TM 9-6115-668-13
SUPERSEDES TM 9-6116-668-13, 02 AUGUST 1996
TECHNICAL MANUAL
OPERATOR, UNIT, AND DIRECT SUPPORT MAINTENANCE MANUAL
GENERATOR SET, DIESEL ENGINE DRIVEN,
SKID MOUNTED,
150 kW, 400 Hz, ALTERNATING CURRENT
(NSN 6115-12-337-8494)
DISTRIBUTION STATEMENT A. Approved for public release; distribution is unlimited.
HEADQUARTERS, DEPARTMENT OF THE ARMY
JUNE 1998
*TM 9-6115-666-13
HEADQUARTERS
DEPARTMENT OF THE ARMY
WASHINGTON D.C., 01 June 1998
TECHNICAL MANUAL
NO. 9-6115-668-13
OPERATOR, UNIT, AND DIRECT SUPPORT MAINTENANCE MANUAL
GENERATOR SET, DIESEL ENGINE DRIVEN, SKID MOUNTED,
150 kW, 400 Hz, ALTERNATING CURRENT (NSN: 6115-12-337-8494)
REPORTING ERRORS AND RECOMMENDING IMPROVEMENTS
You can help improve this manual. If you find any mistakes, or if you know of a way to improve
these procedures, please let us know. Mail your letter or DA Form 2028 (Recommended
Changes to Publications and Blank Forms), or DA Form 2028-2 located in the back of this
manual directly to: Commander, U. S. Army Communications-Electronics Command and Fort
Monmouth, ATTN: AMSEL-LC-LEO-D-CS-CFO, Fort Monmouth, New Jersey 07703-5000.
The fax number is 732-532-1413, DSN 992-1413. You may also e-mail your recommendations
to AMSEL-LC-LEO-PUBS-CHG@cecom3.monmouth.army.mil. Instructions for sending an
electronic 2028 may be found at the back of this manual immediately preceding the hard copy
2028. In either case a reply will be furnished to you.
DISTRIBUTION STATEMENT A. Approved for public release, distribution is unlimited.
TABLE OF CONTENTS
Page
CHAPTER 1
HOW TO USE THIS MANUAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
xiv
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-1
Section I.
General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-2
Section II.
Equipment Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-5
Section III.
Principles of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-15
This manual supersedes TM 9-6115-668-13, 02 August 1996.
I
TM 9-6115-668-13
TABLE OF CONTENTS - continued
Page
CHAPTER 2
CHAPTER 3
CHAPTER 4
OPERATING INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-1
Section I.
Description and Use of Controls and Indicators . . . . . . . . . . . . . . . . . . . .
2-2
Section II.
Operator Preventive Maintenance Checks and Services (PMCS) . . .
2-12
Section III.
Operation under Usual Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-34
Section IV.
Operation under Unusual Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2 - 63
OPERATOR MAINTENANCE INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-1
Section I.
Operator Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-2
Section II.
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-3
Section III.
Maintenance Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-11
UNIT MAINTENANCE INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Section I.
Repair Parts; Tools; Special Tools; Test, Measurement and
Diagnostic Equipment (TMDE); and Support Equipment . . . . . . . . . . . .
4-5
Section II.
Service Upon Receipt of Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-6
Section III.
Unit Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-14
Section IV.
Unit Preventive Maintenance Checks and Services (PMCS) . . . . . . . .
4-15
Section V.
ii
4-1
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-20
Section VI.
Radio Interference Suppression . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-40
Section VII.
Maintenance Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-41
TM 9-6115-668-13
TABLE OF CONTENTS - continued
Page
CHAPTER 5
DIRECT SUPPORT MAINTENANCE INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . .
Section I.
Section II.
Section III.
Repair Parts; Tools; Special Tools; Test, Measurement and
Diagnostic Equipment (TMDE); and Support Equipment . . . . . . . . . . . .
Troubleshooting
..............................................
Maintenance Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-1
5-3
5-4
5-95
APPENDIX A
REFERENCES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
A-1
APPENDIX B
MAINTENANCE ALLOCATION CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
B-1
APPENDIX C
APPENDIX D
APPENDIX E
Section I.
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
B-1
Section II.
MAINTENANCE ALLOCATION CHART FOR GEN SET 150 kW . . . .
B-4
Section III.
Tool and Test Equipment Requirements for Gen Set 150 kW . . . . . . .
B-10
Section IV. REMARKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
B-11
COMPONENTS OF END ITEM (COEI) AND
BASIC ISSUE ITEMS (Bll) LISTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
C-1
Section I.
Introduction.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
C-1
Section II.
Components of End Item . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
C-2
Section III.
Basic Issue Items . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
C-3
ADDITIONAL AUTHORIZATION LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
D-1
Section I.
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
D-1
Section II.
Additional Authorized Items List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
D-2
EXPENDABLE AND DURABLE ITEMS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
E-1
Section I.
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
E-1
Section II.
Expendable and Durable Items List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
E-2
iii
TM 9-6115-668-13
TABLE OF CONTENTS - continued
Page
APPENDIX F
OPERATOR’S LUBRICATION INSTRUCTIONS . . . . . . . . . . . . . . . . . . . F - 1
Section I.
APPENDIX G
GLOSSARY
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
F-1
TORQUE LIMITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
G-1
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . GLOSSARY - 1
Section I.
Section II.
INDEX
iv
Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
GLOSSARY - 1
Definition of Unusual Terms . . . . . . . . . . . . . . . . . . . . . . . . . GLOSSARY - 2
..............................................................
INDEX - 1
TM 9-6115-668-13
LIST OF ILLUSTRATIONS
Figure
Title
Page
1-1
Generator Set 150 kW. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-3
1-2
Generator Set 150 kW, Location of Major Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1 - 10
1-3
Generator Set 150 kW, Dimensions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1 - 14
1-4
Generator Set 150 kW, Block Diagram. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-17
2-1
Control Cabinet Assembly, Controls and Indicators. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-2
2-2
Control Cabinet Assembly, Circuit Breakers (sheet 1 of 2). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-7
2-3
Control Cabinet Assembly, Receptacles. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2 - 10
2-4
Base Frame Assembly, J3 SLAVE RECEPTACLE 24 VOLTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2 - 11
2-5
Operator PMCS Routing Diagram (sheet 1 of 6). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2 - 15
2-6
Control Cabinet Assembly Lamp Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2 - 35
2-7
Diesel Engine Oil Removal Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2 - 39
2-8
Diesel Engine Oil Level Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2 - 40
2-9
Viscosity Class (SAE Class). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2 - 42
2-10
Refueling. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2 - 45
2-11
Connect Battery Cable. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2 - 46
2-12
Connecting Control and Power Cables. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2 - 48
2-13
Generator Set 150 kW Identification Plate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2 - 49
2-14
Generator Set 150 kW CG Plate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2 - 49
2-15
Generator Set 150 kW Transportation Data Plate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2 - 49
2-16
Engine Preheating Plate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2 - 50
2-17
Generator Set 150 kW Short Operating Instructions Plate (sheet 1 of 2). . . . . . . . . . . . . . . . . . . .
2 - 51
2-18
Operating the Generator Set 150 kW. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2 - 56
v
TM 9-6115-668-13
LIST OF ILLUSTRATIONS - continued
Figure
Title
Page
2-19
Generator Set 150 kW Shutdown. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2 - 57
2-20
BATTLE SHORT Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2 - 59
2-21
Disconnecting Control and Power Cables. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2 - 61
2-22
Disconnect Battery Cable. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2 - 62
2-23
Disconnect Ground Cable. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2 - 62
2-24
Operating the Engine Preheating Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-64
2-25
Operating the Flame Glowplug System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2 - 66
2-26
Fuel Injection Pump Actuator Linkage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2 - 68
3-1
BATTERY CHARGING CONTROL and OIL PRESSURE lamps do not light up. . . . . . . . . . . . . .
3-4
3-2
HEATING FAILURE lamp lights up or READY TO START IF HEATING IS ON
vi
lamp does not light up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-5
3-3
GLOWPLUG ON lamp does not light up. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-6
3-4
Oil pressure too low, or no oil pressure indication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-7
3-5
Generator frequency cannot be adjusted, or no frequency indication. . . . . . . . . . . . . . . . . . . . . . . .
3-8
3-6
Generator voltage cannot be adjusted, or no voltage indication. . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-9
3-7
AC CIRCUIT INTERRUPTER ON lamp does not light up. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3 - 10
3-8
Air Filter Assembly Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3 - 13
4-1
Original Packaging in Container. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-9
4-2
Unpacking the container . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4 - 10
4-3
Generator Set 150 kW, Unpacked. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4 - 11
4-4
Lubricate synchronous generator bearings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4 - 14
4-5
Unit PMCS Routing Diagram. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4 - 17
TM 9-6115-666-13
LIST OF ILLUSTRATIONS - continued
Figure
Title
4-6
BATTERY CHARGING CONTROL and OIL PRESSURE lamps do not light up. . . . . . . . . . . . . .
4-7
HEATING FAILURE lamp lights up or READY TO START IF HEATING IS ON
Page
4 - 22
lamp does not light up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4 - 23
4-8
GLOWPLUG ON lamp does not light up. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4 - 24
4-9
Diesel engine cannot be started. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4 - 25
4-10
Oil pressure too low, or no oil pressure indication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4 - 26
4-11
Battery set is not being charged, or no charging current indication. . . . . . . . . . . . . . . . . . . . . . . . . .
4 - 27
4-12
Generator frequency cannot be adjusted, or no frequency indication. . . . . . . . . . . . . . . . . . . . . . . .
4 - 28
4-13
Generator voltage cannot be adjusted, or no voltage indication. . . . . . . . . . . . . . . . . . . . . . . . . . . .
4 - 29
4-14
AC CIRCUIT INTERRUPTER ON lamp does not light up. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4 - 30
4-15
No line currents are flowing, or no line current indication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4 - 31
4-16
No power indication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4 - 32
4-17
BATTERY CHARGING CONTROL lamp lights up during operation. . . . . . . . . . . . . . . . . . . . . . . . .
4 - 33
4-18
OIL PRESSURE lamp lights up during operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4 - 34
4-19
OIL TEMP-CYLINDER HEAD lamp lights up during operation, . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4 - 35
4-20
UNDER/OVER FREQUENCY lamp lights up during operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4 - 36
4-21
UNDER/OVER VOLTAGE lamp lights up during operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4 - 37
4-22
GENERATOR OVER TEMPERATURE lamp lights up during operation. . . . . . . . . . . . . . . . . . . . .
4 - 38
4-23
OVERLOAD lamp lights up during operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4 - 39
4-24
Unit Hood Flap Ground Strap Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4 - 44
4-25
Unit Hood Assembly Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4 - 47
4-26
Unit Hood-Base Frame Ground Strap Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4 - 49
Vii
TM 9-6115666-13
LIST OF ILLUSTRATIONS - continued
Figure
Title
4-27
Unit Hood Assembly Air Ducts and Air Cooling Inlet Grate Maintenance Maintenance. . . . . . . . .
4-54
4-28
Unit Hood Flap Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-58
4-29
Control Cabinet Assembly, Light Indicator Assembly Maintenance . . . . . . . . . . . . . . . . . . . . . . . . .
4 - 61
4-30
Bulb in Indicator Lamps Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4 - 63
4-31
Bulb illuminated Switch Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-63
4-32
Panel Light H6 Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-67
4-33
Illuminated Meter Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-69
4-34
Cabinet Light Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4 - 71
4-35
Air Fitter Cartridge Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-74
4-36
Oil Filter, Subcurrent Filter Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-77
4-37
Fuel Prefilter Cartridge, Two Step Fuel Filter Cartridges Maintenance. . . . . . . . . . . . . . . . . . . . . .
4 - 82
4-38
Battery Charging Alternator V Belt Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-86
4-39
Diesel Engine Cylinder Cooling Fins and Oil Cooler Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . .
4-88
4-40
Priming Pump Assembly Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4 - 90
4-41
Diesel Engine Fuel Pipes and Fuel Filter Assembly Maintenance.
4-93
4-42
Fuel Prefilter, Two Step Fuel Filter Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4 - 98
4-43
Fuel Line Assembly Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-103
4-44
Control Cabinet Assembly Maintenance (Sheet 1 of 2). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-107
4-45
Control Cabinet Assembly, Pushbutton Switch and Indicator Assembly Maintenance. . . . . . . . .
4 - 113
4-46
Control Cabinet Assembly, Pushbutton Switch Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-116
4-47
Control Cabinet Assembly, Panel Illumination H6 Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-118
viii
.........................
TM 9-6115-668-13
LIST OF ILLUSTRATIONS
Title
Figure
4-48
Page
Control Cabinet Assembly, Preheating Resistor R1, BATTLE SHORT Switch S21,
VOLTAGE SELECTOR SWITCH S11, GLOWPLUG/START Switch S2, MASTER SWITCH S1
Maintenance
4-49
......................................................................
4 - 127
Control Cabinet Assembly, FREQUENCY ADJUST R4, VOLTAGE ADJUST R3,
PANEL DIMMER S16/R2 Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4 - 134
4-50
Control Cabinet Assembly, Meter Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-139
4-51
Control Cabinet Assembly, Cabinet Illumination H7, Door Contact Switch S3,
Brightness Control N5 Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4 - 143
Control Cabinet Assembly, Auxiliary Contactor with Semiconductor, Auxiliary Contactor,
Transformer, Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4 - 146
4-53
Diodes, Time Relay, Power Supply Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4 - 151
4-54
Control Cabinet Assembly, Circuit Breaker F1 to F11, Thermistor relay F12, . . . . . . . . . . . . . . . .
4 - 157
4-55
Control Cabinet Assembly, Relays K19, K20, Digital lsochronous Load Sharing Module N4,
4-52
Speed Governor Assembly N1, Resistor Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4 - 160
4-56
Control Cabinet Assembly, Contactor K1 Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4 - 164
4-57
Control Cabinet Assembly, Engine Preheating Control Board, Circuit Breaker Maintenance. . . .
4 - 170
4-58
Control Cabinet Assembly, Connection Panel, Connector Maintenance. . . . . . . . . . . . . . . . . . . . .
4 - 177
4-59
Air Filter Assembly, J3 Slave Receptacle 24 V Connector Maintenance. . . . . . . . . . . . . . . . . . . . .
4 - 179
4-60
Shunt Resistor R11, EHG Regulator N7, Generator Regulator N6, Battery Set Maintenance. . .
4 - 186
4-61
Fuel Tank Assembly, Electrical Fuel Pump Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4 - 192
4-62
Fuel Level Switch and Sensor Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4 - 199
4-63
Silencer Assembly, Left Side Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4 - 204
4-64
Silencer Assembly, Right Side Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4 - 209
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. . . . . . . . . . . . .
4-217
ix
TM 9-6115-688-13
LIST OF ILLUSTRATIONS
Figure
Title
4-66
Battery Charging Alternator Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4 - 221
4-67
Generator, Starter Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4 - 224
BATTERY CHARGING CONTROL and OIL PRESSURE lamps do not light up (sheet 1 of 7). .
5-7
5-1
5-2
HEATING FAILURE lamp lights up or READY TO START IF HEATING IS ON
lamp does not light up (sheet 1 of 7). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-14
5-3
GLOWPLUG ON lamp does not light up (sheet 1 of 4). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5 - 21
5-4
Diesel engine cannot be started (sheet 1 of 10). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5 - 25
5-5
Oil pressure too low, or no oil pressure indication (sheet 1 of 3). . . . . . . . . . . . . . . . . . . . . . . . . . . .
5 - 35
5-6
Battery set is not being charged, or no charging current indication (sheet 1 of 2). . . . . . . . . . . . .
5 - 38
5-7
Generator frequency cannot be adjusted, or no frequency indication (sheet 1 of 5). . . . . . . . . . .
5 - 40
5-8
Generator voltage cannot be adjusted, or no voltage indication (sheet 1 of 7). . . . . . . . . . . . . . . .
5 - 45
5-9
AC CIRCUIT INTERRUPTER ON lamp does not light up (sheet 1 of 11). . . . . . . . . . . . . . . . . . . .
5 - 52
5-10
No line currents are flowing, or no line current indication (sheet 1 of 5). . . . . . . . . . . . . . . . . . . . . .
5 - 63
5-11
No power indication (sheet 1 of 2). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5 - 68
5-12
BATTERY CHARGING CONTROL lamp lights up during operation. . . . . . . . . . . . . . . . . . . . . . . . .
5 - 70
5-13
OIL PRESSURE lamp lights up during operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5 - 71
5-14
OIL TEMP-CYLINDER HEAD lamp lights up during operation (sheet 1 of 3). . . . . . . . . . . . . . . .
5 - 72
5-15
UNDER/OVER FREQUENCY lamp lights up during operation (sheet 1 of 6). . . . . . . . . . . . . . . . .
5 - 75
5-16
UNDER/OVER VOLTAGE lamp lights up during operation (sheet 1 of 6). . . . . . . . . . . . . . . . . . . .
5 - 81
5-17
GENERATOR OVER TEMPERATURE lamp lights up during operation (sheet 1 of 4). . . . . . . . .
5 - 87
5-18
OVERLOAD lamp lights up during operation (sheet 1 of 4). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5 - 91
5-19
Control Cabinet Assembly, Auxilliary Contactor with Semiconductor, Auxiliary Contactor,
Transformer, Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
x
Page
5-101
TM 9-6115-668-13
LIST OF ILLUSTRATIONS - continued
Figure
Title
Page
5-20
Time Relays K3, K10, K13 and K26 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5 - 105
5-21
Time Relay K17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5 - 106
5-22
Time Relay K25 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5 - 107
5-23
Diodes, Time Relay, Power Supply Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5 - 109
5-24
Control Cabinet Assembly, Circuit Breaker F1 to F11, Thermistor relay F12,
True Power Measuring Transformer P4A Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5 - 111
5-25
Digital lsochronous Load Sharing Module N4, Location of Potentiometers and Test Points, . . . .
5 - 114
5-26
Speed Governor Assembly N1, Location of Potentiometers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5 - 119
5-27
Control Cabinet Assembly, Relays K19, K20, Digital lsochronous Load Sharing Module N4,
Speed Governor Assembly N1, Resistor Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5 - 120
5-28
Voltage Regulator N2, Location of Circuit Boards and Potentiometers. . . . . . . . . . . . . . . . . . . . . .
5 - 123
5-29
Control Cabinet Assembly, Voltage Regulator N2 Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . .
5 - 125
5-30
Voltage regulator N2, Location of Circuit Boards and Potentiometers. . . . . . . . . . . . . . . . . . . . . . .
5 - 129
5-31
Control Cabinet Assembly, Safety Device N3 Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5 - 135
5-32
Control Cabinet Assembly, Filter Box FK, Current Transformers, Resistors Maintenance . . . . . .
5 - 141
5-33
Time Relay K106 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5 - 147
5-34
Time Relay K107 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5 - 148
5-35
Time Relay K108 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5 - 149
5-36
Time Relay K110 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5 - 151
5-37
Control Cabinet Assembly, Engine Preheating Control Board, Auxiliary Contactor K109,
Diodes, Time Relay Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5 - 152
5-38
Miniature Relay, Power Relay Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5 - 157
5-39
Control Cabinet Assembly, Connection Panel, Connector Receptacle L1 to L3 and N,
Interlock Switch Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5 - 162
xi
TM 9-6115-668-13
LIST OF ILLUSTRATIONS - continued
Figure
Title
Page
5-40
Air Filter Assembly, J3 Slave Receptacle 24 V Connector Maintenance . . . . . . . . . . . . . . . . . . . . .
5-167
5-41
Subcurrent Fitter Assembly, Oil Lines Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5 - 172
5-42
Flame Glowplug System Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5 - 176
5-43
Preheating Assembly Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5 - 179
5-44
Temperature Switch, Glowplug Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5 - 183
5-45
Preheating Cable Assembly Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5 - 186
5-46
Air Flap Puller Magnet, Electric Oil Pump, Air-Oil Heat Exchanger Maintenance. . . . . . . . . . . . . .
5 - 192
5-47
Oil Hose, Oil Temperature Switch Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5 - 197
5-48
Actuator Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5 - 200
5-49
Actuator Cable, Pick-up, Pick-up Cable Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5 - 207
5-50
EHG and Cylinder Head Temperature Sensor Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-210
5-51
Generator Wiring Harness Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-213
5-52
Diesel Engine and Synchronous Generator Maintenance (Sheet 1 of 2). . . . . . . . . . . . . . . . . . . . .
5 - 223
5-53
Diesel Engine Maintenance (Sheet 1 of 2). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5 - 228
5-54
Synchronous Generator Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5 - 232
5-55
Clutch Assembly Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5 - 235
xii
FO-1 Generator Set 150 kW Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FP-1/FP-2 Blank
FO-2 Engine Preheating Assembly Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FP-23/FP-24 Blank
TM 9-6115-668-13
LIST OF TABLES
Number
Title
Page
1-1
Nomenclature Cross-Reference List. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-4
1-2
Description of Major Components, Generator Set 150 kW. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-6
1-3
Tabulated Data for Generator Set 150 kW. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1 - 11
1-4
BATTLE SHORT Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-23
1-5
J9 PARALLEL OPERATION Receptacle, Monitoring and Control Functions. . . . . . . . . . . . . . . . .
1-25
2-1
Control Cabinet Assembly, Description of Controls and Indicators. . . . . . . . . . . . . . . . . . . . . . . . . .
2-3
2-2
Control Cabinet Assembly, Description of Circuit Breakers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-9
2-3
Control Cabinet Assembty, Description of Receptacles, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2 - 10
2-4
Operator Preventive Maintenance Checks and Services. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2 - 21
2-5
SHPD Oils Approved for Diesel Engine BF8L513. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2 - 41
2-6
Oil change intervals. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2 - 43
4-1
Fuel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4 - 12
4-2
Lubricating Oil. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4 - 13
4-3
Unit Preventive Maintenance Checks and Services for Generator Set 150 kW. . . . . . . . . . . . . . .
4 - 18
xiii
TM 9-6115-668-13
HOW TO USE THIS MANUAL
DESCRIPTION OF THE MANUAL.
Manual Organization. This manual is designed to help you operate and maintain the generator set 150 kW. Warning pages are located in the front of this manual. Read the warnings before operating or doing maintenance on the equipment.
The major elements of this manual are the chapters and appendices. Each chapter has one or
more sections. The Table of Contents, beginning on page i, is provided for quick reference to
the subjects covered by each chapter, section, and appendix. Each chapter also has a chapter
index. The chapter index lists the chapter sections and pargraphs.
A glossary follows the last appendix. The glossary lists and explains the special or unique abbreviations and the unusual terms used in this manual.
An alphabetical index follows the glossary. That index is for use in locating specific items of information.
Chapters. This manual has five chapters and eight appendices. Each chapter is divided into
sections. Each section is divided into descriptive paragraphs. The paragraphs have specific
information about the generator set 150 kW and their major components.
Paragraph Numbering. All paragraphs are numbered. This helps you find what you need
when you need it. USE THE TABLE OF CONTENTS OR ALPHABETICAL INDEX TO FIND
THE SECTION OR PARAGRAPH YOU NEED. Some paragraphs have a related illustration, to
show the items discussed in the paragraph. Also, some paragraphs have a related table that
provides a detailed list of items introduced by the paragraph. Each primary paragraph, illustration, and table is identified by the number of the chapter in which it appears, followed by a
dash and another number. The number afte the dash indicates the sequence in which the
paragraph, illustration, or table appears in the chapter. Some paragraphs are further divided
into subparagraphs. Subparagraphs are identified by the number of the primary paragraph followed by a decimal number, as follows:
Examples:
4.5. is the fifth paragraph in chapter 4.
4.5.1 is the first subparagraph of paragraph 4.5.
4.5.2 is the second subparagraph of paragraph 4.5.
4.5.2.1 is the first subparagraph under 4.5.2.
Figure 3-3. is the third illustration in chapter 3.
Table 2-1. is the first table in chapter 2.
Amendices. Each appendix covers a specific subject.
xiv
TM 9-6115-668-13
CHAPTER 1 - INTRODUCTION.
Chapter 1 provides an introduction to the generator set 150 kW. It is divided into three sections, as follows:
Section I - General Information. This section provides general information about this manual
and the related forms and records. Instructions are provided for making equipment improvement recommendations, Coverage includes a reference to the TM that contains instructions on
destruction of material to prevent enemy use. Also, a nomenclature cross-reference list is provided.
Section II - Equipment Description. This section describes generator set 150 kW capabilities, characteristics, and features. It provides basic equipment data and shows the locations of
major generator set 150 kW components. Descriptions of the major components are also provided.
Section Ill - Principles of Operation. This section provides functional descriptions of th generator set 150 kW.
CHAPTER 2 - OPERATING INTRODUCTIONS.
Chapter 2 provides introductions for operating the generator set 150 kW. The chapter is divided into four sections, as follows:
Section I - Description and Use of Operator’s Controls and Indicators. This section contains information on operator’s controls and indicators for the generator set 150 kW.
Section II - Operator Preventive Maintenance Checks and Services (PMCS). This section
contains detailed instructions for the before, during, and after operation preventive maintenance checks and services that the operator must perform.
Section Ill - Operation Under Usual Conditions. This section contains instructions for preparing the generator set 150 kW for use and operating under usual conditions.
Section IV - Operation Under Unusual Conditions. This section contains instructions for
preparing the generator set 150 kW for use and operating under unusual conditions.
CHAPTER 3 - OPERATOR MAINTENANCE INSTRUCTIONS.
Chapter 3 covers maintenance of the generator set 150 kW that is to be performed by the operator. Its purpose is to provide you with the information you need to keep the equipment in
good operating condition. This chapter is divided into three sections, as follows:
Section I - Operator Lubrication. This section provides references to the applicable lubrication instructions.
Section II - Troubleshooting. This section covers troubleshooting procedures and corrective
actions that are to be performed at the operator maintenance level.
Section Ill - Maintenance Procedures. This section refers the operator to the preventive
maintenance checks and services required by section II of chapter 2.
xv
TM 9-6115-668-13
CHAPTER 4 - UNIT MAINTENANCE INSTRUCTIONS.
Chapter 4 provides instructions covering the generator set 150 kW maintenance that must be
performed at unit level. This chapter is divided into seven sections, as follows:
Section I - Lubrication Instructions. This section contains specific lubrication instructions for
the generator set 150 kW.
Section II - Repair Parts: Tools: Special Tools: Test, Measurement, and Diagnostic
Equipment (TMDE): and Support Equipment. This section lists the documents that contain
the needed information.
Section Ill - Service Upon Receipt of Equipment. This section contains instructions for inspecting and servicing each generator set 150 kW when it is received. It includes instructions
for unpacking the equipment when it is received. The instructions include unpacking and stowing the basic issue items that accompany the generator set 150 kw. Also included are instructions on positioning the generator set 150 kW for operating and connecting an external fuel
source.
Section IV - Unit Preventive Maintenance Checks and Services (PMCS). This section contains instructions covering the PMCS that must be performed at the unit maintenance level. A
table provides information on maintenance intervals and actions required.
Section V - Troubleshooting. This section covers troubleshooting procedures and corrective
actions that are to be performed at the unit maintenance level.
Section VI - Radio Interference Suppression. This section describes procedures which
have been performed on the Generator Set 150 kW to avoid Electro Magnetic Induction (EMI).
Section VII - Maintenance Procedures. This section contains detailed instructions on unit
level maintenance of the generator set 150 kW.
CHAPTER 5 - DIRECT SUPPORT MAINTENANCE INTRODUCTIONS.
Chapter 5 provides instructions for the maintenance actions designated to be performed at the
direct support maintenance level. The chapter is divided into three sections, as follows:
Section I - Repair Parts: Tools: Special Tools: Test. Measurement, and Diagnostic Equipment (TMDE); and Support Equipment. This section lists the documents that contain the
needed information.
Section II - Troubleshooting. This section includes instructions for troubleshooting faults in
the operation of the control cabinet assembly. It includes eighteen go-no-go flowcharts for
eighteen possible control cabinet malfunctions.
Section Ill - Maintenance Procedures. This section contains detailed instructions for direct
support maintenance of the generator set 150 kW.
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APPENDICES.
Appendix A - References. This appendix lists all publications that are referenced in the various chapters of the technical manual. The listing includes the title of each publication.
Appendix B - Maintenance Allocation Chart (MAC). This appendix has four sections, as
follows:
Section I - Introduction. This section explains what is covered in the maintenance allocation
chart.
Section II - Maintenance Allocation Chart. This section contains a tabular listing that assigns maintenance functions to specific maintenance levels. It lists the work time needed to
perform each maintenance function at the assigned level. It also contains a column that has
entries keyed to the tools and equipment listed in section III. Another column has entries keyed
to the remarks in section IV.
Section Ill - Tool and Test Equipment Requirements. This section contains complete identification information for the items referenced in the tools and equipment column of section II.
Section IV - Remarks. This section provides additional information for each entry in the remarks column of section II.
Appendix C - Components of End Item (COEI) and Basic Issue Items (Bll) Lists. This appendix lists the items that are usually packaged separately but needed for installation and operation of the generator set 150 kW. The appendix has three sections, as follows:
Section I - Introduction. This section explains what is covered in section II and section III.
Section II - Components of End Item. The generator set 150 kW is shipped fully assembled,
so this section is not applicable.
Section Ill - Basic Issue Items. This section contains a list of the accessories needed for
installation and operation of the generator set 150 kW.
Appendix D - Additional Authorization List (AAL). This appendix lists additional items you
are authorized for support of the generator set 150 kW.
Appendix E - Expendable and Durable Items List. This appendix lists expendable/durable
supplies and materials needed to operate and maintain the generator set 150 kW. The appendix contains two sections, as follows:
Section I - Introduction. This section explains the entries in section II.
Section II - Expendable and Durable Supplies and Materials List. The list indicates the
maintenance level that needs each item and identifies the items by National Stock Number,
description, and unit of measure.
Appendix F - Operator’s Lubrication Instructions. This appendix contains instructions for
lubrication, if necessary.
Appendix G - Torque Limits. This appendix lists standard torque values for bolts and screws
used in the generator set 150 kW.
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Glossary. This Glossary has two sections, as follows:
Section I - Abbreviations. This section lists the special or unique abbreviations used in this
technical manual. Special or unique abbreviations are those not listed in MIL-STD-12D.
Section II - Definition of Unusual Terms. This section lists and defines the terms used in
this technical manual that are not listed in the Army dictionary (AR 310-25).
INDEX.
An alphabetical index at the back of this technical manual provides a listing of subjects covered, cross-referenced to the applicable paragraph.
HOW TO FIX A GENERATOR SET 150 kW MALFUNCTION.
Determining the Cause. Finding the cause of a malfunction, troubleshooting, is the first step
in fixing the generator set 150 kW and returning it to operation. Follow these simple steps to
determine the cause of the problem:
a. Turn to the Table of Contents in this manual (page i).
b. Locate “Troubleshooting” under the chapter that covers your level of maintenance.
Turn to the page indicated.
c. For operator troubleshooting, follow the instructions in the references listed in
Chapter 3.
d. For troubleshooting at the unit maintenance level, find the malfunction listing in the
troubleshooting symptom index. Follow the instructions in the figure (troubleshooting chart) indicated
by the symptom index.
Preparing for a Task. Be sure that you understand the entire maintenance procedure before
beginning any maintenance task. Make sure that all parts, materials, and tools are handy.
Read all steps before beginning. Prepare to do the task as follows:
a. Carefully read the entire task before starting. It tells you what you will need and
what you have to know to start the task. DO NOT START THE TASK UNTIL:
(1)
You know what is needed
(2)
You have everything you need
(3)
You understand what to do
b. If parts are listed, they can be drawn from technical supply. Before you start the
task, check to make sure you can get the needed parts. National Stock Numbers
(NSNs) and part numbers for the generator set 150 kW parts are listed in the Re
pair Parts and Special Tools List (RPSTL) manual, TM 9-6115-668-23P.
c. If expendable/durable supplies or materials are needed, get them before starting
the task. Refer to Appendix E for the correct nomenclature and NSN.
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How to do the Task. Before starting read the entire task. Be sure that you understand the entire procedure before you begin the task. As you read, remember the following:
a. PAY ATTENTION TO WARNINGS, CAUTIONS, AND NOTES.
b. Use the GLOSSARY if you do not understand the special abbreviations or unusual
terms used in this manual.
c. The following are standard maintenance practices. Instructions about these prac
tices are usually not included in task steps. When standard maintenance practices
do not apply, the task steps will tell you. The standard maintenance practices are:
(1)
Tag electrical wiring before disconnecting it.
(2)
Discard used preformed packing, retainers, gaskets, cotter pins, lock wash
ers, and similar items. Install new parts to replace the discarded items.
(3)
Coat packing before installation, in accordance with the task instructions.
(4)
Disassembly procedures describe the disassembly needed for total autho
rized repair. You may not need to disassemble an item as far as described in
the task. Follow the disassembly steps only as far as needed to repair/re
place worn or damaged parts.
(5)
Clean the assembly, subassembly, or part before inspecting it.
(6)
Before installing components having mating surfaces, inspect the mating sur
faces to make sure they are in serviceable condition.
(7)
Hold the bolt (or screw) head with a wrench (or screwdriver) while tightening
or loosening a nut on the bolt (or screw).
(8)
Torque to the special torque cited when the task instructions include the
words “torque to.” Use standard torques at all other times.
(9)
When a cotter pin is required, align the cotter pin holes within the allowable
torque range.
(10)
Inspect for foreign objects after performing maintenance.
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