT AND DIAGNOSTIC EQUIPMENT (TMDE); AND SUPPORT EQUIPMENT - TM-9-6115-668-13_139Section II. SERVICE UPON RECEIPT OF EQUIPMENT4.4.2 Unpacking Equipment.4.4.3 Checking Unpacked Generator Set 150 kWFigure 4-1 Original Packaging in Container.Figure 4-2 Unpacking the Container.Figure 4-3 Generator Set 150 kW, Unpacked.4.5 INSTALLATION INSTRUCTIONS4.6.3 Lubricating Oil.Section III. Unit LubricationSection IV. UNIT PREVENTIVE MAINTENANCE CHECKS AND SERVICES Dry cleaning solventFigure 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-continuedSection V. TROUBLESHOOTING - TM-9-6115-668-13_154SYMPTOM INDEX - TM-9-6115-668-13_155Figure 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 upFigure 4-8 GLOWPLUG ON lamp does not light up.Figure 4-9 Diesel engine cannot be startedFigure 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 indicationFigure 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 indicationFigure 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 SUPPRESSIONSECTION VII. MAINTENANCE PROCEDURESRemoval/ Installation operation4.13 UNIT HOOD FLAP GROUND STRAP MAINTENANCEFigure 4-24 Unit Hood Flap Ground Strap Maintenance.4.14 UNIT HOOD ASSEMBLY MAINTENANCE.INSTALLATION - TM-9-6115-668-13_180Figure 4-25. Unit Hood Assembly Maintenance4.15 UNlT HOOD-BASE FRAME GROUND STRAP MAINTENANCE.Figure 4-26 Unit Hood-Base Frame Ground Strap Maintenance.4.16 SUPPLY AIR DUCT MAINTENANCE4.17 AIR LEADING DUCT MAINTENANCE4.18 AIR COOLING INLET GRATE MAINTENANCE4.19 COVER AND CASE FOR CONNECTION PANEL MAINTENANCEFigure 4-27 Unit Hood Assembly Air Ducts and Air Cooling Inlet Grate Maintenance4.20 TWIST GRIP AND LOCK MAINTENANCE4.21 GAS-CYLINDER AND PROP MAINTENANCE.4.22 FLAP MOUNT MAINTENANCE.Figure 4-28 Unit Hood Flap Maintenance.4.23 LIGHT INDICATOR ASSEMBLY MAINTENANCEINSTALLATION - TM-9-6115-668-13_194Figure 4-29 Control Cabinet Assembly, Light Indicator Assembly Maintenance4.24 BULB IN INDICATOR LAMP MAINTENANCEFigure 4-30 Bulb in Indicator Lamps Maintenance.4.25 BULB IN ILLUMINATED SWITCH MAINTENANCEFigure 4-31 Bulb in Illuminated Switch Maintenance4.26 REPLACE BULB IN PANEL LIGHT H6Figure 4-32 Panel Light H6 Maintenance4.27 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 MAINTENANCEINSTALLATION - TM-9-6115-668-13_207Figure 4-35. Air Filter Cartridge Maintenance4.30 OIL FILTER MAINTENANCE4.31 SUBCURRENT FILTER CARTRIDGE MAINTENANCEFigure 4-36. Oil Filter, Subcurrent Filter Maintenance4.32 FUEL PREFILTER CARTRIDGE MAINTENANCEINSTALLATION - TM-9-6115-668-13_2134.33 TWO STEP FUEL FILTER CARTRIDGE MAINTENANCEINSTALLATION - TM-9-6115-668-13_215Figure 4-37 Fuel Prefilter Cartridge, Two Step Fuel Filter Cartridges Maintenance.4.34 BATTERY CHARGING ALTERNATOR V BELT4.35 BATTERY CHARGING ALTERNATOR V BELT MAINTENANCEBleed screws Figure 4-38. Battery Charging AIternator of V Belt Malntenance.4.36 DIESEL ENGINE CYLINDER COOLING FINS AND OIL COOLER MAINTENANCEFigure 4-39 Diesel Engine Cylinder Cooling Fins and Oil Cooler Maintenance4.37 PRIMING PUMP MAINTENANCEFigure 4-40. Priming Pump Assembly Maintenance.4.38 FUEL LINES AND PREFILTER ASSEMBLY MAINTENANCE4.39 FUEL LINES AND TWO STEP FUEL FILTER ASSEMBLY MAINTENANCEFigure 4-41 Diesel Engine Fuel Pipes and Fuel Filter Assembly Maintenance4.40 FUEL PREFILTER ASSEMBLY MAINTENANCEINSTALLATION - TM-9-6115-668-13_2294.41 TWO STEP FUEL FILTER ASSEMBLY MAINTENANCE.INSTALLATION - TM-9-6115-668-13_231Figure 4-42. Fuel Prefilter, Two Step Fuel Filter Maintenance4.42 FUEL LINE ASSEMBLY MAINTENANCE.7. Fuel supply lineINSTALLATION - TM-9-6115-668-13_2356. Fuel lineFigure 4-43. Fuel Line Assembly Maintenance4.43 CONTROL CABINET ASSEMBLY MAINTENANCE6. Record labeling and position of cablesContact with filter box FKFigure 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_24321. Place cover4.44 PUSHBUTTON SWITCH AND INDICATOR ASSEMBLY MAINTENANCEINSTALLATION - TM-9-6115-668-13_246Figure 4-45 Control Cabinet Assembly, Pushbutton Switch and Indicator Assembly Maintenance.4.45 PUSHBUTTON SWITCH MAINTENANCE.INSTALLATION - TM-9-6115-668-13_249Figure 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 MAINTENANCEINSTALLATION - TM-9-6115-668-13_2544.48 BATTLE SHORT SWITCH S21 MAINTENANCE5. Connect cable4.49 VOLTAGE SELECTOR SWITCH S11 MAINTENANCEINSTALLATION - TM-9-6115-668-13_2584.50 GLOWPLUG/START SWITCH S2 MAINTENANCE.4.51 MASTER SWITCH S1 MAINTENANCEFigure 4-48 Control Cabinet Assembly, Preheating Resistor R1, BATTLE SHORT Switch S21, VOLTAGE SELECTOR SWITCH S11 GLOWPLUG/START Switch S2, MASTER SWITCH S1 Maintenance4.52 FREQUENCY ADJUST R4 MAINTENANCEINSTALLATION - TM-9-6115-668-13_2634.53 VOLTAGE ADJUST R3 MAINTENANCEINSTALLATION - TM-9-6115-668-13_2654.54 PANEL DIMMER S16/R2 MAINTENANCEINSTALLATION - TM-9-6115-668-13_267Figure 4-49 Control Cabinet Assembly, FREQUENCY ADJUST R4, VOLTAGE ADJUST R3, PANEL DIMMER S16/R2 Maintenance.4.55 FREQUENCY METER P5 MAINTENANCE4. Install cover panel 4.56 METER MAINTENANCE.INSTALLATION - TM-9-6115-668-13_272Figure 4-50 Control Cabinet Assembly, Meter Maintenance4.57 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_279Figure 4-52 Control Cabinet Assembly, Auxiliary Contactor with Semiconductor, Auxiliary Contactor, Transformer Maintenance4.61 DIODE MAINTENANCE.INSTALLATION - TM-9-6115-668-13_2824.62 DIODE V3 MAINTENANCEINSTALLATION - TM-9-6115-668-13_284Figure 4-53 Diodes, Time Relay, Power Supply Maintenance4.63 CIRCUIT BREAKER MAINTENANCE.INSTALLATION - TM-9-6115-668-13_2874. Close cable conduit 4.64 TRUE POWER MEASURING TRANSFORMER P4A MAINTENANCE.INSTALLATION - TM-9-6115-668-13_290Figure 4-54 Control Cabinet Assembly, Circuit Breaker F1 to F11, Thermistor relay F12, True Power Measuring Transformer P4A Maintenance4.65 RESISTOR R100 TO R102 MAINTENANCEINSTALLATION - TM-9-6115-668-13_293Figure 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_2966. 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_3004.68 CIRCUIT BREAKER MAINTENANCEINSTALLATION - TM-9-6115-668-13_3022. Circuit breaker assembly F102Figure 4-57 Control Cabinet Assembly, Engine Preheating Control Board, Circuit Breaker Maintenance.4.69 CONNECTOR J9 MAINTENANCE.INSTALLATION - TM-9-6115-668-13_3064.70 J1/120 V 400 HZ DOUBLE CONNECTOR RECEPTACLE MAINTENANCEINSTALLATION - TM-9-6115-668-13_3084.71 J2/24 V CONNECTOR RECEPTACLE MAINTENANCE.INSTALLATION - TM-9-6115-668-13_310Figure 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 Maintenance4.73 SHUNT R11 MAINTENANCE4.74 BATTERY SET MAINTENANCE.TEST - TM-9-6115-668-13_3167. 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 Maintenance4.77 FUEL TANK MAINTENANCE.REMOVAL - TM-9-6115-668-13_322INSTALLATION - TM-9-6115-668-13_323Hylomar 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_3284.80 LOWER FUEL LEVEL SWITCH MAINTENANCE.INSTALLATION - TM-9-6115-668-13_3304.81 FUEL LEVEL SENSOR 2R4 MAINTENANCE.2. Noting correct labeling and position, install cableFigure 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_335INSTALLATION - TM-9-6115-668-13_336f . Align exhaust pipe with header Figure 4-63. Silencer Assembly, Left Side Maintenance4.83 SILENCER ASSEMBLY, RIGHT SIDE MAINTENANCE4. Remove connector pipes and brackets - TM-9-6115-668-13_340INSTALLATION - TM-9-6115-668-13_3415. Install unit hood assembly Figure 4-64. Silencer Assembly, Right Side MaintenanceINSTALLATION - TM-9-6115-668-13_3442. 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 Maintenance4.89 BATTERY CHARGING ALTERNATOR MAINTENANCETEST - TM-9-6115-668-13_3533. Noting correct labeling and positionFigure 4-66. Battery Charging Alternator Maintenance.4.90 STARTER MAINTENANCEINSTALLATION - TM-9-6115-668-13_357Figure 4-67. Generator, Starter Maintenance.CHAPTER 5 DIRECT SUPPORT MAINTENANCE INSTRUCTIONSSubject IndexSection I. REPAIR PARTS; TOOLS; SPECIAL TOOLS; TEST, MEASUREMENT AND DIAGNOSTIC EQUIPMENT (TMDE); AND SUPPORT EQUIPMENT - TM-9-6115-668-13_361Section II. TROUBLESHOOTING - TM-9-6115-668-13_36224 VDC operating voltageSYMPTOM INDEX - TM-9-6115-668-13_364Figure 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 PROCEDURESPerformed after any removal/Installation operation5.6 AUXILIARY CONTACTOR WITH SEMICONDUCTOR DEVICE MAINTENANCE.INSTALLATION - TM-9-6115-668-13_4565.7 AUXILIARY CONTACTOR MAINTENANCEINSTALLATION - TM-9-6115-668-13_458Figure 5-19 Control Cabinet Assembly, Auxiliary Contactor with Semiconductor, Auxiliary Contactor, Transformer, Maintenance.5.8 TIME RELAY K3, K10, K13, K17, K25, K26 MAINTENANCETESTING - TM-9-6115-668-13_461ADJUSTMENT - TM-9-6115-668-13_462Figure 5-20 Time Relays K3, K10, K13 and K26Figure 5-21 Time Relay k17Figure 5-22 Time Relay K255.9 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 Maintenance5.11 DIGITAL ISOCHRONOUS LOAD SHARING MODULE N4 MAINTENANCEADJUSTMENT 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_4745.13 SPEED GOVERNOR ASSEMBLY N1 MAINTENANCE.ADJUSTMENT - TM-9-6115-668-13_476Figure 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 Maintenance5.14 VOLTAGE REGULATOR N2 MAINTENANCE.REPAIR - TM-9-6115-668-13_480Figure 5-28 Voltage Regulator N2, Location of Circuit Boards and Potentiometers.INSTALLATION - TM-9-6115-668-13_482Figure 5-29 Control Cabinet Assembly Voltage Regulator N2 Maintenance5.15 SAFETY DEVICE N3 MAINTENANCEREPAIR - TM-9-6115-668-13_485k. Check trip timesFigure 5-30 Voltage Regulator N2, Location of Circuit Boards and Potentiometers.To adjust reverse power for Generator Set2. 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-./01f. Adjust undervoltagej. Adjust underfrequencyINSTALLATION - TM-9-6115-668-13_492Figure 5-31 Control Cabinet Assembly, Safety Device N3 Maintenance5.16 FILTER BOX FK MAINTENANCE.INSTALLATION - TM-9-6115-668-13_4955.17 CURRENT TRANSFORMER MAINTENANCEINSTALLATION - TM-9-6115-668-13_497Installation procedure for current transformer Figure 5-32 Control Cabinet Assembly, Filter Box FK, Current Transformers, Resistors Maintenance5.18 AUXILIARY CONTACTOR K109 MAINTENANCE.5.19 DIODE MAINTENANCE.INSTALLATION - TM-9-6115-668-13_5025.20 TIME RELAY MAINTENANCE.TESTING - TM-9-6115-668-13_504ADJUSTMENT - TM-9-6115-668-13_505Figure 5-34 Time Relay K107Figure 5-35 Time Relay K1085.21 POWER SUPPLY NT2 24 V~ MAINTENANCE.Figure 5-36 Time Relay K110Figure 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_5125.23 POWER RELAY K101, K102 MAINTENANCE.XXPINSTALLATION - TM-9-6115-668-13_514Figure 5-38 Miniature Relay, Power Relay Maintenance.5.24 CONNECTOR RECEPTACLE L1 TO L3 AND N MAINTENANCE.INSTALLATION - TM-9-6115-668-13_5175.25 INTERLOCK SWlTCH MAINTENANCE.INSTALLATION - TM-9-6115-668-13_519Figure 5-39 Control Cabinet Assembly, Connection Panel, Connector Receptacle L1 to L3 and N, lnterlock Switch Maintenance5.26 J3 SLAVE RECEPTACLE 24 VOLTS CONNECTOR MAINTENANCEINSTALLATION - TM-9-6115-668-13_5225.27 AIR FILTER HOUSING AND PIPING MAINTENANCE.INSTALLATION - TM-9-6115-668-13_524Figure 5-40 Air filter Assembly, J30 slave receptacle 24 V Connector Maintenance.5.28 SUBCURRENT FILTER ASSEMBLY MAINTENANCE.INSTALLATION - TM-9-6115-668-13_5275.29 SUBCURRENT FILTER OIL LINES MAINTENANCE.INSTALLATION - TM-9-6115-668-13_529Figure 5-41 Subcurrent Filter Assembly, Oil Lines Maintenance.5.30 FLAME GLOWPLUG SYSTEM MAINTENANCETEST - TM-9-6115-668-13_532INSTALLATION - TM-9-6115-668-13_533Figure 5-42 Flame Glowplug System Maintenance5.31 ENGINE PREHEATING ASSEMBLY MAINTENANCE.TEST - TM-9-6115-668-13_536Figure 5-43 Preheating Assembly Maintenance.5.32 BURNER MONITORING TEMPERATURE SWlTCH MAINTENANCE.5.33 GLOWPLUG MAINTENANCE5.34 OVERTEMPERATURE SWITCH MAINTENANCEFigure 5-44 Temperature Switch, Glowplug Maintenance.5.35 PREHEATlNG ASSEMBLY CABLEINSTALLATION - TM-9-6115-668-13_543Figure 5-45 Preheating Cable Assembly Maintenance.5.36 AIR FLAP PULLER MAGNET MAINTENANCE.5.37 ELECTRIC OIL PUMP MAINTENANCEINSTALLATION - TM-9-6115-668-13_5475.38 AIR-OIL HEAT EXCHANGER MAINTENANCE.INSTALLATION - TM-9-6115-668-13_549Figure 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_5525.40 OIL TEMPERATURE SWITCH MAINTENANCE.INSTALLATION - TM-9-6115-668-13_554Figure 5-47 Oil Hose, Oil Temperature Switch Maintenance5.41 ACTUATOR ASSEMBLY MAINTENANCE.INSTALLATION - TM-9-6115-668-13_557Figure 5-48 Actuator Maintenance.5.42 ACTUATOR CABLE MAINTENANCE.INSTALLATION - TM-9-6115-668-13_5605.43 ACTUATOR CABLE MAINTENANCE.INSTALLATION - TM-9-6115-668-13_5625.44 PICK-UP CABLE MAINTENANCE.INSTALLATION - TM-9-6115-668-13_564Figure 5-49 Actuator Cable, Pick-up Cable Maintenance.5.45 EHG TEMPERATURE SENSOR MAINTENANCE.INSTALLATION - TM-9-6115-668-13_567Figure 5-50 EHG and Cylinder Head Temperature Sensor Maintenance5.46 GENERATOR WIRING HARNESS MAINTENANCEINSTALLATION - TM-9-6115-668-13_570Figure 5-51 Generator Wiring Harness Maintenance.5.47 DIESEL ENGINE AND SYNCHRONOUS GENERATOR MAINTENANCE.REMOVAL - TM-9-6115-668-13_573INSTALLATION - TM-9-6115-668-13_5748. Remove long eyebolt 5.48 DIESEL ENGINE SHOCK ABSORBERS MAINTENANCE.INSTALLATION - TM-9-6115-668-13_5775.49 SYNCHRONOUS GENERATOR SHOCK ABSORBERS MAINTENANCE.REMOVAL - TM-9-6115-668-13_579For easier positioning of componentsFigure 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 MAINTENANCE3. Remove generator wiring harnessINSTALLATION - TM-9-6115-668-13_585Figure 5-53 Diesel Engine Maintenance (Sheet 1 of 2)Figure 5-53 Diesel Engine Maintenance (Shett 2 of 2).5.51 SYNCHRONOUS GENERATOR MAINTENANCEINSTALLATION - TM-9-6115-668-13_589Figure 5-54 Synchronous Generator Maintenance.5.52 CLUTCH ASSEMBLY MAINTENANCE.INSTALLATION - TM-9-6115-668-13_592Figure 5-55 Clutch Assembly Maintenance5.53 LOAD BANK PROCEDURES (AVTRON 150 kW RESISTIVE).2. Start generator set.SHUTDOWN PROCEDURE5.54 CHECKING AND ADJUSTING VALVES.INSTALLATION - TM-9-6115-668-13_598Figure 5-57 -- Figure 5-605.55 Cooling Blower Assembly Maintenance.Figure 5-61. Cooling Blower AssemblyAPPENDIX A R E F E R E N C E SA.7 TECHNICAL MANUALSAPPENDIX B MAINTENANCE ALLOCATION CHARTB.3 EXPLANATION OF COLUMNS IN THE MACB.4 EXPLANATION OF COLUMNS IN TOOL AND TEST EQUIPMENT REQUIREMENTSection II, MAINTENANCE ALLOCATION CHART (MAC) FOR GEN SET 150 KWCOMPONENT/ASSEMBLY - TM-9-6115-668-13_608COMPONENT/ASSEMBLY - TM-9-6115-668-13_609COMPONENT/ASSEMBLY - TM-9-6115-668-13_610COMPONENT/ASSEMBLY - TM-9-6115-668-13_611COMPONENT/ASSEMBLY - TM-9-6115-668-13_612COMPONENT/ASSEMBLY - TM-9-6115-668-13_613COMPONENT/ASSEMBLY - TM-9-6115-668-13_614COMPONENT/ASSEMBLY - TM-9-6115-668-13_615COMPONENT/ASSEMBLY - TM-9-6115-668-13_616Section III, Tool and Test Equipment Requirements FOR GEN SET 150 KWSection IV, REMARKS FOR GEN SET 150 KWAPPENDIX C COMPONENTS OF END ITEM (COEI) AND BASIC ISSUE ITEMS (BII) LISTSSection II. COMPONENTS OF END ITEM - TM-9-6115-668-13_620Section Ill. BASIC ISSUE ITEMSAPPENDIX D ADDITIONAL AUTHORIZATION LIST - TM-9-6115-668-13_622Section II. ADDITIONAL AUTHORIZED ITEMS LISTAPPENDIX E EXPENDABLE AND DURABLE ITEMS LIST - TM-9-6115-668-13_624Section II. EXPENDABLE AND DURABLE ITEMS LISTAPPENDIX F OPERATORS LUBRICATION INSTRUCTIONSAPPENDIX G TORQUE LIMITS - TM-9-6115-668-13_627GLOSSARY - TM-9-6115-668-13_628Section II. DEFINITION OF UNUSUAL TERMSFO-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