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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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