TM-5-6115-593-34 Generator Set Diesel Engine Driven Tactical Skid Mtd. 600 Kw 3 Phase 4 Wire 120/208 and 240/416 Volts Manual



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Tm-5-6115-593-34

Chapter 1 Introduction
Tabulated Data
Tabulated Data (Cont)
Engine And Controls
Table 1-1. Special Torque Data
Table 1-1. Special Torque Data - Continued
Table 1-2. Repair And Replacement Standards
Table 1-2. Repair And Replacement Standards - Continued
Table 1-2. Repair And Replacement Standards - Continued
Table 1-2. Repair And Replacement Standards - Continued
Table 1-2. Repair And Replacement Standards - Continued
Table 1-2. Repair And Replacement Standards - Continued
Table 1-2. Repair And Replacement Standards - Continued
Table 1-2. Repair And Replacement Standards - Continued
Table 1-3. Parameters Ac-0% Droop
Table 1-4. Electrical Performance Characteristic Parameters Ac-3% Droop
Chapter 2 General Maintenance Instructions
Welding
Table 2-1. Special Tools, Test, And Support Equipment (Cont'd)
Table 2-2. Generator Set, Troubleshooting
Table 2-2. Generator Set, Troubleshooting - Continued
Table 2-2. Generator Set, Troubleshooting - Continued
Ac-Dc Control Box Assembly.
Figure 2-1. Location Of Major Components
Figure 2-2. Ac-Dc Control Box Assembly, Removal And Installation
Figure 2-3. External Power Box Assembly, Removal And Installation (Sheet 1 Of 2)
Figure 2-3. External Power Box Assembly, Removal And Installation (Sheet 2 Of 2)
Radiator Assembly
Figure 2-4. Radiator Assembly, Removal And Installation
Installation
Figure 2-5. Engine, Removal And Installation.
Chapter 3 Maintenance Of External Power Assembly
Figure 3-1. External Power Box Assembly, Exploded View
Legend For Figure 3-1
Figure 3-2. Preheat System Contactor K107 And Heater Contactor K109, Exploded View
Figure 3-3. Transfer Contactor K108, Exploded View
Figure 3-4. Contactor K120 Exploded View And Test Setup
Chapter 4 Maintenance Of Ac-Dc Control Box Assembly
Section Ii. Battery Charger
Figure 4-1. Ac-Dc Control Box Assembly, Exploded View
Figure 4-2. Fuel Transfer Pump Relay K20, Test Setup
Diodes
Repair.
Figure 4-3. Battery Charger Schematic
Figure 4-4. Battery Charger, Exploded View
Section Iii. Governor Controller
Removal And Replacement
Figure 4-5. Governor A106, Test Setup
Figure 4-6. Governor Controller, Exploded View
Repair
Section Iv. Voltage Regulator
On-Equipment Power Output Test
Section V. Panel Component Base Assembly
Figure 4-8. Voltage Regulator
Ac-Dc Control Relay Assembly Tb9
Figure 4-9. Voltage Regulator Schematic
Figure 4-10. Component Base Assembly, Exploded View
Figure 4-11. Component Assembly Panel, Relay K1 And K50, Test Setup
Figure 4-12. Ac-Dc Control Relay Assembly, Test Setup
Test Of Td1
Figure 4-13. Time Delay Module Td1
Figure 4-14. Time Delay Module Td3
Test.
Figure 4-15. Motor Operated Potentiometer, Exploded View
Figure 4-16. Motor-Operated Potentiometer, Test Setup
Figure 4-17. Motor-Operated Potentiometers, Cam Adjustment
Section Vi. Capacitor, Diode, And Circuit Cards
Chapter 5 Maintenance Of Control Cubicle
Figure 5-1. Control Cubicle, Exploded View (Sheet 1 Of 2 )
Figure 5-1. Control Cubicle, Exploded View (Sheet 2 Of 2)
Replacement.
Figure 5-2. Transducers A107 And A108, Test Setup
Figure 5-3. Transducer A103, Test Setup
Figure 5-4. Transformers T101 And T102, Schematic
Figure 5-5. Transformer T103, Schematic
Figure 5-6. Relay K23, Test Setup
Figure 5-7. Overvoltage Relay K102, Test Setup
Figure 5-8. Phase Sequence Relay K103, Test Setup
Figure 5-9. Sync Check Relay K106, Test Setup
Figure 5-10. Undervoltage Relay K111, Test Setup
Figure 5-11. Reverse Power Relay K112, Test Setup
Figure 5-12. Short Circuit Relay K113, Test Setup
Figure 5-13. Overload Relay K114, Test Setup
Figure 5-14. Time Delay Td2, Test Setup
Figure 5-15. Control Relay Assembly Tb10, Test Setup
Figure 5-16. Annunciator Control Assembly, Tb6 (Sheet 1 Of 2)
5-16. Annunciator Control Assembly, Tb6 (Sheet 2 Of 2)
Figure 5-17. Synchroscope, Test Setup
Synchroscope
Figure 5-18. Digital Clock, M111
Figure 5-19. Control Cubicle, Relay Panel
Figure 5-20. Under And Overfrequency Devices, Test Setup
Figure 5-21. Over/Under Voltage Device, Test Setup
Figure 5-22. Relay Test Setup
Figure 5-23. Synchronizer, Test Setup
Synchronizing Relay
Chapter 6 Maintenance Of The Support Frame Assembly
Figure 6-1. Support Frame Assembly
Chapter 7 Maintenance Of Radiator Assembly
Radiator Repair, Code A
Figure 7-1. Radiator Assembly, Code A, Exploded View
Legend For Figure 7-1
Fan And Bearing Replacement, Code A
Figure 7-2. Radiator Fan Motor, Code A
Replacement
Figure 7-3. Radiator Assembly, Code B, Exploded View (Sheet 1 Of 2)
Figure 7-3. Radiator Assembly, Code B, Exploded View (Sheet 2 Of 2)
Legend For Figure 7-3
Radiator Repair, Code B.
Reassembly.
Figure 7-4. Radiator Fan Motor, Code B
Chapter 8 Maintenance Of Engine Preheat Assembly
Figure 8-1. Preheat Installation
Figure 8-2. Heater Assembly
Figure 8-4. Thermostate Test Set-Up
Chapter 9 Maintenance Of Fuel Transfer Pump Assembly
Solenoid Valve L3
Figure 9-1. Fuel Transfer Pump Installation, Exploded View
Legend For Figure 9-1
Figure 9-2. Fuel Transfer Pump, Exploded View
Section I. Maintenance Of Interconnecting Electrical Harnesses
Figure 10-1. Parallel Cables, Diagram
Chapter 11 Maintenance Of Generator And Reconnection Assembly
Figure 11-1. Generator Reconnection And Box Assembly, Exploded View (Sheet 1 Of 2)
Legend For Figure 11-1 (Sheet 1)
Figure 11-1. Generator-Reconnection And Box Assembly (Sheet 2 Of 2)
Legend For Figure 11-1 (Sheet 2)
Figure 11-2. Current Transformer Assembly, Exploded View
Generator.
Generator And Excitation System Test
Generator And Excitation System Test (Cont)
Replacement.
Air Cleaners
Figure 11-3. Generator Assembly, Exploded View
Legend For Figure 11-3
Figure 11-4. Air Cleaner Assembly Removal
Figure 11-5. Generator Mounting Bolts
Figure 11-6. Checking Flywheel Face Runout
Figure 11-8. Checking Flywheel Housing Runout
Figure 11-9. Obtaining Dimension Y
Figure 11-10. Obtaining Dimension C
Table 11-1. Repair Of Generator Components
Permanent Magnet Stator And Frame Assembly
Figure 11-11. Removing Exciter Armature And Rotating Rectifier Assembly
Figure 11-12. Installing Exciter Armature And Rotating Rectifier Assembly
Rotating Rectifier
Figure 11-14. Testing Rotation Rectifiers With An Ohmmeter
Figure 11-15. Removing Bearing From Generator Shaft
Figure 11-16. Install Bearing On Generator Shaft
Figure 11-17. Drive Plate Assembly
Rotor Assembly
Replacement
Exciter Stator
Replacement.
Rebuild.
Rebuild. (Cont)
Exciter Armature
Figure 11-19. Exciter Stator Winding Data
Figure 11-20. Exciter Rotor Winding Data
Frame And Stator Combination
Repair
Chapter 12 Maintenance Of Electric Hydraulic Actuator
Figure 12-1. Speed Setting Adapter Plate
Figure 12-2. Actuator Test Circuit
Figure 12-3. Governor Actuator, Exploded View
Legend For Figure 12-3
Adjustments
Figure 12-4. Governor/Actuator Mounting On Engine And Actuator Test Connections
Figure 12-5. Pilot Valve Wrench P/N 370109
Repair
Figure 12-7. Check Valve Installation
Overhaul
Figure 12-9. Governor Pilot Valve Assembly
Figure 12-11. Clamp Bracket Subassembly
Figure 12-14. Power Piston Linkage Assembly
Figure 12-15. Power Piston Assembly
Figure 12-17. Piston Placement
Figure 12-18. Piston Link Assembly
Figure 12-22. Ball Head Assembly
Figure 12-28. Speed Droop Lever Assembly
Governor Linkage Adjustment
Chapter 13 Maintenance Of Engine Assembly
Figure 13-1. Speed Switch,-Exploded View (Mechanical Type Switch) (Code "A")
Figure 13-2. Speed Switch Sensitivity Tests (Mechanical Type Switch) (Code “A")
Speed Switch Disassembly
Figure 13-3. Speed Switch Test (Electronic Type) (Code B)
Inspection
Cleaning.
Legend For Figure 13-4
Figure 13-4. Starter Assembly, Exploded View (Code A)
Figure 13-6. Checking Solenoid Hold-In And Pull-In Windings (Code A)
Figure 13-7. Circuit For Checking Pinion Clearance (Code A)
Starter Assembly
Figure 13-9. Starter Assembly, Exploded View (Code B)
Legend For Figure 13-9
Figure 13-10. No-Load Test Circuit (Code B)
Figure 13-11. Adjusting Starter Pinion Clearance
Armature Test.
Repair/Overhaul.
Repair/Overhaul.
Assembly
Installation
Figure 13-12. Mainshaft-Cover And Tachometer Drive, Exploded View, Code A
Assembly.
Removal.
Section Iii. Oil Filter And Sensors
Figure 13-13. Mainshaft Cover And Tachometer Drive, Exploded View, Code B
Legend For Figure 13-14
Figure 13-14. Lubricating Oil Cooler, Exploded View, Code A
Inspection And Test.
Figure 13-15. Lubricating Oil Cooler, Exploded View, Code B
Flow Test.
Figure 13-16. Injector, Exploded View
Adjustment And Reassembly
Adjustment And Reassembly (Cont)
Figure 13-17. Injection Leakage Tester
Figure 13-18. Spray Angle Tester
Figure 13-19. Injector Test Stand
Figure 13-20. Fuel Injection Pump, Exploded View, Code A
Figure 13-21. Fuel Injection Pump, Exploded View, Code B
Figure 13-22. Fuel Shut-Off Valve, Exploded View
Figure 13-23. Governor Spring Pack, Exploded View
Figure 13-25. Fuel Pump Damper, Exploded View
Setting Idle Speed.
Housing Porosity Check
Figure 13-26. Fuel Pump Test Stand
Adjustment On Engine
Overhaul And Rebuilding
Governor Barrel Replacement
Throttle Shaft Replacement.
Governor Barrel Replacement.
Pulsation Damper Overhaul.
Governor Spring Pack Overhaul.
Figure 13-27. Turbocharger, Exploded View, Code A
Legend For Figure 13-27
Figure 13-28. Turbocharger, Exploded View, Code B
Section Iv. Water Pump
Figure 13-29. Water Pump, Exploded View
Legend For Figure 13-29
Water Pump With Idler Assembly
Figure 13-30. Water Pump With Idler Assembly
Legend For Figure 13-30
Repair.
Figure 13-31. Crankshaft Pulley Vibration Damper, Exploded View
Figure 13-32. Vibration Damper Wobble Check Points
Figure 13-33. Engine Front Support, Exploded View
Figure 13-34. Oil Pan Assembly, Exploded View
Repair.
Oil Pump
Figure 13-35. Oil Pump, Exploded View
Section Vi. Flywheel And Housing
Figure 13-35a. Ring Gear, Flywheel, And Flywheel Housing
Figure 13-36. Gear Case, Exploded View
Figure 13-37. Timing Gear, Exploded View
Section Vii. Cylinder Head And Valve Operating Mechanism
Figure 13-38. Rocker Arm Shaft And Rocker Arm Assembly, Exploded View
Pushrods And Tappets
Figure 13-39. Pushrods And Tappets, Code A
Figure 13-40. Pushrods And Tappets, Code B
Figure 13-41. Cylinder Head, Exploded View
Figure 13-42. Head Capscrew Tightening Sequence
Hydrostatic Testing
Figure 13-43. Crosshead Dimensions
Rebuilding.
Figure 13-44. Valve Seat Insert, Cross Sections
Rebuilding. (Cont)
Assembly And Testing
Intake And Exhaust Valves And Springs
Figure 13-45. Minimum Valve Head Rim Thk
Section Viii. Piston And.Rings
Figure 13-47. Piston And Connecting Rod, Exploded View
Connecting Rods
Figure 13-48. Piston Check Points
Installation
Figure 13-49. Cylinder Liner Check Points
Removal.
Figure 13-50. Cylinder Block, Exploded View
Camshaft Bushings.
Figure 13-51. Crankshaft, Exploded View
Hole Repair
Figure 13-52. Cylinder Block Height Checking Location
Cylinder Liner Lower Bore.
Figure 13-53. Sleeve And Block Boring Dimensions 13-102
Reassembly.
Reassembly. (Cont)
Figure 13-54. Engine Injection Timing Procedure Diagram
Injection Timing
Chapter 14 Maintenance Of Base Assembly
Figure 14-1. Base Assembly, Exploded View
Chapter 15 Materiel Used In Conjunction With The Generator Set
Figure 15-1. Remote Cable Assembly
Figure 15-2. Synchroscope, Test Setup
Figure 15-3. Remote Control Module, Plate Assembly, Exploded View
Figure 15-4. Undervoltage Relay K115, Test Setup
Figure 15-5. Underfrequency Relay K116, Test Setup
Replacement. Transducers
Figure 15-6. Transducer A103, Test Setup
Figure 15-7. Transducer A107 And A108, Test Setup
Figure 15-8. Annunciator Control Assembly A20 (Sheet 1 Of 2)
Figure 15-8. Annunciator Control Assembly A20 (Sheet 2 Of 2)
Transformer T103
Figure 15-9. Automatic Control Module
Legend For Figure 15-9
Figure 15-10. Under/Over Voltage Relay, Test Setup
Figure 15-11. Underfrequency And Overfrequency-Relay, Test Setup
Replacement
Replacement
Figure 15-12. Time Delay Relay, Test Setup
Figure 15-14. Lr, Lrdt, Test Setup
Section Iv. Housing Kit
Figure 15-16. Housing Kit, Door And Shutter Assembly
Right Side
Figure 15-17. Housing Kit, Right Side
Legend For Figure 15-17
Figure 15-18. Housing Kit Front
Figure 15-19. Housing Kit, Left Side
Legend For Figure 15-19
Rear.
Figure 15-20. Housing Kit, Rear
Legend For Figure 15-20
Figure 15-21. Housing Kit, Top (Sheet 1 Of 2)
Figure 15-21. Housing Kit, Top (Sheet 2 Of 2)
Figure 15-22. Housing Kit, Shutter Assembly
Shutter Assembly
Figure 15-23. Housing Kit Wiring
Shutter Assembly
Left Side.
Front.
Door And Shutter Assembly.
Limit Switches
Figure 15-24. Actuator Control Relay Assembly
Chapter 16 Generator Set Test And Inspection After Repair Or Overhaul
Table 16-1. Operational Tests
Table 16-1. Operational Tests - Continued
Section Iii. Operational Tests
Parallel Operation Provisions (Real Power)
Regulator Range Test.
Preparation For Test.
Frequency And Voltage Regulation, Stability And Transient Response Test (Short Term)
Test.
Test. (Cont)
Figure 16-1. Overshoot And Undershoot Chart Recording
Frequency Adjustment Range Test
Procedure
Overspeed Protective Device Test
Circuits Interrupter Test (Overload Current)
Circuit Interrupter Test (Overvol- Tage And Undervoltage)
Test.
Results.
Low Oil Pressure Protective Device Test
Maximum Power Test
Test
Test (Cont)
Chapter 17 Generator Set Installation Practices
Section Ii. Location
Figure 17-1. Generator Set Operational Requirements (Sheet 1 Of 2)
Figure 17-1. Generator Set Operational Requirements (Sheet 2 Of 2)
Table 17-1. Weight And Dimensions
Figure 17-2. Mounting Bolt Layout In Concrete Pad
Figure 17-3. Cross Section View Of Pad And Mounting Bolt Installation
Figure 17-4. Vibration Isolator (12 Required)
Figure 17-5. 500 Kw Generator Set Installation
Figure 17-6. Fixed Louvers For Air Inlet
Figure 17-9. Exhaust Fan
Table 17-4. Radiator And Crankcase Capacities
Figure 17-10. 500 Kw Deaerating Top Tank Design
Figure 17-11. 500 Kw Dod Deaerating Top Tank Piping
Figure 17-12. Recommended Auxiliary Tank Piping
Figure 17-13. Remote Radiator Application "A"
Figure 17-14. Remote Radiator Application "B"
Figure 17-15. Remote Radiator Application "C"
Table 17-5. 500 Kw Dod Generator Set Radiator Data
Table 17-6. Fuel Consumption For 500 Kw Dod Generator Set
Figure 17-16. Auxiliary Diesel Fuel System
Figure 17-17. 500 Kw Generator Set Installation
Figure 17-18. 500 Kw Generator Set Anti-Siphon Installation
Section Viii. Exhaust System
Figure 17-19. 500 Kw Levelometer System Installation
Section Ix. Electrical Requirements
Figure 17-20. Double Thimble-Wall Outlet Details
Figure 17-21. 500 Kw Exhaust System
System Description
Figure 17-22. Installation Of Mufflers On Generator Set.
Figure 17-23. Muffler Provided With Generator Set
Figure 17-24. Generator Voltages And Schematic
Figure 17-25. Service Points On 500 Kw Generator Set
Table 17-10. Installation Check List
Appendix A References
Appendix A References (Cont)
Index
Index (Cont)
Index (Cont)
Index (Cont)
Index (Cont)
Index (Cont)
Index (Cont)
Iindex (Cont)
Iindex (Cont)
Iindex (Cont)
Iindex (Cont)
Fo-1. Generator Set, Electrical Layout
Fo-2. Main Control Harness (Sheet 1 Of 2)
Fo-3. Main Control Harness (Sheet 2 Of 2)
Fo-4. Ac Power Wiring Harness
Fo-5. External Power Box Harness Assembly (Sheet 1 Of 2)
Fo-6. External Power Box Harness Assembly (Sheet 2 Of 2)
Fo 7. Ac-Dc Control Box Harness Assembly (Sheet 1 Of 5)
Fo 8. Ac-Dc Control Box Harness Assembly (Sheet 2 Of 5)
Fo 9. Ac-Dc Control Box Harness Assembly (Sheet 3 Of 5)
Fo 10. Ac-Dc Control Box Harness Assembly (Sheet 4 Of 5)
Fo-11. Ac-Dc Control Box Harness Assembly (Sheet 5 Of 5)
Fo-12. Control Box Harness Assembly (Sheet 1 Of 8)
Fo-13. Control Box Harness Assembly (Sheet 2 Of 8)
Fo-14. Control Box Harness Assembly (Sheet 3 Of 8)
Fo-15. Control Box Harness Assembly (Sheet 4 Of 8)
Fo-16. Control Box Harness Assembly (Sheet 5 Of 8)
Fo-17. Control Box Harness Assembly (Sheet 6 Of 8)
Fo-18. Control Box Harness Assembly (Sheet 7 Of 8)
Fo-19. Control Box Harness Assembly (Sheet 8 Of 8)
Fo-20. Reconnection Box Harness Assembly
Fo-21. Reconnection Harness
Fo-22. Engine Accessory Harness (Sheet 1 Of 3)
Fo-23. Engine Accessory Harness (Sheet 2 Of 3)
Fo-24. Engine Accessory Harness (Sheet 3 Of 3)
Fo-25. Remote Control Cable Assembly (Sheet 1 Of 2)
Fo-26. Remote Control Cable Assembly (Sheet 2 Of 2)
Fo-27. Remote Control Box Harness Assembly (Sheet 1 Of 4)
Fo-28. Remote Control Box Harness Assembly (Sheet 2 Of 4)
Fo-29. Remote Control Box Harness Assembly (Sheet 3 Of 4)
Fo-30. Remote Control Box Harness Assembly (Sheet 4 Of 4)
Fo-31. Paralleling Cables, Governor Control
Fo-32. Paralleling Cables, Voltage Regulator
Fo-33. Louver Harness Assembly (Sheet 1 Of 2 )
Fo-34. Louver Harness Assembly (Sheet 2 Of 2 )
Fo-35. Louver Control Harness (External Power Box )
Fo-36. Auxiliary Power Harness
Fo-37. Electrical Cable Assembly
Fo-38. Ac Neutral Power Cable
Fo-39. Ac-Dc Control Cable Assembly
Fo-40. Battery Cables
Fo-41. Cables 25- And 37 -Conductor
Fo-42. Acm Wiring Harness (Sheet 1 Of 3)
Fo-43. Acm Wiring Harness (Sheet 2 Of 3)
The Metric System And Equivalents

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