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Figure  2-2.  Generator  Removal
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TM-5-6115-545-34 Generator Set Diesel Engine Driven Tactical Skid Mtd. 30 Kw 3 Phase 4 Wire 120/208 and 240/416 Volts Manual
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Figure   2-3.   Engine   Removal

m. Connect tagged cables and harness wires to lugs  on  rear  of  voltage  reconnection  panel.  Mount reconnection board with attaching hardware on left side.  Right  side  of  panel  will  attach  to  load  contac- tor. Reconnect the ground cable to the battery. n. If the generator has been renewed or repaired refer to Chapter 16, Section II and conduct the follow- ing  tests. g. (1) Phase balance test. (2) Regulator and governor stability and transit response. 2-13.  Engine  Removal. a. Drain the engine cooling and lube systems and-the hydraulic sump, as instructed in the Operators and Organizational Maintenance Manual. b.  Disconnect  the  ground  from  the  batteries. c. Drain fuel from the day tank and secondary fuel  filters. d.  Refer  to  the  Operator  and  Organizational Maintenance  Manual  for  sequential  removal  of  the following items: (1)  Crankcase  breather  cover  and  tubing. (2) Rain cap and exhaust system. (3)  Receptacle  panels. (4)  Housing  and  cooling  groups. (5)  Manual  speed  control. (6)  Interconnecting  wiring  harnesses. (7) Fuel filters, day tank, mounting bracket, and related fuel lines. (8) Engine drain lines. (9) On precise sets only, hydraulic sump and filter. (10) Winterization kits (if installed). e. Remove all components of the relay table group and load connection group as instructed in paragraph  2-11. f. Remove the top bracket from the lifting frame assembly. (fig. 11-1) Position jacking studs under rear of engine an adjust to support engine weight (fig. 2-2). Remove four fan coupling screws (para 2-11)which are to be used as attaching hardware for the jacking support bracket. Remove alternate fan coupling screws only at this time. h.  Attach  suitable  lifting  device  to  engine  hoist brackets, i. Uncouple generator from engine (para 2-11). Remove the remaining four coupling screws. j. Remove two screws securing engine front mounting bracket to skid base (fig. 2-3). k.  Hoist  engine  up  and  forward  to  clear  genera- tor, and lift out of skid base. Place engine on flat surface with a supporting block under front support or place in engine support stand. 2-14.  Engine  Installation. a.  Place  jacking  studs  on  engine  flywheel  housing with  mounting  hardware. b. Hoist engine with suitable lifting device and lower engine into mounting position. c. As engine front mounting bracket nears en- gagement  with  skid  base,  adjust  jacking  studs,  lower engine until it rests on the skid base and its flywheel housing  mates  with  generator  front  mating  flange. d.  Secure  front  mounting  bracket  with  attaching hardware.  Torque  engine  mount  bolts  to  90-100 foot-pounds. e.  Couple  engine  to  generator. f. Install relay table with attaching hardware. g. Install control relay boxes and excitation system assembly with attaching hardware. h. Install top bracket with attaching hardware. (fig.11-1.) i.  Install  housing.    Refer  to  the  Operator  and Organizational  Maintenance  Manual  and  install  the following: (1) Winterization kits (if installed). (2) On precise sets only, hydraulic sump and filter. (3) Engine drain lines. (4) Fuel filters, day tank, mounting bracket and related fuel lines. (5) (6) (7) (8) Interconnecting  wiring  harnesses. Manual  speed  control. Housing  and  cooling  groups. Receptacle panels (as applicable). Change 1  2-23

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